# Patent

## Title
Assemblies containing polyetherketoneketone tie layers

## Abstract

Tie layers comprised of amorphous polyetherketoneketone are used to join substrates to form laminates and other assemblies.

## Background
CROSS-REFERENCE TO RELATED APPLICATIONS
This application is a national stage application under 35 U.S.C. §371 of PCT/US2010/023131, filed Feb. 4, 2010, which claims benefit to U.S. Provisional Application No. 61/150,128, filed on Feb. 5, 2009, all of which are hereby incorporated by reference.


FIELD OF THE INVENTION
The invention relates to the use of amorphous polyetherketoneketones as tie layers in assemblies such as composites, laminates, and the like.
DISCUSSION OF THE RELATED ART
In recent decades, considerable development effort has been invested in the design of laminates, composites and other assemblies comprising multiple layers of different materials. For many end-use applications, it is not feasible to use a single material to fabricate a desired component due to particular multiple performance requirements that cannot be met by any known material. For example, a part may need to be simultaneously high in strength and stiffness as well as pressure resistant, solvent/chemical resistant, and dimensionally stable at high temperatures. However, it has often proven to be challenging to achieve satisfactory adhesion or bonding directly between the dissimilar layers that may need to be utilized in a composite or laminate. Poor compatibility between composite layers can limit the properties exhibited by such assemblies. In particular, certain thermoplastics (particularly crystalline and/or high temperature thermoplastics) exhibit poor adhesion to other materials, which has been attributed to the inability of such thermoplastics to adequately “wet” surfaces of dissimilar substances, leading to problems with delamination and loss of structural integrity when the composite is placed in use in a highly demanding environment. Accordingly, it would be advantageous to develop improved methods of assembling composites, laminates and the like which avoid such difficulties by ensuring good bonding between the composite or laminate layers.
BRIEF SUMMARY OF THE INVENTION
An assembly is provided by the present invention which is comprised of a first substrate and a second substrate, wherein a tie layer comprised of amorphous polyetherketoneketone is positioned between and in contact with said first substrate and said second substrate. Such assemblies may be prepared by coating one substrate with amorphous polyetherketoneketone and then joining the other substrate with the coated substrate by pressing the substrates together while heating the polyetherketoneketone tie layer. Alternatively, a coextrusion process can be utilized. The invention is especially useful where one substrate is comprised of a crystalline and/or high temperature thermoplastic such as a crystalline poly(aryletherketone) that does not exhibit completely satisfactory adhesion to the surface of the other substrate in the absence of the tie layer.



BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 Shows micrographs of fibers sized with PEKK and PEEK, and demonstrates the failure mode in fibers of each sizing.



DETAILED DESCRIPTION OF CERTAIN EMBODIMENTS OF THE INVENTION
Assemblies in accordance with the present invention are advantageously manufactured using tie layers comprised of amorphous polyetherketoneketone. The amorphous polyetherketoneketones suitable for use in the present invention comprise (and preferably consist essentially of or consist of) repeating units represented by the following formulas I and II:

-A-C(═O)—B—C(═O)—  I

-A-C(═O)-D-C(═O)—  II

where A is a p,p′-Ph-O-Ph- group, Ph is a phenylene radical, B is p-phenylene, and D is m-phenylene. The Formula I:Formula II (T:I) isomer ratio in the polyetherketoneketone is varied so as to provide an amorphous (non-crystalline) polymer. An amorphous polymer, for purposes of this invention, means a polymer that does not exhibit a crystalline melting point by differential scanning calorimetry (DSC).

Polyetherketoneketones are well-known in the art and can be prepared using any suitable polymerization technique, including the methods described in the following patents, each of which is incorporated herein by reference in its entirety for all purposes: U.S. Pat. Nos. 3,065,205; 3,441,538; 3,442,857; 3,516,966; 4,704,448; 4,816,556; and 6,177,518. Mixtures of polyetherketoneketones may be employed.
In particular, the Formula I:Formula II ratio (sometimes referred to in the art as the T/I ratio) can be adjusted as desired by varying the relative amounts of the different monomers used to prepare the polyetherketoneketone. For example, a polyetherketoneketone may be synthesizing by reacting a mixture of terephthaloyl chloride and isophthaloyl chloride with diphenyl ether. Increasing the amount of terephthaloyl chloride relative to the amount of isophthaloyl chloride will increase the Formula I:Formula II (T/I) ratio. Generally speaking, a polyetherketoneketone having a relatively high Formula I:Formula II ratio will be more crystalline than a polyetherketoneketone having a lower Formula I:Formula II ratio. An amorphous polyetherketoneketone having a T/I ratio of from about 55:45 to about 65:35 is particularly suitable for use in the present invention.
Suitable amorphous polyetherketoneketones are available from commercial sources, such as, for example, certain of the polyetherketoneketones sold under the brand name OXPEKK by Oxford Performance Materials, Enfield, Conn., including OXPEKK-SP polyetherketoneketone.
The polymeric composition used to form the tie layer may additionally be comprised of components other than the amorphous polyetherketoneketone, such as stabilizers, pigments, processing aids, fillers, and the like. In certain embodiments of the invention, the polymeric composition consists essentially of or consists of amorphous polyetherketoneketone. For example, the polymeric composition may be free or essentially free of any type of polymer other than amorphous polyetherketoneketone.
The present invention is useful for multilayer structures, such as, for example, films, sheets, pipes and hollow bodies, such as storage tanks, wherein a tie layer comprised of amorphous polyetherketoneketone is used to adhere a first substrate layer to a second substrate layer. The multilayer structure thus may comprise a tie layer (T), a first substrate layer (S1) directly attached to a first face (surface) of tie layer (T), and a second substrate layer (S2) directly attached to a second face (surface) of tie layer (T), such that the tie layer (T) is sandwiched between first substrate layer (S1) and second substrate layer (S2). Of course, additional layers and components may be present in the assembly, including one or more further tie layers positioned between other substrate layers.
One or both of the substrate layers joined by the tie layer can, for example, be a sheet or a thin film. The substrates may be comprised of any suitable material such as, for example, metal, plastic (thermoplastic or thermoset), ceramic, or glass. The substrate may be a composite material such as, for example, glass fiber-reinforced plastic. The thickness of the thin film or of the sheet can be suitably chosen and can be, for example, from approximately 0.01 to approximately 10 mm.
In one embodiment, at least one of either the first substrate or the second substrate is comprised of a crystalline (including semi-crystalline) and/or high temperature thermoplastic as these materials often exhibit interfacial adhesion to various types of substrate surfaces that is not completely satisfactory. A tie layer of amorphous polyetherketoneketone in accordance with the present invention helps to improve such adhesion, thereby enhancing the mechanical and other properties of the resulting assembly. Suitable crystalline and/or high temperature thermoplastics include, but are not limited to, polyaryletherketones (such as crystalline polyetherketone (PEK), crystalline polyetheretherketone (PEEK), crystalline polyetherketoneketone (PEKK), polyetheretheretherketone (PEEEK), polyetheretherketoneketone (PEEKK), polyetherketoneetheretherketone (PEKEKK), and polyetherketoneketoneketone (PEKKK)), polyimides, polyetherimides, polyamideimides, polysulfones, polyethersulfones, polyarylethers, polycarbonates, liquid crystal polymers, polyphenylene sulfides, polyarylenes (polyphenylenes), polyamides, polyphthalamides, polyaromatic esters and the like.
In another embodiment, at least one of either the first substrate or the second substrate is metallic, e.g., a metal sheet, foil, or the like. The substrate may be comprised of any suitable metal or metal alloy such as steel, aluminum, aluminum alloy, copper, gold, silver or the like.
The tie layer typically is relatively thin, e.g., from about 1 to about 100 microns thick. In one embodiment of the invention, the interface between the first and second substrate surfaces is completely filled or covered by the tie layer, although in other embodiments the tie layer may be discontinuous.
In one embodiment, the assemblies of the invention are manufactured by adapting known coextrusion processes, particularly where both of the substrate layers joined by the tie layer are based on thermoplastic polymers. For example, the apparatus used for making such assemblies can be any conventional or standard extruder, dies or stream distributors generally employed for the coextrusion of thermoplastic polymers. The thickness of each of the polymeric layers will depend on the regulation of the flow rate of each of the extruders. Generally, the die and extruder temperatures should be selected based on the characteristics and properties of the polymers to be used in the tie layer and the substrate layers so that the materials are rendered capable of being extruded.
The assemblies of the invention can be extruded into any conventional form, including film, plate, sheeting, tubing or any other shape conventionally obtainable by coextrusion.
Compression molding, intermittent matched die consolidation, double belt press consolidation, composite roll forming, transfer molding, as well as other such techniques can also be utilized in connection with the present invention. For example, the assembly may be prepared by placing a sheet or film corresponding in composition to the desired tie layer between a first substrate and a second substrate and heating the resulting “sandwich” at a temperature effective to soften at least one of the layers sufficiently to enable it to flow and come into intimate contact with an adjacent layer, thereby forming an adhesive bond when the assembly is cooled. Typically, it will be desirable to apply pressure on the “sandwich” so as to enhance the degree of adhesion achieved between the tie layer and the substrate layers. Thermoforming of the assembly can be carried out so as to attain a particular desired shape or contour.
In yet another embodiment, the assembly may be formed by first adhering a tie layer in accordance with the present invention to a first substrate. This may, for example, be accomplished by coextrusion of the tie layer and the first substrate or by pressing a sheet of the tie layer and a sheet of the first substrate together while heating or by extruding the tie layer onto the first substrate. The resulting tie layer/first substrate subassembly can then be joined to a second substrate by bringing the second substrate into contact with the other side of the tie layer, with sufficient heat and pressure being applied so as to create the desired degree of adhesion between the tie layer and the surface of the second substrate. Overmolding or extrusion molding techniques could also be utilized. For example, the tie layer/first substrate subassembly can be positioned in a mold and a heated polymeric composition (corresponding to the composition of the desired second substrate) introduced into the mold such that it comes into contact with at least a portion of the available surface of the tie layer. If desired, the overmolding conditions may be selected such that the tie layer/first substrate subassembly undergoes a change in shape during such overmolding (e.g., the subassembly may be thermoformed). Alternatively, the heated polymeric composition may be extrusion molded as a coating onto the tie layer surface to form the second substrate layer.
In yet another embodiment, a melt of the tie layer may be extruded between preformed sheets of the first and second substrate layers. This could be done just prior to lamination of the two sheets.
The tie layer may also be formed by applying a solution of the amorphous polyetherketoneketone to a substrate surface and then removing the solvent. Suitable solvents for amorphous polyetherketoneketones are known in the art and include, for example, halogenated hydrocarbons (particularly chlorinated hydrocarbons such as o-dichlorobenzene, 1,2,4-trichlorobenzene, methylene chloride and tetrachloroethylene), nitrobenzene, and aqueous mineral acids (e.g., sulfuric acid and/or nitric acid). The solvent may be removed from the coated substrate by any suitable method such as heating and/or application of vacuum.
Assemblies prepared in accordance with the present invention may be utilized in any of the end use applications where such laminates or composites conventionally are employed or have been proposed to be employed. Representative applications include composites and laminates (including two- and three dimensional panels and sheets) for aerospace/aircraft, automobiles and other vehicles, boats, machinery, heavy equipment, storage tanks, pipes, sports equipment, tools, biomedical devices (including devices to be implanted into the human body), building components, wind blades and the like. Benefits of the invention described herein include higher tensile strength, higher compressive strength, higher peel strength, enhanced solvent, chemical and water resistance, and improved resistance to delamination, as compared to assemblies prepared without tie layers based on amorphous polyetherketoneketone.
EXAMPLES
Example 1
Production of PEKK film—A thin film of amorphous polyetherketoneketone A-PEKK (OXPEKK SP from Oxford Performance materials, T/I ratio of 60/40) was produced by melt processing pellets of A-PEKK on 1 inch Davis Standard extruder fitted with a 12 inch film die. The polymer was processed with a relatively low screw speed (20-80 RPM) and at 315-325° C. The extruder was fitted with a standard cast film take off stack from Davis standard operating at 150° C.
Films of crystalline grades, with T/I ratios of 70/30 or higher, are also possible but more difficult to produce. The rapid cooling and crystallization of these films requires higher extruder temperatures and melt temperatures (365-375° C.), and higher temperatures for the take off equipment (220-250° C. or higher).
Example 2
Production and testing of laminated materials using PEKK as the tie layer—Test samples consisted of 1′′ by 5′′ metal or glass strips (see table 1) and 1′′ by 1′′ by 0.07′′ sheets of PEKK formed by the process described in Example 1. The surfaces of the test samples were cleaned with acetone to remove any grease or oil prior to molding. The samples were compression molded using a Carver press and two 12-inch by 12-inch aluminum blocks with small 1′′ by 5′′ indentations to hold the test samples. The press mold was preheated to 220-230° C. (for A-PEKK sheets) or 260-290° C. for crystalline PEKK. After preheating the mold was removed from the press and the test sheets and 1′′×1′′ PEKK sheets carefully assembled into a 3 layer structure so as to not contaminate the bonding surfaces. The construction consisted of one PEKK sheet between two sheets of the appropriate tests materials. The mold was then reassembled and placed back in the press and reheated to the test temperature for c.a. 1 minute. The assemblies were then pressed at 2000 psi for 5 minutes and then removed and allowed to remain at room temperature for at least 24 hrs at 50% relative humidity prior to testing the strength of the bonding.
The strength of the bond was evaluated using a Zwick-Roell Z050 tensile testing in a instrument using a method similar to ASTM D3528-96 (2008) Standard Test Method For Strength Properties Of Double Lap Shear Adhesive Joints By Tension Loading with a cross head speed of 1.27 mm/min. The results are presented in Table 1 and Table 2 below.







TABLE 1







Lap shear tests of similar substrates using PEKK as an adhesive













Max Stress
Max Stress
Break Stress
Break Stress
Failure


Substrate
Avg (psi)
Std Dev.
Avg (psi)
Std Dev
Mode















Aluminum
1491
97.17
1380
99.1
cohesive


Steel
2589
427.1
2590
427
cohesive


Stainless Steel
1779
319.4
1730
365
cohesive


Galvanized Steel
1046
628.4
1010
650
cohesive


Anodized
1521
229.4
1520
229
cohesive


Aluminum


Glass
N/A
N/A
N/A
N/A
substrate


Alclad
1684
280.8
1540
191
cohesive


Aluminum








Zinc Dichromate
Samples broke during assembly, zinc coating delaminated
















TABLE 2







Lap shear tests of using PEKK as an adhesive for similar and dissimilar substrates













Max Stress
Max Stress
Break Stress
Break Stress
Failure


Substrate
Avg (psi)
Std Dev.
Avg (psi)
Std Dev
Mode















Aluminum-
1417
123.7
1320
143
cohesive


Aluminum


AramidFilm
146.9
12.64
142
16.5
cohesive/


Nomex-




substrate


Aluminum


AramidFilm
108.8
10.84
114
4.79
cohesive


Nomex-


AramidFilm


Nomex-


AramidFilm
140.5
8.9259
139
11.3
cohesive


Nomex - Steel


AramidFilm
144.2
15.92
138
12
cohesive/


Nomex- Grit




substrate


Blasted Steel


Grit Blasted Steel-
1817
349.3
1820
349
cohesive


Aluminum


Grit Blasted Steel-
2107
273.4
2110
273
cohesive


Grit Blasted Steel


Prepreg Tape -
1116
191.1
498
190
substrate


Grit Blasted Steel


Grit Blasted Steel-
2217
579
2220
579
cohesive


Steel


Aluminum-
234
192.4
186
151
adhesive/


Prepreg Tape




substrate


Prepreg Tape -
1256
217.3
859
284
substrate/


Prepreg Tape




adhesive


Prepreg Tape -
333.5
66.96
136
99.6
substrate


Steel


Steel - Aluminum
1250
226.4
1250
226
cohesive/







adhesive


Steel - Steel
2811
223.4
2790
230
cohesive









Illustration of the Improved Adhesion that PEKK Provides Vs Other Similar High Temperature Polymers
Polyether-ether-ketone is a polymer with a similar structure and use temperatures to PEKK, however it is produced with a pure para structure with no isophthalate (i.e. T/I=100). The microphotographs of the FIGURE illustrate that PEEK has much poorer adhesion to glass fibers as the fibers seem to pull away from the matrix when cryrofractured, while the microphotograph of the samples made with PEKK show that the fibers do not pull out and that PEKK is still attached to the fibers. As the FIGURE illustrates, the failure in the PEKK composite is cohesive as the failure is in the PEKK matrix. The fracture surface in this case shows significant ductility produced as a consequence of the effective load transfer between the fiber and the PEKK matrix. In contrast, the failure in the PEEK system is adhesive as the fibers are cleanly pulled from the matrix. The fractured surface shows a clean brittle rupture process, indicating that in this case the interaction of the fiber with the matrix is not as effective. Load transfer is not expected to be efficient in this system. The energy of breaking a piece by cohesive failure is dependant on the strength of the matrix itself and is generally regarded as higher than an adhesive failure.

## Claims

1. An assembly comprising a first substrate and a second substrate, wherein a discontinuous tie layer consisting of amorphous polyetherketoneketone is positioned between and directly in contact with said first substrate and said second substrate, and wherein the amorphous polyetherketoneketone consists of repeating units represented by formulas I and II:


-A-C(═O)—B—C(═O)—  I



-A-C(═O)-D-C(═O)—  II

where A is a p,p′-Ph-O-Ph- group, Ph is a phenylene radical, B is p-phenylene, and D is m-phenylene and the isomer ratio of formula I:formula II (T:I) is 60:40 so as to provide amorphous polyetherketoneketone; wherein a contact surface of said first substrate is the same as or different from a contact surface of said second substrate and each of the contact surface of said first substrate and the contact surface of said second substrate is selected from the group consisting of glass, prepreg tape, and aramid films.

2. The assembly of claim 1, wherein said discontinuous tie layer is from about 1 to about 100 microns thick.

3. A method of making an assembly, said method comprising joining a first substrate to a second substrate using a discontinuous tie layer consisting of amorphous polyetherketoneketone said amorphous polyetherketone ketone consisting of repeating units represented by formulas I and II:


-A-C(═O)—B—C(═O)—  I



-A-C(═O)-D-C(═O)—  II

where A is a p,p′-Ph-O-Ph- group, Ph is a phenylene radical, B is p-phenylene, and D is m-phenylene and the isomer ratio of formula I:formula II (T:I) is 60:40 so as to provide amorphous polyetherketoneketone; wherein a contact surface of said first substrate is the same as or different from a contact surface of said second substrate and wherein each of the contact surface of said first substrate and the contact surface of said second substrate is selected from the group consisting of glass, prepreg tape, and aramid films, said method further comprising the step of positioning the discontinuous tie layer between said first and second substrates, whereby said discontinuous tie layer is directly in contact with a surface of said first substrate and directly in contact with a surface of said second substrate.

4. A multilayered laminated assembly comprising a first substrate, a second substrate, and a discontinuous tie layer, said discontinuous tie layer having first and second surfaces and positioned between said first substrate and said second substrate, the laminated assembly being configured such that the first substrate is directly attached to said first surface of the discontinuous tie layer, and the second substrate is directly attached to said second surface of the discontinuous tie layer, wherein said discontinuous tie layer is from about 1 to about 100 microns, and consists of amorphous polyetherketoneketone, wherein the amorphous polyetherketoneketone consists of repeating units represented by formulas I and II:


-A-C(═O)—B—C(═O)—  I



-A-C(═O)-D-C(═O)—  II

wherein A is a p,p′-Ph-O-Ph- group, Ph is a phenylene radical, B is p-phenylene, and D is m-phenylene and the isomer ratio of formula I:formula II (T:I) is 60:40 so as to provide amorphous polyetherketoneketone; wherein a contact surface of said first substrate is selected from the group consisting of glass, prepreg tape, and aramid films, and wherein a contact surface of said second substrate is selected from the group consisting of glass, prepreg tape, aramid films, and metals, wherein said assembly is laminated.