Classifications

• • C—CHEMISTRY; METALLURGY
  • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
  • C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
  • C08L81/00—Compositions of macromolecular compounds obtained by reactions forming in the main chain of the macromolecule a linkage containing sulfur with or without nitrogen, oxygen or carbon only; Compositions of polysulfones; Compositions of derivatives of such polymers
  • C08L81/06—Polysulfones; Polyethersulfones
• • C—CHEMISTRY; METALLURGY
  • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
  • C08K—Use of inorganic or non-macromolecular organic substances as compounding ingredients
  • C08K3/00—Use of inorganic substances as compounding ingredients
• • C—CHEMISTRY; METALLURGY
  • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
  • C08K—Use of inorganic or non-macromolecular organic substances as compounding ingredients
  • C08K5/00—Use of organic ingredients
• • C—CHEMISTRY; METALLURGY
  • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
  • C08K—Use of inorganic or non-macromolecular organic substances as compounding ingredients
  • C08K7/00—Use of ingredients characterised by shape
  • C08K7/02—Fibres or whiskers
• • C—CHEMISTRY; METALLURGY
  • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
  • C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
  • C08L71/00—Compositions of polyethers obtained by reactions forming an ether link in the main chain; Compositions of derivatives of such polymers
• • C—CHEMISTRY; METALLURGY
  • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
  • C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
  • C08L71/00—Compositions of polyethers obtained by reactions forming an ether link in the main chain; Compositions of derivatives of such polymers
  • C08L71/08—Polyethers derived from hydroxy compounds or from their metallic derivatives
  • C08L71/10—Polyethers derived from hydroxy compounds or from their metallic derivatives from phenols
  • C08L71/12—Polyphenylene oxides
• • C—CHEMISTRY; METALLURGY
  • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
  • C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
  • C08L81/00—Compositions of macromolecular compounds obtained by reactions forming in the main chain of the macromolecule a linkage containing sulfur with or without nitrogen, oxygen or carbon only; Compositions of polysulfones; Compositions of derivatives of such polymers
  • C08L81/02—Polythioethers; Polythioether-ethers
• • C—CHEMISTRY; METALLURGY
  • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
  • C08K—Use of inorganic or non-macromolecular organic substances as compounding ingredients
  • C08K3/00—Use of inorganic substances as compounding ingredients
  • C08K3/18—Oxygen-containing compounds, e.g. metal carbonyls
  • C08K3/24—Acids; Salts thereof
  • C08K3/26—Carbonates; Bicarbonates
  • C08K2003/262—Alkali metal carbonates
• • C—CHEMISTRY; METALLURGY
  • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
  • C08K—Use of inorganic or non-macromolecular organic substances as compounding ingredients
  • C08K3/00—Use of inorganic substances as compounding ingredients
  • C08K3/32—Phosphorus-containing compounds
  • C08K2003/321—Phosphates
  • C08K2003/324—Alkali metal phosphate

Definitions

• the present invention relates to high-performance compatibilized polymer compositions including a poly(/?ara-phenylene sulfide) (PPS) and at least one poly(aryl ether sulfone) (PAES).
• PPS poly(/?ara-phenylene sulfide)
• PAES poly(aryl ether sulfone)
• Polymers may be blended to achieve new compositions with desirable properties; however, the vast majority of polymers are immiscible with each other. Attempts to blend polymers often results in heterogeneous multi-phase compositions when the polymers are immiscible with each other. Such compositions may exhibit several thermal transition temperatures (Tg, Tm), usually exhibit poor mechanical properties, and suffer from delamination and/or aesthetical defects.
• Tg, Tm thermal transition temperatures
• the mechanical properties and ease of processing of a particular blend depend on the degree of compatibility of the polymer components.
• the main polymer component is usually referred to as the continuous phase or matrix, whereas the minor polymer component is typically defined as the dispersed phase.
• the degree of compatibility can be characterized by the dimensions of the dispersed phase in the continuous phase and the level of adhesion between the matrix and the dispersed phase. Certain highly immiscible blends are impossible to extrude in normal operating conditions due to a high die swell and are therefore not commercially available.
• PPS is known to have very good chemical resistance and low melt viscosity
• PAESs are known to have excellent mechanical properties and good thermal stability. Therefore, it would be desirable to blend these polymers to achieve a combination of their properties.
• blends of PPS and PAES are not always very compatible, exhibiting poor tensile properties in some instances because of the existence of large domains of the individual polymers in blends of these polymers and because of a poor adhesion between the phases.
• FIG. 1 shows transmission electron microscopy (TEM) images of the compositions of Example 1 (FIG. 1A) and Comparative Example 11 (FIG. IB).
• TEM transmission electron microscopy
• FIG. 2 shows TEM images of the compositions of Example 2 (FIG. 2A) and Comparative Example 12 (FIG. 2B).
• FIG. 3 shows TEM images of the compositions of Example 3 (FIG. 3 A) and Comparative Example 13 (FIG. 3B).
• FIG. 4 shows TEM images of the compositions of Example 4 (FIG. 4A) and Comparative Example 14 (FIG. 4B).
• FIG. 5 shows TEM images of the compositions of Example 5 (FIG. 5A) and Example 6 (FIG. 5B).
• FIG. 6 shows TEM images of the compositions of Example 7 (FIG. 6A) and Example 8 (FIG. 6B).
• FIG. 7 shows TEM images of the compositions of Example 9 (FIG. 7A) and Example 10 (FIG. 7B).
• FIG. 8 shows TEM images of the compositions of Example 15 (FIG. 8A) and Comparative Example 18 (FIG. 8B).
• FIG. 9 shows TEM images of the compositions of Example 17 (FIG. 8A) and Comparative Example 21 (FIG. 8B).
• FIG. 10 shows a TEM image of the composition of Comparative
• FIG. 11 shows a TEM image of the composition of Comparative
• FIG. 12 shows a TEM image of the composition of Comparative
• FIG. 13 shows a TEM image of the composition of Example 30.
• polymer blends with increased compatibility, including blends of highly immiscible polymers such as poly(/?ara-phenylene sulfide) (PPS) and poly(aryl ether sulfone) (PAES).
• PPS poly(/?ara-phenylene sulfide)
• PAES poly(aryl ether sulfone)
• Exemplary embodiments are directed to a polymer composition including PPS, at least one PAES, and about 0.05 to about 2 wt.% of at least one alkali metal carbonate, based on the total weight of polymers in the composition.
• the weight ratio of the PPS to the at least one PAES ranges from 0.2 to 20.
• the polymer composition is free or substantially free of solvents, that-is-to-say that the composition does not comprise solvent and comprises solvent(s) in an amount not exceeding 2 wt.% (based on the total weight of the composition), for example less than 1 wt.%, less than 0.5 wt.% or less than 0.1 wt.%.
• the polymer composition is free or substantially free of a polyetherimide (PEI), that-is-to-say that the composition does not comprise PEI and comprises PEI in an amount not exceeding 2 wt.% (based on the total weight of the composition), for example less than 1 wt.%, less than 0.5 wt.% or less than 0.1 wt.%.
• PEI polyetherimide
• the polymer composition is free or substantially free of an epoxy, that-is-to-say that the composition does not comprise epoxy and comprises epoxy in an amount not exceeding 2 wt.% (based on the total weight of the composition), for example less than 1 wt.%, less than 0.5 wt.% or less than 0.1 wt.%.
• alkali metal carbonate includes an alkali metal carbonate and any reagent from which the alkali metal carbonate can be derived in situ during processing at high temperature, for example alkali metal bicarbonate.
• solvent means a liquid in which at least one of the polymers in the polymer composition will at least partially dissolve
• substantially free of solvent means less than 2 wt.% of solvent, for example less than 1 wt.%, less than 0.5 wt.% or less than 0.1 wt.% (based on the total weight of the composition);
• substantially free of a polyetherimide (PEI) means less than 2 wt.% of polyetherimide (PEI), for example less than 1 wt.%, less than 0.5 wt.% or less than 0.1 wt.% (based on the total weight of the composition);
• substantially free of an epoxy means less than 2 wt.% of epoxy, for example less than 1 wt.%, less than 0.5 wt.% or less than 0.1 wt.% (based on the total weight of the composition);
• substantially free of rPAES means less than 2 wt.% of rPAES, based on the total weight of the polymers in the polymer composition;
• substantially free of die swell means less than 5% die swell
• halogen includes fluorine, chlorine, bromine, and iodine, unless indicated otherwise.
• the PPS and PAES have a weight average molecular weight ranging from 5,000 g/mol to 150,000 g/mol, preferably from 10,000 g/mol to 100,000 g/mol.
• an element or component is said to be included in and/or selected from a list of recited elements or components, it should be understood that in related embodiments explicitly contemplated here, the element or component can also be any one of the individual recited elements or components, or can also be selected from a group consisting of any two or more of the explicitly listed elements or components; any element or component recited in a list of elements or components may be omitted from such list; and
• a "poly(/?ara-phenylene sulfide) (PPS)" denotes any polymer of which at least 50 mol % of the recurring units are recurring units (Rpps) of formula (L):
• At least 60 mol %, 70 mol %, 80 mol %, 90 mol %, 95 mol %, 99 mol %, and most preferably all of the recurring units in the PPS are recurring units (RPPS).
• PPS is manufactured and sold under the trade name Ryton ® PPS by Solvay Specialty Polymers USA, LLC.
• the PPS may be acid washed or not acid washed. In some embodiments, the PPS is acetic acid washed PPS.
• Poly(aryl ether sulfone)s (PAES) PAES
• PAES poly(aryl ether sulfone)
• each R is selected from a halogen, an alkyl, an alkenyl, an alkynyl, an aryl, an ether, a thioether, a carboxylic acid, an ester, an amide, an imide, an alkali or alkaline earth metal sulfonate, an alkyl sulfonate, an alkali or alkaline earth metal phosphonate, an alkyl phosphonate, an amine, and a quaternary ammonium;
• each h equal to or different from each other, is an integer ranging from 0 to 4.
• T is selected from the group consisting of a bond, a sulfone group
• Rj and Rk are selected from a hydrogen, a halogen, an alkyl, an alkenyl, an alkynyl, an ether, a thioether, a carboxylic acid, an ester, an amide, an imide, an alkali or alkaline earth metal sulfonate, an alkyl sulfonate, an alkali or alkaline earth metal phosphonate, an alkyl
• R j and R k are preferably methyl groups.
• At least 60 mol %, 70 mol %, 80 mol %, 90 mol %, 95 mol %, 99 mol %, and most preferably all of recurring units in the PAES are recurring units (RPAES).
• the PAES is a polyphenylsulfone (PPSU).
• PPSU polyphenylsulfone
• K'-A formula (K'-A):
• PPSU Preferably at least 60 mol %, 70 mol %, 80 mol %, 90 mol %, 95 mol %, 99 mol %, and most preferably all of the recurring units in the PPSU are recurring units of formula (K'-A).
• PPSU can be prepared by known methods and is notably available as RADEL ® PPSU from Solvay Specialty Polymers USA, L.L.C.
• the PAES is a polyethersulfone (PES).
• PES polyethersulfone
• a "polyethersulfone (PES)" denotes any polymer of which at least 50 mol % of the recurring units are recurring units of formula (K'-B):
• At least 60 mol %, 70 mol %, 80 mol %, 90 mol %, 95 mol %, 99 mol %, and most preferably all of the recurring units in the PES are recurring units of formula (K'-B).
• PES can be prepared by known methods and is notably available as VERADEL ® PESU from Solvay Specialty Polymers USA, L.L.C.
• the PAES is a polysulfone (PSU).
• PSU polysulfone
• a "polysulfone (PSU)" denotes any polymer of which at least 50 mol % of the recurring units are recurring units of formula (K'-C): (K'-C)
• At least 60 mol %, 70 mol %, 80 mol %, 90 mol %, 95 mol %, 99 mol %, and most preferably all of the recurring units in the PSU are recurring units of formula (K'-C).
• PSU can be prepared by known methods and is available as UDEL ® PSU from Solvay Specialty Polymers USA, L.L.C.
• PAES was selected from the group consisting of PPSU, PES, PSU, or a combination thereof.
• the polymer composition includes at least one alkali metal carbonate in an amount ranging from about 0.05 to about 2 wt.%, about 0.1 to about 1.8 wt.%, about 0.1 to about 1.6 wt.%>, about 0.1 to about 1.5 wt.%>, about 0.1 to about 1.3 wt.%), about 0.1 to about 1.0 wt.%>, about 0.1 to about 0.8 wt.%>, about 0.1 to about 0.5 wt.% based on the total weight of polymers in the polymer
• the amount of alkali metal carbonate ranges from about 0.1 to about 0.5 wt.%>, about 0.2 to about 0.5 wt.%>, about 0.4 to about 0.5 wt.% based on the total weight of polymers in the polymer composition. In some embodiments, the amount of alkali metal carbonate is less than or equal to 1.0 wt.%, 0.9 wt.%, 0.8 wt.%, 0.7 wt.%, 0.6 wt.%, 0.5 wt.%, 0.4 wt.%, 0.3 wt.%), 0.2 wt.%), 0.1 wt.%) based on the total weight of polymers in the polymer composition.
• the alkali metal carbonate may be selected from sodium carbonate, potassium carbonate, cesium carbonate and lithium carbonate. Potassium carbonate is preferred. Mixtures of two or more alkali metal carbonates may be used.
• the particle size D50 (median diameter or the medium value of the particle size distribution) ranges from 2 microns to 1000 microns, preferably from 2 to 500 microns, most preferably from 3 to 200 microns.
• the PPS and the at least one PAES may be present in either a reactive form (i.e. a reactive polymer) or a non-reactive form.
• the polymers include at least 5, at least 10, at least
• rPES reactive polyethersulfone
• the polymer composition includes at least one reactive poly(aryl ether sulfone) (rPAES) in addition to the PPS and at least one PAES.
• the rPAES is preferably selected from a reactive polysulfone (rPSU), a reactive polyethersulfone (rPES) and a reactive polyphenylsulfone (rPPSU).
• the total amount of rPAES in the polymer composition ranges from 0 to 60 wt.%, 1 to 50 wt.%, 5 to 30 wt.%, 5 to 25 wt.%, 5 to 20 wt.%, 5 to 15 wt.%), most preferably about 10 wt.%, based on the total weight of the polymers in the polymer composition.
• the PPS and PAES include one or more non- reactive end groups.
• the non-reactive end groups are preferably -CI, -F, or -O-CH 3 .
• the non-reactive polymers include at least 20, preferably more than 50 microequivalents per gram ⁇ eq/g) of non-reactive end groups.
• the polymer composition may be free or substantially free ofrPAESs.
• PPS poly(/?ara-phenylene sulfide)
• PPS poly(/?ara-phenylene sulfide)
• a large selection of reinforcing fillers may be added to the polymer composition. They are preferably selected from fibrous and particulate fillers.
• a fibrous reinforcing filler is considered herein to be a material having length, width and thickness, wherein the average length is substantially larger than both the width and thickness.
• such a material has an aspect ratio, defined as the average ratio between the length and the smallest of the width and thickness of at least 5.
• the aspect ratio of the reinforcing fibers is at least 10, more preferably at least 20, still more preferably at least 50.
• the particulate fillers have an aspect ratio of at most 5, preferably at most 2.
• the reinforcing filler is selected from mineral fillers, such as talc, mica, titanium dioxide, kaolin, calcium carbonate, calcium silicate, magnesium carbonate; glass fibers; carbon fibers, boron carbide fibers;
• mineral fillers such as talc, mica, titanium dioxide, kaolin, calcium carbonate, calcium silicate, magnesium carbonate; glass fibers; carbon fibers, boron carbide fibers;
• wollastonite silicon carbide fibers; boron fibers, graphene, carbon nanotubes (CNT), and the like.
• the reinforcing filler may be present in the polymer composition in an amount of at least 5 wt. %, preferably at least 10 wt. %, more preferably at least 15 wt. %, based on the total weight of the polymer composition.
• the reinforcing filler is also preferably present in an amount of at most 60 wt. %, more preferably at most 50 wt. %, still more preferably at
• the amount of the reinforcing filler ranges from 0.1 wt. % to 60 wt. %, more preferably from 5 wt. % to 50 wt. %, still more preferably from 10 wt. % to 40 wt. % of the polymer composition.
• the polymer composition is free of a fibrous filler.
• the polymer composition may be free of a particulate filler.
• the polymer composition is preferably free of reinforcing fillers. Additional Optional Ingredients
• the polymer composition consists or consists essentially of the PPS, the at least one PAES and the alkali metal carbonate; however, in other aspects, the polymer composition may include one or more additional additives.
• the polymer composition may further optionally include other ingredients such as a colorant such as a dye and/or a pigment such as titanium dioxide, zinc sulfide, zinc oxide, ultraviolet light stabilizers, heat stabilizers, antioxidants such as organic phosphites and phosphonites, acid scavengers, processing aids, nucleating agents, lubricants, flame retardants, a smoke-suppressing agents, an anti-static agents, anti-blocking agents, and/or conductivity additives such as carbon black.
• a colorant such as a dye and/or a pigment such as titanium dioxide, zinc sulfide, zinc oxide, ultraviolet light stabilizers, heat stabilizers, antioxidants such as organic phosphites and phosphonites, acid scavengers, processing aids, nucleating agents, lubricants, flame retardants, a smoke-suppressing agents, an anti-static agents, anti-blocking agents, and/or conductivity additives such as carbon black.
• their total weight is preferably less than 20 wt.%, less than 10 wt.%, less than 5 wt.% and most preferably less than 2 wt.%, based on the total weight of polymer composition.
• organic and inorganic acid components having a pKa ⁇ 7.5, preferably ⁇ 7, are able to stabilize the melt viscosity of the polymer composition of the invention.
• Non-limiting examples of organic and inorganic components having a pKa ⁇ 7.5 are sodium hydrogen phosphate (NaH 2 P0 4) , monosodium citrate, sodium hydrogen oxalate, and sodium hydrogen phthalate.
• Inorganic components, such as, for example, NaH 2 PC"4, having a pKa ⁇ 7 are preferred. Excellent results were obtained with organic and inorganic components having a pKa as follows : 2.5 ⁇ pKa ⁇ 7.5, preferably 3 ⁇ pKa ⁇ 7 .
• the organic or inorganic acid component having a pKa ⁇ 7.5 may be present in an amount ranging from 0.05 wt.% to 5 wt.%, preferably from 0.1 wt.%) to 2 wt.%, more preferably from 0.2 wt.% to 1 wt.%, based on the total weight of polymers in the polymer composition.
• Preferred polymer compositions are shown in Table 1. Each polymer composition may include other ingredients in addition to those listed. Each preferred polymer composition also includes an alkali metal carbonate, preferably potassium or sodium carbonate, in an amount ranging from 0.05 to about 2 wt.% , or in another amount as disclosed herein. Each preferred polymer composition may optionally include an acid component as described herein.
• the concentration of each of the PPS, the PAES, and the rPAES is independently selected from 0 wt.%, preferably at least 1 wt.%, 2 wt.%, 5 wt.%, 10 wt.%, 15 wt.%, 20 wt.%, 25 wt.%, 30 wt.%, 35 wt.%, 40 wt.%, 45 wt.%, 50 wt.%, 55 wt.%, 60 wt.%, 65 wt.%, 70 wt.%, 75 wt.%, 80 wt.%, 85 wt.%, 90 wt.%, 95 wt.%, 98 wt.%, 99 wt.% of the total weight of polymers in the polymer composition.
• the polymer composition includes about 85 wt.%>, preferably about 75 wt.%>, more preferably about 65 wt.%>, and most preferably about 50 wt.% of PPS or PAES and about 15 wt.%, preferably about 25 wt.%, more preferably about 35 wt. %>, most preferably about 50 wt.%>, respectively, of the other of the PPS or PAES, based on the total weight of the polymers in the polymer composition.
• the polymer composition includes (i) from 15 wt.%> to 85 wt.%, preferably 25 to 75 wt. %, 30 to 70 wt.%, 40 to 60 wt.%, 45 to 55 wt.%, most preferably about 45%> wt.
• %> of the PPS (ii) from 85 to 15 wt.%>, preferably 75 to 25 wt.%, 70 to 30 wt.%, 60 to 40 wt.%, 55 to 45 wt.%, most preferably about 45 wt.%) of the PAES, and (iii) from 1 wt.%> to 20 wt.%>, preferably about 10 wt.% of the rPAES, based on the total weight of the polymers in the polymer composition.
• the weight ratio of the PPS to the at least one PAES ranges from 0.2 to 20, 0.3 to 15, 0.4 to 10, 0.5 to 5, and most preferably 1 to 3.
• the weight ratio of the PPS to the amount of the at least one PAES ranges from 0.5 to 5, preferably 1 to 3, and the polymer composition includes 0.15 to 0.4 wt.%>, preferably 0.2 to 0.4 wt.%> of the least one alkali metal carbonate, preferably potassium or sodium carbonate, based on the total weight of polymers in the composition.
• the polymer composition comprises:
• the polymer compositions of the present invention may include a dispersed phase that is dispersed in a continuous phase or matrix.
• An example of a dispersed phase is shown in FIG. 4A.
• the average surface area per dispersed particle is preferably less than or equal to about 4 ⁇ 2 , about 3 ⁇ 2 , about 2 ⁇ 2 , about 1 ⁇ 2 , about 0.5 ⁇ 2 , about 0.25 ⁇ 2 . .
• the maximum diameter of particles of the dispersed phase is ⁇ 3 ⁇ , preferably ⁇ 2 ⁇ , ⁇ 1 ⁇ , ⁇ 0.8 ⁇ , ⁇ 0.6 ⁇ , ⁇ 0.4 ⁇ , most preferably ⁇ 0.1 ⁇ .
• the polymer blends may include co-continuous phases characterized by the presence of continuous ribbons of the polymer components when viewed by transmission electron microscopy (TEM).
• TEM transmission electron microscopy
• the average width of the ribbons is preferably less than or equal to about 3 ⁇ , more preferably less than or equal to about 2 ⁇ , where the average width is calculated by taking 10 random measurements of the ribbon width, discarding the longest and shortest measurements, and dividing the sum of the remaining measurements by 8.
• the polymer composition of the invention exhibits a
• the polymer composition may exhibit at least two different glass transition temperatures (Tg) corresponding to each of the at least two different polymers; however, these Tgs may be different (i.e. shifted) as compared with the Tgs of the same polymers when not in the polymer composition.
• the difference between the respective Tgs in the polymer composition (the ATg) is at least 0.5 °C, preferably at least 1 °C, more preferably from 5 to 50 °C, even more preferably from 5 to 10°C.
• the polymer composition is free or substantially free of die swell when the polymer composition is extruded as a melt from an extruder and the temperature of the melt ranges from 300 to 430 °C.
• the invention includes a method of making the polymer compositions described herein by melt mixing i) a PPS, ii) at least one PAES, and iii) about 0.05 to about 2 wt.% of at least one alkali metal carbonate, based on the total weight of polymers in the composition.
• the weight ratio of the PPS to the at least one PAES ranges from 0.2 to 20, preferably 0.3 to 15, 0.4 to 10, 0.5 to 5, and most preferably, 1 to 3.
• the polymer composition is free or substantially free of solvent.
• the PPS and PAES may be independently reactive or non-reactive.
• the PPS is preferably a reactive polymer.
• the PPS may be acid washed or not acid washed.
• the components of the mixture may be added or mixed in any order, in any amount or fraction their total amount, and may be mixed separately or
• the preparation of the polymer composition can be carried out by any known melt-mixing process that is suitable for preparing thermoplastic molding compositions. Such a process may be carried out by heating the polymers above the melting temperature of the semi-crystalline polymers to form a melt of the polymers and/or above the Tg of the amorphous polymers. In some
• the processing temperature ranges from about 250-450°C, preferably from about 280-420°C.
• the processing temperature is at least 15°C, preferably at least 50°C, preferably at least 100°C, preferably at least 150°C greater than the glass transition temperature (Tg) of the highest Tg polymer in the polymer composition and/or at least 15°C greater than the melting temperature (Tm) of the highest Tm polymer in the polymer composition.
• the components for forming the polymer composition are fed to the melt-mixing apparatus and melt-mixed in that apparatus.
• Suitable melt-mixing apparatuses are, for example, kneaders, Banbury mixers, single-screw extruders, and twin-screw extruders.
• the extruder is equipped with one or more ports allowing dosing to the melt at different barrels during the extrusion process.
• the components may be fed simultaneously as a powder mixture or granule mixture, also known as dry-blend, or may be fed separately.
• all of the polymers and the alkali metal carbonate are added to the throat of the extruder, preferably simultaneously or substantially simultaneously.
• one or more of the polymers may be added with the alkali metal carbonate to the throat of the extruder, and one or more other polymers is subsequently added to the melt at a barrel of the extruder.
• the PPS and a rPAES preferably an rPES
• the PAES may be added subsequently at a downstream barrel of the extruder.
• the acid component may be added at the throat of the extruder, or to the melt at any barrel of the extruder.
• the acid component is added to the melt at a downstream barrel such that it contacts the melt shortly before the melt is extruded.
• the acid component is added at a time after the addition of the alkali metal carbonate.
• multiple-pass extrusion may be performed.
• extrudate from a first pass is reintroduced into the extruder, preferably at the throat, such that it passes through the extruder a second time.
• two, three, four, or more passes may be performed, and the polymers, alkali metal carbonate, acid component, or other ingredients may be added at any point on the extruder line in any pass.
• the PPS may be added to the throat of the extruder with the alkali metal carbonate
• the extrudate from a first pass may then be recycled to the extruder with addition of the at least one PAES, and the acid component can be added toward the end of the second pass.
• the extrudate resulting from the second pass may be recycled for a third pass during which, for example, an acid component and/or filler material may be added to the melt prior to extrusion into a final product.
• At least two passes may be performed, and components may be added to the extrudate and/or a process performed (for example, mixing) on the extrudate before it is recycled to the extruder for one or more additional passes.
• the extruder may be operated at any suitable speed.
• the extruder speed and the temperatures of the extruder barrels may be constant or varied.
• the extruder screw(s) are rotated at about 100 to about 900, preferably from about 200 to about 500 rpm; however, speed and temperature may be adjusted based on the particular polymer composition being blended.
• total residence time means the total time that the longest-residing component spends in the extruder, including multiple passes, if any.
• the total residence time preferably ranges from about 15 seconds to about 4 minutes, preferably from about 30 seconds to about 2 minutes.
• polymer compositions described herein are advantageously provided in the form of pellets, which may be used in injection molding or extrusion processes known in the art.
• the method includes:
• the method includes:
• Exemplary embodiments also include articles comprising the above- described polymer composition.
• the articles may be made from the polymer composition using any suitable melt-processing method.
• they may be made by injection molding, extrusion molding, roto-molding, or blow-molding.
• the polymer composition may be well suited for the manufacture of articles useful in a wide variety of end uses.
• Comparative Examples 11 - 14 Blends of PPSU and PPS without K 2 C0 3 Materials:
• the blends were compounded using a Coperion® ZSK-26 co-rotating twin-screw extruder having an L/D ratio of 48: 1 at 200-300 rpm and 12-18 kg/hr. Barrel temperature set points were 360°C for zones 1 through 6, 340°C for zones 7 through 12, and 360°C at the die.
• the melt viscosity was measured according to ASTM D5630 at 360°C and 400 1/sec.
• Examples 5 through 10 illustrate the effects of varying the PPS:PPSU ratio and the amount of K 2 C0 3 .
• Examples 15 - 18 Blends of PPSU, PPS, and K 2 C0 3 where the PPS was washed with acetic acid.
• Comparative Examples 19 - 22 Blends of PPSU, PPS, and K 2 C0 3 where the
• Comparative Example 22 Blend of PPS/PES.
• compositions are described in Table 4.
• compositions of Table 4 were subjected to melt compounding using a 26 mm diameter Coperion® ZSK-26 co-rotating partially intermeshing twin screw extruder having an L/D ratio of 48:1.
• the barrel sections 2 through 12 and the die were heated to set point temperatures as follows:
• the resins and additives were fed at barrel section 1 and at barrel section 5 using gravimetric feeders at throughput rates in the range
• Vacuum was applied at barrel zone 10 with a vacuum level of about 27 inches of mercury.
• a single-hole die was used for all the compounds and the molten polymer strand exiting the die was cooled in a water trough and then cut in a pelletizer.
• the chemical resistance was evaluated by exposing flex bars under variable stress to methyl ethyl ketone for 24 hours. The time of exposure to methyl ethyl ketone was increased in the case where the materials did not show any breakage or crazing.
• Comparative Example 27 blend PPS/PES 50/50 parts, for 5 min residence time.
• Comparative Example 28 blend PPS/PES/rPES 45/45/10 parts, for 5 min residence time.
• Comparative Example 29 blend PPS/PES/rPES/ZnO 45/45/10/2 parts, for 3 min residence time.
• Example 30 blend PPS/PES/rPES/K 2 C0 3 45/45/10/0.5 parts, for 3 min residence time.
• rPES Reactive poly(ether sulfone)
• the blends were compounded in a DSM Xplore® twin-screw (100 rpm) extruder heated at 380°C and equipped with a recirculation loop allowing control of residence time.
• the materials total of 7g were introduced simultaneously and mixed for a time (residence time) before being extruded into a strand.
• the torque needed to rotate the extruder screws was measured during blending.
• the torque correlates with the viscosity of the molten blend with a higher force indicating a higher viscosity.
• the level of die swell was observed at the exit of the extruder and ranked as follows:— very large die swell, - some die swell, +limited die swell, ++no die swell.
• the thermal properties i.e., melting temperature and crystallization temperature were determined by DSC.
• FIG. 11 introduction of rPES (hydroxyl terminated PES) did not significantly compatibihze the polymers and very large die swell was observed. Moreover, as shown in FIG. 12, the further addition of the base, ZnO, also did not result in a dramatic change in the morphology of the PPS and PES blend, and some die swell was still observed.
• rPES hydroxyl terminated PES
• Example 30 Surprisingly, however, when another base, K 2 CO 3 , was added to the PPS, PES and rPES polymer composition, good compatibilization of PPS and PES was observed, as shown by the dispersed phase of Example 30 (FIG. 13). In addition, the polymer composition of Example 30 also unexpectedly exhibited no die swell, which is advantageous, for example, in extruding strands of a regular size.

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