Fiber reinforced polyaryletherketone resin compositions
View Patent ↗Disclosed herein are methods and fiber reinforced thermoplastic composition comprising: a polyaryletherketone (PAEK) component; a polyimide component, wherein the polyimide component comprises a blend of at least a first polyimide (PI) having glass transition temperature of at least 300° C. and a second polyimide (PI) having glass transition temperature less than the glass transition temperature of the first polyimide; and a reinforcement fiber component. The resulting fiber reinforced thermoplastic compositions exhibit improved mechanical performance.
1. A fiber reinforced thermoplastic composition comprising
a. a thermoplastic polymer blend comprising
i. a polyaryletherketone (PAEK) component; and
ii. a polyimide component, wherein the polyimide component comprises a blend of at least a first polyimide having glass transition temperature of at least 300° C. and a second polyimide having glass transition temperature less than the glass transition temperature of the first polyimide; wherein neither the first polyimide nor the second polyimide contains fluorine or silicon atoms; and
b. a reinforcement fiber component,
wherein the polyaryletherketone component is present in an amount in the range of from 30 to 60 weight percent relative to the total weight of the composition.
2. The fiber reinforced thermoplastic composition of claim 1 , wherein the polyaryletherketone component comprises polyetheretherketone, polyetherketone, polyetherketoneketone, polyetherketoneetherketoneketone, or polyetheretherketoneketone, or a combination thereof.
3. The fiber reinforced thermoplastic composition of claim 1 , wherein the polyimide component is present in an amount in the range of from 30 to 60 weight percent relative to the total weight of the composition.
4. The fiber reinforced thermoplastic composition of claim 1 , wherein the second polyimide is present in the polyimide component in a weight fraction in the range of from 0.05 to 0.95 relative to the total weight of the polyimide component.
5. The fiber reinforced thermoplastic composition of claim 1 , wherein the second polyimide is present in the polyimide component in a weight fraction in the range of from 0.2 to 0.9 relative to the total weight of the polyimide component.
6. The fiber reinforced thermoplastic composition of claim 1 , wherein the second polyimide is present in the polyimide component in a weight fraction in the range of from 0.4 to 0.8 relative to the total weight of the polyimide component.
7. The fiber reinforced thermoplastic composition of any preceding claim, wherein the first polyimide has a glass transition temperature in the range of from 300° C. to 320° C.
8. The fiber reinforced thermoplastic composition of claim 1 , wherein the second polyimide has a glass transition temperature less than 300° C.
9. The fiber reinforced thermoplastic composition of claim 1 , wherein the second polyimide has a glass transition temperature less than 280° C.
10. The fiber reinforced thermoplastic composition of claim 1 , wherein the second polyimide has a glass transition temperature less than 260° C.
11. The fiber reinforced thermoplastic composition of claim 1 , wherein the polyaryletherketone component has a melt viscosity in the range of from 50 to 800 Pascal-seconds measured at 400° C. and under a shear rate of 1000/s.
12. The fiber reinforced thermoplastic composition of claim 1 , wherein the polyaryletherketone component has a melt viscosity in the range of from 70 to 500 Pascal-seconds measured at 400° C. and under a shear rate of 1000/s.
13. The fiber reinforced thermoplastic composition of claim 1 , wherein the reinforcement fiber component is present in the composition in an amount in the range of from 5 to 50 weight percent relative to the total weight of the composition.
14. The fiber reinforced thermoplastic composition of claim 1 , wherein the reinforcement fiber component is present in the composition in an amount in the range of from 10 to 40 weight percent relative to the total weight of the composition.
15. The fiber reinforced thermoplastic composition of claim 1 , wherein the reinforcement fiber component comprises carbon fibers.
16. The fiber reinforced thermoplastic composition claim 1 , wherein the reinforcement fiber component comprises carbon fibers having a tensile modulus in the range of from 28 to 48 MSI.
17. The fiber reinforced thermoplastic composition of claim 1 , wherein the reinforcement fiber component comprises carbon fibers having a tensile strength in the range of from 400 to 1200 KSI.
18. The fiber reinforced thermoplastic composition of claim 1 , wherein the reinforcement fiber component comprises glass fibers.
19. The fiber reinforced thermoplastic composition of claim 1 , wherein the reinforcement fiber component comprises glass fibers having a tensile modulus in the range of from 9 to 15 MSI.
20. The fiber reinforced thermoplastic composition of claim 1 , wherein the reinforcement fiber component comprises glass fibers having a tensile strength in the range of from 300 to 900 KSI.
21. The fiber reinforced thermoplastic composition of claim 1 , wherein the first polyimide or the second polyimide comprises a polyetherimide sulfone.
22. The fiber reinforced thermoplastic composition of claim 21 , wherein the first polyimide is a polycondensation reaction product of 4,4′-oxydiphthalic dianhydride and 4,4′-diaminodiphenyl sulfone.
23. The fiber reinforced thermoplastic composition of claim 21 , wherein the second polyimide is a polycondensation reaction product of 4,4′-Bisphenol A dianhyride and 4,4′-diaminodiphenyl sulfone.
24. The fiber reinforced thermoplastic composition of claim 1 , wherein a molded part formed from the thermoplastic composition exhibits a greater tensile strength compared to a molded part formed from a substantially identical reference composition comprising the same weight percentage of the polyaryletherketone component, the same weight percentage of the reinforcement fiber component, and the same weight percentage of the polyimide component but in the absence of the second polyimide.
25. The fiber reinforced thermoplastic composition of claim 1 , wherein a molded part formed from the thermoplastic composition exhibits a greater flexural strength compared to a molded part formed from a substantially identical reference composition comprising the same weight percentage of the polyaryletherketone component, the same weight percentage of the reinforcement fiber component, and the same weight percentage of the polyimide component but in the absence of the second polyimide.
26. The fiber reinforced thermoplastic composition of claim 1 , wherein a molded part formed from the thermoplastic composition exhibits an increased toughness compared to a molded part formed from a substantially identical reference composition comprising the same weight percentage of the polyaryletherketone component, the same weight percentage of the reinforcement fiber component, and the same weight percentage of the polyimide component but in the absence of the second polyimide.
27. The fiber reinforced thermoplastic composition of claim 1 , wherein a molded part formed from the thermoplastic composition exhibits a greater notched Izod impact strength compared to a molded part formed from a substantially identical reference composition comprising the same weight percentage of the polyaryletherketone component, the same weight percentage of the reinforcement fiber component, and the same weight percentage of the polyimide component but in the absence of the second polyimide.
28. The fiber reinforced thermoplastic composition of claim 1 , wherein a molded part formed from the thermoplastic composition exhibits a greater unnotched Izod impact strength compared to a molded part formed from a substantially identical reference composition comprising the same weight percentage of the polyaryletherketone component, the same weight percentage of the reinforcement fiber component, and the same weight percentage of the polyimide component but in the absence of the second polyimide.
29. A fiber reinforced thermoplastic composition comprising
a. from 60 to 90 weight percent of a thermoplastic polymer blend comprising:
i. a polyetheretherketone (PEEK) component; and
ii. a polyimide component comprising a blend of at least a first polyimide having glass transition temperature of at least 300° C. and a second polyimide having glass transition temperature in the range of from 240° C. to 260° C., wherein the second polyimide is present in the polyimide component in a relative weight fraction in the range of from 0.2 to 0.8 relative to the total weight of the polyimide component; wherein neither the first polyimide nor the second polyimide contains fluorine or silicon atoms; and
b. from greater than 10 to 40 weight percent of a reinforcement fiber component,
wherein the polyetheretherketone component is present in an amount in the range of from 30 to 60 weight percent relative to the total weight of the composition.
30. The fiber reinforced thermoplastic composition of claim 29 , wherein the reinforcement fiber component comprises carbon fibers having a tensile modulus in the range of from 28 to 48 MSI.
31. The fiber reinforced thermoplastic composition of claim 29 , wherein the polyimide component is present in an amount in the range of from 30 to 60 weight percent relative to the total weight of the composition.
32. The fiber reinforced thermoplastic composition of claim 29 , wherein a molded part formed from the thermoplastic composition exhibits a greater tensile strength compared to a molded part formed from a substantially identical reference composition comprising the same weight percentage of the polyetheretherketone component, the same weight percentage of the reinforcement fiber component, and the same weight percentage of the polyimide component but in the absence of the second polyimide.
33. The fiber reinforced thermoplastic composition of claim 29 , wherein a molded part formed from the thermoplastic composition exhibits a greater flexural strength compared to a molded part formed from a substantially identical reference composition comprising the same weight percentage of the polyetheretherketone component, the same weight percentage of the reinforcement fiber component, and the same weight percentage of the polyimide component but in the absence of the second polyimide.
34. The fiber reinforced thermoplastic composition of claim 29 , wherein a molded part formed from the thermoplastic composition exhibits an increased toughness compared to a molded part formed from a substantially identical reference composition comprising the same weight percentage of the polyetheretherketone component, the same weight percentage of the reinforcement fiber component, and the same weight percentage of the polyimide component but in the absence of the second polyimide.
35. The fiber reinforced thermoplastic composition of claim 29 , wherein a molded part formed from the thermoplastic composition exhibits a greater notched Izod impact strength compared to a molded part formed from a substantially identical reference composition comprising the same weight percentage of the polyetheretherketone component, the same weight percentage of the reinforcement fiber component, and the same weight percentage of the polyimide component but in the absence of the second polyimide.
36. The fiber reinforced thermoplastic composition of claim 29 , wherein a molded part formed from the thermoplastic composition exhibits a greater unnotched Izod impact strength compared to a molded part formed from a substantially identical reference composition comprising the same weight percentage of the polyetheretherketone component, the same weight percentage of the reinforcement fiber component, and the same weight percentage of the polyimide component but in the absence of the second polyimide.
37. An article of manufacture comprising the fiber reinforced thermoplastic composition of claim 1 .