Description

Glass-filed polymer composition comprising a poly(aryl ether sulfone), a poly(aryl ether ketone), at least one polyphenylene sulfide and glass fibers

Related application

[0001] This application claims priority to U.S. provisional application No. 62/550,824, filed on Aug 28, 2017, the whole content of each of these applications being incorporated herein by reference for all purposes.

Technical Field

[0002] The present invention relates to high performance polymer compositions and articles made therefrom. In particular, the present invention relates to compositions comprising at least one poly(aryl ether sulfone) (PAES), at least one poly(aryl ether ketone) (PAEK), at least one polyphenylene sulfide (PPS), and glass fibers.

Background Art

[0003] Polymer compositions having high melt flow are advantageous in

numerous applications and manufacturing techniques. For example, high melt flow polymers are necessary for injection molding of shaped articles with thin parts, in thermoplastic continuous fiber (glass, carbon, aramide) composites and in additive manufacturing methods where more viscous polymers would be unsuitable because. In some such applications, for example, structural components for mobile electronic devices, it may be necessary to produce thin structures having a thickness less than 10 mm, less than 5 mm, less than 3 mm, or even less than 1 mm. Moreover, in additive manufacturing methods such as fused filament fabrication (FFF) and selective laser sintering (SLS), high melt flow is essential for adequate deposition and spreading of successive layers of polymer in the printing process. [0004] The present invention is directed to a glass-filed polymer composition comprising a poly(aryl ether sulfone) (PAES), for example PSU, PPSU or PES, a poly(ether ether ketone) (PEEK) and a polyphenylene sulfide (PPS). This composition has a low melt viscosity, without compromising the mechanical performances of the polymer.

[0005] Several documents describe compositions made of ternary polymer

blends, having valuable properties.

[0006] WO 01/09248 A1 (Solvay) describes a ternary resin blend comprising

poly(biphenyl ether sulfone) (PPSU), poly(ether sulfone) (PES) and polysulfone (PSU). Articles made from the ternary blend can be steam- sterilized repeatedly without stress cracking and have good chemical resitance which makes it for example useful in medical applications.

[0007] WO 2013/092628 A1 (Solvay) relates to another ternary polymer blend comprising polyaryletherketone (PAEK), poly(biphenyl ether sulfone) (PPSU), polysulfone (PSU) and glass fibers having an elastic modulus of at least 76 GPa as measured according to ASTM D2343. Polymer composition is very well suited for the manufacture of articles useful in areas as various as plumbing and electronics.

[0008] WO 2016/102330 A1 (Solvay) relates to a composition comprising at least one poly(aryl ether ketone) (PAEK), at least one poly(biphenyl ether sulfone) (PPSU), at least one polyethersulfone (PES) polymer, and at least one reinforcing filler. This ternary composition has a low melt viscosity poly(aryl ether ketone) (PAEK) compositions with improved mechanical properties such as strength and toughness.

[0009] None of these documents however describe glass-filed polymer

compositions comprising a poly(aryl ether sulfone) (PAES), for example PSU, PPSU or PES, a poly(ether ether ketone) (PEEK) and a

polyphenylene sulfide (PPS), with a high melt flow making it well-suited for notably injection molding of shaped articles with thin parts or additive manufacturing methods, without compromising the mechanical

performances of the polymers. Summary of invention

[0010] The present invention relates to a polymer composition (C1 ) comprising:

- at least one poly(aryl ether sulfone) (PAES), for example is selected from the group consisting of a polysulfone (PSU), a polyphenylsulfone (PPSU) and a polyethersulfone (PES);

- at least one poly(aryletherketone) (PAEK), for example wherein the PAEK is a poly(ether ether ketone) (PEEK) comprising at least 50 mol.% of recurring units (RPEEK) of formula (J-A), based on the total number of moles of recurring units in the polymer:

where

R', at each location, is independently selected from the group consisting of halogen, alkyl, alkenyl, alkynyl, aryl, ether, thioether, carboxylic acid, ester, amide, imide, alkali or alkaline earth metal sulfonate, alkyl sulfonate, alkali or alkaline earth metal phosphonate, alkyl phosphonate, amine and quaternary ammonium; and j', for each R', is independently an integer ranging from 0 to 4.

- at least one polyphenylsulfide (PPS) ; and

- glass fibers.

[001 1] The present invention also relates to articles comprising the polymer composition (C1 ), for example selected from the group consisting of a pipe, a fitting, a manifold, a valve, a medical instrument or part of instrument, a medical case or tray, an aircraft interior component, a cookware, a laboratory animal cage, a laboratory equipment, and a structural part of an electronic device. Detailed description of the invention

[0012] Described herein are polymer compositions (C1) comprising:

- at least one poly(aryl ether sulfone) (PAES);

- at least one poly(aryl ether ketone) (PAEK) ;

- at least one polyphenylsulfide (PPS) ; and

- glass fibers.

[0013] The polymer compositions of the present invention comprise at least three polymers and glass fibers. In some embodiments, the polymer

composition may, for example, consist essentially of three, four or five polymers and glass fibers.

[0014] The polymer compositions of the present invention have a high melt flow in comparison to compositions comprising PSU and glass fibers or compositions comprising two polymers (for example PSU + PEEK or PSU + PPS). The polymer compositions also have improved tensile strength, tensile elongation and unnotched impact resistance in comparison to compositions comprising PSU and glass fibers.

[0015] In the present application:

- any description, even though described in relation to a specific

embodiment, is applicable to and interchangeable with other embodiments of the present invention;

- where 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

- any recitation herein of numerical ranges by endpoints includes all numbers subsumed within the recited ranges as well as the endpoints of the range and equivalents. [0016] Poly(aryl ether sulfone) (PAES)

[0017] The polymer compositions (C1) of the present invention comprise at least one PAES.

[0018] For the purpose of the present invention, a "poly(aryl ether

sulfone) (PAES)" denotes any polymer of which at least 50 mol. % of the recurring units are recurring units (RPAES) of formula (K), the mol.% being based on the total number of moles of recurrin units in the polymer:

where

R, at each location, is independently selected from the group consisting of 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;

h, for each R, is independently zero or an integer ranging from 1 to 4, and T is selected from the group consisting of a bond, a sulfone group

[-S(=O)2-], and a group -C(Rj)(Rk)-, where Rj and Rk, equal to or different from each other, 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 phosphonate, an amine, and a quaternary ammonium.

[0019] T is preferably a bond, a sulfone group or a group -C(Rj)(Rk)- in which Rj and Rk are preferably methyl groups.

[0020] According to an embodiment of the present invention, at least 60 mol. % (based on the total number of moles of recurring units in the polymer), at least 70 mol. %, at least 80 mol. %, at least 90 mol. %, at least 95 mol. %, at least 99 mol. % or all of the recurring units in the PAES are recurring units (RPAES). [0021] The polymer composition (C1 ) may comprise PAES in an amount of at least 10 wt. %, for example at least 15 wt. %, at least 20 wt. %, at least 25 wt. %, at least 30 wt. %, at least 35 wt. %, or at least 40 wt. %, based on the total weight of the polymer composition (C1 ).

[0022] The polymer composition (C1 ) may comprise PAES in an amount of less than 59 wt. %, for example less than 55 wt. %, less than 53 wt. %, less than 51 wt. %, less than 49 wt. %, less than 47 wt. %, less than 45 wt. %, or less than 43 wt. %, based on the total weight of the polymer

composition (C1 ).

[0023] Preferably, the polymer composition (C1 ) may comprise PAES in an

amount ranging from 10 to 55 wt. %, for example from 15 to 50 wt. %, from 20 to 45 wt. % or from 25 to 40 wt. %, based on the total weight of the polymer composition (C1 ).

[0024] In one preferred embodiment, the PAES polymer is a polysulfone (PSU).

[0025] For the purpose of the present invention, a polysulfone (PSU) denotes any polymer comprising at least 50 mol. % recurring units (Rpsu) of formula (L), the mol. % being based on the total number of moles in the polymer:

where

R, at each location, is independently 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;

h, for each R, is independently zero or an integer ranging from 1 to 4.

[0026] According to formula (L), each aromatic cycle of recurring unit (Rpsu) may contain from 1 to 4 radical groups R. When h is 0, the corresponding aromatic cycle does not contain any radical group R. [0027] According to an embodiment, each R is, at each location in formula (L) above, independently selected from the group consisting of a C1 -C12 moiety, optionally comprising one or more than one heteroatoms; sulfonic acid and sulfonate groups; phosphonic acid and phosphonate groups; amine and quaternary ammonium groups.

[0028] According to an embodiment, h is zero for each R. In other words,

according to this embodiment, the recurring units (Rpsu) are units of formula (!_'):

[0029] According to an embodiment of the present invention, at least 60 mol. % (based on the total number of moles of recurring units in the polymer), at least 70 mol. %, at least 80 mol. %, at least 90 mol. %, at least 95 mol. %, at least 99 mol. % or all of the recurring units in the PSU are recurring units (Rpsu) of formula (L) and/or (U).

[0030] According to another embodiment of the present disclosure, a polysulfone (PSU) denotes any polymer comprising at least 50 mol.% of the recurring units are recurrin units (Rpsu) of formula (!_"):

(the mol. % being based on the total number of moles of recurring units in the polymer).

[0031] According to an embodiment of the present disclosure, at least 60 mol. % (based on the total number of moles of recurring units in the polymer), at least 70 mol. %, at least 80 mol. %, at least 90 mol. %, at least 95 mol. %, at least 99 mol. % or all of the recurring units in the PSU are recurring units (Rpsu) of formula (L").

[0032] The PSU polymer of the present invention can be a homopolymer or a copolymer. If the PSU polymer is a copolymer, it can be a random, alternate or block copolymer. When the polysulfone (PSU) is a copolymer, it can include recurring units (R*PSU), different from and in addition to recurring units (Rpsu), such as recurring units of formula (M), (N) and/or (O) :

[0034] PSU is available as Udel® PSU from Solvay Specialty Polymers USA, L.L.C.

[0035] The weight average molecular weight Mw of the PSU may be from 30,000 to 80,000 g/mol, for example from 35,000 to 75,000 g/mol or from 40,000 to 70,000 g/mol.

[0036] The weight average molecular weight (Mw) of PSU can be determined by gel permeation chromatography (GPC) using methylene chloride as a mobile phase (2x 5μ mixed D columns with guard column from Agilent Technologies ; flow rate: 1.5 mL/min; injection volume: 20 μΙ_ of a 0.2w/v% sample solution), with polystyrene standards.

[0037] More precisely, the weight average molecular weight (Mw) can be

measured by gel permeation chromatography (GPC), using methylene chloride as the mobile phase. In the experimental part, the following method was used: two 5μ mixed D columns with guard column from Agilent Technologies were used for separation. An ultraviolet detector of 254nm was used to obtain the chromatogram. A flow rate of 1.5ml/min and injection volume of 20 μΙ_ of a 0.2w/v% solution in mobile phase was selected. Calibration was performed with 12 narrow molecular weight polystyrene standards (Peak molecular weight range: 371 ,000 to 580 g/mol). The weight average molecular weight (Mw) was reported.

[0038] Polysulfone polymer can be produced by a variety of methods. For

example U.S. Pat. Nos. 4,108,837 and 4,175,175 describe the preparation of polyarylethers and in particular polyarylethersulfones. Several one-step and two-step processes are described in these patents, which patents are incorporated herein by reference in their entireties. In these processes, a double alkali metal salt of a dihydric phenol is reacted with a

dihalobenzenoid compound in the presence of sulfone or sulfoxide solvents under substantially anhydrous conditions. In a two-step process, a dihydric phenol is first converted, in situ, in the presence of a sulfone or sulfoxide solvent to the alkali metal salt derivative by reaction with an alkali metal or an alkali metal compound. In the case of PSU manufacture, the starting monomers are bisphenol A and a 4,4'-dihalodiphenylsulfone, typically 4,4'-dichlorodiphenylsulfone. The bisphenol A is first converted to the dialkali metal salt derivative by first reacting with a base like sodium hydroxide, NaOH, in a 1 :2 stoichiometric molar ratio to produce the disodium salt of bisphenol A. This disodium salt of bisphenol A is then reacted with 4,4'-dichlorodiphenylsulfone in a second step to produce the polymer. Sodium chloride salt is produced as a byproduct of the

polymerization.

[0039] The polymer composition (C1 ) may comprise PSU in an amount of at least 10 wt. %, for example at least 15 wt. %, at least 20 wt. %, at least 25 wt. %, at least 30 wt. %, at least 35 wt. %, or at least 40 wt. %, based on the total weight of the polymer composition (C1).

[0040] The polymer composition (C1 ) may comprise PSU in an amount of less than 55 wt. %, for example less than 53 wt. %, less than 51 wt. %, less than 49 wt. %, less than 47 wt. %, less than 45 wt. %, or less than 43 wt. %, based on the total weight of the polymer composition (C1 ).

[0041] Preferably, the polymer composition (C1 ) may comprise PSU in an amount ranging from 10 to 55 wt. %, for example from 15 to 50 wt. %, from 20 to 45 wt. % or from 25 to 40 wt. %, based on the total weight of the polymer composition (C1 ). [0042] In one other embodiment, the PAES is a polyphenylsulfone (PPSU).

[0043] As used herein, a polyphenylsulfone (PPSU) denotes any polymer

comprising at least 50 mol. % recurring units (Rppsu) of formula (M), the mol. % being based on the total number of moles of recurring units in the polymer:

[0044] According to an embodiment of the present disclosure, at least 60 mol. % (based on the total number of moles of recurring units in the polymer), at least 70 mol. %, at least 80 mol. %, at least 90 mol. %, at least 95 mol. %, at least 99 mol. % or all of the recurring units in the PSU are recurring units (Rppsu) of formula (M).

[0045] PPSU can be prepared by known methods and is notably available as RADEL® PPSU from Solvay Specialty Polymers USA, L.L.C.

[0046] The polymer composition (C1 ) may comprise PPSU in an amount of at least 10 wt. %, for example at least 15 wt. %, at least 20 wt. %, at least 25 wt. %, at least 30 wt. %, at least 35 wt. %, or at least 40 wt. %, based on the total weight of the polymer composition (C1 ).

[0047] The polymer composition (C1 ) may comprise PPSU in an amount of less than 55 wt. %, for example less than 53 wt. %, less than 51 wt. %, less than 49 wt. %, less than 47 wt. %, less than 45 wt. %, or less than 43 wt. %, based on the total weight of the polymer composition (C1 ).

[0048] Preferably, the polymer composition (C1 ) may comprise PPSU in an

amount ranging from 10 to 55 wt. %, for example from 15 to 50 wt. %, from 20 to 45 wt. % or from 25 to 40 wt. %, based on the total weight of the polymer composition (C1 ).

[0049] In one another embodiment, the PAES is a polyethersulfone (PES).

[0050] As used herein, a polyethersulfone (PES) denotes any polymer comprising at least 50 mol. % recurring units (RPES) of formula (O), the mol. % being based on the total number of moles of recurring units in the polymer:

[0051] According to an embodiment of the present disclosure, at least 60 mol.

%(based on the total number of moles of recurring units in the polymer), at least 70 mol. %, at least 80 mol. %, at least 90 mol. %, at least 95 mol. %, at least 99 mol. % or all of the recurring units in the PES are recurring units (RPES) of formula (O).

[0052] PES can be prepared by known methods and is notably available as

VERADEL ^® PESU from Solvay Specialty Polymers USA, L.L.C.

[0053] The polymer composition (C1 ) may comprise PES in an amount of at least

10 wt. %, for example at least 15 wt. %, at least 20 wt. %, at least 25 wt.

%, at least 30 wt. %, at least 35 wt. %, or at least 40 wt. %, based on the total weight of the polymer composition (C1).

[0054] The polymer composition (C1 ) may comprise PES in an amount of less than 55 wt. %, for example less than 53 wt. %, less than 51 wt. %, less than 49 wt. %, less than 47 wt. %, less than 45 wt. %, or less than 43 wt.

%, based on the total weight of the polymer composition (C1 ).

[0055] Preferably, the polymer composition (C1 ) may comprise PES in an amount ranging from 10 to 55 wt. %, for example from 15 to 50 wt. %, from 20 to

45 wt. % or from 25 to 40 wt. %, based on the total weight of the polymer composition (C1 ).

[0056] Poly(aryl ether ketone) (PAEK)

[0057] The polymer compositions (C1) of the present invention comprise at least one PAEK.

[0058] As used herein, a poly(aryl ether ketone) (PAEK) denotes any polymer comprising recurring units (RPAEK) comprising a Ar'-C(=O)-Ar ^* group, where Ar' and Ar ^* , equal to or different from each other, are aromatic groups, the mol.% being based on the total number of moles of recurring units in the polymer. The recurring units (RPAEK) are selected from the group consisting of units of formulae (J-A) to (J-D) below:

where

R', at each location, is independently selected from the group consisting of halogen, alkyl, alkenyl, alkynyl, aryl, ether, thioether, carboxylic acid, ester, annide, imide, alkali or alkaline earth metal sulfonate, alkyl sulfonate, alkali or alkaline earth metal phosphonate, alkyl phosphonate, amine and quaternary ammonium; and

j' is independently zero or an integer ranging from 1 to 4.

In recurring unit (RPAEK), the respective phenylene moieties may

independently have 1 ,2-, 1 ,4- or 1 ,3-linkages to the other moieties different from R' in the recurring unit (RPAEK). Preferably, the phenylene moieties have 1 ,3- or 1 ,4- linkages, more preferably they have a 1 ,4-linkage.

[0060] In recurring units (RPAEK), j' is preferably at each location zero so that the phenylene moieties have no other substituents than those linking the main chain of the polymer.

[0061] The polymer composition (C1 ) may comprise PAEK in an amount of at least 1 wt. %, for example at least 1.5 wt. %, at least 2 wt. %, at least 2.5 wt. %, at least 3 wt. %, at least 3.5 wt. %, or at least 4 wt. %, based on the total weight of the polymer composition (C1).

[0062] The polymer composition (C1 ) may comprise PAEK in an amount of less than 50 wt. %, for example less than 45 wt. %, less than 40 wt. %, less than 35 wt. %, less than 30 wt. %, less than 25 wt. %, or less than 20 wt.

%, based on the total weight of the polymer composition (C1 ).

[0063] Preferably, the polymer composition (C1 ) may comprise PAEK in an

amount ranging from 1 to 50 wt. %, for example from 1.5 to 45 wt. %, from

2 to 40 wt. % or from 3 to 35 wt. %, based on the total weight of the polymer composition (C1 ).

[0064] According to an embodiment, the PAEK is a poly(ether ether ketone)

(PEEK).

[0065] As used herein, a poly(ether ether ketone) (PEEK) denotes any polymer comprising recurring units (RPEEK) of formula (J-A), based on the total number of moles of recurrin units in the polymer:

where

R', at each location, is independently selected from the group consisting of halogen, alkyl, alkenyl, alkynyl, aryl, ether, thioether, carboxylic acid, ester, amide, imide, alkali or alkaline earth metal sulfonate, alkyl sulfonate, alkali or alkaline earth metal phosphonate, alkyl phosphonate, amine and quaternary ammonium; and j', for each R', is independently zero or an integer ranging from 1 to 4 (for example 1 , 2, 3 or 4).

[0066] According to formula (J-A), each aromatic cycle of the recurring unit

(RPEEK) may contain from 1 to 4 radical groups R'. When j' is 0, the corresponding aromatic cycle does not contain any radical group R'.

[0067] Each phenylene moiety of the recurring unit (RPEEK) may, independently from one another, have a 1 ,2-, a 1 ,3- or a 1 ,4-linkage to the other phenylene moieties. According to an embodiment, each phenylene moiety of the recurring unit (RPEEK), independently from one another, has a 1 ,3- or a 1 ,4-linkage to the other phenylene moieties. According to another embodiment yet, each phenylene moiety of the recurring unit (RPEEK) has a 1 ,4-linkage to the other phenylene moieties.

[0068] According to an embodiment, R' is, at each location in formula (J-A)

above, independently selected from the group consisting of a C1 -C12 moiety, optionally comprising one or more than one heteroatoms; sulfonic acid and sulfonate groups; phosphonic acid and phosphonate groups; amine and quaternary ammonium groups.

[0069] According to an embodiment, j' is zero for each R'. In other words,

according to this embodiment, the recurring units (RPEEK) are according to formula (J'-A):

[0070] at least 95 mol. %, at least 99 mol. % or all of the recurring units in the PAEK are recurring units (RPEEK) of formulae (J-A) and/or (J'-A).

[0071] According to another embodiment of the present disclosure, a poly(ether ether ketone) (PEEK) denotes any polymer comprising at least 10 mol.% of the recurring units are recurring units (RPEEK) of formula (J-A"):

the mol. % being based on the total number of moles of recurring units in the polymer.

[0072] According to an embodiment of the present disclosure, at least 10 mol.% (based on the total number of moles of recurring units in the polymer), at least 20 mol.%, at least 30 mol.%, at least 40 mol.%, at least 50 mol.%, at least 60 mol. % , at least 70 mol. %, at least 80 mol. %, at least 90 mol. %, at least 95 mol. %, at least 99 mol. % or all of the recurring units in the PEEK are recurring units (RPEEK) of formula (J"-A).

[0073] The PEEK polymer of the present disclosure can therefore be a

homopolymer or a copolymer. If the PEEK polymer is a copolymer, it can be a random, alternate or block copolymer.

[0074] When the PEEK is a copolymer, it can be made of recurring units (R*PEEK), different from and in addition to recurring units (RPEEK), such as recurring units of formula J-D):

where

R', at each location, is independently selected from the group consisting of halogen, alkyl, alkenyl, alkynyl, aryl, ether, thioether, carboxylic acid, ester, amide, imide, alkali or alkaline earth metal sulfonate, alkyl sulfonate, alkali or alkaline earth metal phosphonate, alkyl phosphonate, amine and quaternary ammonium; and j', for each R', is independently zero or an integer ranging from 1 to 4.

[0075] According to formula (J-B), each aromatic cycle of the recurring unit

(R*PEEK) may contain from 1 to 4 radical groups R'. When j' is 0, the corresponding aromatic cycle does not contain any radical group R'.

[0076] According to an embodiment, R' is, at each location in formula (J-B)

above, independently selected from the group consisting of a C1 -C12 moiety, optionally comprising one or more than one heteroatoms; sulfonic acid and sulfonate groups; phosphonic acid and phosphonate groups; amine and quaternary ammonium groups.

[0077] According to an embodiment, j' is zero for each R'. In other words,

according to this embodiment, the recurring units (R*PEEK) are according to formula (J'-D):

[0078] According to another embodiment of the present disclosure, the recurring units R*PEEK) are according to formula (J"-D):

[0079] According to an embodiment of the present disclosure, less than 90 mol.% (based on the total number of moles of recurring units in the polymer), less than 80 mol.%, less than 70 mol.%, less than 60 mol.%, less than 50 mol. %, less than 40 mol. %, less than 30 mol. %, less than 20 mol. %, less than 10 mol. %, less than 5 mol. %, less than 1 mol. % or all of the recurring units in the PEEK are recurring units (R*PEEK) of formulas (J-B), (J'-B), and/or (J"-B). [0080] According to an embodiment, the PEEK polymer is a PEEK-PEDEK copolymer. As used herein, a PEEK-PEDEK copolymer denotes a polymer comprising recurring units (RPEEK) of formula (J-A), (J'-A) and/or (J "-A) and recurring units (R*PEEK) of formulas (J-B), (J'-B) or (J"-B) (also called hereby recurring units (RPEDEK)). The PEEK-PEDEK copolymer may include relative molar proportions of recurring units (RPEEK/RPEDEK) ranging from 95/5 to 5/95, from 90/10 to 10/90, or from 85/15 to 15/85. The sum of recurring units (RPEEK) and (RPEDEK) can for example represent at least 60 mol.%, 70 mol.%, 80 mol.%, 90 mol.%, 95 mol.%, 99 mol.%, of recurring units in the PEEK copolymer. The sum of recurring units (RPEEK) and (RPEDEK) can also represent 100 mol.%, of recurring units in the PEEK copolymer.

[0081] Defects, end groups and monomers' impurities may be incorporated in very minor amounts in the polymer (PEEK) of the present disclosure, without undesirably affecting the performance of the polymer in the polymer composition (C1 ).

[0082] PEEK is commercially available as KetaSpire® PEEK from Solvay

Specialty Polymers USA, LLC.

[0083] PEEK can be prepared by any method known in the art. It can for example result from the condensation of 4,4'-difluorobenzophenone and

hydroquinone in presence of a base. The reactor of monomer units takes place through a nucleophilic aromatic substitution. The molecular weight (for example the weight average molecular weight Mw) can be adjusting the monomers molar ratio and measuring the yield of polymerisation (e.g. measure of the torque of the impeller that stirs the reaction mixture).

[0084] According to one embodiment of the present disclosure, the PEEK

polymer has a weight average molecular weight (Mw) ranging from 75,000 to 100,000 g/mol, for example from 77,000 to 98,000 g/mol, from 79,000 to 96,000 g/mol, from 81 ,000 to 95,000 g/mol, or from 85,000 to 94,500 g/mol (as determined by gel permeation chromatography (GPC) using phenol and trichlorobenzene (1 : 1 ) at 160°C, with polystyrene standards).

[0085] The polymer composition (C1 ) may comprise PEEK in an amount of at least 1 wt. %, for example at least 1.5 wt. %, at least 2 wt. %, at least 2.5 wt. %, at least 3 wt. %, at least 3.5 wt. %, or at least 4 wt. %, based on the total weight of the polymer composition (C1).

[0086] The polymer composition (C1 ) may comprise PEEK in an amount of less than 50 wt. %, for example less than 45 wt. %, less than 40 wt. %, less than 35 wt. %, less than 30 wt. %, less than 25 wt. %, or less than 20 wt.

%, based on the total weight of the polymer composition (C1 ).

[0087] Preferably, the polymer composition (C1 ) may comprise PEEK in an

amount ranging from 1 to 50 wt. %, for example from 1.5 to 45 wt. %, from

2 to 40 wt. % or from 3 to 35 wt. %, based on the total weight of the polymer composition (C1 ).

[0088] In another embodiment, the PAEK is poly(ether ketone ketone) (PEKK).

[0089] As used herein, a poly(ether ketone ketone) (PEKK) denotes a polymer comprising more than 50 mol. % of the recurring units of formulas (J-Bi) and (J-B2), the mol. % being based on the total number of moles of recurring units in the polymer:

(J-Bi)

wherein

R ¹ and R ² , at each instance, is independently selected from the group consisting of 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; and i and j, at each instance, is an independently selected integer ranging from 0 to 4.

[0090] According to an embodiment, R ¹ and R ² are, at each location in formula (J-B2) and (J-Bi) above, independently selected from the group consisting of a C1 -C12 moiety, optionally comprising one or more than one

heteroatoms; sulfonic acid and sulfonate groups; phosphonic acid and phosphonate groups; amine and quaternary ammonium groups.

[0091] According to another embodiment, i and j are zero for each R ¹ and R ² group. According to this embodiment, the PEKK polymer comprises at least 50 mol.% of recurring units of formulas (J'-Bi) and (J'-B2), the mol. % being based on the total number of moles of recurring units in the polymer:

[0092] According to an embodiment of the present disclosure, at least 55 mol. %, at least 60 mol. %, at least 70 mol. %, at least 80 mol. %, at least 90 mol. %, at least 95 mol. %, at least 99 mol. % or all of the recurring units in the PEKK are recurring units of formulae (J-B1) and (J-B2).

[0093] According to an embodiment of the present disclosure, in the PEKK

polymer, the molar ratio of recurring units (J-B2) or/and (J'-B2) to recurring units (J-Bi) or/and (J'-Bi) is at least 1 : 1 to 5.7: 1 , for example at least 1.2: 1 to 4: 1 , at least 1.4: 1 to 3: 1 or at least 1.4: 1 to 1.86: 1.

[0094] The PEKK polymer has preferably an inherent viscosity of at least 0.50 deciliters per gram (dL/g), as measured following ASTM D2857 at 30 °C on 0.5 wt./vol.% solutions in concentrated H2SO ₄ (96 wt.% minimum), for example at least 0.60 dL/g or at least 0.65 dL/g and for example at most

1.50 dL/g, at most 1.40 dL/g, or at most 1.30 dL/g.

[0095] The polymer composition (C1 ) may comprise PEKK in an amount of at least 1 wt. %, for example at least 1.5 wt. %, at least 2 wt. %, at least 2.5 wt. %, at least 3 wt. %, at least 3.5 wt. %, or at least 4 wt. %, based on the total weight of the polymer composition (C1).

[0096] The polymer composition (C1 ) may comprise PEKK in an amount of less than 50 wt. %, for example less than 45 wt. %, less than 40 wt. %, less than 35 wt. %, less than 30 wt. %, less than 25 wt. %, or less than 20 wt.

%, based on the total weight of the polymer composition (C1 ).

[0097] Preferably, the polymer composition (C1 ) may comprise PEKK in an

amount ranging from 1 to 50 wt. %, for example from 1.5 to 45 wt. %, from

2 to 40 wt. % or from 3 to 35 wt. %, based on the total weight of the polymer composition (C1 ).

[0098] Polyphenylene sulfide (PPS)

[0099] The polymer composition (C1 ) comprises a polyphenylene sulfide polymer (PPS).

[00100] In its broadest definition, the PPS of the present invention can be made of substituted and/or unsubstituted phenylene sulfide groups.

[00101] According to the present invention, a PPS polymer denotes any polymer comprising at least 50 mol. % of recurring units (Rpps) of formula (U) (mol.

% being based on the total number of moles of recurring units in the PPS polymer):

where

R is independently selected from the group consisting of halogen, C1-C12 alkyl groups, C7-C24 alkylaryl groups, C7-C24 aralkyl groups, C6-C24 arylene groups, C1-C12 alkoxy groups, and C6-C18 aryloxy groups, and

i is independently zero or an integer from 1 to 4. [00102] According to formula (U), the aromatic cycle of the recurring unit (Rpps) may contain from 1 to 4 radical groups R. When i is zero, the

corresponding aromatic cycle does not contain any radical group R.

[00103] According to an embodiment of the present invention, the PPS polymer denotes any polymer comprising at least 50 mol. % of recurring units (RPPS) of formula (IT)

[00104] According to an embodiment of the present invention, the PPS polymer is such that at least 60 mol. %, at least 70 mol. %, at least 80 mol. %, at least 90 mol. %, at least 95 mol. %, at least 99 mol. % of the recurring units in the PPS are recurring units (Rpps) of formula (U) or (IT). The mol.% are based are based on the total number of moles of recurring units in the PPS polymer.

[00105] According to an embodiment of the present invention, the PPS polymer is such that 100 mol. % of the recurring units are recurring units (Rpps) of formula (U) or (IT). According to this embodiment, the PPS polymer consists essentially of recurring units (Rpps) of formula (U) or (IT).

[00106] PPS is commercially available under the tradename Ryton ^® PPS from

Solvay Specialty Polymers USA, LLC.

[00107] The melt flow rate (at 316°C under a weight of 5 kg according to ASTM D1238, procedure B) of the PPS may be from 50 to 400 g/10 min, for example from 60 to 300 g/10 min or from 70 to 200 g/10 min.

[00108] The polymer composition (C1 ) may comprise PPS in an amount of at least 1 wt. %, for example at least 5 wt. %, at least 10 wt. %, at least 15 wt. %, at least 20 wt. %, at least 25 wt. %, or at least 30 wt. %, based on the total weight of the polymer composition (C1 ).

[00109] The polymer composition (C1 ) may comprise PPS in an amount of less than 50 wt. %, for example less than 45 wt. %, less than 40 wt. %, less than 35 wt. %, less than 30 wt. %, less than 25 wt. %, or less than 23 wt. %, based on the total weight of the polymer composition (C1 ). [001 10] Preferably, the polymer composition (C1 ) may comprise PPS in an amount ranging from 1 to 50 wt. %, for example from 3 to 46 wt. %, from 6 to 42 wt. % or from 12 to 38 wt. %, based on the total weight of the polymer composition (C1 ).

[001 1 1] Glass fibers

[001 12] The polymer composition (C1 ) also comprises glass fibers. Glass fibers are silica-based glass compounds that contain several metal oxides which can be tailored to create different types of glass. The main oxide is silica in the form of silica sand; other oxides, such as oxides of calcium, sodium and aluminium, are incorporated to reduce the melting temperature and impede crystallization. Glass fibers may have a round cross-section or a non-circular cross-section (so called "flat glass fibers"), including oval, elliptical or rectangular. The glass fibers may be added as endless fibers or as chopped glass fibers, whereas chopped glass fibers are preferred. The glass fibers have generally a diameter of 5 to 20 μηη preferably of 5 to 15 μηη and more preferably of 5 to 10 μηη.

[001 13] According to an embodiment, the polymer composition (C1 ) comprises E- glass fibers.

[001 14] According to an embodiment, the polymer composition (C1 ) comprises high modulus glass fibers having an elastic modulus (also called tensile modulus of elasticity) of at least 76, preferably at least 78, more preferably at least 80, and most preferably at least 82 GPa as measured according to ASTM D2343.

[001 15] According to an embodiment, the polymer composition (C1 ) comprises high modulus glass fibers selected from the group consisting of R, S and T glass fibers. They are notably described in Fiberglass and Glass

Technology, Wallenberger, Frederick T. ; Bingham, Paul A. (Eds.), 2010, XIV. R, S and T glass fibers are composed essentially of oxides of silicon, aluminium and magnesium. In particular, R, S and T glass fibers comprise typically from 62-75 wt. % of SiO ₂ , from 16-28 wt. % of AI ₂ O ₃ and from 5- 14 wt. % of MgO. Additionally, R, S and T glass fibers generally comprise less than 10 wt. % of CaO. [001 16] The polymer composition (C1 ) may comprise glass fibers in an amount of at least 5 wt. %, for example at least 10 wt. %, at least 15 wt. %, at least 20 wt. %, at least 25 wt. %, at least 26 wt. %, or at least 28 wt. %, based on the total weight of the polymer composition (C1 ).

[001 17] The polymer composition (C1 ) may comprise glass fibers in an amount of less than 70 wt. %, for example less than 65 wt. %, less than 60 wt. %, less than 55 wt. %, less than 50 wt. %, less than 45 wt. %, or less than 40 wt. %, based on the total weight of the polymer composition (C1).

[001 18] Preferably, the polymer composition (C1 ) may comprise glass fibers in an amount ranging from 7 to 65 wt. %, for example from 9 to 61 wt. %, from 12 to 58 wt. % or from 14 to 56 wt. %, based on the total weight of the polymer composition (C1 ).

[001 19] Optional ingredients

[00120] The polymer composition (C1 ) may further optionally comprise one or more additional additives selected from the group consisting of ultraviolet light stabilizers, heat stabilizers, acid scavengers (i.e. zinc oxide, magnesium oxide), antioxidants, pigments, processing aids, lubricants, flame retardants, and/or conductivity additive (i.e. carbon black and carbon nanofibrils).

[00121] The polymer composition (C1 ) may also further comprise other polymers than PSU, PEEK and PPS. In particular, the polymer composition (C1 ) may further comprise polymers such as poly(biphenyl ether sulfone) (PPSU), poly(ether sulfone) (PES) and/or polycarbonate (PC).

[00122] The polymer composition (C1 ) may further comprise flame retardants such as halogen and halogen free flame retardants.

[00123] Methods of making the polymer composition (C1 )

[00124] Exemplary embodiments also include methods of making the polymer composition (C1 ).

[00125] The polymer composition (C1 ) can be made by methods well known to the person of skill in the art. For example, such methods include, but are not limited to, melt-mixing processes. Melt-mixing processes are typically carried out by heating the polymer components above the melting temperature of the thermoplastic polymers thereby forming a melt of the thermoplastic polymers. In some embodiments, the processing

temperature ranges from about 280-450°C, preferably from about 290- 440°C, from about 300-430°C or from about 310-420°C. Suitable melt- mixing apparatus are, for example, kneaders, Banbury mixers, single- screw extruders, and twin-screw extruders. Preferably, use is made of an extruder fitted with means for dosing all the desired components to the extruder, either to the extruder's throat or to the melt. In the process for the preparation of the part material, the components of the polymer composition, e.g. the PSU, the PEEK, the PPS, the glass fibers, and optional additives, are fed to the melt-mixing apparatus and melt-mixed in that apparatus. The components may be fed simultaneously as a powder mixture or granule mixer, also known as dry-blend, or may be fed separately.

[00126] The order of combining the components during melt-mixing is not

particularly limited. In one embodiment, the component can be mixed in a single batch, such that the desired amounts of each component are added together and subsequently mixed. In other embodiments, a first sub-set of components can be initially mixed together and one or more of the remaining components can be added to the mixture for further mixing. For clarity, the total desired amount of each component does not have to be mixed as a single quantity. For example, for one or more of the

components, a partial quantity can be initially added and mixed and, subsequently, some or all of the remainder can be added and mixed.

[00127] Shaped Articles and Methods of Making

[00128] Exemplary embodiments also include shaped articles comprising the

above-described polymer composition and methods of making the shaped articles.

[00129] The polymer composition may be well suited for the manufacture of

articles useful in a wide variety of applications. For example, the high- flow, toughness, and chemical resistance properties of the polymer composition makes it especially suitable for use in thin walled articles, structural components for mobile electronic devices (e.g., framework or housing), thermoplastic continuous fiber composites (e.g. for aeronautics and automotive structural parts), medical implants and medical devices, and shaped articles made by additive manufacturing methods as discussed below.

[00130] In some aspects, the shaped articles may be made from the polymer

composition using any suitable melt-processing method such as injection molding, extrusion molding, roto-molding, or blow-molding.

[00131] Exemplary embodiments are also directed to methods of making shaped articles by additive manufacturing, where the shaped article is printed from the polymer composition. The methods include printing layers of the shaped article from the polymer composition as described below.

[00132] Additive manufacturing systems are used to print or otherwise build a

shaped object from a digital representation of the shaped object by one or more additive manufacturing techniques. Examples of commercially available additive manufacturing techniques include extrusion-based techniques, selective laser sintering, powder/binder jetting, electron-beam melting, and stereolithography processes. For each of these techniques, the digital representation of the shaped object is initially sliced into multiple horizontal layers. For each layer, a tool path is then generated, which provides instructions for the particular additive manufacturing system to print the given layer.

[00133] For example, in an extrusion-based additive manufacturing system, a

shaped article may be printed from a digital representation of the shaped article in a layer-by-layer manner by extruding and adjoining strips of the polymer composition. The polymer composition is extruded through an extrusion tip carried by a print head of the system, and is deposited as a sequence of roads on a platen in an x-y plane. The extruded material fuses to previously deposited material and solidifies as it cools. The position of the print head relative to the substrate is then incremented along a z-axis (perpendicular to the x-y plane), and the process is repeated to form a shaped article resembling the digital representation. An example of an extrusion-based additive manufacturing system is Fused Filament Fabrication (FFF). [00134] As another example, in a powder-based additive manufacturing system, a laser is used to locally sinter powder into a solid part. A shaped article is created by sequentially depositing a layer of powder followed by a laser pattern to sinter an image onto that layer. An example of a powder-based additive manufacturing system is Selective Laser Sintering (SLS).

[00135] As another example, carbon-fiber composite shaped articles can be

prepared using a continuous Fiber-Reinforced Thermosplastic (FRTP) printing method. This method is based on fused-deposition modeling (FDM) and prints a combination of fibers and resin.

[00136] The flowability of the polymer composition (C1) is particularly important in additive manufacturing applications where, for example, the polymer must flow readily from printing nozzles and must spread quickly and evenly to produce a uniform surface before cooling; however it is also important that the flowability needed for printing not come at the significant expense of mechanical properties of the resin in the resulting printed object. As discussed above, glass-filed polymer compositions (C1 ) including for example PSU, PEEK and PPS exhibit reduced melt viscosity without compromising the mechanical properties, as compared with PSU alone, or a blend of PSU and PE, making such polymer compositions particularly suitable for applications, such as, for example, structural components for mobile electronic devices, and additive manufacturing methods such as selective laser sintering (SLS) and fused filament fabrication (FFF).

[00137] Accordingly, some embodiments include a method of making a shaped article comprising printing layers of the polymer composition to form the shaped article by an extrusion-based additive manufacturing system (for example FFF), a powder-based additive manufacturing system (for example SLS), or a continuous Fiber-Reinforced Thermosplastic (FRTP) printing method.

[00138] Some embodiments include a filament including the polymer composition (C1 ). Preferably, the filament is suitable for use in additive manufacturing methods as described above, such as FFF.

[00139] The term "filament" refers to a thread-like object or fiber including the

polymer composition. The filament may have a cylindrical or substantially cylindrical geometry, or may have a non-cylindrical geometry, such as a ribbon-shaped filament. The filament may be hollow, or may have a core- shell geometry, with a different polymer composition comprising either the core or the shell.

[00140] When the filament has a cylindrical geometry, the diameter of the cross- section of the fiber preferably ranges from 0.5 to 5 mm, preferably from 0.8 to 4 mm, preferably from 1 mm to 3.5 mm. The diameter of the filament can be chosen to feed a specific FFF 3D printer. An example of filament diameter used extensively in FFF processes is about 1.75 mm or about 2.85 mm. The filament is preferably made by extruding the polymer composition.

[00141] According to some embodiments, the polymer composition is in the form of microparticles or a powder, for example having an average diameter ranging from 1 to 200 μηη, preferably from 10 to 100 μηη, preferably from 20 to 80 μηη as measured by electron microscopy.

[00142] Exemplary embodiments also include shaped articles made, at least in part, by the additive manufacturing methods described above using the polymer composition described above. Such shaped articles can be used in a variety of final applications such as implantable medical devices, dental prostheses, and brackets and complex shaped parts in the aerospace and automotive industries.

[00143] Exemplary embodiments will now be described in the following non-limiting examples.

[00144] Should the disclosure of any patents, patent applications, and publications which are incorporated herein by reference conflict with the description of the present application to the extent that it may render a term unclear, the present description shall take precedence.

[00145] EXAMPLES

[00146] The effects on melt viscosity and mechanical properties were evaluated for various binary and ternary polymer blends.

[00147] Starting materials

[00148] UDEL® PSU P-1700 from Solvay Specialty Polymers USA, L.L.C. [00149] KETASPIRE® PEEK KT-880 from Solvay Specialty Polymers USA, LLC.

[00150] RYTON® PPS QA-250N from Solvay Specialty Polymers USA, LLC.

[00151] OCV 91 OA chopped E-fiberglass from Owens-Corning Vetrotex

[00152] General description of the compounding process of the

PSU/PEEK/PPS/glass fiber polymer compositions

[00153] Each formulation was melt compounded 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: Barrels 2-6: 350 °C; Barrels 7-12: 360 °C; Die: 360 °C.

[00154] In each case, the resin blends were fed at barrel section 1 using a

gravimetric feeder at throughput rates in the range 30-35 Ib/hr. The extruder was operated at screw speeds of around 200 RPM. 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 to give a filament approximately 2.6 to 2.7 mm in diameter and the polymer filament exiting the die was cooled in water and fed to the pelletizer to generate pellets approximately 2.7 mm in length. Pellets were dried prior being injection molded.

[00155] Evaluation of Rheological and Mechanical Properties

[00156] Mechanical properties were tested for all the formulations using injection molded 0.125 in (3.2 mm) thick ASTM test specimens which consisted of Type I tensile bars. The following ASTM test methods were employed in evaluating the mechanical properties of the formulations:

Melt viscosity (350 °C, 5kg): ASTM D3835

Tensile properties: ASTM D638

Izod unnotched impact resistance (unnotched): ASTM D256

[00157] Experimental Results

Table 1 : Ternary blend PSU/PEEK/PPS (5 wt.% of PEEK) with Glass Fibers C1 C2 C3 1 2 3

PSU 70 65 - 45 35 15

PEEK - 5 5 5 5 5

PPS - - 65 20 30 50

Glass fibers 30 30 30 30 30 30

Melt Flow

350°C, 5 kg (g/10 min) 10 8.6 145.6 25.8 60.4 90.5

Mechanical properties

Tensile Strength (MPa) 108 nd 167 154 164 172

Tensile elongation (%) 2 nd 1 .6 2.4 2.3 2

Unnotched Impact resistance

390 nd 477 763 737 550 (J/m) nd: non determined

[00158] The addition of 5 wt.% of PEEK (C2) to glass-filled PSU leads to a

decrease of the melt flow, and the mechanical properties were therefore not determined. The addition of 5 wt.% of PEEK (C3) to glass-filed PPS results in a high flow binary composition at the expense of tensile elongation, leading to a brittle compound.

[00159] The ternary compositions of examples 1 to 3 demonstrate a synergistic effect is obtained and all properties including melt flow and mechanicals can be maximized.

Table 2: Ternary blend PSU/PEEK/PPS (10 wt.% of PPS) with Glass Fibers C4 C5 4 5 6 7

PSU 60 - 50 40 30 15

PEEK - 60 10 20 30 45

PPS 10 10 10 10 10 10

Glass fibers 30 30 30 30 30 30

Melt Flow

350°C, 5 kg

14.4 9.12 12.5 17.3 1 1.93 1 1.75 (g/10 min)

Mechanical Properties

Tensile

Strength 137 nd 141 153 157 175

(MPa)

Tensile

elongation 2.3 nd 2.7 2.6 2.5 2.6

(%)

Unnotched

Impact 603 nd 790 854 1015 1015 resistance nd: not determined

[00160] The addition of 10 wt.% of PPS (C4) to glass-filled PSU leads to a

increase of the melt flow, and a slight increase of the mechanical properties compared to a glass-filled PSU (composition C1).

[00161] The addition of 10 wt.% PPS to a glass-filed PEEK (C5) leads to a

decrease of the melt flow, and the mechanical properties were therefore not determined. [00162] By maintaining the same content of PPS, the introduction of PEEK as the third component in the compositions at various levels allows for an improvement of the melt flow and at the same of the mechanical properties, in particular tensile and impact properties, resulting in stronger and tougher polymer compositions.

Table 3: Ternary blend PSU/PEEK/PPS (10 wt.% of PEEK) with Glass Fibers

nd: not determined [00163] The addition of 10 wt.% PEEK to a glass-filed PSU (C6) leads to a decrease of the melt flow in comparison to a glass-filed PSU (composition C1 ), and the mechanical properties were therefore not determined.

[00164] The addition of 10 wt.% PEEK to a glass-filed PPS (C7) leads to a

increase of the melt flow in comparison to a glass-filed PSU (composition C1 ), and the mechanical properties were therefore not determined.

[00165] The compositions of examples 8 to 1 1 allow for an improvement of the melt flow and at the same of the mechanical properties, in particular tensile and impact properties, resulting in stronger and tougher polymer compositions.