Process for the manufacture of thermoplastic polymer particles, thermoplastic polymer particles prepared thereby, and articles prepared therefrom

1. A process for the manufacture of thermoplastic polymer particles, the process comprising

combining a first solution comprising a polyetherimide, a polycarbonate, or a combination thereof and an organic solvent with an aqueous solution comprising an effective amount of a surfactant to provide a mixture;

agitating the mixture using a shear force generating device at a preselected peripheral rotational speed to provide an emulsion;

heating the emulsion to a temperature of greater than 35° C. to remove the organic solvent and provide an aqueous polymer dispersion comprising thermoplastic polymer particles; and

recovering the thermoplastic polymer particles from the aqueous polymer dispersion in a yield of greater than 80%;

wherein

when the preselected peripheral rotational speed is 2 to less than 14 m/s, and the effective amount of the surfactant is 0.005 to 0.05 weight percent, based on the weight of the aqueous solution, the thermoplastic polymer particles are spherical particles having

a Dv50 diameter of 35 to 80 micrometers; and

a particle size distribution span of 1.0 to 1.5;

when the preselected peripheral rotational speed is 14 to 23.5 m/s, and the effective amount of the surfactant is 0.005 to 0.05 weight percent, based on the weight of the aqueous solution, the thermoplastic polymer particles are spherical particles having

a Dv50 diameter of 5 to 25 micrometers; and

a particle size distribution span of 1.1 to 2.0;

when the preselected peripheral rotational speed is 2 to less than 14 m/s, and the effective amount of the surfactant is greater than 0.05 to 1 weight percent, based on the weight of the aqueous solution, the thermoplastic polymer particles are spherical particles having

a Dv50 diameter of 15 to 40 micrometers; and

a particle size distribution span of 1.0 to 2.0; and

when the preselected peripheral rotational speed is 14 to 23.5 m/s, and the effective amount of the surfactant is greater than 0.05 to 1 weight percent, based on the weight of the aqueous solution, the thermoplastic polymer particles are spherical particles having

a Dv50 diameter of 1 to 20 micrometers; and

a particle size distribution span of 1.1 to 2.0.

2. The process of claim 1 , wherein the first solution comprises a polyetherimide.

3. The process of claim 1 , wherein the first solution comprises a polycarbonate.

4. The process of claim 1 , wherein the first solution comprises the polyetherimide, the polycarbonate, or combination thereof in an amount of 3 to 30 weight percent, based on the total weight of the first solution.

5. The process of claim 1 , wherein the emulsion comprises water in a water:organic solvent weight ratio of greater than or equal to 0.2.

6. The process of claim 1 , wherein heating the emulsion comprises transferring the emulsion into a receiving water at a temperature of greater than 35° C. to remove the organic solvent.

7. The process of claim 1 , wherein heating the emulsion is to a temperature of greater than 40 to 99° C.

8. The process of claim 1 , wherein recovering the thermoplastic polymer particles comprises filtering the aqueous dispersion to form a wet cake.

9. The process of claim 8 , further comprising

washing the wet cake with water, preferably deionized water at a temperature of 25 to 100° C.; and

drying the wet cake, preferably drying the wet cake under heat, vacuum, or both.

10. The process of claim 1 , wherein the organic solvent has a boiling point that is less than 100° C. and is substantially immiscible with water.

11. The process of claim 1 , wherein the surfactant comprises an anionic surfactant.

12. The process of claim 1 , wherein agitating the emulsion is for a time of

0.5 to 30 minutes; or

5 minutes to 24 hours.

13. The process of claim 1 , wherein

the first solution further comprises an additive comprising a particulate filler, antioxidant, heat stabilizer, light stabilizer, ultraviolet light stabilizer, UV absorbing additive, NIR absorbing additive, IR absorbing additive, plasticizer, lubricant, release agent, antistatic agent, anti-fog agent, antimicrobial agent, colorant, laser marking additive, surface effect additive, radiation stabilizer, flame retardant, anti-drip agent, a fragrance, a fiber, or a combination comprising at least one of the foregoing, preferably a colorant; and

the thermoplastic polymer particles recovered from the aqueous polymer dispersion comprise the additive.

14. The process of claim 1 , wherein the preselected peripheral rotational speed is 2 to 3.3 m/s, and the effective amount of the surfactant is 0.005 to 0.05 weight percent, based on the weight of the aqueous solution, and the thermoplastic polymer particles are spherical particles having

a Dv10 diameter of 15 to 45 micrometers;

a Dv50 diameter of 35 to 80 micrometers;

a Dv90 diameter of 65 to 130 micrometers; and

a particle size distribution span of 1.0 to 1.8.

15. The process of claim 1 , wherein the preselected peripheral rotational speed is 14 to 19 m/s, and the effective amount of the surfactant is 0.005 to 0.05 weight percent, based on the weight of the aqueous solution, and the thermoplastic polymer particles are spherical particles having

a Dv10 diameter of 1 to 10 micrometers;

a Dv50 diameter of 3 to 30 micrometers;

a Dv90 diameter of 5 to 50 micrometers; and

a particle size distribution span of 1.1 to 2.8.

16. The process of claim 1 , wherein the preselected peripheral rotational speed is 2 to 3.3 m/s, and the effective amount of the surfactant is 0.05 to 1 weight percent, based on the weight of the aqueous solution, and the thermoplastic polymer particles are spherical particles having

a Dv10 diameter of 5 to 25 micrometers;

a Dv50 diameter of 15 to 40 micrometers;

a Dv90 diameter of 30 to 80 micrometers; and

a particle size distribution span of 1.1 to 2.4.

17. The process of claim 1 , wherein the preselected peripheral rotational speed is 14 to 19 m/s, and the effective amount of the surfactant is 0.05 to 1 weight percent, based on the weight of the aqueous solution, and the thermoplastic polymer particles are spherical particles having

a Dv10 diameter of 1 to 5 micrometers;

a Dv50 diameter of 2 to 20 micrometers;

a Dv90 diameter of 4 to 30 micrometers; and

a particle size distribution span of 1.2 to 2.5.

18. Thermoplastic polymer particles prepared according to the process of claim 1 .

19. An article prepared from the thermoplastic polymer particles of claim 18 .