Films and membranes of poly(aryl ketones) and methods of casting the same from solution

Abstract

A method of manufacturing a film or membrane includes: (a) dissolving at least one polymer comprising a poly(aryl ketone) in at least one solvent to form a dope; (b) depositing the dope on a substrate to form a coated substrate at appropriate conditions; and (c) drying the coated substrate to form the film or membrane. The dope may also include additional polymers or fillers, such as carbon nanotubes.

What is claimed: 
     
         1 . A method of forming a fiber comprising the steps of:
 dissolving at least one polymer comprising polyetherketoneketone (PEKK) in solvent to form a dope;   wherein the solvent consists of solvents (A) and (B) which are different from each other, each having a boiling point at atmospheric pressure of not greater than 250° C., and optionally an aromatic solvent selected from the group consisting of 4-chloro-2-methyl phenol (4-Cl-o-cresol), 4-chloro-3-methyl phenol (4-Cl-m-cresol), 3-chloro phenol, 4-chlorophenol, 4-methyl-phenol (p-cresol) and mixtures thereof, where (A) is selected from the group consisting of brominated, idodinated, and/or fluorinated organic acids having a pKa of from 1 to 3, and (B) is selected from the group consisting of dichloromethane (DCM), toluene, dichloroethane, ethyl acetate, and mixtures thereof, or where (A) is selected from the group consisting of chlorinated organic acids and (B) is selected from the group consisting of dichloromethane (DCM), toluene, dichloroethane, ethyl acetate, trifluoroacetic acid, and mixtures thereof,   extruding the dope to form a fiber; and   removing the solvent from the fiber to form a dried fiber.   
     
     
         2 . A method of forming a fiber according to  claim 1 , wherein the solvent is removed by drying the fiber. 
     
     
         3 . A method of forming a fiber according to  claim 1 , wherein the solvent is removed by dipping the fiber into a coagulation bath, thereby removing the solvent. 
     
     
         4 . A method of forming a fiber according to  claim 1 , wherein solvent (A) is a brominated, iodinated, and/or fluorinated organic acid having a pKA of from 1 to 3 and solvent (B) is selected from the group consisting of dichloromethane (DCM), toluene, dichloroethane, ethyl acetate, or mixtures thereof. 
     
     
         5 . A method of forming a fiber according to  claim 1 , wherein solvent (A) is a chlorinated organic acid and solvent (B) is selected from the group consisting of dichloromethane (DCM), toluene, dichloroethane, ethyl acetate, trifluoroacetic acid, or mixtures thereof. 
     
     
         6 . A method of forming a fiber according to  claim 1 , wherein the solvent includes said aromatic solvent. 
     
     
         7 . A method of forming a fiber according to  claim 1 , wherein solvent (A) is a chlorinated organic acid that is selected from at least one of monochloroacetic acid, dichloroacetic acid, trichloroacetic acid, tetrachlorophthalic acid, or mixtures thereof. 
     
     
         8 . A method of forming a fiber according to  claim 1 , wherein the solvent consists of solvent (A) is dichloroacetic acid (DCAA) and solvent (B) is dichloromethane (DCM). 
     
     
         9 . A method of forming a fiber according to  claim 1 , wherein the dope further comprises at least one additional component selected from the group consisting of additional polymers, additives, fillers, core-shell impact modifiers, carbon nanotubes, glass fibers, carbon fibers, plasticizers, pigments, dyes, thermal stabilizers, ultraviolet light stabilizers, antioxidants, processing aids, lubricants, flame retardants, and mixtures thereof. 
     
     
         10 . A method of forming a fiber according to  claim 1 , wherein the dope comprises carbon nanotubes. 
     
     
         11 . A method of forming a fiber comprising:
 dissolving at least one polymer comprising polyetherketoneketone (PEKK) in at least one solvent to form a dope;   wherein the at least one solvent comprises at least one of 4-chloro-2-methyl phenol (4-Cl-o-cresol), 4-chloro-3-methyl phenol (4-Cl-m-cresol), 3-chloro phenol, 4-chloro-phenol, or 4-methyl-phenol (p-cresol),   extruding the dope to form a fiber; and   removing the solvent from the fiber to form a dried fiber.   
     
     
         12 . A method of forming a fiber according to  claim 11 , wherein the solvent is removed by drying the fiber. 
     
     
         13 . A method of forming a fiber according to  claim 11 , wherein the solvent is removed by dipping the fiber into a coagulation bath, thereby removing the solvent. 
     
     
         14 . A method of forming a fiber according to  claim 11 , wherein the at least one solvent comprises a mixture of 4-chloro-phenol and 4-chloro-3-methyl phenol (4-Cl-m-cresol). 
     
     
         15 . A method of manufacturing a coated substrate according to  claim 11 , wherein the at least one solvent comprises a mixture of 4-chloro-phenol, 4-chloro-3-methyl phenol (4-Cl-m-cresol) and ortho dichlorobenzene (ODCB). 
     
     
         16 . A method of forming a fiber according to  claim 11 , wherein the dope further comprises at least one additional component selected from the group consisting of additional polymers, additives, fillers, core-shell impact modifiers, carbon nanotubes, glass fibers, carbon fibers, plasticizers, pigments, dyes, thermal stabilizers, ultraviolet light stabilizers, antioxidants, processing aids, lubricants, flame retardants, and mixtures thereof. 
     
     
         17 . A method of forming a fiber according to  claim 11 , wherein the dope comprises carbon nanotubes. 
     
     
         18 . A method of forming a fiber comprising:
 dissolving at least one polymer comprising polyetherketoneketone (PEKK) in at least one solvent to form a dope;   wherein the at least one solvent comprises a mixture of 4-chloro-phenol and 4-chloro-3-methyl phenol (4-Cl-m-cresol), including from about 50 weight percent to less than 100 weight percent of 4-chloro-phenol and up to about 50 weight percent 4-chloro-3-methyl phenol (4-Cl-m-cresol) based on the total weight of solvent to form a dope,   extruding the dope to form a fiber; and   removing the solvent from the fiber to form a dried fiber.