PEDEK-PEEK Microporous Membranes via Plasticizer Extraction
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Solution Overview
Problem
The challenge lies in developing a convenient and efficient method for manufacturing microporous articles from polyaryl ether ketone polymers, such as PEDEK-PEEK, that offer a balance of thermal, mechanical, and chemical resistance suitable for demanding applications, while overcoming the insolubility of these materials in common solvents.
Innovation Solution
A method involving processing a blend of PEDEK-PEEK copolymer and an additional polymer into a film, followed by thermal treatment to induce partial crystallization, and subsequent solvent treatment to remove the additional polymer, resulting in microporous articles with controlled pore dimensions and enhanced mechanical properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If PAEK polymers are used for microporous membranes, then chemical resistance and thermal stability are improved, but processing difficulty increases due to insolubility in common solvents
Solution Approach 1:
The patent uses a plasticizer as an intermediary substance that temporarily modifies the PAEK polymer to enable processing. The plasticizer penetrates the polymer matrix, reduces its crystallinity and melting point, and allows the material to be processed at lower temperatures. After processing, the plasticizer is removed by extraction, leaving the desired microporous structure while maintaining the original chemical resistance of PAEK.
Solution Approach 2:
The patent changes the physical and chemical parameters of PAEK by introducing a plasticizer, which lowers the melting point and reduces crystallinity. This parameter modification enables processing at temperatures below 300°C instead of requiring extremely high temperatures, making the manufacturing process more feasible while preserving the final product's chemical resistance properties.
2Temperature
If plasticizer is used to process PEEK polymer, then processing temperature is reduced, but manufacturing complexity increases due to additional leaching step
Solution Approach 1:
The patent applies extraction by immersing the processed membrane in a solvent that selectively removes the plasticizer from the polymer matrix. This leaching step extracts the plasticizer molecules while leaving the PAEK polymer structure intact, creating the final microporous membrane with the desired properties and pore structure.
3Shape
If microporous membranes are formed by traditional dissolution method, then pore formation is achieved, but polymer solubility requirement creates manufacturing limitations
Solution Approach 1:
The patent uses a plasticizer as a mediator that enables pore formation without requiring polymer solubility. The plasticizer penetrates the polymer matrix, facilitates phase separation and pore formation during processing, and is subsequently removed by extraction. This approach allows microporous membrane formation from insoluble PAEK polymers, overcoming the traditional solubility limitation.
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
This approach enables the production of microporous articles with improved mechanical properties, thermal stability, and chemical resistance, facilitating their use in harsh environments with reduced annealing burdens and efficient solvent processing.
Implementation Method 1
thermal treatment to induce partial crystallization
Implementation Method 2
treating the film with a solvent for obtaining the microporous article
Implementation Method 3
removing at least partially said additional polymer by contacting the thermally treated article with a solvent
Data Source
AI summary
This invention relates to certain microporous articles comprising certain PEDEK-PEEK copolymers, to a method for making said microporous articles, in particular to a method of making microporous articles from a blend comprising said PEDEK-PEEK copolymer and at least one additional polymer, comprising processing said blend into a film and treating the film with a solvent for obtaining the microporous article.