Films and membranes of poly (aryl ketones) and methods of casting the same from solution

Patent metadata

Field	Value
Publication number	US-10087295-B2
Application number	US-201214122306-A
Country	US
Kind code	B2
Filing date	May 15, 2012
Priority date	May 27, 2011
Publication date	Oct 2, 2018
Grant date	Oct 2, 2018

Abstract

A method of manufacturing a film or membrane includes: (a) dissolving at least one polymer comprising a poly(aryl ketone) in at least one solvent to form a dope; (b) depositing the dope on a substrate to form a coated substrate at appropriate conditions; and (c) drying the coated substrate to form the film or membrane. The dope may also include additional polymers or fillers, such as carbon nanotubes.

First claim

What is claimed:

1. A method of manufacturing a film or membrane using a solvent cast process comprising:
dissolving at least one polymer comprising polyetherketoneketone (PEKK) in solvent to form a dope;

wherein the solvent consists of solvents (A) and (B) which are different from each other, each having a boiling point at atmospheric pressure of not greater than 250° C., and optionally an aromatic solvent selected from the group consisting of 4-chloro-2-methyl phenol (4-Cl-o-cresol), 4-chloro-3-methyl phenol (4-Cl-m-cresol), 3-chloro phenol, 4-chlorophenol, 4-methyl-phenol (p-cresol) and mixtures thereof, where (A) is selected from the group consisting of brominated, iodinated and/or fluorinated organic acids having a pKa of from 1 to 3, and (B) is selected from the group consisting of dichloromethane (DCM), toluene, dichloroethane, ethyl acetate, or mixtures thereof, or where (A) is selected from the group consisting of chlorinated organic acids and (B) is selected from the group consisting of dichloromethane (DCM), toluene, dichloroethane, ethyl acetate, trifluoroacetic acid, or mixtures thereof,
depositing the dope on a substrate to form a coated substrate; and
drying the coated substrate to form the film or membrane.

2. A method of manufacturing a film or membrane according to claim 1 , wherein solvent (A) is a brominated, iodinated and/or fluorinated organic acid having a pKA of from 1 to 3 and solvent (B) is selected from the group consisting of dichloromethane (DCM), toluene, dichloroethane, ethyl acetate, or mixtures thereof.

3. A method of manufacturing a film or membrane according to claim 1 , wherein solvent (A) is a chlorinated organic acid and solvent (B) is selected from the group consisting of dichloromethane (DCM), toluene, dichloroethane, ethyl acetate, trifluoroacetic acid, or mixtures thereof.

4. A method of manufacturing a film or membrane according to claim 1 , wherein the solvent includes said aromatic solvent.

5. A method of manufacturing a film or membrane according to claim 1 , wherein solvent (A) is a chlorinated organic acid that is selected from at least one of monochloroacetic acid, dichloroacetic acid, trichloroacetic acid, tetrachlorophthalic acid or mixtures thereof.

6. A method of manufacturing a film or membrane according to claim 1 , wherein solvent (A) is dichloroacetic acid (DCAA).

7. A method of manufacturing a film or membrane according to claim 1 , wherein solvent (B) is dichloromethane (DCM).

8. A method of manufacturing a film or membrane according to claim 1 , wherein the solvent consists of solvent (A) which is dichloroacetic acid (DCAA) and solvent (B) which is dichloromethane (DCM).

9. A method of manufacturing a film or membrane according to claim 1 , wherein the dope comprises an additional component selected from the group consisting of additional polymers, additives, fillers, and mixtures thereof.

10. A method of manufacturing a film or membrane according to claim 1 , wherein the dope comprises carbon nanotubes.

11. A method of manufacturing a film or membrane according to claim 10 , wherein the dope comprises up to 45 wt. % carbon nanotubes.

12. A method of manufacturing a film or membrane according to claim 1 , wherein the substrate is selected from the group consisting of glass, polymer film, metal sheet, and silicon wafer.

13. A method of manufacturing a film or membrane according to claim 1 , wherein the at least one polymer is dissolved at or above room temperature.

14. A method of manufacturing a film or membrane according to claim 1 , wherein the coated substrate is dried at or above room temperature.

15. A method of manufacturing a film or membrane according to claim 11 , wherein the coated substrate is dried at a temperature below the boiling point of the highest boiling point solvent in the dope.

16. A method of manufacturing a film or membrane according to claim 1 further comprising depositing at least one additional coating of dope on the substrate.

Assignees

• Roger Christophe
• GARCIA LEINER Manuel A
• Laffitte Jean Alex
• Boyer Julie
• Moyses Stephan
• Judovits Lawrence H
• Arkema Inc

Inventors

• Roger Christophe
• Garcia-Leiner Manuel A
• Laffitte Jean-Alex
• Boyer Julie
• Moyses Stephan
• Judovits Lawrence H

Classifications

• C08G65/46

  Post-polymerisation treatment, e.g. recovery, purification, drying · CPC title

• C08J5/18 Primary

  Manufacture of films or sheets · CPC title

• B29C39/003

  characterised by the choice of material · CPC title

• C08G65/00

  Macromolecular compounds obtained by reactions forming an ether link in the main chain of the macromolecule · CPC title

• C08L71/00 Primary

  Compositions of polyethers obtained by reactions forming an ether link in the main chain (of polyacetals C08L59/00; of epoxy resins C08L63/00; of polythioether-ethers C08L81/02; of polyether-sulfones C08L81/06); Compositions of derivatives of such polymers · CPC title