Polyarylene Ether Sulfone Composition with Polyphenylene Sulfide for Toughness
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Solution Overview
Problem
Existing polyarylene ether sulfone polymers reinforced with fibrous or particulate fillers face limitations in toughness due to weak interaction with the polymer matrix, and the high processing and thermal stability requirements are challenging, necessitating improved mechanical properties and processing stability in thermoplastic molding compositions.
Innovation Solution
A thermoplastic molding composition comprising 14 to 80% non-sulfonated polyarylene ether sulfone polymer, 1 to 10% sulfonated polyarylene ether sulfone polymer, 4 to 70% fibrous and/or particulate filler, and 15 to 60% polyphenylene sulfide, with a specific preparation process that includes a one-stage polycondensation reaction using a carbonate method to enhance adhesion and stability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If polyarylene ether sulfone polymers are reinforced with fibrous or particulate fillers, then stiffness and strength increase, but toughness is limited due to weak interaction between fillers and polymer matrix
Solution Approach 1:
The patent introduces a compatibilizer (polyarylene ether sulfone with carboxylic acid groups or hydroxyl end groups) as an intermediary substance between the fibrous/particulate fillers and the polymer matrix. This compatibilizer enhances the interaction and adhesion between the filler and matrix, thereby improving toughness while maintaining the stiffness and strength provided by the fillers.
Solution Approach 2:
The patent creates a multi-component composite material system consisting of polyarylene ether sulfone polymer, fibrous/particulate fillers, and compatibilizer. This composite structure allows the combination of different materials with complementary properties, achieving both high strength/stiffness from fillers and improved toughness through enhanced interfacial interaction.
2Temperature
If polyarylene ether sulfone polymers are used for high temperature applications, then thermal stability is excellent, but processing temperature requirements are demanding
Solution Approach 1:
The patent modifies the chemical structure parameters of the polyarylene ether sulfone polymer by introducing sulfonated recurring units (1-7.5 mol-%). This structural modification changes the thermal and rheological properties of the polymer, enabling it to maintain thermal stability while improving processability at lower processing temperatures.
3Strength
If fibrous or particulate fillers are added to improve mechanical properties, then stiffness and strength increase, but adhesion to polymer matrix is weak
Solution Approach 1:
The compatibilizer acts as a mediator that chemically or physically interacts with both the filler surface and the polymer matrix, creating strong interfacial adhesion. The carboxylic acid groups or hydroxyl end groups of the compatibilizer can form hydrogen bonds or chemical bonds with filler surfaces while being compatible with the polymer matrix, thereby enhancing adhesion forces.
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 composition exhibits high temperature resistance, good processability, excellent thermal stability, and improved mechanical properties, with molded articles showing good tensile properties and stability against hydraulic fluids like Skydrol.
Implementation Method 1
Several approaches to functionalize polyarylene ether sulfone polymers for better adhesion to fibrous or particulate fillers are known in the art
Implementation Method 2
High-performance thermoplastics such as polyarylene ether sulfone polymers are formed by polycondensation reactions
Data Source
AI summary
The present invention relates to a thermoplastic molding composition comprising as components at least one non-sulfonated polyarylene ether sulfone polymer (P), at least one sulfonated polyarylene ether sulfone polymer (sP) and at least one fibrous and/or particulate filler and at least one polyphenylene sulfide. The present invention furthermore relates to a process for the manufacturing of a molded article using the thermoplastic molding composition and a molded article obtained by this process.