Polyphenylene-poly(aryl ether sulfone) blends, articles and method
AssigneeSolvay Advanced Polymers, L.L.C.
InventorsNikica Maljkovic, Roy L. Carter, David B. Thomas, Leslie J. Myrick, Todd S. Rushing
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Abstract
Compositions comprising blends of polyphenylene and poly(aryl ether sulfone) and methods for making such blends are disclosed. Miscible blends of polyphenylene and poly(aryl ether sulfone) are also disclosed. The blends are useful in numerous applications such as in the preparation of articles and of foams having reduced density.
Claims33
A blend composition comprising at least one polyphenylene and at least one poly(aryl ether sulfone) other than a polyphenylsulfone, wherein the polyphenylene comprises a homopolymer or copolymer comprising a first repeat unit having the structure
- and optionally a second repeat unit having the structure
- wherein R1, R2, R3, R4, R5, R6, R7, and R8 are each independently selected from the group consisting of hydrogen, alkyl, aryl, alkoxy, aryloxy, alkylketone, arylketone, fluoroalkyl, fluoroaryl, bromoalkyl, bromoaryl, chloroalkyl, chloroaryl, alkylsulfone, arylsulfone, alkylamide, arylamide, alkylester, arylester, fluoro, chloro, and bromo.
A blend composition comprising at least one polyphenylene and at least one poly(aryl ether sulfone), wherein the polyphenylene comprises a homopolymer or copolymer comprising a first repeat unit having the structure
- and optionally a second repeat unit having the structure
- wherein R1, R2, R3, R4, R5, R6, R7, and R8 are each independently selected from the group consisting of hydrogen, alkyl, aryl, alkoxy, aryloxy, alkylketone, arylketone, fluoroalkyl, fluoroaryl, bromoalkyl, bromoaryl, chloroalkyl, chloroaryl, alkylsulfone, arylsulfone, alkylamide, arylamide, alkylester, arylester, fluoro, chloro, and bromo;
- and wherein the poly(aryl ether sulfone) is selected from the group consisting of polysulfones, polyethersulfones and polyimidoethersulfones.
A foam comprising a blend composition comprising at least one polyphenylene and at least one poly(aryl ether sulfone), wherein the polyphenylene comprises a homopolymer or copolymer comprising a first repeat unit having the structure
- and optionally a second repeat unit having the structure
- wherein R1, R2, R3, R4, R5, R6, R7, and R8 are each independently selected from the group consisting of hydrogen, alkyl, aryl, alkoxy, aryloxy, alkylketone, arylketone, fluoroalkyl, fluoroaryl, bromoalkyl, bromoaryl, chloroalkyl, chloroaryl, alkylsulfone, arylsulfone, alkylamide, arylamide, alkylester, arylester, fluoro, chloro, and bromo.
A method for making a blend composition comprising at least one polyphenylene and at least one poly(aryl ether sulfone), wherein the polyphenylene comprises a homopolymer or a copolymer comprising a first repeat unit having the structure
- and optionally a second repeat unit having the structure
- wherein R1, R2, R3, R4, R5, R6, R7, and R8 are each independently selected from the group consisting of hydrogen, alkyl, aryl, alkoxy, aryloxy, alkylketone, arylketone, fluoroalkyl, fluoroaryl, bromoalkyl, bromoaryl, chloroalkyl, chloroaryl, alkylsulfone, arylsulfone, alkylamide, arylamide, alkylester, arylester, fluoro, chloro, and bromo;
- which method comprises the steps of (a) preparing a master mixture by intimately mixing a blend comprising polyphenylene and poly(aryl ether sulfone) in a wt./wt. ratio in a range of between 10:90 and 90:10, and (b) either
- (b1) preparing a final blend comprising a reduced amount of polyphenylene by diluting the master mixture with poly(aryl ether sulfone) and intimately mixing in at least one additional process step, or
- (b2) preparing a final blend comprising a reduced amount of polyphenylene by diluting and intimately mixing the master mixture with poly(aryl ether sulfone) in a single extrusion step by throat feeding of the master mixture components and down-stream feeding of additional poly(aryl ether sulfone), or
- (b3) preparing a final blend comprising a reduced amount of poly(aryl ether sulfone) by diluting the master mixture with polyphenylene and intimately mixing in at least one additional process step, or
- (b4) preparing a final blend comprising a reduced amount of poly(aryl ether sulfone) by diluting and intimately mixing the master mixture with polyphenylene in a single extrusion step by throat feeding of the master mixture components and down-stream feeding of additional polyphenylene.
The method of claimed 29, wherein step (b) consists in either
- (b′1) preparing a final blend comprising less than 10 wt. % polyphenylene by diluting the master mixture with poly(aryl ether sulfone) and intimately mixing in at least one additional process step, or
- (b′2) preparing a final blend comprising less than 10 wt. % polyphenylene by diluting and intimately mixing the master mixture with poly(aryl ether sulfone) in a single extrusion step by throat feeding of the master mixture components and down-stream feeding of additional poly(aryl ether sulfone), or
- (b′3) preparing a final blend comprising less than 10 wt. % poly(aryl ether sulfone) by diluting the master mixture with polyphenylene and intimately mixing in at least one additional process step.
The method of claimed 29, wherein step (a) consists in preparing a master mixture by intimately mixing a blend comprising polyphenylene and poly(aryl ether sulfone) in a 50:50 wt./wt. ratio and step (b) consists in either
- (b″1) preparing a final blend comprising less than 50 wt. % polyphenylene by diluting the master mixture with poly(aryl ether sulfone) and intimately mixing in at least one additional process step, or
- (b″2) preparing a final blend comprising less than 50 wt. % polyphenylene by diluting and intimately mixing the master mixture with poly(aryl ether sulfone) in a single extrusion step by throat feeding of the master mixture components and down-stream feeding of additional poly(aryl ether sulfone), or
- (b″3) preparing a final blend comprising less than 50 wt. % poly(aryl ether sulfone) by diluting the master mixture with polyphenylene and intimately mixing in at least one additional process step.
The method of claimed 29, wherein the poly(aryl ether sulfone) is selected from the group consisting of polysulfones, polyethersulfones and polyimidoethersulfones.
The method of claimed 29, wherein the poly(aryl ether sulfone) is a polyphenylsulfone.
Dependencies are inferred from the claim text.