Patent ID: 11879036
Assignee: CYTEC INDUSTRIES INC.
Field: Macromolecular chemistry, polymers (Chemistry)
Classification: CPC C | IPC C

Claim 4:
5. A method [method (MC)] of making a composite comprising a polymer matrix including a poly(ether ketone ketone) polymer [PEKKC polymer], said method comprising the following steps:
(I*) preparing a poly(ether ketone ketone) (PEKKC) polymer by reacting, in a reaction mixture, at least one low-metal bis(hydroxybenzoyl) benzene monomer [monomer (HB)] and at least one low-metal bis(halobenzoyl) benzene monomer [monomer (FB)] in the presence of Na2CO3, K2CO3 and a solvent,
wherein the relative amounts of the components reactants in step (I) are selected according the following Formulae:

Σ=(% Na2CO3−105)+6*|% K2CO3−1|+0.25*|37−% Monomers|−(% XSDFDK)  (EQ1)

and

0%≤K2CO3<5 and  (EQ2)

0.7%<% XSDFDK and  (EQ3)

25%≤Monomers≤44% and  (EQ4)

wherein
(a) Σ<6
(b) % Na2CO3 is the concentration, in mol. %, of Na2CO3 relative to the number of moles of said monomer (HB);
(c) % K2CO3 is the concentration, in mol. %, of K2CO3 relative to the number of moles of said monomer (HB) and where % K2CO3 ranges from 0 mol. % to less than 5 mol. %;
(d) % Monomers is the total concentration, in wt. %, of said monomer (HB) and said monomer (FB), relative to the weight of said monomer (HB), of said monomer (FB) and solvent, and where % Monomers is from 25 wt. % to 44 wt. %; and
(e) % XSDFDK is the concentration, in mol. %, of said monomer (FB) in excess of an equimolar concentration of said monomer (HB);
said monomer (HB) and said monomer (FB) being independently represented by one of the following formulae:

X5-Mm-X5  (13)

X6-Mp-X6  (14)

wherein
X5 and X6 are —OH for said monomers (HB) and a halogen for said monomers (FB), and
Mm and Mp are represented by the following formulae, respectively:, wherein
each of R1 and R2 is independently selected from the group consisting of
alkyl, alkenyl, alkynyl, aryl, ether, thioether, carboxylic acid, ester, amide, imide, alkali or alkaline earth metal sulfonate, alkyl sulfonate, alkali or alkaline earth metal phosphonate, alkyl phosphonate, amine and
quaternary ammonium; and
each of i and j is independently selected from 0 or an integer from 1 to 4;

to provide a polymer matrix comprising at least one PEKKC polymer comprising
at least one recurring unit (RM*PEKK) of general formula -[Mm-O—]—; and
at least one recurring unit (RP*PEKK) of general formula -[Mp-O—]—;

wherein Mm and Mp are represented above formulae (3) and (4), respectively; and
(II*) impregnating reinforcing fibers with the polymer matrix as obtained in step (I*) above, to form a composite.