Sintered polymeric particles for porous structures

Patent metadata

Field	Value
Publication number	US-11879047-B2
Application number	US-202117541502-A
Country	US
Kind code	B2
Filing date	Dec 3, 2021
Priority date	Mar 7, 2014
Publication date	Jan 23, 2024
Grant date	Jan 23, 2024

Abstract

Disclosed are porous elements that include sintered polymeric particles. The polymeric particles can be formed of a thermoplastic composition that includes a polyarylene sulfide. The polymeric particles sintered to form the porous elements have a very narrow size distribution. The porous elements can maintain their functionality and morphology even when utilized in high temperature applications.

First claim

What is claimed is:

1. A porous element comprising sintered polymeric particles, the polymeric particles comprising a thermoplastic composition that includes a polyarylene sulfide and an impact modifier that includes an epoxy-functionalized olefin copolymer, the polymeric particles having a median particle size and a particle size distribution, the particle size distribution being such that 50% of the polymeric particles have a size between about 60% of the median particle size and about 140% of the median particle size, and such that 10% of the polymeric particles have a maximum particle diameter that is between about 35% and about 60% of the median particle size of the polymeric particles.

2. The porous element of claim 1 , the particle size distribution being such that 50% of the polymeric particles have a size between about 80% of the median particle size and about 120% of the median particle size.

3. The porous element of claim 1 , the particle size distribution being such that 80% of the polymeric particles have a size between about 35% of the median particle size and about 175% of the median particle size.

4. The porous element of claim 1 , wherein the median particle size of the polymeric particles is about 1000 micrometers or less as determined via laser diffraction.

5. The porous element of claim 1 , wherein the porous element has a porosity of about 30% or greater as determined according to DIN 66 133 testing protocol.

6. The porous element of claim 1 , wherein the porous element defines a median pore size that is from about 10 micrometers to about 150 micrometers as determined according to DIN 66 133 testing protocol.

7. The porous element of claim 1 , wherein the porous element has a tensile elongation at break of less than about 15% as determined according to ISO Test no. 527 at a temperature of 23° C. and a test speed of 5 mm/min.

8. The porous element of claim 1 , wherein the porous element has a tensile strength at break of about 2 megapascals or greater as determined according to ISO Test no. 527 at a temperature of 23° C. and a test speed of 5 mm/min.

9. The porous element of claim 1 , wherein the porous element has a tensile modulus of about 40 megapascals or greater as determined according to ISO Test no. 527 at a temperature of 23° C. and a test speed of 5 mm/min.

10. The porous element of claim 1 , wherein the thermoplastic composition has a complex viscosity of about 20,000 poise or less at a temperature of about 200° C. or greater as determined according to a low shear sweep method.

11. The porous element of claim 1 , wherein the polyarylene sulfide is a polyphenylene sulfide.

12. The porous element of claim 11 , wherein the polyphenylene sulfide is a linear polyphenylene sulfide.

13. The porous element of claim 1 , the thermoplastic composition comprising one or more additives.

14. The porous element of claim 1 , the porous element comprising secondary particles.

15. The porous element of claim 14 , wherein the secondary particles comprise inorganic particles.

16. The porous element of claim 15 , the inorganic particles comprising particles of silica, quartz powder, silicates, aluminum silicate, kaolin, talc, mica, clay, diatomaceous earth, wollastonite, calcium carbonate, zeolites, carbon molecular sieves, activated carbon, or mixtures of inorganic particles.

17. The porous element of claim 1 , the porous element further comprising a fibrous filler.

18. The porous element of claim 1 , the porous element further comprising a secondary polymeric material.

19. The porous element of claim 1 , wherein the porous element is a separation element.

20. The porous element of claim 1 , wherein the porous element is a tubular structure.

21. A filter element comprising the porous element of claim 1 .

22. The filter element of claim 21 , wherein the porous element has an average pore size of from about 10 micrometers to about 150 micrometers and a porosity of about 30% or greater.

23. The filter element of claim 21 , the filter element withstanding operation at a temperature of about 100° C. or greater without exhibiting deformation.

24. The porous element of claim 1 , wherein the epoxy-functionalized olefin copolymer is an ethylene copolymer.

25. The porous element of claim 1 , wherein the epoxy-functionalized olefin copolymer includes methacrylic monomer units.

26. The porous element of claim 25 , wherein the methacrylic monomer units are epoxy-functionalized.

27. The porous element of claim 24 , wherein the epoxy-functionalized olefin copolymer is poly(ethylene-co-methylacrylate-co-glycidyl methacrylate).

28. The porous element of claim 1 , wherein the concentration of the impact modifier in the thermoplastic composition from about 0.05% to about 40% by weight.

29. The porous element of claim 1 , wherein the thermoplastic composition has a melt viscosity of about 3,000 poise or greater as determined by use of a capillary rheometer at 316° C. and 400 sec −1 .

30. The porous element of claim 1 , wherein the thermoplastic composition has a melt viscosity of 10,000 poise or greater as determined by use of a capillary rheometer at 316° C. and 400 sec −1 .

31. The porous element of claim 1 , wherein the thermoplastic composition exhibits a degradation temperature of greater than 400° C.

32. The porous element of claim 1 , wherein the porous element exhibits shrinkage during sintering of about 8% or less.

33. The porous element of claim 1 , wherein the thermoplastic composition further comprises a crosslinking agent.

34. The porous element of claim 33 , wherein the crosslinking agent comprises a polyfunctional carboxylic acid.

35. The porous element of claim 33 wherein the crosslinking agent comprises a metal salt of a fatty acid.

36. The porous element of claim 35 , wherein the fatty acid includes 6 to 40 carbon atoms.

37. The porous element of claim 35 , wherein the crosslinking agent comprises a metal stearate or a metal montanate.

38. The porous element of claim 1 , wherein the polymeric particles comprise heat treated polymeric particles.

Assignees

• Ticona Llc

Inventors

• Senoz Erman
• Chen Dian
• Mcgrady Christopher
• Luo Jun
• Luo Rong

Classifications

• C08J9/24 Primary

  by surface fusion and bonding of particles to form voids, e.g. sintering (of expandable particles C08J9/232) · CPC title

• B01D39/1661

  sintered or bonded · CPC title

• C08J9/0061

  characterized by the use of several polymeric components · CPC title

• C08J9/0066

  Use of inorganic compounding ingredients · CPC title

• C08J9/0085

  Use of fibrous compounding ingredients (C08J9/0076 takes precedence) · CPC title