PAEK/PTFE Polymer Composition for Melt Extrusion
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Solution Overview
Problem
There is a shortfall in PAEK/PTFE compositions suitable for manufacturing thin PAEK-based films and wire coatings that offer enhanced electrical insulation properties, high temperature performance, mechanical strength, chemical resistance, and improved processability, while minimizing arc tracking, tearing, and surface defects during melt manufacturing and coating extrusion.
Innovation Solution
A composition comprising 0.1 to 99.9% PAEK polymer with a melt flow rate of at least 8 g/10 min at 400°C, 0.1 to 50% PTFE polymer with a D50 particle size below 10 μm and melt viscosity ≤1×105 Pa·s at 372°C, and optional 0 to 50% PAES polymer, with specific provisos on the presence of PAES and PTFE percentages, to enhance melt and coating extrusion processes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If low molecular weight PTFE with lower melt viscosity is used to enable melt flow, then melt processability is improved, but molecular weight is reduced which deprives the material of strength causing articles to break upon handling
Solution Approach 1:
The invention creates a composite material system combining PAEK polymer with low molecular weight PTFE. The PAEK provides the structural strength and mechanical properties, while the low MW PTFE contributes to melt flowability and electrical insulation. This composite approach allows both contradictory requirements (strength and processability) to be satisfied simultaneously through synergistic material combination
Solution Approach 2:
The invention changes the molecular weight parameter of PTFE from conventional high MW (>2,000,000) to low MW (50,000-700,000) to enable melt flow. By controlling the PTFE molecular weight within this specific range and optimizing the blend ratio with PAEK, the material achieves both processability and sufficient strength for thin films and wire coatings
2Reliability
If PTFE polymer is added to enhance electrical insulation properties and reduce arc tracking, then electrical insulation is improved, but melt viscosity increases making melt fabrication difficult
Solution Approach 1:
The invention changes the molecular weight parameter of PTFE to low MW (50,000-700,000) which fundamentally alters the melt viscosity characteristics. Low MW PTFE has significantly lower melt viscosity compared to conventional high MW PTFE, enabling it to flow during melt extrusion while still providing the desired electrical insulation and arc tracking resistance properties
3Volume of moving object
If thin films are manufactured to meet application requirements, then film thickness is reduced, but tearing and surface defects increase during manufacturing
Solution Approach 1:
The invention changes the rheological parameters of the polymer blend by using low MW PTFE with controlled melt viscosity. This creates an optimal melt flow characteristic that allows thin films to be extruded smoothly without defects. The specific MFR range of low MW PTFE (17-200 g/10min) provides sufficient flow to fill thin-gauge dies completely while maintaining surface integrity and preventing tearing during processing
Data Source
AI summary
A composition [composition (C)] comprising at least one poly(aryl ether ketone) polymer having a melt flow rate (MFR) equal to or higher than 8 g/10 min at 400.degree. C. and under a load of 2.16 kg, [(PAEKHMF) polymer], from 0.1 to 50 wt. % of at least one poly(tetrafluoroethylene) polymer having a D50 particle size equal to or below 10.mu.m, and having a melt viscosity equal to or lower than 1.times.105 Pas at 372.degree. C., from 0 to 50% wt. % of at least one poly(aryl ether sulfone) polymer having a melt flow of at least 15 g/10 min at 365 degree C. and under a load of 5.0 kg, [(PAES) polymer], from 0 to 50% wt. % of at least one reinforcing filler, with the proviso that—should the composition (C) comprise a (PAES) polymer having MFR of more than 22 g/10 min, then the (PTFE) polymer is present in an amount of less than 40 wt. %, and—should the composition (C) comprise a (PAES) polymer having MFR of 22 g/10 min or less, then the (PTFE) polymer is present in an amount of less than 30 wt. %, and wherein all % are based on the total weight of the composition (C).