Polyarylether ketone imide sulfone adhesives

Patent metadata

Field	Value
Publication number	US-9976063-B2
Application number	US-201615247275-A
Country	US
Kind code	B2
Filing date	Aug 25, 2016
Priority date	Mar 11, 2016
Publication date	May 22, 2018
Grant date	May 22, 2018

Abstract

Aspects of the present disclosure generally describe polyarylether ketones and methods of use. In some aspects, a composition includes one or more polymers of formulae (I), (II), or (III):

First claim

What is claimed is:

1. A composition comprising one or more polymers of formulae (I), (II), or (III):

wherein:
X is selected from the group consisting of

and combinations thereof,
Y is selected from the group consisting of

and combinations thereof,
Z is selected from the group consisting of —H,

benzyl, and combinations thereof, where R′ is H, halo, C1-C20 alkyl, cyano, or combinations thereof,
R is selected from the group consisting of:

and combinations thereof,
L is selected from the group consisting of: —CH 2 —, —(CH 3 ) 2 C—, —O—, —S—, —SO 2 —, —CO—, and combinations thereof,
Q is selected from the group consisting of: —S—, —SO 2 — or —(CF 3 ) 2 C—, —O—, —(CH 3 ) 2 C—, and combinations thereof,
j is a positive integer,
m is a positive integer,
n is a positive integer,
p is a positive integer, and
q is a positive integer.

2. The composition of claim 1 , wherein the molecular weight of at least one of the one or more polymers is between about 10 kDa and about 150 kDa.

3. The composition of claim 2 , wherein the molecular weight of at least one of the one or more polymers is between about 50 kDa and about 120 kDa.

4. The composition of claim 3 , wherein the molecular weight of at least one of the one or more polymers is between about 90 kDa and about 110 kDa.

5. The composition of claim 1 , wherein the molecular weight of each moiety of the structure:

does not exceed about 3 kDa.

6. The composition of claim 1 , wherein a ratio of m to n is between about 1:1 and about 1:2.

7. The composition of claim 1 , wherein a ratio of m to p is between about 1:1 and about 1:2.

8. The composition of claim 1 , wherein a ratio of n to p is between about 1:1 and about 1:2.

9. The composition of claim 1 , wherein a ratio of

is between about 1:1 and about 1:2.

10. The composition of claim 1 , wherein the moiety:

is greater than about 33 mol % of the molecular weight of at least one of the one or more polymers.

11. The composition of claim 10 , wherein the moiety:

is greater than about 50 mol % of at least one of the one or more polymers.

12. The composition of claim 1 , wherein the composition has a glass transition temperature between about 135° C. and about 225° C.

13. The composition of claim 12 , wherein the composition has a glass transition temperature between about 135° C. and about 190° C.

14. The composition of claim 1 , wherein the composition has a melting temperature between about 200° C. and about 450° C.

15. The composition of claim 1 , wherein at least one of the one or more polymers of formulae (I), (II), or (III) is a block copolymer.

16. The composition of claim 15 , wherein q is 1, m is an integer between about 1 and about 1,000, and n is an integer between about 1 and about 1,000.

17. The composition of claim 1 , wherein at least one of the one or more polymers of formulae (I), (II), or (III) is a random copolymer.

18. The composition of claim 17 , wherein q is an integer between 2 and about 2,000, m is an integer between about 1 and about 1,000, and n is an integer between about 1 and about 1,000.

19. The composition of claim 1 , further comprising a fiber material.

20. The composition of claim 19 , wherein the fiber material is selected from the group consisting of graphite, fiberglass, nylon, aramid polymers, spectra, and mixtures thereof.

21. A vehicle component including the composition of claim 1 .

22. The composition of claim 21 , wherein the vehicle component is a tail cone, a panel, a coated lap joint between two or more panels, a wing-to-fuselage assembly, structural aircraft composite, fuselage body-joint or wing rib-to-skin joint.

23. A method comprising:
using the composition of claim 1 as an adhesive.

24. The method of claim 23 , wherein the molecular weight of at least one of the one or more polymers is between about 10 kDa and about 150 kDa.

25. A method comprising: coating a surface with the composition of claim 1 .

26. The method of claim 25 , wherein the molecular weight of at least one of the one or more polymers is between about 10 kDa and about 150 kDa.

27. A method comprising: forming a three dimensional structure at least partially comprising the composition of claim 1 .

28. The method of claim 27 , wherein the three dimensional structure further comprises a reinforcement agent selected from the group consisting of glass, carbon fibers, chopped carbon fibers, carbon black, and carbon nanotubes.

29. The method of claim 27 , wherein forming the three dimensional structure comprises fused filament fabrication and/or selective laser sintering.

30. A three dimensional structure comprising the composition of claim 1 .

31. The three dimensional structure of claim 30 , further comprising a reinforcing agent.

32. A method comprising:
coating a first surface with the composition of claim 1 to form a coated surface;
contacting the coated surface with a second surface; and
heating the composition to above about 355° C.

33. The method of claim 32 , wherein the first surface comprises a thermoplastic prepreg, thermoset prepreg, and/or metal.

34. The method of claim 33 , wherein the first surface comprises a thermoplastic prepreg, and heating the composition to above about 355° C. consolidates the thermoplastic prepreg.

35. The method of claim 33 , wherein the first surface and the second surface comprises a thermoplastic prepreg, and wherein heating the composition to above about 355° C. consolidates the thermoplastic prepreg of the first surface and the thermoplastic prepreg of the second surface.

36. The method of claim 33 , further comprising coating the second surface with the composition to form a second coated surface.

37. The method of claim 32 , wherein the first surface is a surface of a vehicle component, and the second surface is a surface of a vehicle component.

38. The method of claim 32 , wherein the molecular weight of at least one of the one or more polymers is between about 10 kDa and about 150 kDa.

39. A polymer consisting of:
at least one of

Assignees

• Boeing Co

Inventors

• Childers Christopher H
• Bogucki Gregg R
• Steinman Christopher S
• Heinz Stephen R

Classifications

• C08G2261/3442

  Polyetherketones · CPC title

• C08J2300/22

  Thermoplastic resins · CPC title

• C08L81/06

  Polysulfones; Polyethersulfones · CPC title

• C09J171/00

  Adhesives based on polyethers obtained by reactions forming an ether link in the main chain (based on polyacetals C09J159/00; based on epoxy resins C09J163/00; based on polythioether-ethers C09J181/02; based on polyethersulfones C09J181/06); Adhesives based on derivatives of such polymers · CPC title

• C08G65/4012

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