Solvay Specialty Polymers Usa, LLC

Solvay Advanced Polymers, LLC

Cytec Industries Inc.

Syensqo Specialty Polymers Usa, LLC

Chantal Louis

Mohammad Jamal El-Hibri

David B Thomas

Ryan Hammonds

William Gandy

James Francis Pratte

Edward Ryan

Geoffrey Scott Underwood

Kong Yi

Stéphane Jeol

Satchit Srinivasan

Hemantkumar Patel

Scott A Harding

Luca Merlo

Walter Thomas Reichle

Mattia Bassi

Joel Pollino

Hong Chen

Narmandakh Taylor

Atul Bhatnagar

Christopher Ward

Maryam Momtaz

Jiqiang Xia

Craig K Swanson

William Walter Looney

Olivier Vidberg

Nicholas Almeter

Gregory Goschy

Craig Swanson

Donald R Kelsey

Robert A Clendinning

Ronald Baldwin

Scot A Harding

William W Looney

The present invention relates to a process for preparing a polysulfone (PSU) polymer having a low yellowness index (YI). The present disclosure also relates to a PSU obtained from this process, as well as to articles incorporating this PSU.

Process for preparing a polysulfone (PSU) polymer

Poly(ether ketone ketone) (PEKK) composites include reinforcing fibers in a PEKK polymer matrix that includes a PEKK polymer. It was surprisingly discovered that by washing unneutralized PEKK polymer powder with an acid or base, the melt stability of the PEKK polymers can be improved, as compared with PEKK polymers prepared by conventional methods. The PEKK composites are especially well-suited for fabrication of thick composite parts where melt stability is especially important.

Poly(ether ketone ketone) (PEKK) composites

The present invention generally relates to a powder comprising a PEEK-PEoEK copolymer, wherein the PEEK-PEoEK copolymer having Rand Rrepeat units in a molar ratio R/Rranging from 95/5 to 5/95. The present invention also relates to a method of preparing a three-dimensional (3D) object by sintering layers of the powder.

PEEK-PEoEK copolymer powder and method of preparing the powder

The present invention relates to poly(ether ketone ketone) (PEKK) polymers, a method for the manufacture thereof, to articles and composites made therefrom, to methods of making the composites, and composite articles including the PEKK composites. It was surprisingly discovered that by synthesizing the PEKK polymers from low-metal monomers and selectively controlling the relative amounts of reactants during the synthesis, PEKK polymers having unexpectedly improved melt stability can be obtained. The PEKK composites including the PEKK polymers are especially well-suited for fabrication of thick composite parts where melt stability of the polymer matrix is important.

Poly(ether ketone ketone) (PEKK) polymer and composites

Described herein are poly(ether ketone ketone) ('PEKK') polymers having improved processability. It was surprisingly discovered that by selectively controlling the relative amounts of reactants during the synthesis, PEKK polymers having unexpectedly lower melt viscosities can be obtained. More particularly, by selectively controlling the relative amounts of monomers used to form recurring units of the PEKK polymer, in conjunction with selective control of other reaction components, the resulting PEKK polymers had reduced viscosities, relative to PEKK polymers synthesized by using tradition reaction schemes (“traditional PEKK polymers”). By providing PEKK polymers with lower melt viscosities, the PEKK polymers described herein have improved processability.

Poly (ether ketone ketone) polymers, corresponding synthesis methods and polymer compositions and articles made therefrom

The present disclosure relates to an additive manufacturing (AM) method for making a three-dimensional (3D) object, comprising a) depositing successive layers of a powdered material (M), at least partially recycled, comprising at least one poly(ether ketone ketone) (PEKK), having a phosphorus content of more than 30 ppm, as measured by Inductively Coupled Plasma Optical Emission Spectrometry (ICP-OES), and b) selectively sintering each layer prior to deposition of the subsequent layer.

Additive manufacturing method for making a three-dimensional object using selective laser sintering

The present invention generally relates to a powder comprising a PEEK-PEoEK copolymer, wherein the PEEK-PEoEK copolymer having Rand Rrepeat units in a molar ratio R/Rranging from 95/5 to 5/95. The present invention also relates to a method of preparing the powder, as well as to the uses of the powder for coating, compression molding and to prepare a three-dimensional (3D) object.

The present invention generally relates a composite material containing fibers and a resin matrix that comprises a PEEK-PEoEK copolymer having Rand Rrepeat units in a molar ratio R/Rranging from 95/5 to 5/95 in contact with at least a part of the surface of such fibers. The present invention also relates to methods for making such composite materials, shaped articles made from such composite materials, and methods of making such articles.

Fiber reinforced thermoplastic matrix composite material

A PEKK polymer powder, having a d-value less than 150 μm, wherein the PEKK polymer has a Td(1%) of at least 500° C., as measured by thermal gravimetric analysis according to ASTM D3850, heating from 30° C. to 800° C. under nitrogen using a heating rate of 10° C./min. A method for producing a PEKK powder for the use in a method for manufacturing a 3D object, in which the PEKK has a Td(1%) of at least 500° C., as measured by thermal gravimetric analysis according to ASTM D3850, heating from 30° C. to 800° C. under nitrogen using a heating rate of 10° C./min, and the powder has been manufactured by grinding from a coarser powder and has a d-value less than 150 μm, as measured by laser scattering in isopropanol.

Poly(ether ketone ketone) polymer powder having a low volatiles content

A method of making a PEEK-PEoEK copolymer having Rand RPEoEK repeat units in a molar ratio R/Rranging from 95/5 to 45/55, the PEEK-PEoEK copolymer obtained from the method and the polymer composition including the PEEK-PEoEK copolymer, at least one reinforcing filler, at least one additive, or a combination thereof, shaped articles including the polymer composition, polymer-metal junctions including the polymer composition. Also described are methods of making the polymer composition, methods of making the shaped articles, and methods of making the polymer-metal junctions.

Method of making a PEEK-PEoEK copolymer and copolymer obtained from the method

Described herein are poly(ether ketone ketone) ('PEKK') polymers having improved processability. It was surprisingly discovered that by selectively controlling the relative amounts of reactants during the synthesis, PEKK polymers having unexpectedly lower melt viscosities can be obtained. More particularly, by selectively controlling the relative amounts of monomers used to form recurring units of the PEKK polymer, in conjunction with selective control of other reaction components, the resulting PEKK polymers had reduced viscosities, relative to PEKK polymers synthesized by using tradition reaction schemes ('traditional PEKK polymers'). By providing PEKK polymers with lower melt viscosities, the PEKK polymers described herein have improved processability.

Poly(ether ketone ketone) polymers, corresponding synthesis methods and polymer compositions and articles made therefrom

A method of making a PEEK-PEmEK copolymer having Rand Rrepeat units in a molar ratio R/Rranging from 95/5 to 45/55, the PEEK-PEmEK copolymer obtained from the method and the polymer composition including the PEEK-PEmEK copolymer, at least one reinforcing filler, at least one additive, or a combination thereof, shaped articles including the polymer composition, polymer-metal junctions including the polymer composition. Also described are methods of making the polymer composition, methods of making the shaped articles, and methods of making the polymer-metal junctions.

Method of making a PEEK-PEmEK copolymer and copolymer obtained from the method

The present invention generally relates a polymer-metal junction comprising PEEK-PEoEK copolymers compositions, in contact with at least a part of the surface of a metal substrate, wherein the PEEK-PEoEK copolymer having RPEEK and RPEoEK repeat units in a molar ratio R/Rranging from 95/5 to 5/95. The present invention also relates to shaped articles including the polymer-metal junction, and methods of making the polymer-metal junctions.

Polymer-metal junction comprising PEEK-PEoEK copolymer compositions, in contact with a metal substrate

Described herein are PEKK polymers having improved processability and improved crystallinity. It was surprisingly found that PEKK polymers formed using a specifically adapted nucleophilic synthesis route, in which different monomers are added in to the polymerization reaction at different points during the synthesis, had lower glass transition temperatures ('Tg') and increased crystallinities, relative to PEKK polymers formed using traditional nucleophilic synthesis routes ('traditional PEKK polymers'). Furthermore, compared with PEKK polymers synthesized using an electrophilic synthesis routes, the PEKK polymers described herein and significantly lower halogen content. The synthesis routes includes a first heating of a first monomer blend in a reaction mixture, a subsequent first addition of a second monomer blend to the reaction mixture, and a second heating of the reaction mixture subsequent to the first addition.

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Alpharetta, GA, United States of America

Chantal Louis