Rotomolding processes for poly(aryl ketones) and other high temperature polymers

Patent metadata

Field	Value
Publication number	US-10899047-B2
Application number	US-201314387569-A
Country	US
Kind code	B2
Filing date	Mar 5, 2013
Priority date	Mar 26, 2012
Publication date	Jan 26, 2021
Grant date	Jan 26, 2021

Abstract

A method of manufacturing an article comprises rotomolding at least one polymer comprising a poly(aryl ketone), such as PEKK, under conditions effective to produce a rotomolded article having an impact value of at least 35 in-lbs. A rotomolding method comprises heating the mold for a period of time after the internal air temperature of the mold reaches the highest melting point of the at least one polymer. Methods also include using a PEKK powder with a bulk density of at least about 400 g/L. Rotomolded articles of the present invention have impact values of between about 40 in-lbs to about 95 in-lbs, and in particular embodiments greater than about 95 in-lbs.

First claim

What is claimed is:

1. A method of manufacturing an article comprising:
Rotomolding polymer comprising polyetherketoneketone (PEKK) under conditions effective to produce a rotomolded article having an impact value of at least 35 in-lbs at a thickness of 0.05 inches to 0.06 inches,
Wherein the rotomolding comprising the steps of (i) placing powder having a bulk density of at least about 250 g/L to about 700 g/L comprising PEKK polymer into a mold and optionally one or more flow agents and/or one or more release agents, (ii) heating the mold and (iii) then cooling the mold, wherein a rotomolding temperature profile of internal air in the mold during heating is controlled by substantially maintaining heating of the mold while the mold is rotated for a period of time after internal air temperature of the mold reaches a highest melting point of the polymer and prior to initiating cooling.

2. A method of manufacturing an article according to claim 1 , wherein the polymer further comprises polymer selected from the group consisting of polyetheretherketone (PEEK), polyetherketone (PEK), polyetherketoneetherketoneketone (PEKEKK), and mixtures thereof.

3. A method of manufacturing an article according to claim 1 comprising heating the mold for at least about 10 minutes after the internal air temperature of the mold reaches the highest melting point of the polymer.

4. A method of manufacturing an article according to claim 1 comprising maintaining the internal air temperature of the mold within about 75° F. of the highest melting point of the polymer for at least about 10 minutes.

5. A method of manufacturing an article according to claim 1 comprising maintaining the internal temperature of the mold at above 550° F. for at least above 10 minutes.

6. A method of manufacturing an article according to claim 1 comprising maintaining the internal air temperature of the mold at above 600° F. for at least about 10 minutes.

7. A method of manufacturing an article according to claim 1 comprising maintaining the internal air temperature of the mold at above 600° F. for between about 20 minutes to about 30 minutes.

8. A method of manufacturing an article according to claim 1 , wherein the powder comprises ground PEKK pellets.

9. A method of manufacturing an article according to claim 1 , wherein the powder comprises ground PEKK pellets having a bulk density of between about 400 g/L to about 700 g/L.

10. A method of manufacturing an article according to claim 1 further comprising adding one or more flow agents to the mold.

11. A method of manufacturing an article according to claim 1 further comprising adding one or more mold release agents to the mold.

12. A method of manufacturing an article according to claim 1 , wherein the powder comprises ground PEKK pellets having a bulk density of between about 400 g/L to about 450 g/L.

13. An article formed according to the method of claim 1 .

Assignees

• Arkema Inc

Inventors

• Garcia-Leiner Manuel A
• Clay Bruce

Classifications

• B29C41/04 Primary

  Rotational or centrifugal casting, i.e. coating the inside of a mould by rotating the mould · CPC title

• C08G2650/40

  containing ketone groups, e.g. polyarylethylketones, PEEK or PEK · CPC title

• C08L71/00

  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

• B29K2071/00

  Use of polyethers {, e.g. PEEK, i.e. polyether-etherketone or PEK, i.e. polyetherketone or derivatives thereof}, as moulding material · CPC title

• C08G65/4012

  Other compound (II) containing a ketone group, e.g. X-Ar-C(=O)-Ar-X for polyetherketones · CPC title