Patent US5844036A successfully refreshed from Google Patents.
US5844036A
Expired / Lapsed
US
⏱️ 0.0 years remaining
Highly filled injection moldable polyetherketones
Assignee: PBI Performance Products Inc
•
Filing: 1997-03-31
•
Granted: 1998-12-01
•
Expires: 2017-03-31
Abstract
Abstract Injection moldable, highly filled polymer composites are provided which exhibit high dimensional stability at temperatures above the glass transition temperature of the matrix polymer. The heat distortion temperature of the composites approaches that of the crystal melting temperature of the matrix polymer. The composite includes a polyaryletherketone matrix and at least two types of fillers each providing unique properties. The first filler is a reinforcing fiber filler which provides high strength and stiffness. The second filler is an non-thermoplastic immobilizing filler to immobilize the amorphous portion of the partially crystalline polyaryletherketone polymer and provide resistance to high temperature distortion. Notwithstanding its improved mechanical and heat resistant properties, the composite remains injection moldable and thus capable of low cost manufacturing.
Inventors
- 👤 O. Richard Hughes
Bibliographic Details
Application Number
—
Jurisdiction
US
Data Source
google_patents
Last Synchronized
2026-11-09 14:15
CPC Classifications
C; C08; C08L; C08L71/00; C08K; C08K7/00; C08K7/02
Claims Analysis
Total Claims: 23
Claim 1
Independent Claim
112 words
A polymer composite for molding articles having improved strength and resistance to heat distortion comprising: a) a partially crystalline and partially amorphous polyaryletherketone polymer, b) a reinforcing fiber for providing strength and stiffness to the molded article, c) an immobilizing filler for immobilizing the amorphous portion of the polyaryletherketone polymer to provide additional stiffness and dimensional stability at elevated temperatures, and d) said reinforcing fiber and said immobilizing filler forming at least 40% of the volume of the composite and raising the heat distortion temperature at 264 psi of the composite to above 300° C. and having a melt viscosity of less than 10,000 poise at 1000 sec -1 at 430° C.
Claim 2
Dependent Claim
112 words
A polymer composite for molding articles having improved strength and resistance to heat distortion comprising: a) a partially crystalline and partially amorphous polyaryletherketone polymer, b) a reinforcing fiber for providing strength and stiffness to the molded article, c) an immobilizing filler for immobilizing the amorphous portion of the polyaryletherketone polymer to provide additional stiffness and dimensional stability at elevated temperatures, and d) said reinforcing fiber and said immobilizing filler forming at least 40% of the volume of the composite and raising the heat distortion temperature at 264 psi of the composite to above 300° C. and having a melt viscosity of less than 10,000 poise at 1000 sec -1 at 430° C.
Claim 3
Dependent Claim
25 words
The composite as claimed in claim 1 wherein the polyaryletherketone polymer is selected from the group consisting of polyetherketone, polyetheretherketone, polyetherketoneetherketoneketone, polyetheretherketoneketone and polyetherketoneketone polymers.
Claim 4
Dependent Claim
23 words
The composite as claimed in claim 1 wherein the reinforcing fiber is selected from the group consisting of glass fibers and carbon fibers.
Claim 5
Dependent Claim
23 words
The composite as claimed in claim 1 wherein the immobilizing filler is selected from the group consisting of equiaxed and platelet shaped particles.
Claim 6
Dependent Claim
18 words
The composite as claimed in claim 1 wherein the immobilizing filler has no dimension larger than 200 μm.
Claim 7
Dependent Claim
18 words
The composite as claimed in claim 1 wherein the volume percentage of reinforcing fiber does not exceed 25%.
Claim 8
Dependent Claim
13 words
The composite as claimed in claim 1 further including a solid lubricant filler.
Claim 9
Dependent Claim
27 words
The composite as claimed in claim 7 wherein the solid lubricant is selected from the group consisting of graphite, molybdenum disulfide, and boron nitride in powder form.
Claim 10
Dependent Claim
26 words
The composite as claimed in claim 1 wherein the total volume content contributed by the reinforcing fiber and the immobilizing filler is between 40 and 60%.
Claim 11
Dependent Claim
26 words
A composite as claimed in claim 1 wherein the composite has a melt viscosity of less than 7500 poise at 1000 sec -1 at 430° C.
Claim 12
Dependent Claim
143 words
A polymer composite for molding articles having improved strength and resistance to heat distortion, formed from a homogenous mixture comprising: a) a partially crystalline and partially amorphous polyaryletherketone polymer, b) a reinforcing fiber for providing strength and stiffness, said reinforcing fiber comprising less than 25% by volume of the article. c) a non-thermoplastic immobilizing filler for immobilizing the amorphous portion of the polyaryletherketone polymer, said immobilizing filler being selected from the group consisting of equi-axed and platelet shaped materials; and d) said reinforcing fiber and said immobilizing filler forming at least 40% by volume of the composite and raising the heat distortion temperature of the composite at 264 psi to above 300° C. and within 20° C. of the crystalline melting point of the polyaryletherketone polymer and having a melt viscosity of less than 10,000 poise at 1000 sec -1 at 430° C.
Claim 13
Dependent Claim
143 words
A polymer composite for molding articles having improved strength and resistance to heat distortion, formed from a homogenous mixture comprising: a) a partially crystalline and partially amorphous polyaryletherketone polymer, b) a reinforcing fiber for providing strength and stiffness, said reinforcing fiber comprising less than 25% by volume of the article. c) a non-thermoplastic immobilizing filler for immobilizing the amorphous portion of the polyaryletherketone polymer, said immobilizing filler being selected from the group consisting of equi-axed and platelet shaped materials; and d) said reinforcing fiber and said immobilizing filler forming at least 40% by volume of the composite and raising the heat distortion temperature of the composite at 264 psi to above 300° C. and within 20° C. of the crystalline melting point of the polyaryletherketone polymer and having a melt viscosity of less than 10,000 poise at 1000 sec -1 at 430° C.
Claim 14
Dependent Claim
25 words
The composite as claimed in claim 11 wherein the polyaryletherketone polymer is selected from the group consisting of polyetherketone, polyetheretherketone, polyetherketoneetherketoneketone, polyetheretherketoneketone and polyetherketoneketone polymers.
Claim 15
Dependent Claim
23 words
The composite as claimed in claim 11 wherein the reinforcing fiber is selected from the group consisting of glass fibers and carbon fibers.
Claim 16
Dependent Claim
24 words
The composite as claimed in claim 11 wherein the immobilizing filler is selected from the group consisting of mica, graphite flakes and calcium terephthalate.
Claim 17
Dependent Claim
18 words
The composite as claimed in claim 11 wherein the immobilizing filler has no dimension larger than 200 μm.
Claim 18
Dependent Claim
12 words
The composite as claimed in claim 11 further including a solid lubricant.
Claim 19
Dependent Claim
25 words
The composite as claimed in claim 16 wherein the solid lubricant is selected from the group consisting of graphite powder, molybdenum disulfide and boron nitride.
Claim 20
Dependent Claim
24 words
The composite as claimed in claim 11 wherein the volume percentage of the reinforcing fiber and the immobilizing filler is between 40 and 60%.
Claim 21
Dependent Claim
118 words
A polymer composite for producing melt processable articles having improved strength and resistance to heat distortion formed from a homogenous mixture comprising: a) a partially crystalline and partially amorphous polyaryletherketone polymer, b) a reinforcing fiber filler for providing strength and stiffness, said filler comprising less than 25% by volume of the article. c) a platelet shaped immobilizing filler for immobilizing the amorphous portion of the polyaryletherketone polymer, and d) said reinforcing fiber and said immobilizing filler forming at least 40% by volume of the composite and raising the heat distortion temperature of the composite at 264 psi to above 300° C. and having a melt viscosity of less than 10,000 poise at 1000 sec -1 at 430° C.
Claim 22
Dependent Claim
118 words
A polymer composite for producing melt processable articles having improved strength and resistance to heat distortion formed from a homogenous mixture comprising: a) a partially crystalline and partially amorphous polyaryletherketone polymer, b) a reinforcing fiber filler for providing strength and stiffness, said filler comprising less than 25% by volume of the article. c) a platelet shaped immobilizing filler for immobilizing the amorphous portion of the polyaryletherketone polymer, and d) said reinforcing fiber and said immobilizing filler forming at least 40% by volume of the composite and raising the heat distortion temperature of the composite at 264 psi to above 300° C. and having a melt viscosity of less than 10,000 poise at 1000 sec -1 at 430° C.
Claim 23
Dependent Claim
33 words
The composite as claimed in claim 19 wherein the platelet shaped immobilizing filler is selected from the group consisting of graphite, talc, mica, synthetic hectorite, silicon carbide and melt derived polybenzimidazole thermoplastic particles.
References Cited (Backward Citations)
USPTO Annuity & Maintenance Windows
| Annuity Stage | Window Opens | Payment Deadline | Surcharge Period Until | Estimated Fee | Status |
|---|---|---|---|---|---|
| 3.5 Years (Year 4) | 2001-11-30 | 2002-06-01 | 2002-12-01 | $2000.00 | Window Closed / Lapsed |
| 7.5 Years (Year 8) | 2005-11-30 | 2006-06-01 | 2006-12-01 | $3760.00 | Window Closed / Lapsed |
| 11.5 Years (Year 12) | 2009-11-30 | 2010-06-01 | 2010-12-01 | $7700.00 | Window Closed / Lapsed |