Naphthalene Diol PAES Shaped Articles for Easier Melt Processing
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Solution Overview
Problem
Existing poly(aryl ether sulfone) (PAES) polymers derived from diols like Bisphenol A (BPA) and Bisphenol S (BPS) pose concerns due to endocrine disruption and thermal sensitivity, limiting their use in high-temperature applications and contact with food, beverages, and biological fluids, while high molecular weight PAES exhibit high melt viscosity, complicating processing.
Innovation Solution
Development of PAES polymers based on naphthalene diol monomers, which offer improved thermal stability, low estrogenic activity, and reduced melt viscosity, enabling high-temperature processing and broad application in medical, food, and composite applications.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If high molecular weight PAES polymers are used to improve mechanical properties, then strength and toughness are enhanced, but melt viscosity increases making processing difficult
Solution Approach 1:
The patent changes the chemical structure parameter of the polymer by using naphthalene diol monomers instead of traditional BPA or BPS, which fundamentally alters the polymer's melt viscosity characteristics while maintaining mechanical properties, enabling easier processing at lower temperatures
2Strength
If traditional diol monomers (BPA, BPS) are used to make PAES polymers, then mechanical properties are achieved, but endocrine disruption concerns arise limiting use in food and medical applications
Solution Approach 1:
The patent extracts and eliminates the harmful aromatic hydrocarbon structures (BPA, BPS) from the polymer composition while retaining the desired mechanical properties through alternative naphthalene diol-based monomers that do not exhibit endocrine disruption
Solution Approach 2:
The patent replaces problematic monomers with safer alternative monomers (naphthalene diols) that achieve the same functional goals without the harmful biological effects, making the material suitable for food and medical contact applications
3Ease of manufacture
If PAES polymers are processed at high temperatures to reduce viscosity, then melt flow improves, but thermal degradation and crosslinking occur
Solution Approach 1:
The patent changes the thermal stability parameter of the polymer through naphthalene diol-based structure, which inherently resists thermal degradation and crosslinking, allowing processing at lower temperatures without compromising polymer integrity
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The naphthalene diol-based PAES polymers maintain mechanical properties and thermo-mechanical stability, allowing for efficient melt processing and reduced health risks, suitable for medical devices, food contact, and composite materials.
Implementation Method 1
PAES polymers are highly thermally stable polymers with excellent toughness and impact strength... processed at a temperature between 36 and 400° C. which is far beyond its Tg of 220° C.
Implementation Method 2
PAES have been utilized for making products in different fields of applications, for instance in the medical market, due to their excellent mechanical and thermal properties
Data Source
AI summary
The present invention relates to a shaped article comprising at least one poly(aryl ether sulfone) (PAES) polymer made from at least one naphthalene diol monomer and at least one dihalodiphenyl sulfone monomer; a method of making such article and its use in biomedical, food, beverage applications, automotive, aerospace, electrical, electronic, industrial product applications and/or in composites.