Process of making polyimide micronized particles, particles formed therefrom, and articles prepared therefrom

A method of manufacturing polyimide particles, comprising:

• contacting a polyimide solution comprising a polyimide and an organic solvent with an aqueous solution comprising water in the presence of a surfactant using high shear agitation at a rotational speed from 1,500 to less than 2,500 revolutions per minute to form an emulsion;
• transferring the emulsion into a receiving water at a temperature of 65° C. to 100° C. to remove the organic solvent and form an aqueous polymer dispersion, wherein the concentration of organic solvent in the aqueous polymer dispersion is less than 75 ppm;
• forming a wet cake and an aqueous phase from the aqueous polymer dispersion, wherein the conductivity of the aqueous phase is less than 100 microsiemens;
• and
• optionally, drying the wet cake to recover polyimide particles;
• wherein the polyimide particles are recovered through a centrifuge device at a rate of 5 to 40 kilograms/hour/meter squared (kg/hr/m2), or wherein the polyimide particles are recovered through a pressure filtration device at the rate of 215 to 1500 kg/hr/m2,
• and wherein the polyimide particles have
• a spherical morphology and
• a volume based D10 diameter from 3 to 50 micrometers, and
• a volume based D90 diameter from 3 to 80 micrometers, and
• a volume based D100 diameter from 3 to 100 micrometers.

Polyimide particles comprising

• a spherical morphology,
• a volume based D10 diameter from 3 to 50 micrometers,
• a volume based D90 diameter from 3 to 80 micrometers,
• a surfactant concentration of less than 100 ppm,
• and wherein the particles comprise a volume based D100 diameter from 3 to 100 micrometers.