Polymeric material

1. A method of making a composite material which comprises a polymeric material of a type which includes:

(a) phenyl moieties;

(b) ketone moieties; and

(c) ether moieties;

and a filler means wherein said polymeric material has en MV in the range 0.07 to 0.11 kNsm −2 and wherein said filler means comprises a discontinuous fibrous filler or a non-fibrous filler, the method comprising:

(i) selecting said polymeric material having an MV in the range 0.07 to 0.11 kNsm −2 , wherein said polymeric material is of a type which includes:

(a) phenyl moieties;

(b) ketone moieties; and

(c) ether moieties;

AND

(ii) contacting said polymeric material with a filler means to prepare said composite material.

2. A method according to claim 1 , which comprises extruding said polymeric material and filler means and subsequently forming pellets or granules from extruded material thereby to prepare pellets or granules of said composite material.

3. A method of making a component, the method comprising extruding or injection moulding a polymeric material having an MV in the range 0.07 to 0.11 kNsm −2 , wherein said polymeric material is of a type which includes:

(a) phenyl moieties;

(b) ketone moieties; and

(c) ether moieties.

4. A method according to claim 3 , which includes selecting a precursor material from which to make a component wherein said precursor material comprises a said polymeric material and subjecting the precursor material to a temperature above its melting temperature in an extrusion or injection moulding apparatus.

5. A method of making a component according to claim 4 , wherein said component has a wall which includes a region having a thickness of 3 mm or less.

6. A method according to claim 3 , wherein said polymeric material comprises polyatheretherketone having an MV in the range 0.085 to 0.095 kNsm −2 when measured at a shear rate of 1000s −1 .

7. A method according to claim 3 , the method comprising extruding or injection moulding a composite material which comprises said polymeric material, wherein said composite material comprises:

polyetheretherketone having an MV in the range 0.085 to 0.095 kNsm −2 when measured at a shear rate of 1000s −1 ;

a filler means comprising a discontinuous fibrous filler or a non-fibrous filler;

wherein the ratio of the wt % of polyatheretherketone to the wt % of filler means in said composite material is at least 1.

8. A method according to claim 7 , which comprises selecting pellets or granules comprising said composite material and subjecting said pellets or granules to an extrusion or injection moulding process whereby said component is made.

9. A method according to claim 1 , wherein said polymeric material is selected from the group comprising polyetheretherketone, polyetherketone, polyetherketoneketone, polyetherketoneetherketoneketone, polyetheretherketoneketone, polyether-diphenyl-ether-phenyl-ketone-phenyl-.

10. A method according to claim 1 , wherein said polymeric material comprises polyetheretherketone.

11. A method according to claim 1 , wherein said polymeric material selected in step (i) and the composite material prepared in step (ii) comprise said polymeric material having an MV in the range 0.08 to 0.11 kNsm −2 .

12. A method according to claim 9 , wherein said polymeric material selected in step (i) and the composite material prepared in step (ii) comprise said polymeric material having an MV in the range 0.085 to 0.095 kNsm −2 .

13. A method according to claim 9 , wherein said discontinuous fibrous filler comprises fibres having an average length of less than 10 mm.

14. A method according to claim 9 , wherein said filler means comprises one or more fillers selected from discontinuous glass fibre, discontinuous carbon fibre, carbon black and a fluorocarbon resin.

15. A method according to claim 9 , wherein said composite material comprises 40 to 65 wt % of polymeric material and 35 to 60 wt % of filler means.

16. A method according to claim 9 , wherein said composite material comprising 40 to 60 wt % of polymeric material and 40 to 60 wt % of filler means.

17. A method according to claim 9 , wherein the ratio of the wt % of polymeric material to the wt % of the filler means in said composite material is at least 1.

18. A method according to claim 9 , wherein said composite material includes 50 wt % or more of said filler means.

19. A method according to claim 9 , wherein said composite material includes 55 wt % or more of said filler means.

20. A method according to claim 9 , wherein said polymeric material comprises polyetheretherketone having an MV in the range 0.086 to 0.096 kNsm −2 when measured at a shear rate of 1000s −1 ;

said filler means is selected from discontinuous glass fibre, discontinuous carbon fibre, carbon black and a fluorocarbon resin; and

the ratio of the wt % of filler means to the wt % of polymeric material in said composite material is at least 1.

21. A method according to claim 9 , wherein said polymeric material comprise polyetheretherketone having an MV in the range 0.085 to 0.095 kNsm −2 when measured at a shear rate of 1000s −1 ; said filler means comprises a discontinuous fibrous filler or a non-fibrous filler;

said composite material comprises 40 to 60 wt % of said polymeric material and 40 to 60 wt % of said filler means.

22. A method according to claim 9 , wherein said polymeric material in said composite material has a level of crystallinity of at least 10%.

23. A method according to claim 9 , wherein said polymeric material in said composite material has a level of crystallinity of at least 30%.

24. A method according to claim 3 , wherein said component comprises a polymeric material which is selected from the group comprising polyetheretherketone, polyetherketone, polyetherketoneketone, polyetherketoneetherketoneketone, polyetheretherketoneketone, polyether-diphenyl-ether-phenyl-ketone-phenyl- and has an MV in the range 0.07 to 0.11 kNsm −2 and said method comprises:

(i) selecting a precursor material from which to make said component, wherein said precursor material is selected from the group comprising polyetheretherketone, polyetherketone, polyetherketoneketone, polyetherketoneetherketoneketone, polyetheretherketoneketone, polyether-diphenyl-ether-phenylaketone-phenyl- having an MV in the range 0.07 to 0.11 kNsm −2 ; and

(ii) subjecting said precursor material to a temperature above its melting temperature in an extrusion or injection moulding apparatus.

25. A method according to claim 24 , wherein said polymeric material comprises polyetheretherketone.

26. A method according to claim 24 , wherein said precursor material selected in step (i) arid the component made in the method comprise said polymeric material having an MV in the range 0.08 to 0.11 kNsm −2 .

27. A method according to claim 24 , wherein said precursor material selected in step (i) and the component made in the method comprise said polymeric material having an MV in the range 0.085 to 0.95 kNsm −2 .

28. A method according to claim 24 , wherein said component comprises a polymeric material having a level of crystallinity of at least 10%.

29. A method according to claim 24 , wherein said component comprises a polymeric material having a level of crystallinity of at least 30%.

30. A method according to claim 24 , the method comprising extruding or injection moulding a composite material which comprises said polymeric material, wherein said composite material comprises:

(i) a polymeric material which is selected from the group comprising polyetheretherketone, polyotherketone, polyetherketoneketone, polyetherketoneetherketoneketone, polyetheretherketoneketone, polyether-diphenyl-ether-phenyl-ketone-phenyl- and having an MV in the range 0.07 to 0.11 kNsm −2 ; and

(ii) a filler means comprising a discontinuous fibrous filler or a non-fibrous filler.

31. A method according to claim 30 , wherein said discontinuous fibrous filler comprises fibres having en average length of less than 10 mm.

32. A method according to claim 31 , wherein said filler means comprises one or more fillers selected from discontinuous glass fibre, discontinuous carbon fibre, carbon black and a fluorocarbon resin.

33. A method according to claim 31 , wherein said composite material comprises 40 to 65 wt % of polymeric material and 35 to 60 wt % of filler means.

34. A method according to claim 32 , wherein said composite material comprising 40 to 60 wt % of polymeric material and 40 to 60 wt % of filler means.

35. A method according to claim 31 , wherein the ratio of the wt % of polymeric material to the wt % of the filler means is at least 1.

36. A method according to claim 30 , wherein said composite material includes 50 wt % or more of filler means.

37. A method according to claim 31 , wherein said composite material includes 55 wt % or more filler means.

38. A method of making a composite material which comprises polyetheretherketone having an MV in the range 0.08 to 0.10 kNsm −2 and a filler means comprising a discontinuous fibrous filler or a non-fibrous filler, the method comprising:

(i) selecting a polyetheretherketone having an MV in the range 0.08 to 0.10 kNsm −2 ;

AND

(ii) contacting said polyetheretherketofle with said filler means comprising said, discontinuous fibrous filler or said non-fibrous filler.

39. A method of making a component comprising polyetheretherketone having an MV in the range 0.08 to 0.10 kNsm −2 , the method comprising:

(i) selecting a precursor material from which to make said component, wherein said precursor material comprises polyetheretherketone having an MV in the range 0.08 to 0.10 kNsm −2 ; and

(ii) subjecting said precursor material to a temperature above its melting temperature in an extrusion or injection moulding apparatus.

40. A method according to claim 39 , wherein said precursor material consists essentially of polyetheretherketone.

41. A method of making a component comprising polyetheretherketone having an MV in the range 0.08 to 0.10 kNsm −2 , the method comprising:

(i) selecting a precursor material from which to make said component, wherein said precursor material consists essentially of polyetheretherketone having an MV in the range 0.08 to 0.10 kNsm −2 ; and

(ii) subjecting said precursor material to a temperature above its melting temperature in an extrusion or injection moulding apparatus.