Film for multilayer assembly

Abstract

The invention relates to an assembly comprising a first part and a second part, each part comprising a polymer; and a film located between and adhered to the first part and the second part. The film comprises at least one poly(ether ketone ketone) (PEKK) polymer and at least one nucleating agent. The assembly has improved fracture toughness and overall good mechanical properties.

Description

[0001] This application claims priority to provisional application US 63 / 151820, filed February 22, 2021, and European patent application EP 21181637.6, filed June 25, 2021, the contents of which are incorporated herein by reference in their entirety for all purposes. In the event of any inconsistency between this application and the aforementioned PCT application affecting the clarity of terminology or expression, reference should be made solely to this application. Technical Field

[0002] This invention relates to a component comprising a first component and a second component, each component containing a polymer; and a membrane located between and bonded to the first and second components. The membrane contains at least one poly(ether ketone ketone) (PEKK) polymer and at least one nucleating agent. This component is particularly useful for the manufacture of parts and articles for the aerospace and automotive industries. Background Technology

[0003] In many industries, particularly the aerospace industry, there is extensive use of laminates, composites, and other components comprising multiple layers of different materials, each with specific properties for the final component. Achieving satisfactory adhesion or bonding directly between different layers that may be used in composites or laminates often proves challenging. Poor compatibility between composite layers can limit the properties exhibited by such components. In particular, certain thermoplastic polymers (especially crystalline and / or high-temperature thermoplastics) exhibit poor adhesion to other materials, leading to delamination and loss of structural integrity when components are used in demanding environments.

[0004] Numerous techniques have been proposed for securing and / or bonding thermoplastic parts together. In particular, many different welding processes, such as ultrasonic welding, induction welding, and hot plate welding, have been proposed for securing first and second thermoplastic parts together. However, localized melting of the first and second parts in the welding area can affect the integrity and / or shape of the parts. This can also lead to deformation due to residual stresses that accumulate in the parts during the melting and / or cooling of the thermoplastic in the welding area.

[0005] To address some issues related to welding processes, it has been proposed to provide films and / or adhesives between parts and / or layers to bond them together.

[0006] WO 2011 / 001103 A2 describes the use of amorphous poly(ether ketone ketone) (PEKK) membranes as adhesive layers in components such as composites and laminates. However, given the amorphous nature of the membrane, it is considered unsuitable for structural applications in the aerospace industry. In general, using amorphous materials as adhesive layers in composites may represent the weakest point of the structure, where properties such as solvent resistance are relatively low. Therefore, the joints can be easily eroded by fluids, leading to premature structural failure.

[0007] WO 2015 / 198063 A1 discloses the use of polymeric materials containing PEEK-PEDEK polymers, namely polymers having repeating units of the following formula.

[0008] -O-Ph-O-Ph-CO-Ph- I

[0009] and repeating units with the following formula

[0010] -O-Ph-Ph-O-Ph-CO-Ph- II

[0011] Ph represents the phenylene moiety, which acts as an adhesive between the first and second parts comprising a polyaryletherketone polymer (particularly PEEK). However, the mechanical properties of the PEEK-PEDEK polymer are inferior to those of other polyaryletherketone polymers.

[0012] WO 2021 / 085797, WO 2019 / 243433 and WO 2018 / 115233 are other applications in the field, but they do not disclose the subject matter of claim 1.

[0013] Technical issues

[0014] A membrane is needed that can firmly bond two polymer components (or parts) together to prepare an assembly with improved chemical resistance and improved mechanical properties. The membrane should be processed at a temperature below the melting temperature of the two components to be bonded, and advantageously at a temperature below 310°C.

[0015] The purpose of this invention is to solve this technical problem. Summary of the Invention

[0016] Therefore, one object of the present invention is the component as defined herein.

[0017] Another object of the present invention is a method for manufacturing components as defined herein.

[0018] Another object of the present invention is a part or article of manufacture as defined herein.

[0019] Another object of the invention is the use as defined herein.

[0020] Another objective is compositions containing PEKK polymers as defined herein.

[0021] The following section provides more precise information and details about these purposes.

[0022] Disclosure of the invention

[0023] This invention belongs to the field of laminates, composites, and other components comprising multiple layers of different materials, each material having specific properties for the final component. These components include at least two parts that may be identical or different, and at least one membrane, which is sometimes referred to herein as an "adhesive membrane".

[0024] The membranes used in this disclosure exhibit a set of properties that make them ideally suited for bonding component structures, particularly polymer components in component structures made of poly(aryl ether ketone) (PAEK) polymers. These membranes comprise at least one poly(ether ketone ketone) (PEKK) polymer and at least one nucleating agent. The T / I ratio of the PEKK polymer ranges from 50:50 to 56:44, preferably from 51:49 to 55:45. This PEKK polymer also exhibits crystallinity, which makes it ideally suited for component structures requiring chemical and mechanical resistance, such as composite structures in the aerospace industry.

[0025] The membrane described herein is advantageously compatible with the polymer components to be bonded.

[0026] In this application:

[0027] -Even any description relating to a specific embodiment may be applied to and interchanged with other embodiments disclosed herein;

[0028] - When an element or component is referred to as being included in and / or selected from the list of enumerated elements or components, it should be understood that in the relevant embodiments explicitly considered herein, the element or component may also be any one of these enumerated individual elements or components, or may be a group consisting of any two or more of the explicitly enumerated elements or components; any element or component listed in the list of elements or components may be omitted from this list; and

[0029] - Any enumeration of numerical ranges by endpoints in this document includes all numbers contained within the enumerated range, as well as the endpoints and equivalents of that range.

[0030] The first object of the present invention is a component comprising:

[0031] - First component, which comprises a polymer (P1),

[0032] - The second component, which comprises a polymer (P2), and

[0033] -A membrane located between and bonded to the first component and the second component.

[0034] The membrane contains at least one poly(ether ketone ketone) (PEKK) polymer exhibiting a specific T / I ratio and at least one nucleating agent.

[0035] In the context of this invention, the term "adhesive" means that components are attached to each other or to one another, preferably permanently.

[0036] The membrane of this component may additionally contain loose fabric and / or nonwoven reinforcement and / or lightweight fabric, which help regulate melt flow and / or provide a uniform surface for bonding, and may also affect the local morphology in the bonding line.

[0037] The components of the present invention may also include additional components (a third component, a fourth component, a fifth component, etc.) and membranes, depending on the composite part to be constructed. For example, the components of the present invention may include a third component comprising a polymer (P3) and a membrane between the second and third components, wherein the additional membrane bonds the second and third components together.

[0038] PEKK polymer

[0039] The poly(ether ketone ketone) (PEKK) polymer described herein contains at least 50 mol.% of repeating units having formulas (M) and (P), where mol.% is based on the total number of moles in the polymer:

[0040]

[0041]

[0042] in

[0043] -R 1 and R 2 In each case, the following groups are independently selected: alkyl, alkenyl, alkynyl, aryl, ether, thioether, carboxylic acid, ester, amide, imide, alkali metal or alkaline earth metal sulfonates, alkyl sulfonates, alkali metal or alkaline earth metal phosphonates, alkyl phosphonates, amines, and quaternary ammonium compounds; and

[0044] -i and j are independently chosen integers ranging from 0 to 4 in each case;

[0045] The molar ratio of repeating unit (P) to repeating unit (M) (also referred to herein as the "T / I ratio") is 50:50 to 56:44, preferably 51:49 to 55:45.

[0046] According to an embodiment, R 1 and R 2 At each position in formulas (P) and (M) above, the following groups are independently selected: C1-C12 moieties optionally containing one or more heteroatoms; sulfonic acid and sulfonate / ester groups; phosphonic acid and phosphonate / ester groups; amine and quaternary ammonium groups.

[0047] According to the embodiments disclosed herein, at least 55 mol.%, at least 60 mol.%, at least 70 mol.%, at least 80 mol.%, at least 90 mol.%, at least 95 mol.%, at least 99 mol.%, or all of the repeating units in PEKK are repeating units having formulas (M) and (P).

[0048] In the embodiments, substantially all repeating units of PEKK are repeating units having formulas (M) and (P). In the embodiments, the repeating units of PEKK consist of repeating units having formulas (M) and (P).

[0049] The molar ratio (also known as the "T / I ratio") of repeating units (P) to repeating units (M) of the polymer component PEKK used as the membrane ranges between 50:50 and 56:44, preferably between 51:49 and 55:45. PEKK preferably has a T / I ratio of 54:46 or 53:47.

[0050] According to another embodiment, for each R 1 and R 2 Groups i and j are zero. According to this embodiment, the PEKK polymer contains at least 50 mol.% of repeating units having formulas (M') and (P'), where mol.% is based on the total number of moles in the polymer:

[0051]

[0052] According to the embodiments disclosed herein, at least 55 mol.%, at least 60 mol.%, at least 70 mol.%, at least 80 mol.%, at least 90 mol.%, at least 95 mol.%, at least 99 mol.%, or all of the repeating units in PEKK are repeating units having the formulas (M') and (P').

[0053] In the embodiments, substantially all repeating units of PEKK are repeating units having the formulas (M') and (P'). In the embodiments, the repeating units of PEKK consist of repeating units having the formulas (M') and (P').

[0054] The molar ratio (also known as the "T / I ratio") of repeating units (P') to repeating units (M') of the polymer component PEKK used as the membrane ranges between 50:50 and 56:44, preferably between 51:49 and 55:45. PEKK preferably has a T / I ratio of 54:46 or 53:47.

[0055] As described above, the molar ratio (also known as the "T / I ratio") of repeating units (P) / (P') to repeating units (M) / (M') of the polymer component PEKK used as the membrane ranges between 50:50 and 56:44, preferably between 51:49 and 55:45. PEKK preferably has a T / I ratio of 54:46 or 53:47.

[0056] According to embodiments of this disclosure, the PEKK polymer described herein has a Tm, as measured by differential scanning calorimetry (DSC) according to ASTM D3418, ranging from 270°C to 310°C, preferably from 280°C to 305°C.

[0057] More specifically, the melting temperature Tm was measured according to ASTM D3418 by DSC using a heating and cooling rate of 10 °C / min. Tm was determined during the second heating scan. The following cycle can be followed:

[0058] - First heating cycle: 10.00℃ / min, from 30.00℃ to 400.00℃, isothermal at 400.00℃ for 1 min;

[0059] - First cooling cycle: 10.00℃ / min, from 400.00℃ to 30.00℃, isothermal for 1 min;

[0060] - Second heating cycle: 10.00℃ / min, from 30.00℃ to 400.00℃, isothermal at 400.00℃ for 1 min.

[0061] According to the embodiments disclosed herein, the heat of fusion ΔHf of the PEKK polymer described herein satisfies the following formula:

[0062] ΔH f >1.69 x T m -480 (Formula 1)

[0063] in:

[0064] -Tm is the melting temperature of PEKK in °C, and

[0065] -ΔH f Measured in J / g.

[0066] In the context of this invention, such a formula is an empirical formula that distinguishes PEKK with acceptable crystallinity at a given melting temperature (Tm) from PEKK with unacceptable crystallinity at the same Tm.

[0067] According to embodiments disclosed herein, the heat of fusion ΔHf of the PEKK polymer described herein is at least 5 J / g, at least 6 J / g, or at least 7 J / g. The heat of fusion may be defined as in any one of claims 13-15.

[0068] More specifically, the heat of fusion was measured by DSC during the second heating scan according to ASTM D3418, using a heating and cooling rate of 10 °C / min. The following cycle can be followed:

[0069] - First heating cycle: 10.00℃ / min, from 30.00℃ to 400.00℃, isothermal at 400.00℃ for 1 min;

[0070] - First cooling cycle: 10.00℃ / min, from 400.00℃ to 30.00℃, isothermal for 1 min;

[0071] - Second heating cycle: 10.00℃ / min, from 30.00℃ to 400.00℃, isothermal at 400.00℃ for 1 min.

[0072] Synthesis of PEKK polymer

[0073] The synthesis of PEKK polymers typically involves the steps of polycondensing monomers in a solvent to obtain the PEKK polymer, and the steps of extracting the solvent and salt.

[0074] In a preferred embodiment of the invention, the monomer polycondensation is carried out in the absence of Lewis acids or in the presence of Lewis acids in an amount based on less than 2 wt.%, preferably less than 1 wt.%, more preferably less than 0.5 wt.% of the total weight of the monomers.

[0075] In the context of this invention, Lewis acids can be defined as those selected from the group consisting of BF3, AlCl3, FeCl3, CF3SO3H, and CH3SO3H.

[0076] In a preferred embodiment, the synthesis of the PEKK polymer includes:

[0077] Step a) Polycondense the following monomers (P-OH), (M-OH), (PF), and / or (MF) in a solvent (e.g., DPS) in the absence of Lewis acids or in the presence of Lewis acids in an amount less than 2 wt.%, preferably less than 1 wt.%, more preferably less than 0.5 wt.%, based on the total weight of the monomers:

[0078]

[0079] in:

[0080] -R 3 R 4 R 5 and R 6 In each case, the following groups are selected independently: alkyl, alkenyl, alkynyl, aryl, ether, thioether, carboxylic acid, ester, amide, imide, alkali metal sulfonate or alkaline earth metal sulfonate, alkyl sulfonate, alkali metal phosphonate or alkaline earth metal phosphonate, alkyl phosphonate, amine, and quaternary ammonium.

[0081] -p, q, r, and s are each independently selected from 0 to 4 in each case;

[0082] The molar ratio of (P-OH) and (M-OH) to (PF) and (MF) is such that:

[0083]

[0084] The preferred molar ratio is ≥0.985, ≥0.990, or ≥0.995.

[0085] The preferred molar ratio is ≤1.015, ≤1.010, or ≤1.005.

[0086] Step b) Extract the solvent and salt to obtain a powder.

[0087] Preferably, p = q = r = s = 0.

[0088] The above method produces specific PEKK powders with significantly low volatile content, which helps to obtain specific properties, especially a higher melting enthalpy ΔH. f The PEKK polymer, according to an example, has a Td (1%) of at least 500°C, preferably at least 505°C, more preferably at least 510°C, as measured by thermogravimetric analysis under nitrogen at a heating rate of 10°C / min from 30°C to 800°C according to ASTM D3850. Td (1%) represents the temperature at which a defined amount of volatile material (=1.0 wt.%) leaves the sample.

[0089] In the embodiment, R 3 R 4 R 5 and R 6 At each position in the above formulas (P-OH), (PF), (M-OH), and (MF), the following groups are independently selected: C1-C12 moieties optionally containing one or more heteroatoms; sulfonic acid and sulfonate / ester groups; phosphonic acid and phosphonate / ester groups; amine and quaternary ammonium groups.

[0090] The T / I ratio is controlled by the amounts of (PF)+(P-OH) and (MF)+(M-OH).

[0091] In a preferred embodiment, the polycondensation that produces the PEKK polymer involves only the following monomers: (P-OH), (M-OH), and (PF).

[0092] Step a): The polycondensation in step a) is based on nucleophilic substitution. This polycondensation is carried out in a solvent (such as DPS) in the presence of at least one base selected from the group consisting of Na₂CO₃, K₂CO₃, or combinations thereof. The temperature of step a) is typically between 250°C and 350°C, and more particularly between 300°C and 350°C.

[0093] The amount of base should preferably be sufficient to activate all the OH groups of the monomer. The amount of base is typically slightly higher than the amount of OH groups. A molar excess between 1.0% and 5.0% can be used.

[0094] According to an example, an alkali is added to a mixture comprising a solvent and a monomer, the mixture preferably being at a temperature above 250°C, particularly between 250°C and 350°C. The duration of alkali introduction can be between 10 min and 120 min, preferably between 30 and 90 min.

[0095] According to another preferred embodiment, at the end of polycondensation, monomers (PF) and / or (MF), preferably (PF), are added to the mixture. This ensures that the PEKK polymer contains fluorinated end groups.

[0096] In step b) In this process, the polymer obtained in step a) is treated to remove the solvent and salt. For example, step b) can be carried out by contacting the polymer with a liquid selected from the group consisting of water, alcohols, ethers, ketones, and combinations thereof. The liquid can conveniently be a mixture of water and a liquid selected from the group consisting of water, alcohols, ethers, ketones, and combinations thereof. The liquid may also contain an acid or a base.

[0097] The synthesis method may include the additional step of contacting PEKK with a solution of at least one of sodium dihydrogen phosphate (NaH2PO4), disodium hydrogen phosphate (Na2HPO4), potassium dihydrogen phosphate (KH2PO4), and dipotassium hydrogen phosphate (K2HPO4), or a mixture thereof, preferably washing PEKK with the solution. For example, PEKK may be contacted with a solution containing both NaH2PO4 and Na2HPO4, such as an aqueous solution (e.g., washed with the solution). The phosphate used in the solution may be, for example, anhydrous, monohydrate, dihydrate, or heptahydrate.

[0098] In addition to the step of contacting the PEKK polymer with a solution of at least one of sodium dihydrogen phosphate (NaH2PO4), disodium hydrogen phosphate (Na2HPO4), potassium dihydrogen phosphate (KH2PO4), and dipotassium hydrogen phosphate (K2HPO4), or a mixture thereof, the synthesis method may also include at least one step of contacting PEKK with a solution containing an amount sufficient to neutralize the PEKK polymer, preferably washing the PEKK with the solution.

[0099] Suitable acids and bases include any organic or inorganic acid or base that exhibits a solubility of at least 0.1 wt.% in an organic solvent (such as alcohols, ketones, amides, aromatic hydrocarbons) or water at a temperature below the solvent's boiling point. Preferably, the solvent has a boiling point of at most 250°C, more preferably at most 150°C, and most preferably at most 100°C. The acid preferably has a pK value in the range of 3.0 to 7.5. a Furthermore, the base preferably has a pK value in the range of -1.0 to 8.0. b .

[0100] In some embodiments, the acid is selected from acetic acid, monoalkali metal citrates, and combinations thereof.

[0101] In some embodiments, the base is selected from organic amines, tetraalkylammonium hydroxide, tetraalkylammonium acetate, tetraalkylphosphonium hydroxide, tetraalkylphosphonium acetate, alkali metal or alkaline earth metal hydroxides, alkali metal or alkaline earth metal monohydrogen phosphates, alkali metal or alkaline earth metal phosphates, and combinations thereof.

[0102] Preferred solvents are water, alcohols, ethers, or ketones having a boiling point of up to 150°C; however, any solvent capable of dissolving at least 0.1 wt.% of an acid or base and not adversely reacting with the PEKK polymer may be used. Preferably, the solvent is water, methanol, ethanol, propanol, or isopropanol. More preferably, the solvent is water, methanol, or ethanol. In some embodiments, more than one solvent may be used.

[0103] PEKK polymers can be prepared more specifically according to Examples 1-3, especially according to the formulation disclosed in Example 3, with the T / I ratio varying by changing the amount of monomer (see Tables 1 and 2).

[0104] The preparation methods disclosed herein, generally or according to the specific embodiments disclosed, enable the acquisition of a particular PEKK polymer having one or more of the following properties:

[0105] - PEKK polymers typically contain fluorine in amounts exceeding 100 ppm, preferably exceeding 200 ppm, and even more preferably exceeding 300 ppm. The fluorine bonded to such polymers is an unavoidable distinguishing characteristic of the use of fluorinated monomers;

[0106] - PEKK polymers are essentially aluminum-free. The amount of Al in PEKK polymers is typically less than 50 ppm, preferably less than 25 ppm, and more preferably less than 10 ppm;

[0107] - The PEKK polymer has a Td (1%) of at least 500°C, preferably at least 505°C, more preferably at least 510°C, as measured by thermogravimetric analysis under nitrogen at a heating rate of 10°C / min from 30°C to 800°C according to ASTM D3850.

[0108] The contents of Al and F can be conveniently determined by elemental analysis, such as ICP-OES analysis of Al and combustion-ion chromatography of fluorine.

[0109] nucleating agent

[0110] According to the present invention, the membrane further comprises at least one nucleating agent. The nucleating agent may be selected from the group consisting of: boron-containing compounds (e.g., boron nitride, sodium tetraborate, potassium tetraborate, calcium tetraborate, etc.), alkaline earth metal carbonates (e.g., calcium magnesium carbonate), oxides (e.g., titanium oxide, aluminum oxide, magnesium oxide, zinc oxide, antimony trioxide, etc.), silicates (e.g., talc, sodium aluminum silicate, calcium silicate, magnesium silicate, etc.), salts of alkaline earth metals (e.g., calcium carbonate, calcium sulfate, etc.), nitrides, etc. The nucleating agent may also be carbon-based. Nucleating agents in this category include graphite, graphene, graphite nanosheets, and graphene oxide. It may also be carbon black and other forms of carbon.

[0111] When the nucleating agent is boron nitride, particularly good results have been obtained.

[0112] The proportion of nucleating agent is typically less than 2.0 wt.%, or even less than 1.5 wt.%, relative to the weight of the PEKK polymer. This proportion is typically greater than 0.1 wt.%, or even greater than 0.5 wt.%. This proportion is typically between 0.5 wt.% and 2.0 wt.%, or between 0.5 wt.% and 1.5 wt.%.

[0113] Other additives

[0114] In some embodiments, the membrane comprises at least one additive as an additional component besides the PEKK polymer and the nucleating agent. Suitable additives include, but are not limited to: (i) colorants, such as dyes; (ii) pigments, such as titanium dioxide, zinc sulfide, and zinc oxide; (iii) light stabilizers, such as UV stabilizers; (iv) heat stabilizers; (v) antioxidants, such as organophosphites and phosphonites; (vi) acid scavengers; (vii) processing aids; (ix) internal and / or external lubricants; (x) flame retardants; (xi) smoke suppressants; (x) antistatic agents; (xi) anti-caking agents; (xii) conductive additives, such as carbon black and carbon nanofibers; (xiii) plasticizers; (xiv) flow modifiers; (xv) fillers; (xvi) metal deactivators; and (xvii) flow aids, such as silica. The film may contain at least one additive, two, three or more additives of the same or different categories as those listed above, such as a heat stabilizer and a pigment.

[0115] According to these embodiments, the amount of such additive is less than 20 wt.%, preferably less than 10 wt.%, more preferably less than 5 wt.%, and even more preferably less than 2 wt.%, most preferably less than 1 wt.%, based on the total weight of the film.

[0116] In another embodiment, the membrane contains no filler or contains less than 0.5 wt.%, preferably less than 0.1 wt.% of any filler.

[0117] In another embodiment, the membrane contains no filler but includes "reinforcing fibers" as described below, such as loose fabric, nonwoven fabric, or lightweight fabric. The term "reinforcing fibers" can include one or more fibrous materials suitable for reinforcing the composite structure, i.e., "reinforcing fibers". As used herein, the term "fiber" refers to organic and / or inorganic fibers having a length of at least 0.5 mm.

[0118] As described herein, the membrane comprises a polymer component and at least one nucleating agent, the polymer component being at least one PEKK polymer. As used herein, the term "polymer component" means a compound having repeating units and a molecular weight of at least 2,000 g / mol.

[0119] In some embodiments, the PEKK polymer, as detailed above, is the only polymer component in the membrane.

[0120] In some other embodiments, the polymer component of the membrane comprises a blend of more than one polymer (e.g., several PEKK polymers) or a blend of different polymers.

[0121] For example, the polymer component of the membrane may consist of a blend of PEKK and an additional different polymer, wherein at least 60 wt.% of the polymer component consists of PEKK as described above, and less than 40 wt.% consists of at least one polymer different from the PEKK polymer described above. As another example, the polymer component of the membrane consists of at least 70 wt.% of the PEKK described above and less than 30 wt.% of at least one polymer different from the PEKK polymer described above. As yet another example, the polymer component of the membrane consists of at least 80 wt.% of the PEKK described above and less than 20 wt.% of at least one polymer different from the PEKK polymer described above. As yet another example, the polymer component of the membrane consists of at least 90 wt.% of the PEKK described above and less than 10 wt.% of at least one polymer different from the PEKK polymer described above.

[0122] In some embodiments, the polymer component of the membrane comprises less than 3 wt.%, less than 2 wt.%, less than 1 wt.%, or less than 0.5 wt.%, of a polymer different from the PEKK polymer described above.

[0123] These different polymers can be selected from the group consisting of poly(aryl ether sulfone) (PAES) polymers and poly(aryl ether ketone) (PAEK) polymers. When the additional polymer component is a PAES polymer, it can be selected from the group consisting of polysulfone (PSU), polyphenylsulfone (PPSU), and poly(ether sulfone) (PES). When the additional polymer component is a PAEK polymer, it can be advantageously selected from the group consisting of poly(ether ether ketone) (PEEK) polymers, poly(ether ketone ketone) (PEKK) polymers, poly(ether ketone) (PEK), poly(ether ketone ether ketone ketone) (PEKEKK), and PEEK-PEDEK copolymers. The additional polymer component can also be a polyimide, such as polyetherimide (PEI) or poly(amide imide) (PAI).

[0124] In some embodiments, the membrane comprises at least 90 wt.% of a PEKK polymer and at least one additive. Most preferably, the membrane comprises at least 95 wt.%, preferably at least 98 wt.%, of a PEKK polymer and at least one additive based on the total weight of the membrane.

[0125] Loose fabrics, nonwovens and lightweight reinforcements

[0126] The membrane of this component may additionally contain loose fabric and / or nonwoven reinforcement and / or lightweight fabric, which help regulate melt flow and / or provide a uniform surface for bonding, and may also affect the local morphology in the bonding line.

[0127] The membranes described herein may advantageously include sparse fabrics or sparse fabric layers. Sparse fabrics may be made of natural fabrics, synthetic fabrics, non-woven fabrics, knitted fabrics (including but not limited to weft-knitted fabrics) or plastics.

[0128] The membranes described herein may also advantageously include nonwovens, also known as nonwoven fabrics or fiber webs.

[0129] Such loosely woven, nonwoven, or lightweight fabrics are advantageous because they help maintain a uniform thickness of the bonding line.

[0130] Membrane preparation process

[0131] The membrane described herein may have a thickness ranging from 15 μm to 800 μm, 25 μm to 600 μm, preferably 30 μm to 500 μm, more preferably 40 μm to 300 μm, and most preferably 50 μm to 250 μm.

[0132] The membrane described can be prepared by any conventional method known in the field of polymer processing. For example, the components of the membrane can be processed in membrane form by casting extrusion, optionally with uniaxial or biaxial orientation.

[0133] In some embodiments, the method of manufacturing the film includes melt-blending a physical mixture of the film components. Conventional melt-blending equipment can be used, such as co-rotating and counter-rotating extruders, single-screw extruders, co-kneaders, disc extruders, and a variety of other types of extrusion equipment. Preferably, an extruder, more preferably a twin-screw extruder, can be used.

[0134] According to an embodiment, the components of the membrane are contacted in a solvent of PEKK (such as DPS), and the mixture is stirred at a temperature at which the polymer is completely or partially dissolved in the solvent. The solvent is then extracted, for example, using the method already disclosed above. Example 4 illustrates this embodiment.

[0135] According to an embodiment, a physical mixture containing membrane components is compounded in an extruder and then cut into granules or pellets. The granules or pellets can then be further processed to manufacture the membrane.

[0136] Alternatively, the physical mixture is compounded in an extruder and then directly formed into a film.

[0137] A particularly suitable technique for manufacturing this film involves extruding a molten composition through a die with an elongated shape to obtain an extruded strip and casting / calendering the extruded strip to obtain a film. The strip can be calendered into a film by passing it through suitable rollers, which can be maintained at an appropriate temperature and whose speed can be adjusted to obtain the desired thickness. The thickness of the film is adjusted at the die orifice. Depending on the cooling temperature used to cure the film, the film can be amorphous or semi-crystalline in finished (extruded) form.

[0138] In an advantageous embodiment, the membrane is a single-layer membrane, i.e., it consists of only one layer containing a PEKK copolymer.

[0139] When the membrane comprises loosely woven fabric, nonwoven material, or lightweight fabric, these reinforcing layers or fabric reinforcements can be applied using various methods, such as the APC process, slurry impregnation process, or membrane lamination with PEKK polymer impregnation. For example, the process may include:

[0140] - The fabric is impregnated in a liquid medium comprising a PEKK component in the form of polymer powder particles, at least one aqueous solvent, and at least one surfactant.

[0141] -Heat the impregnated fabric to a temperature higher than the melting point of PEKK, and

[0142] - To shape the fabric, for example, by using a mold of at least one specific geometry.

[0143] Polymers (P1) and (P2)

[0144] As used herein, the expression "first component comprising polymer (P1)" refers to a component comprising polymer (P1) having at least one surface (particularly the surface in contact with the adhesive film). The first component may consist of said polymer (P1). Alternatively, the first component includes a surface comprising polymer (P1). The surface comprising polymer (P1) typically has a thickness suitable for forming an adhesion with the adhesive film. The thickness may suitably be equal to or greater than 5 μm.

[0145] As used herein, the expression "second component comprising polymer (P2)" refers to a component comprising polymer (P2) having at least one surface (particularly the surface in contact with the adhesive film). The second component may be composed of said polymer (P2). Alternatively, the second component includes a surface comprising polymer (P2). The surface comprising polymer (P2) typically has a thickness suitable for forming an adhesion with the adhesive film. The thickness may suitably be equal to or greater than 5 μm.

[0146] Polymer (P1) and polymer (P2) can be the same or different.

[0147] Polymer (P1) and polymer (P2) may be independently selected from the group consisting of crystalline and / or high-temperature thermoplastic polymers. Non-limiting examples include, but are not limited to, poly(aryl ether ketone) (PAEK), poly(ether imide) (PEI), poly(amide imide) (PAI), poly(aryl ether sulfone) (PAES), poly(aryl sulfone) (PAS), poly(phthalamide) (PPA), polyamide (PA), polycarbonate (PC), liquid crystal polymer (LCP), poly(aromatic ester) (PAE), and blends thereof.

[0148] In a preferred embodiment, polymers (P1) and (P2) are independently selected from the group consisting of PAEK and blends of PAEK. PAEK can be, for example, selected from the group consisting of: poly(ether ether ketone) (PEEK) polymers, PEEK copolymers, poly(ether ketone ketone) (PEKK) polymers, poly(ether ketone) (PEK), and poly(ether ketone ether ketone ketone) (PEKEKK). PEEK copolymers can be, for example, PEEK-PEDEK copolymers.

[0149] Poly(aryl ether ketone) (PAEK)

[0150] As used herein, poly(aryl ether ketone) (PAEK) signifies the presence of repeating units (R... PAEK Any polymer containing Ar'-C(=O)-Ar* groups, where Ar' and Ar* are the same or different from each other, and are aromatic groups, mol.% is based on the total number of moles of repeating units in the polymer. Repeating unit (R PAEK Select a group consisting of units having the following formulas (JA) to (JD):

[0151]

[0152] in

[0153] R', at each position, is independently selected from the group consisting of: halogens, alkyl, alkenyl, alkynyl, aryl, ethers, thioethers, carboxylic acids, esters, amides, imides, alkali metal or alkaline earth metal sulfonates, alkyl sulfonates, alkali metal or alkaline earth metal phosphonates, alkyl phosphonates, amines, and quaternary ammonium compounds; and

[0154] j' is independently zero or an integer ranging from 1 to 4.

[0155] In the repeating unit (R) PAEK In ), the corresponding phenylene moiety can independently possess the properties associated with the repeating unit (R). PAEK The R' in the phenyl group is 1,2-linked, 1,4-linked, or 1,3-linked to other parts. Preferably, the phenyl group has 1,3-linked or 1,4-linked bonds, more preferably they have 1,4-linked bonds.

[0156] In the repeating unit (R) PAEK In ), j' is preferably zero at each position, such that the phenylene moiety has no other substituents besides those that connect to the main chain of the polymer.

[0157] According to the examples, PAEK is poly(ether ether ketone) (PEEK).

[0158] As used herein, poly(etheretherketone) (PEEK) signifies containing repeating units (R) having the formula (JA). PEEK (Any polymer based on the total number of repeating units in the polymer):

[0159]

[0160] in

[0161] R', at each position, is independently selected from the group consisting of: halogens, alkyl, alkenyl, alkynyl, aryl, ethers, thioethers, carboxylic acids, esters, amides, imides, alkali metal or alkaline earth metal sulfonates, alkyl sulfonates, alkali metal or alkaline earth metal phosphonates, alkyl phosphonates, amines, and quaternary ammonium compounds; and

[0162] For each R', j' is independently zero or an integer ranging from 1 to 4 (e.g., 1, 2, 3, or 4).

[0163] According to formula (JA), the repeating unit (R) PEEK Each aromatic ring of the compound can contain 1 to 4 groups R'. When j' is 0, the corresponding aromatic ring does not contain any groups R'.

[0164] Repeating unit (R) PEEK Each phenylene moiety can independently have 1,2-, 1,3-, or 1,4-bonds to other phenylene moietyes. According to an embodiment, the repeating unit (R...) PEEK Each phenylene moiety of the repeating unit (R) independently has 1,3- or 1,4-bonded to other phenylene moietyes. According to yet another embodiment, the repeating unit (R) PEEK Each phenylene moiety has a 1,4-bond to the other phenylene moiety.

[0165] According to the embodiments, R', at each position in the above formula (JA), is independently selected from the group consisting of: C1-C12 moieties optionally containing one or more heteroatoms; sulfonic acid and sulfonate / ester groups; phosphonic acid and phosphonate / ester groups; amine and quaternary ammonium groups.

[0166] According to an embodiment, for each R', j' is zero. In other words, according to this embodiment, the repeating unit (R) PEEK) is based on formula (J'-A):

[0167]

[0168] According to another embodiment of this disclosure, poly(ether ether ketone) (PEEK) refers to any polymer containing at least 10 mol.% repeating units, which are repeating units having the formula (JA”) (R) PEEK ):

[0169]

[0170] mol.% is based on the total number of moles of repeating units in the polymer.

[0171] According to the embodiments disclosed herein, at least 10 mol.% (based on the total number of moles of repeating units in the polymer), at least 20 mol.%, at least 30 mol.%, at least 40 mol.%, at least 50 mol.%, at least 60 mol.%, at least 70 mol.%, at least 80 mol.%, at least 90 mol.%, at least 95 mol.%, at least 99 mol.%, or all of the repeating units in PEEK are repeating units (R) having the formula (JA), (J'-A), and / or (J”-A). PEEK ).

[0172] Therefore, PEEK polymers can be homopolymers or copolymers. If a PEEK polymer is a copolymer, it can be a random copolymer, an alternating copolymer, or a block copolymer.

[0173] When PEEK is a copolymer, it can be composed of repeating units (R... PEEK Different and other repeating units (R*) PEEK ) is made, such as repeating units with formula (JD):

[0174]

[0175] in

[0176] R', at each position, is independently selected from the group consisting of: halogens, alkyl, alkenyl, alkynyl, aryl, ethers, thioethers, carboxylic acids, esters, amides, imides, alkali metal or alkaline earth metal sulfonates, alkyl sulfonates, alkali metal or alkaline earth metal phosphonates, alkyl phosphonates, amines, and quaternary ammonium compounds; and

[0177] For each R', j' is independently zero or an integer ranging from 1 to 4.

[0178] According to formula (JD), the repeating unit (R*) PEEKEach aromatic ring of the compound can contain 1 to 4 groups R'. When j' is 0, the corresponding aromatic ring does not contain any groups R'.

[0179] According to the embodiments, R', at each position in the above formula (JD), is independently selected from the group consisting of: C1-C12 moieties optionally containing one or more heteroatoms; sulfonic acid and sulfonate / ester groups; phosphonic acid and phosphonate / ester groups; amine and quaternary ammonium groups.

[0180] According to an embodiment, for each R', j' is zero. In other words, according to this embodiment, the repeating unit (R*) PEEK ) is based on formula (J'-D):

[0181]

[0182] According to another embodiment of this disclosure, the repeating unit (R*) PEEK ) is based on formula (J”-D):

[0183]

[0184] According to the embodiments disclosed herein, in PEEK, less than 90 mol.% (based on the total number of moles of repeating units in the polymer), less than 80 mol.%, less than 70 mol.%, less than 60 mol.%, less than 50 mol.%, less than 40 mol.%, less than 30 mol.%, less than 20 mol.%, less than 10 mol.%, less than 5 mol.%, less than 1 mol.%, or all repeating units are repeating units (R*) having the formula (JD), (J'-D), and / or (J”-D). PEEK ).

[0185] According to the examples, the PEEK polymer is a PEEK-PEDEK copolymer. As used herein, a PEEK-PEDEK copolymer refers to a copolymer comprising repeating units (R) having the formula (JA), (J'-A), and / or (J”-A). PEEK ) and repeating units (R*) with the formula (JD), (J'-D) or (J”-D). PEEK (This is also referred to here as a repeating unit (R)) PEDEK The PEEK-PEDEK copolymer may contain a relative molar ratio (Ri) of repeating units ranging from 95 / 5 to 5 / 95, 90 / 10 to 10 / 90, or 85 / 15 to 15 / 85. PEEK / R PEDEK Repeating unit (R) PEEK ) and (R PEDEKThe sum of these repeating units can, for example, account for at least 60 mol.%, 70 mol.%, 80 mol.%, 90 mol.%, 95 mol.%, or 99 mol.% of the repeating units in the PEEK copolymer. PEEK ) and (R PEDEK The sum of these can also account for 100 mol.% of the repeating units in the PEEK copolymer.

[0186] PEEK is sourced from Solvay Specialty Polymers USA, LLC. PEEK is commercially available.

[0187] According to one embodiment of this disclosure, the PEEK polymer has a weight-average molecular weight (Mw) in the range of 55,000 g / mol to 105,000 g / mol, for example 65,000 g / mol to 85,000 g / mol (as determined by gel permeation chromatography (GPC) using phenol and trichlorobenzene (1:1) with a polystyrene standard at 160°C).

[0188] In another embodiment, PAEK is poly(ether ketone ketone) (PEKK). The PEKK described in conjunction with polymers (P1) and (P2) may be different from the PEKK of the film used to prepare the two components of the adhesive assembly. It is worth noting that this PEKK polymer may have different T / I ratios. Polymers (P1) and (P2) themselves may be the same or different PEKKs, for example, PEKKs with different T / I ratios.

[0189] More precisely, the poly(ether ketone ketone) (PEKK) polymer that can be used as the first and second components of this assembly actually represents a polymer containing more than 50 mol.% of repeating units having formulas (J-B1) and (J-B2), where mol.% is based on the total number of moles of repeating units in the polymer:

[0190]

[0191] in

[0192] R 1 and R 2 In each case, the following groups are independently selected: alkyl, alkenyl, alkynyl, aryl, ether, thioether, carboxylic acid, ester, amide, imide, alkali metal or alkaline earth metal sulfonates, alkyl sulfonates, alkali metal or alkaline earth metal phosphonates, alkyl phosphonates, amines, and quaternary ammonium compounds; and

[0193] i and j are independently chosen integers ranging from 0 to 4 in each case.

[0194] According to an embodiment, R 1 and R 2 At each position in the above formulas (J-B2) and (J-B1), the following groups are independently selected: C1-C12 portions optionally containing one or more heteroatoms; sulfonic acid and sulfonate / ester groups; phosphonic acid and phosphonate / ester groups; amine and quaternary ammonium groups.

[0195] According to another embodiment, for each R 1 and R 2 In this embodiment, groups i and j are zero. The PEKK polymer contains at least 50 mol.% of repeating units having formulas (J'-B1) and (J'-B2), where mol.% is based on the total number of moles of repeating units in the polymer.

[0196]

[0197]

[0198] According to the embodiments disclosed herein, at least 55 mol.%, at least 60 mol.%, at least 70 mol.%, at least 80 mol.%, at least 90 mol.%, at least 95 mol.%, at least 99 mol.%, or all of the repeating units in PEKK are repeating units having formulas (J-B1) and (J-B2).

[0199] In some embodiments, polymers (P1) and (P2) are independently selected from PEKK polymers as defined above, wherein the molar ratio (also known as the T / I ratio) of repeating unit (J-B1) / (J'-B1) to repeating unit (J-B2) / (J'-B2) ranges from 55 / 45 to 85 / 15, preferably from 57 / 43 to 80 / 20, and more preferably from 58 / 42 to 75 / 25.

[0200] It is known that PEKK polymers are characterized by the T / I ratio, which is the molar ratio of terephthaloyl (T) moieties to isophthaloyl (I) moieties present in the polymer.

[0201] In other embodiments, polymers (P1) and (P2) may be independently selected from compositions comprising first and second PEKK polymers, each PEKK polymer characterized by a T / I ratio, wherein the T / I ratio of the first PEKK polymer differs from that of the second PEKK polymer, particularly those compositions having a melt temperature less than or equal to 330°C. In one aspect of this embodiment, the first PEKK polymer preferably has a T / I ratio of a) at least 50 / 50, preferably at least 54 / 46, more preferably at least 56 / 44, most preferably at least 57 / 43 and / or b) at most 64 / 36, preferably at most 63 / 37, more preferably at most 62 / 38. The second PEKK polymer preferably has a T / I ratio of a) at least 65 / 35, preferably at least 66 / 34, more preferably at least 67 / 33 and / or b) at most 85 / 15, preferably at most 83 / 17, more preferably at most 82 / 18.

[0202] PEKK, especially from Solvay Specialty Polymers LLC in the United States, is a prime example. PEKK, or as FC and DS is available for commercial purchase.

[0203] In one embodiment, polymers (P1) and / or (P2) are nucleophilic PEKK, meaning that PEKK is generated by polycondensation of monomers in the absence of Lewis acids, wherein the monomers are aromatic compounds containing dihydroxy and difluorobenzoyl groups and / or aromatic compounds containing hydroxy-fluorobenzoyl groups.

[0204] In an alternative embodiment, the polymer PEKK is nucleophilic PEKK.

[0205] In another embodiment, PAEK is poly(ether ketone) (PEK). As used herein, the terms "poly(ether ketone)" and "polymer (PEK)" indicate a repeating unit (R) of greater than 50 mol.%. PEK ) is any polymer having repeating units of the formula (K'-C):

[0206]

[0207] mol.% is based on the total number of moles of repeating units in the PEK.

[0208] According to this embodiment, the PEK polymer can be at least 60 mol.%, at least 70 mol.%, at least 80 mol.%, at least 1 mol.%, at least 95 mol.%, at least 99 mol.%, or even substantially all repeating units (R). PEK(K'-C) is a repeating unit. Preferred PEK polymers are those in which substantially all repeating units are units having the formula (K'-C), and it should be understood that end groups, defects, and small amounts of impurities may be present.

[0209] In some embodiments, the polymer (PAEK) is poly(ether diphenyl ether ketone) (PEDEK). As used herein, the terms "poly(ether diphenyl ether ketone)" or "polymer (PEDEK)" indicate a repeating unit (R) of greater than 50 mol.%. K (K'-D) is any polymer having repeating units of the formula (K'-D).

[0210]

[0211] mol.% is based on the total number of moles of repeating units in this PEDEK.

[0212] According to these embodiments, at least 60 mol.%, at least 70 mol.%, at least 80 mol.%, at least mol.%, at least 95 mol.%, at least 99 mol.%, or even substantially all repeating units (R K The repeating unit (K'-D) is as detailed above. Preferred PEDEK polymers are those in which substantially all repeating units are units having the formula (K'-D), and it should be understood that end groups, defects, and small amounts of impurities may be present.

[0213] In some embodiments, the first component of the assembly may include a polymer (P1) and a filler. The filler may include fibrous fillers or non-fibrous fillers. The filler may include both fibrous fillers and non-fibrous fillers.

[0214] Alternatively, the second component of the assembly may comprise a polymer (P2) and a filler. The filler may include fibrous fillers or non-fibrous fillers. Alternatively, the filler may include both fibrous and non-fibrous fillers.

[0215] According to a preferred embodiment, both the first and second components of the assembly contain at least one filler, which may be the same or different. According to this embodiment, the membrane located between the first and second components may itself contain filler, which may be the same as or different from the filler used in the first or second component of the assembly. Alternatively, the membrane located between the first and second components preferably does not contain filler (or contains filler in an amount less than 1 wt.%, less than 0.5 wt.%, or even less than 0.1 wt.% of the total weight of the membrane).

[0216] Suitable fiber fillers include, for example, carbon fibers, graphite fibers, glass fibers such as E-glass fibers, ceramic fibers such as silicon carbide fibers, synthetic polymer fibers such as aramid fibers, polyimide fibers, high-modulus polyethylene (PE) fibers, polyester fibers, and polybenzoxazole fibers such as poly(p-phenylene-benzobisoxazole) (PBO) fibers, aramid fibers, boron fibers, basalt fibers, quartz fibers, alumina fibers, zirconia fibers, and mixtures thereof. The fibers can be continuous or discontinuous, and can be aligned or randomly oriented.

[0217] In some embodiments, the fiber comprises at least one carbon fiber. As used herein, the term "carbon fiber" is intended to include graphitized, partially graphitized, and ungraphitized carbon-reinforced fibers, and mixtures thereof. Carbon fibers can be obtained by heat treatment and pyrolysis of various polymer precursors, such as synthetic fibers, polyacrylonitrile (PAN), aromatic polyamides, or phenolic resins; carbon fibers can also be obtained from pitch materials. The term "graphite fiber" is intended to refer to carbon fibers obtained by high-temperature pyrolysis (above 2000°C) of carbon fibers, wherein the carbon atoms are arranged in a manner similar to that of graphite. Carbon fibers are preferably selected from the group consisting of PAN-based carbon fibers, pitch-based carbon fibers, graphite fibers, and mixtures thereof.

[0218] In some embodiments, the fiber comprises at least one glass fiber. The glass fiber may have a circular or non-circular cross-section (such as an elliptical or rectangular cross-section). When the glass fiber used has a circular cross-section, it preferably has an average glass fiber diameter of 3 to 30 μm, particularly preferably 5 to 12 μm. Depending on the type of glass from which they are made, different types of glass fibers with circular cross-sections are commercially available. Glass fibers made of E- or S-glass are particularly exemplified. In some embodiments, the glass fiber is a standard E-glass material with a non-circular cross-section. In some embodiments, the first and second components of the assembly comprise S-glass fibers with a circular cross-section.

[0219] In embodiments, the first and second components of the components of the present invention comprise continuous fibers. As referred to herein, "continuous fibers" means fibers having a length greater than or equal to 3 mm, more typically greater than or equal to 10 mm, and an aspect ratio greater than or equal to 500, more typically greater than or equal to 5000.

[0220] In embodiments of the invention, the first component is a composite material (also known as a laminated material) comprising one or more layers, such as a polymer (P1) and fibers. The polymer (P1) may, for example, be impregnated, coated, or laminated onto the fibers.

[0221] In another embodiment of the invention, the second component is a composite material (also known as a laminate) comprising one or more layers, such as fibers and a polymer (P2). The polymer (P2) may, for example, be impregnated, coated, or laminated onto the fibers.

[0222] A second object of the present invention is a method for manufacturing an assembly using the membrane described above. The method includes the following steps:

[0223] a) The membrane is disposed between a first component containing polymer (P1) and a second component containing polymer (P2); and

[0224] b) subject the membrane to a temperature (T) m x ),in:

[0225] T m x ≥T m (1), or

[0226] T m x >T m (2), or

[0227] T m x >T m +5 (3), or

[0228] T m x >T m +10 (4),

[0229] Where T m It is the melting temperature (°C) of the film.

[0230] In other words, temperature (T) m x The temperature (T) is the suitable processing temperature for melting the film. m x The temperature of the film is equal to, and preferably higher than, its melting temperature (T). m ).

[0231] Temperature (T) m x Temperature (T) can be below 330°C, preferably below 320°C, and more preferably below 310°C. m x Temperatures can exceed 270°C, for example, above 275°C. (T) m x It can be in the range of 274°C to 328°C, for example, in the range of 278°C to 315°C.

[0232] According to some embodiments, temperature (T) m x ) lower than the melting temperature (T) of the polymer (P1) m1 ) and / or below the melting temperature (T) of the polymer (P2). m2 ):

[0233] T m x <T m1 (5), and / or

[0234] T m x <T m2 (6).

[0235] Where T m1 and T m2 These are the melting temperatures of polymer (P1) and polymer (P2), respectively.

[0236] Advantageously, temperature (T) m x ) lower than the melting temperature (T) of the polymer (P1) m1 The melting temperature (T) of the polymer (P2) and the polymer (P2) m2 Both.

[0237] According to some embodiments:

[0238] T m x <T m1 -5 (7),

[0239] T m x <T m2 -5 (8),

[0240] T m x <T m1 -10(9), and / or

[0241] T m x <T m2 -10 (10).

[0242] In some preferred embodiments, when the membrane of the component, as well as the first and second components, are subjected to a temperature (T... m x The method further includes applying pressure to the component to solidify it. In other words, the method preferably further includes subjecting the membrane to a temperature (T) in step b). m x Pressure is applied to both the first and second components simultaneously.

[0243] The method of the present invention preferably further includes step c), which comprises controlled cooling of the component. This additional step is advantageous in order to establish crystallinity in the membrane. The membrane in the component preferably exhibits at least 3%, preferably at least 5%, more preferably at least 15%, and particularly at least 20% crystallinity after cooling, the crystallinity being measured as described in the examples below.

[0244] A third aspect of the invention relates to the use of the components described herein in the manufacture of parts or articles intended for various end applications. Applications in the aerospace and automotive industries may be mentioned. For example, parts and articles comprising or composed of components of the invention may include, but are not limited to, brackets, clips, stiffeners, and other similar types of parts.

[0245] The present invention will be described in more detail below by way of non-limiting examples.

[0246] If any patent, patent application, or publication incorporated herein by reference conflicts with the description of this application to the extent that it may lead to ambiguity in terminology, this description shall prevail.

[0247] Example

[0248] Raw materials used

[0249] 1,2-Dichlorobenzene, terephthaloyl chloride, isophthaloyl chloride, 3,5-dichlorobenzoyl chloride, aluminum chloride (AlCl3), and methanol were purchased from Sigma Aldrich.

[0250] 1,4-Bis(4-phenoxybenzoyl)benzene is prepared according to IN patent 193687 (filed on 21 June 1999 and incorporated herein by reference).

[0251] Diphenyl sulfone (polymer grade) was purchased from Proviron (99.8% pure).

[0252] Sodium carbonate, light soda ash, was purchased from Solvay SA, France and dried before use. Its particle size is such that its d... 90 It is 130μm.

[0253] Having d 90 Potassium carbonate with a particle size of <45μm was sourced from Armand Products and dried before use.

[0254] The lithium chloride (anhydrous powder) was purchased from Acros.

[0255] NaH2PO4·2H2O and Na2HPO4 were purchased from Sigma-Aldrich.

[0256] 1,4-bis(4'-fluorobenzoyl)benzene (1,4-DFDK) and 1,3-bis(4'-fluorobenzoyl)benzene (1,3-DFDK) were prepared by Friedel-Crafts acylation of fluorobenzene according to Example 1 in U.S. Patent No. 5,300,693 (filed November 25, 1992 and incorporated herein by reference in its entirety). A fraction of 1,4-DFDK was purified by recrystallization in chlorobenzene as described in U.S. Patent No. 5,300,693, and another fraction was purified by recrystallization in DMSO / ethanol. 1,4-DFDK purified by recrystallization in DMSO / ethanol was used as 1,4-DFDK in the polymerization reaction to produce PEKK as described below, while 1,4-DFDK recrystallized in chlorobenzene was used as a precursor of 1,4-bis(4'-hydroxybenzoyl)benzene (1,4-BHBB).

[0257] 1,4-BHBB and 1,3-bis(4'-hydroxybenzoyl)benzene (1,3-BHBB) were produced by hydrolyzing 1,4-DFDK and 1,3-DFDK, respectively, following the procedure described in Example 1 of U.S. Patent No. 5,250,738 to Hackenbruch et al. (filed February 24, 1992, and incorporated herein by reference in its entirety). They were purified by recrystallization in DMF / ethanol.

[0258] Boron nitride: S1-SF, a hexagonal boron nitride grade commercially available from 3M.

[0259] Glass transition temperature (Tg), melting temperature (T) m Crystallization temperature (Tc) and heat of fusion (ΔH) f The determination of )

[0260] Glass transition temperature (Tg), melting temperature (T) m Crystallization temperature (Tc) and heat of fusion (ΔH) f The heating and cooling rates were determined according to ASTM D3418 using a differential scanning calorimeter (DSC) at a rate of 10 °C / min.

[0261] T g (Midpoint, using the half-height method), heat of fusion ΔH f and T m The peak temperature (of melting endothermic peak) was determined during the second heating scan. c The peak temperature of the exothermic crystallization curve was determined during the first cooling scan.

[0262] The melting point of the composition is considered as the area above a linear baseline drawn from 220°C to temperatures above the last endothermic temperature. When evaluating the crystallinity of the film in an adhesive structure (part), the heat of melting is determined during the first heating scan.

[0263] The procedure details are as follows: A TA instrument DSC Q20 was used, with nitrogen as the carrier gas (99.998% purity, 50 mL / min). Temperature and heat flow rate calibration were performed using indium. Sample volumes ranged from 5 to 7 mg. Weights were recorded to ±0.01 mg. Heating cycles were:

[0264] - First heating cycle: 10.00℃ / min, from 30.00℃ to 400.00℃, isothermal at 400.00℃ for 1 min;

[0265] - First cooling cycle: 10.00℃ / min, from 400.00℃ to 30.00℃, isothermal for 1 min;

[0266] - Second heating cycle: 10.00℃ / min, from 30.00℃ to 400.00℃, isothermal at 400.00℃ for 1 min.

[0267] Determination of Melt Flow Index

[0268] The melt flow index was determined according to ASTM D1238 at the indicated temperature (340°C to 380°C, depending on the melting point of the material) using a weight of 3.8 kg. The final MFI for a weight of 8.4 kg was obtained by multiplying the resulting value by 2.35.

[0269] Synthesis Example

[0270] PEKK#1, where T / I = 71 / 29

[0271] In a 500 mL 4-necked reaction flask equipped with a stirrer, an N2 inlet tube, a Claisen adapter with a thermocouple inserted into the reaction medium, and a Dean-Stark trap with a condenser and dry ice trap, 112.50 g of diphenyl sulfone (DPS), 23.054 g of 1,3-BHBB, 16.695 g of 1,4-BHBB, and 41.292 g of 1,4-DFDK were introduced. The contents of the flask were evacuated under vacuum and then filled with high-purity nitrogen (containing less than 10 ppm of O2). The reaction mixture was then placed under constant nitrogen purging (60 mL / min). The reaction mixture was slowly heated to 270 °C. At 270 °C, 13.725 g of Na2CO3 and 0.078 g of K2CO3 were added to the reaction mixture over 60 minutes via a powder dispenser. At the end of the addition, the reaction mixture was heated to 310°C at 1°C / min. After 2 minutes at 310°C, 1.107 g of 1,4-DFDK was added to the reaction mixture while the reactor was purged with nitrogen. After 5 minutes, 0.741 g of lithium chloride was added to the reaction mixture. After 10 minutes, an additional 0.402 g of 1,4-DFDK was added to the reactor and the reaction mixture was maintained at the temperature for 15 minutes. An additional 15 g of diphenyl sulfone was added to the reaction mixture and it was maintained with stirring for 15 minutes.

[0272] The reactor contents were then poured into a stainless steel pan and cooled. The solids were crushed and ground in a grinder (through a 2 mm sieve). Diphenyl sulfones and the salts were extracted from the mixture using acetone and water at a pH between 1 and 12. 0.67 g of NaH₂PO₄·2H₂O and 0.62 g of Na₂HPO₄ were dissolved in 1200 mL of DI water for final washing. The powder was then removed from the reactor and dried under vacuum at 120 °C for 12 hours, yielding 72 g of yellow powder.

[0273] PEKK#2 and PEKK#3: PEKK polymers with variable T / I and different melt viscosities (MV)

[0274] Follow the same procedure as in Example 1, using the amounts of reagents specified in Table 1 below.

[0275]

[0276]

[0277] Table 1

[0278]

[0279] Table 2

[0280] General procedure for solution blending of the PEKK composition in Example 4

[0281] In a 500 mL 4-necked reaction flask equipped with a stirrer, an N2 inlet tube, a Claisen adapter with a thermocouple inserted into the reaction medium, and a condenser, 235.00 g of diphenyl sulfone (DPS) and boron nitride as a nucleating agent (Table 3) were introduced. The contents of the flask were slowly heated to 330 °C. At 330 °C, 100 g of PEKK polymer powder #3 was slowly added to the molten DPS via a tubing. At the end of the addition, the stirring speed was increased to provide good mixing, and the mixture was maintained at 330 °C for another hour.

[0282] The reactor contents were then poured into a stainless steel pan and cooled. The solids were crushed and ground in a grinder (through a 2 mm sieve). Diphenyl sulfone was extracted from the mixture using acetone and water. 0.67 g of NaH₂PO₄·2H₂O and 0.62 g of Na₂HPO₄ were dissolved in 1200 mL of DI water for final washing. The powder was then removed from the reactor and dried under vacuum at 120 °C for 12 hours, yielding 90-95 g of yellow powder.

[0283] Example 1c 2c 3c 4 Boron nitride pph 0 0 0 1.2 PEKK#1 wt.% 100 PEKK#2 wt.% 100 PEKK#3 wt.% 100 100

[0284] Table 3

[0285] thermal properties

[0286]

[0287] As the data collected above show, the PEKK composition of Example 4 (according to the present invention) exhibits improved crystallinity and crystallinity compared to the PEKK compositions (without nucleating agents) of Examples 1-3.

[0288] The measured enthalpy of fusion ΔHf of the PEKK composition in Example 4 is higher than the minimum ΔHf calculated according to Equation 1 below, which means that the PEKK composition in Example 4 satisfies the following formula:

[0289] ΔH f >1.69xT m -480 (Formula 1)

[0290] in:

[0291] -Tm is the melting point in °C, and

[0292] -ΔH f Measured in J / g.

[0293] Therefore, the PEKK composition according to Example 4 of the present invention exhibits a set of properties:

[0294] Melting point T m ≤310℃;

[0295] ·Heat of fusion ΔH f >5J / g; and

[0296] ·ΔH f Satisfies Formula 1,

[0297] This makes it ideal for processing into membranes intended for use in laminated structures.

[0298] In terms of comparative examples:

[0299] PEEK#1 with a T / I ratio of 71 / 29 exhibits an excessively high Tm, exceeding 310℃, and does not satisfy Equation 1;

[0300] PEKK#2, with a T / I ratio of 58 / 42, does not satisfy Equation 1 because its measured heat of fusion ΔH f It equals the minimum heat of fusion ΔH calculated according to Formula 1. f ;and

[0301] PEKK#3 with a T / I ratio within the scope of this invention (50:50 to 56:44) is amorphous (without Tm) and therefore unsuitable for structural applications because it is susceptible to fluid erosion, which can lead to premature structural failure.

Claims

1. A component comprising: - First component, which comprises polymer P1 - The second component, which comprises polymer P2, and - A membrane located between and bonded to the first component and the second component. The membrane comprises or is made of the following: a) At least one poly(ether ketone ketone) polymer, The poly(ether ketone ketone) polymer contains at least 50 mol.% of repeating units having formulas (M) and (P), where mol.% is based on the total number of moles in the polymer: in - R 1 and R 2 In each case, the following groups are independently selected: alkyl, alkenyl, alkynyl, aryl, ether, thioether, carboxylic acid, ester, amide, imide, alkali metal sulfonate, alkaline earth metal sulfonate, alkyl sulfonate, alkali metal phosphonate, alkaline earth metal phosphonate, alkyl phosphonate, amine, and quaternary ammonium; and - i and j are independently chosen integers ranging from 0 to 4 in each case; The molar ratio of repeating unit (P) to repeating unit (M) is between 50:50 and 56:

44. (b) At least one nucleating agent, wherein the nucleating agent is selected from the group consisting of boron-containing compounds, oxides, silicates, alkaline earth metal salts, nitrides and carbon-based compounds.

2. The component according to claim 1, wherein, For each R 1 and R 2 Groups, i and j are 0.

3. The component according to claim 1, wherein, The alkaline earth metal salt is an alkaline earth metal carbonate.

4. The component according to any one of claims 1-3, wherein, The poly(ether ketone ketone) polymer contains at least 95 mol.% of repeating units having the formulas (M) and (P).

5. The component according to any one of claims 1-3, wherein, The poly(ether ketone ketone) polymer contains at least 99 mol.% of repeating units having the formulas (M) and (P).

6. The component according to any one of claims 1-3, wherein, The molar ratio of repeating unit (P) to repeating unit (M) is 51:49 to 55:

45.

7. The component according to any one of claims 1-3, wherein, The molar ratio of repeating unit (P) to repeating unit (M) is 54:46 to 53:

47.

8. The component according to any one of claims 1-3, wherein, This poly(ether ketone ketone) polymer exhibits a melt temperature Tm ranging from 270°C to 310°C as measured by DSC according to ASTM D3418.

9. The component according to any one of claims 1-3, wherein, This poly(ether ketone ketone) polymer exhibits a melt temperature Tm ranging from 280°C to 305°C as measured by DSC according to ASTM D3418.

10. The component according to any one of claims 1-3, wherein, The heat of fusion ΔH of the poly(ether ketone ketone) polymer f Satisfy the following formula: ΔH f > 1.69 x T m - 480 (Formula 1) in: - Tm is the melting temperature of poly(ether ketone ketone) in °C, and - ΔH f Measured in J / g.

11. The component according to any one of claims 1-3, wherein, This poly(ether ketone ketone) polymer exhibits the following set of properties: • Melting point T m ≤ 310°C; and • Heat of fusion ΔH f > 5 J / g; and •ΔH f > 1.69 x T m - 480 (Formula 1) in: •Tm is the melting temperature of poly(ether ketone ketone) in °C, and •ΔH f Measured in J / g.

12. The component according to any one of claims 1-3, wherein, The heat of fusion ΔH of the poly(ether ketone ketone) polymer f It is at least 5.0 J / g.

13. The component according to any one of claims 1-3, wherein, The poly(ether ketone ketone) polymer is manufactured in a solvent in the absence of Lewis acids or in the presence of Lewis acids in an amount of less than 2 wt.% based on the total weight of these monomers.

14. The component according to any one of claims 1-3, wherein, The poly(ether ketone ketone) polymer is manufactured in a solvent in the absence of Lewis acids or in the presence of Lewis acids in an amount of less than 1 wt.% based on the total weight of these monomers.

15. The component according to any one of claims 1-3, wherein, The poly(ether ketone ketone) polymer is manufactured in a solvent in the absence of Lewis acids or in the presence of Lewis acids in an amount of less than 0.5 wt.% based on the total weight of these monomers.

16. The component according to any one of claims 1-3, wherein, This poly(ether ketone ketone) polymer contains more than 100 ppm of polymer-bound fluorine.

17. The component according to any one of claims 1-3, wherein, This poly(ether ketone ketone) polymer contains more than 200 ppm of polymer-bound fluorine.

18. The component according to any one of claims 1-3, wherein, This poly(ether ketone ketone) polymer contains more than 300 ppm of polymer-bound fluorine.

19. The component according to any one of claims 1-3, wherein, The amount of Al in this poly(ether ketone ketone) polymer is less than 50 ppm.

20. The component according to any one of claims 1-3, wherein, The amount of Al in this poly(ether ketone ketone) polymer is less than 25 ppm.

21. The component according to any one of claims 1-3, wherein, The amount of Al in this poly(ether ketone ketone) polymer is less than 10 ppm.

22. The component according to any one of claims 1-3, wherein, The poly(etherketoneketone) polymer exhibits a Td (1%) of at least 500°C as measured by thermogravimetric analysis under nitrogen at a heating rate of 10°C / min from 30°C to 800°C, according to ASTM D3850, where Td (1%) represents the temperature at which 1.0 wt.% of the volatile material leaves the sample.

23. The component according to any one of claims 1-3, wherein, The poly(etherketoneketone) polymer exhibits a Td (1%) of at least 505°C as measured by thermogravimetric analysis under nitrogen at a heating rate of 10°C / min from 30°C to 800°C, according to ASTM D3850, where Td (1%) represents the temperature at which 1.0 wt.% of the volatile material leaves the sample.

24. The component according to any one of claims 1-3, wherein, The poly(etherketoneketone) polymer exhibits a Td (1%) of at least 510°C as measured by thermogravimetric analysis under nitrogen at a heating rate of 10°C / min from 30°C to 800°C, according to ASTM D3850, where Td (1%) represents the temperature at which 1.0 wt.% of the volatile material leaves the sample.

25. The component according to any one of claims 1-3, wherein, The membrane has a thickness ranging from 15 µm to 800 µm.

26. The component according to any one of claims 1-3, wherein, The membrane has a thickness ranging from 25 µm to 600 µm.

27. The component according to any one of claims 1-3, wherein, The membrane has a thickness ranging from 30 µm to 500 µm.

28. The component according to any one of claims 1-3, wherein, The membrane has a thickness ranging from 40 µm to 300 µm.

29. The component according to any one of claims 1-3, wherein, The membrane has a thickness ranging from 50 µm to 250 µm.

30. The component according to any one of claims 1-3, wherein, Polymer P1 and polymer P2 are independently selected from the group consisting of: poly(aryl ether ketone), poly(ether imide), poly(amide imide), poly(aryl ether sulfone), poly(aryl sulfide), polyamide, polycarbonate, liquid crystal polymer, poly(aromatic ester), and blends thereof.

31. The component of claim 30, wherein, The polyamide is poly(phthalamide).

32. The component according to any one of claims 1-3, wherein, Polymer P1 and / or polymer P2 are independently selected from the group consisting of polyetheretherketone and poly(etherketoneketone), wherein: Polyetheretherketone (PEEK) refers to any polymer containing at least 10 mol.% of the following repeating units, which are repeating units having the formula (J''-A) (R). PEEK ): (J'-A) The mol.% figure is based on the total number of moles of repeating units in the polymer. and Poly(etherketoneketone) means any polymer containing at least 50 mol.% of repeating units having the formulas (J'-B1) and (J'-B2), where mol.% is based on the total number of moles of repeating units in the polymer: (J'-B1) (J'-B2)。 33. The component according to any one of claims 1-3, wherein, Polymer P1 and polymer P2 are independently selected from poly(ether ketone ketone) polymers and mixtures thereof with a T / I ratio in the range of 55 / 45 to 85 / 1, where T / I refers to the molar ratio of repeating unit (P) to repeating unit (M).

34. The component according to any one of claims 1-3, wherein, Polymer P1 and polymer P2 are independently selected from poly(ether ketone ketone) polymers and mixtures thereof with a T / I ratio in the range of 57 / 43 to 80 / 20, where T / I refers to the molar ratio of repeating unit (P) to repeating unit (M).

35. The component according to any one of claims 1-3, wherein, Polymer P1 and polymer P2 are independently selected from poly(ether ketone ketone) polymers and mixtures thereof with a T / I ratio in the range of 58 / 42 to 75 / 25, where T / I refers to the molar ratio of repeating unit (P) to repeating unit (M).

36. The component according to any one of claims 1-3, wherein: - The first component is a composite material comprising one or more layers containing fibers and polymer P1. - The second component is a composite material comprising one or more layers containing fibers and polymer P2, and / or - The membrane contains at least one loosely woven fabric, nonwoven material, or lightweight fabric.

37. The component according to any one of claims 1-3, wherein, The proportion of nucleating agent is less than 2.0 wt.%, which is relative to the weight of the poly(ether ketone ketone) polymer.

38. The component according to any one of claims 1-3, wherein, The proportion of nucleating agent is less than 1.5 wt.%, which is relative to the weight of the poly(ether ketone ketone) polymer.

39. A method of manufacturing a component according to any one of claims 1-38, the method comprising the following steps: - The membrane is disposed between a first component containing polymer P1 and a second component containing polymer P2; and - subject the membrane to a temperature (T) suitable for melting the membrane but not melting polymers P1 and P2. m x ).

Images