[go: up one dir, main page]

WO2021119385A1 - Composite à base de mousse et procédé et article associés - Google Patents

Composite à base de mousse et procédé et article associés Download PDF

Info

Publication number
WO2021119385A1
WO2021119385A1 PCT/US2020/064429 US2020064429W WO2021119385A1 WO 2021119385 A1 WO2021119385 A1 WO 2021119385A1 US 2020064429 W US2020064429 W US 2020064429W WO 2021119385 A1 WO2021119385 A1 WO 2021119385A1
Authority
WO
WIPO (PCT)
Prior art keywords
poly
polymer
composition
polyetherimide
phenylene ether
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Ceased
Application number
PCT/US2020/064429
Other languages
English (en)
Inventor
Erin DIKEMAN
Mohammad KASIM-HASAN
Peter Heinrich Angeline Marcus MINTJENS
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
SHPP Global Technologies BV
Original Assignee
SHPP Global Technologies BV
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by SHPP Global Technologies BV filed Critical SHPP Global Technologies BV
Publication of WO2021119385A1 publication Critical patent/WO2021119385A1/fr
Anticipated expiration legal-status Critical
Ceased legal-status Critical Current

Links

Classifications

    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
    • C08J9/00—Working-up of macromolecular substances to porous or cellular articles or materials; After-treatment thereof
    • C08J9/36—After-treatment
    • C08J9/365—Coating
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C64/00—Additive manufacturing, i.e. manufacturing of three-dimensional [3D] objects by additive deposition, additive agglomeration or additive layering, e.g. by 3D printing, stereolithography or selective laser sintering
    • B29C64/10—Processes of additive manufacturing
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
    • B29C70/68—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts by incorporating or moulding on preformed parts, e.g. inserts or layers, e.g. foam blocks
    • B29C70/74—Moulding material on a relatively small portion of the preformed part, e.g. outsert moulding
    • B29C70/747—Applying material, e.g. foam, only in a limited number of places or in a pattern, e.g. to create a decorative effect
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B33—ADDITIVE MANUFACTURING TECHNOLOGY
    • B33Y—ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3-D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3-D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
    • B33Y10/00—Processes of additive manufacturing
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B33—ADDITIVE MANUFACTURING TECHNOLOGY
    • B33Y—ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3-D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3-D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
    • B33Y70/00—Materials specially adapted for additive manufacturing
    • B33Y70/10—Composites of different types of material, e.g. mixtures of ceramics and polymers or mixtures of metals and biomaterials
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
    • C08J9/00—Working-up of macromolecular substances to porous or cellular articles or materials; After-treatment thereof
    • C08J9/0066—Use of inorganic compounding ingredients
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
    • C08J9/00—Working-up of macromolecular substances to porous or cellular articles or materials; After-treatment thereof
    • C08J9/0085—Use of fibrous compounding ingredients
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08K—Use of inorganic or non-macromolecular organic substances as compounding ingredients
    • C08K7/00—Use of ingredients characterised by shape
    • C08K7/02—Fibres or whiskers
    • C08K7/04—Fibres or whiskers inorganic
    • C08K7/14—Glass
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
    • C08J2201/00—Foams characterised by the foaming process
    • C08J2201/02—Foams characterised by the foaming process characterised by mechanical pre- or post-treatments
    • C08J2201/03—Extrusion of the foamable blend
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
    • C08J2203/00—Foams characterized by the expanding agent
    • C08J2203/12—Organic compounds only containing carbon, hydrogen and oxygen atoms, e.g. ketone or alcohol
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
    • C08J2203/00—Foams characterized by the expanding agent
    • C08J2203/18—Binary blends of expanding agents
    • C08J2203/182—Binary blends of expanding agents of physical blowing agents, e.g. acetone and butane
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
    • C08J2205/00—Foams characterised by their properties
    • C08J2205/04—Foams characterised by their properties characterised by the foam pores
    • C08J2205/052—Closed cells, i.e. more than 50% of the pores are closed
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
    • C08J2379/00—Characterised by the use of macromolecular compounds obtained by reactions forming in the main chain of the macromolecule a linkage containing nitrogen with or without oxygen, or carbon only, not provided for in groups C08J2361/00 - C08J2377/00
    • C08J2379/04—Polycondensates having nitrogen-containing heterocyclic rings in the main chain; Polyhydrazides; Polyamide acids or similar polyimide precursors
    • C08J2379/08—Polyimides; Polyester-imides; Polyamide-imides; Polyamide acids or similar polyimide precursors
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
    • C08J2479/00—Characterised by the use of macromolecular compounds obtained by reactions forming in the main chain of the macromolecule a linkage containing nitrogen with or without oxygen, or carbon only, not provided for in groups C08J2461/00 - C08J2477/00
    • C08J2479/04—Polycondensates having nitrogen-containing heterocyclic rings in the main chain; Polyhydrazides; Polyamide acids or similar polyimide precursors
    • C08J2479/08—Polyimides; Polyester-imides; Polyamide-imides; Polyamide acids or similar polyimide precursors

Definitions

  • Thermoplastic foams have been used in aerospace interior applications based on their high strength-to-weight ratio.
  • Thermoplastic foams that do not provide sufficient strength have been structurally supplemented with reinforcements (e.g., structural ribs) that are adhered to or inserted into the foam.
  • reinforcements e.g., structural ribs
  • such combinations of thermoplastic foams and structural reinforcements typically require additional materials (e.g., adhesives) and/or complex processing steps that complicate their manufacture. There is therefore a need for a reinforced, foam-based composite with improved manufacturability.
  • thermoplastic foam has a density of 20 to 150 kilograms per meter 3 determined at 23 °C according to ASTM D1622-14 and comprises a first composition comprising a first polymer selected from the group consisting of polyethylene terephthalate)s, polypropylenes, polycarbonates, polyimides, poly(aryl ether sulfone)s, thermoplastic polyurethanes, poly(phenylene ether)/polystyrene blends, poly(phenylene ether)/polyamide blends, poly(phenylene ether)/polypropylene blends, poly(phenylene ether)- polysiloxane/polystyrene blends, poly(phenylene ether)-polysiloxane/polyamide blends, poly(phenylene ether)-polysiloxane/polypropylene blends, and combinations thereof; and
  • Another embodiment is an article comprising the composite in any of its variations.
  • Another embodiment is a method of forming a composite, comprising: additively manufacturing a secondary structure in contact with and at least partially embedded in a primary structure; wherein the primary structure comprises a thermoplastic foam having a density of 20 to 150 kilograms per meter 3 determined at 23 °C according to ASTM D1622-14; wherein the thermoplastic foam comprises a first composition comprising a first polymer selected from the group consisting of polyethylene terephthalate)s, polypropylenes, polycarbonates, polyimides, poly(aryl ether sulfone)s, thermoplastic polyurethanes, poly(phenylene ether)/polystyrene blends, poly(phenylene ether)/polyamide blends, poly(phenylene ether)/polypropylene blends, poly(phenylene ether) -poly siloxane/poly styrene blends, poly(phenylene ether)- polysiloxane/polyamide blends, poly((pheny
  • Figure 1 is a schematic illustration of a foam extrusion apparatus.
  • Figure 2 is a schematic illustration of a cross section of the outlet portion of a die in a foam extrusion apparatus.
  • Figure 3 is a photographic image of a primary structure (i.e., an unreinforced foam sheet).
  • Figure 4 is a photographic image of a composite comprising a primary structure and a secondary structure in contact with and at least partially embedded in the primary structure.
  • Figure 5 is a photographic image of a broken edge of a composite.
  • the present inventors have determined that a reinforced, foam-based composite is conveniently manufactured in a process in which additive manufacturing is used to produce a reinforcing “secondary” structure that self-adheres to and is at least partially embedded in a foam -based “primary” structure.
  • one embodiment is a composite comprising: a primary structure comprising a thermoplastic foam; wherein the thermoplastic foam has a density of 20 to 150 kilograms per meter 3 determined at 23 °C according to ASTM D1622-14 and comprises a first composition comprising a first polymer selected from the group consisting of polyethylene terephthalate)s, polypropylenes, polycarbonates, polyimides, poly(aryl ether sulfone)s, thermoplastic polyurethanes, poly(phenylene ether)/polystyrene blends, poly(phenylene ether)/polyamide blends, poly(phenylene ether)/polypropylene blends, poly(phenylene ether)- polysiloxane/polystyrene blends, poly(phenylene ether)-polysiloxane/polyamide blends, poly(phenylene ether)-polysiloxane/polypropylene blends, and combinations thereof
  • the composite comprises a primary structure and a secondary structure in contact with and at least partially embedded in the primary structure.
  • the phrase “at least partially embedded in” is used in its ordinary sense and means that the secondary structure is at least partially surrounded by the primary structure.
  • An example of a secondary structure in contact with and at least partially embedded in a primary structure is provided in Figure 4, which shows a composite 100 comprising a primary structure 10 and a secondary structure 20.
  • An example of a secondary structure in contact with but not at least partially embedded in a primary structure is taught in International Patent Application Publication Number WO 2018/130668 A2 of Thi Ly et al., which teaches using an unfoamed material to additively manufacturing an article on a build sheet comprising a foamed material.
  • the additively manufactured article is in contact with the build sheet, but the additively manufactured article is not at least partially embedded in the build sheet. Furthermore, a skilled person would not have been motivated to modify the reference to add an embedding feature, because the embedding feature would destroy the intended purpose of providing a build sheet that is easily separated from the additively manufactured article.
  • An example of a secondary structure that is not in contact with and not at least partially embedded in a primary structure is taught in U.S.
  • Patent Application Publication Number US 2018/0194917 Al of Dikeman et al. which teaches, inter alia, a structure comprising a foam body comprising first and second major surfaces, first and second adhesive layers respectively in contact with the first and second surfaces of the foam body, and first and second skin layers respectively adhered to the first and second adhesive layers.
  • the first and second skin layers are not in contact with the foam body, because they are separated from the foam body by the first and second adhesive layers, respectively.
  • the first and second skin layers are not at all embedded in the foam body.
  • a skilled person would not have been motivated to modify the reference to omit the first and second adhesive layers, because doing so would have resulted in insufficient adhesion of the skin layers to the foam body.
  • the secondary structure is in contact with and partially (i.e., not fully) embedded in the primary structure.
  • the primary structure comprises a thermoplastic foam having a density of 20 to 150 kilograms per meter 3 determined at 23 °C according to ASTM D 1622- 14. Within the range of 20 to 150 kilograms per meter 3 , the density can be 20 to 100 kilograms per meter 3 , or 20 to 60 kilograms per meter 3 .
  • the thermoplastic foam comprises a first composition comprising a first polymer selected from the group consisting of poly(ethylene terephthalate)s, polypropylenes, polycarbonates (including linear and branched polycarbonates, carbonate homopolymers, carbonate copolymers, block polycarbonate-polysiloxanes, block polyestercarbonates, and block polyestercarbonate-polysiloxanes), polyimides (including polyetherimides), poly(aryl ether sulfone)s (including polysulfones (PSU), polyethersulfones (PES), and polyphenylsulfones (PPSU)), thermoplastic polyurethanes, poly(phenylene ether)/polystyrene blends, poly(phenylene ether)/polyamide blends, poly(phenylene ether)/polypropylene blends, poly(phenylene ether) -poly siloxane/poly styrene blends, poly(phenylene
  • the first polymer can comprise a polyethylene terephthalate).
  • a polyethylene terephthalate is a polymer comprising ethylene terephthalate units having the structure
  • the first polymer can comprise a polypropylene.
  • a polypropylene is a homopolymer of propylene, also known as propene.
  • Polypropylenes include atactic polypropylenes and isotactic polypropylenes.
  • the first polymer can comprise a polycarbonate.
  • a polycarbonate is copolymer comprising carbonate units having the structure wherein at least 60 percent of the total number of R 1 groups are aromatic divalent groups.
  • the aromatic divalent groups are Ce-Cu aromatic divalent groups. When not all R 1 groups are aromatic, the remainder are C2-C24 aliphatic divalent groups.
  • each R 1 is a radical of the formula wherein each of A 1 and A 2 is independently a monocyclic divalent aryl radical, and Y 1 is a bridging radical having one or two atoms that separate A 1 from A 2 .
  • Examples of A 1 and A 2 include 1,3-phenylene and 1,4-phenylene, each optionally substituted with one, two, or three Ci- Ce alkyl groups.
  • the bridging radical Y 1 can be a C1-C12 (divalent) hydrocarbylene group.
  • hydrocarbyl whether used by itself, or as a prefix, suffix, or fragment of another term, refers to a residue that contains only carbon and hydrogen unless it is specifically identified as “substituted hydrocarbyl”.
  • the hydrocarbyl residue can be aliphatic or aromatic, straight-chain or cyclic or branched, saturated or unsaturated.
  • hydrocarbyl residue can also contain combinations of aliphatic, aromatic, straight chain, cyclic, bicyclic, branched, saturated, and unsaturated hydrocarbon moieties.
  • hydrocarbyl residue When the hydrocarbyl residue is described as substituted, it can contain heteroatoms in addition to carbon and hydrogen. In some embodiments, one atom separates A 1 from A 2 .
  • Y 1 radicals are -0-, -S-, -S(O)-, -S(0) 2 -, -C(O)-, methylene (-CH2-; also known as methylidene), ethylidene (-CH(CH3)-), isopropylidene (-C(CH3)2-), neopentylidene, cyclohexylidene, cyclopentadecylidene, cyclododecylidene, adamantylidene, cyclohexylidene methylene, cyclohexylmethylene, and 2-[2.2.1]-bicycloheptylidene.
  • Polycarbonates which can be linear or branched, include carbonate homopolymers, carbonate copolymers, block polycarbonate -polysiloxanes, block polyestercarbonates, block polyestercarbonate-polysiloxanes, and combinations thereof.
  • the first polymer comprises a polycarbonate
  • the polycarbonate comprises a block polyestercarbonate-polysiloxane.
  • a block polyestercarbonate- polysiloxane is a copolymer comprising at least one polyester block, at least one polycarbonate block, and at least one polysiloxane block.
  • the block polyestercarbonate-polysiloxane can comprise more than one of each of these block types.
  • the at least one polyester block comprises resorcinol ester units, each resorcinol ester unit having the structure the at least one polycarbonate block comprises carbonate units, each carbonate unit having the structure wherein at least 60 percent of the total number of R 1 groups are aromatic divalent groups, and the at least one polysiloxane block comprises dimethylsiloxane units.
  • the resorcinol ester units comprise resorcinol isophthalate/terephthalate units
  • the carbonate units comprise resorcinol carbonate units and bisphenol A carbonate units.
  • the first polymer comprises a polycarbonate
  • the polycarbonate comprises a block polyestercarbonate-polysiloxane.
  • the block polyestercarbonate-polysiloxane can comprise, based on total moles of carbonate units and ester units, 30 to 90 mole percent of the resorcinol ester units, 5 to 35 mole percent of carbonate units wherein R 1 is 1,3-phenylene (i.e., the carbonate units are resorcinol carbonate units), and 5 to 35 mole percent of carbonate units wherein R 1 is
  • the carbonate units are bisphenol A carbonate units.
  • the content of resorcinol ester units can be 50 to 90 mole percent, or 70 to 90 mole percent.
  • the content of resorcinol carbonate units can be 5 to 25 mole percent, or 5 to 15 mole percent.
  • the content of bisphenol A carbonate units can be 5 to 25 mole percent, or 5 to 15 mole percent.
  • the block polyestercarbonate-polysiloxane further comprises, based on the weight of the block polyestercarbonate-polysiloxane, 0.2 to 4 weight percent dimethylsiloxane units. Within this range, the content of dimethylsiloxane units can be 0.4 to 2 weight percent, or 0.5 to 2 weight percent.
  • the block polyestercarbonate-polysiloxane comprises, based on total moles of carbonate and ester units, 70 to 90 mole percent of resorcinol isophthalate/terephthalate units, 5 to 15 mole percent of resorcinol carbonate units, and 5 to 15 mole percent of bisphenol A carbonate units, and further comprises dimethylsiloxane units in an amount, based on the total weight of the block polyestercarbonate-polysiloxane, of 0.5 to 2 weight percent.
  • the first polymer can comprise a polyimide.
  • a polyimide is a polymer comprising a plurality of imide units having the structure wherein U is independently at each occurrence atetravalent linker selected from the group consisting of substituted or unsubstituted, saturated, unsaturated, or aromatic monocyclic and polycyclic groups having 5 to 50 carbon atoms, substituted or unsubstituted alkyl groups having 1 to 30 carbon atoms, and substituted or unsubstituted alkenyl groups having 2 to 30 carbon atoms; and R 3 is independently at each occurrence a divalent group selected from the group consisting of substituted or unsubstituted divalent aromatic hydrocarbon moieties having 6 to 20 carbons, straight or branched chain alkylene moieties having 2 to 20 carbons, cycloalkylene moieties having 3 to 20 carbon atom, and divalent moieties of the general formula wherein Q is a divalent moiety that can be -O-, -S-,
  • the number of imide units in the polyimide can be, for example, 10 to 1,000, or 10 to 500.
  • Exemplary tetravalent linkers, U include tetravalent aromatic radicals of the formula wherein W is a divalent moiety such as -0-, -S-, -C(O)-, -SO2-, -SO-, -C y H2 y - (y being an integer of 1 to 20), and halogenated derivatives thereof, including perfluoroalkylene groups, or a group of the Formula -O-Z-O- wherein the divalent bonds of the -O- or the -O-Z-O- group are in the 3,3', 3,4', 4,3', or the 4,4' positions, and wherein Z includes divalent moieties of the formula wherein Q is a divalent moiety that can be -0-, -S-, -C(O)-, -SO2-, -SO-, -C y H2 y -
  • the first polymer comprises a polyimide
  • the polyimide comprises a polyetherimide.
  • a polyetherimide is a polymer comprising etherimide units having the formula wherein T is -O- or a group of the Formula -O-Z-O- wherein the divalent bonds of the -O- or the -O-Z-O- group are in the 3,3’, 3,4’, 4,3’, or the 4,4’ positions of the phthalimide groups;
  • substituted means including at least one substituent such as a halogen (i.e., F, Cl, Br, I), hydroxyl, amino, thiol, carboxyl, carboxylate, amide, nitrile, sulfide, disulfide, nitro,
  • a halogen i.e., F, Cl, Br, I
  • hydroxyl amino, thiol, carboxyl, carboxylate, amide, nitrile, sulfide, disulfide, nitro
  • each occurrence of R 2 is independently /lara-phcnylcnc or raeto-phenylene, and T is a group of the formula -O-Z-O- wherein Z is
  • the polyetherimide is free of halogens.
  • the number of etherimide units in the polyetherimide can be, for example, 10 to 1,000, or 10 to 500.
  • the polyetherimide has a weight average molecular weight of 30,000 to 80,000 grams per mole and a dispersity of 2.7 to 4.5, determined by gel permeation chromatography using polystyrene standards. Dispersity (sometimes referred to as polydispersity index), is the ratio of weight average molecular weight to number average molecular weight. Within the range of 30,000 to 80,000 grams per mole, the polyetherimide weight average molecular weight can be 45,000 to 80,000 grams per mole, or 55,000 to 75,000 grams per mole. Within the range of 2.7 to 4.5, the polyetherimide dispersity can be 2.8 to 4.5, or 3 to 4.
  • the first polymer can comprise a poly(aryl ether sulfone).
  • a poly(aryl ether sulfone) is a polymer in which each repeat unit comprises a divalent aryl ether group and a divalent sulfone group.
  • Poly(aryl ether sulfone)s include polysulfones (PSU), polyethersulfones (PES), and polyphenylsulfones (PPSU).
  • the first polymer can comprise a thermoplastic polyurethane.
  • a thermoplastic polyurethane is a thermoplastic elastomer containing soft segments derived from polyalkylene ethers and hard segments derived from aromatic diisocyanates.
  • the first polymer can comprise a poly(phenylene ether)/polystyrene blend.
  • a poly(phenylene ether) is a polymer comprising phenylene ether units having the structure wherein each occurrence of Z 1 is independently halogen, unsubstituted or substituted C1-C12 hydrocarbyl provided that the hydrocarbyl group is not tertiary hydrocarbyl, C1-C12 hydrocarbylthio, C1-C12 hydrocarbyloxy, or C2-C12 halohydrocarbyloxy wherein at least two carbon atoms separate the halogen and oxygen atoms; and each occurrence of Z 2 is independently hydrogen, halogen, unsubstituted or substituted C1-C12 hydrocarbyl provided that the hydrocarbyl group is not tertiary hydrocarbyl, C1-C12 hydrocarbylthio, C1-C12 hydrocarbyloxyl, or C2-C12 halohydrocarbyl
  • the poly(phenylene ether) is a poly(2,6- dimethyl-l,4-phenylene ether).
  • a polystyrene is a homopolymer of styrene.
  • the poly(phenylene ether)/polystyrene blend, which is miscible, can contain the poly(phenylene ether) and the polystyrene in a weight ratio of 10:90 to 70:30.
  • the first polymer can comprise a poly(phenylene ether)/polyamide blend.
  • Poly(phenylene ether)s are described above.
  • Polyamides also known as nylons, are polymers containing amide (-C(O)NH-) linking groups.
  • Polyamides include polyamide-6, polyamide-6,6, polyamide-4, polyamide-4,6, polyamide-12, polyamide-6,10, polyamide 6,9, polyamide-6,12, polyamide 9T, polyamide 6/6T and polyamide 6,6/6T with triamine contents below 0.5 weight percent, and combinations thereof.
  • the polyamide comprises polyamide-6, polyamide-6,6, or a combination thereof.
  • the poly(phenylene ether)/polyamide blend can contain the poly(phenylene ether) and the polyamide in a weight ratio of 10:90 to 70:30.
  • the first polymer can comprise a poly(phenylene ether)/polypropylene blend.
  • Poly(phenylene ether)s and polypropylenes are described above.
  • the poly(phenylene ether)/polypropylene blend can contain the poly(phenylene ether) and the polypropylene in a weight ratio of 10:90 to 70:30.
  • the first polymer can comprise a poly(phenylene ether)-polysiloxane/polystyrene blend. Polystyrenes are described above.
  • a poly(phenylene ether) -poly siloxane is a copolymer comprising at least one poly(phenylene ether) block and at least one polysiloxane block.
  • the poly(phenylene ether) -polysiloxane can comprise more than one poly(phenylene ether) block and/or more than one polysiloxane block.
  • the at least one poly(phenylene ether) block comprises phenylene ether units having the structure wherein each occurrence of Z 1 is independently halogen, unsubstituted or substituted C1-C12 hydrocarbyl provided that the hydrocarbyl group is not tertiary hydrocarbyl, C1-C12 hydrocarbylthio, C1-C12 hydrocarbyloxy, or C2-C12 halohydrocarbyloxy wherein at least two carbon atoms separate the halogen and oxygen atoms; and each occurrence of Z 2 is independently hydrogen, halogen, unsubstituted or substituted C1-C12 hydrocarbyl provided that the hydrocarbyl group is not tertiary hydrocarbyl, C1-C12 hydrocarbylthio, C1-C12 hydrocarbyloxy, or C2-C12 halohydrocarbyloxy wherein at least two carbon atoms separate the halogen and oxygen atoms.
  • Z 1 is independently halogen, un
  • the phenylene ether units comprise 2,6- dimethyl-l,4-phenylene ether units.
  • the at least one polysiloxane block comprises siloxane units having the structure wherein each occurrence of R 4 is independently C1-C12 hydrocarbyl. In some embodiments, each occurrence of R 4 is methyl.
  • the poly(phenylene ether)-polysiloxane/polystyrene blend can include the poly(phenylene ether)-polysiloxane and the polystyrene in a weight ratio of 10:90 to 70:30.
  • the first polymer can comprise a poly(phenylene ether)-polysiloxane/polyamide blend.
  • Poly(phenylene ether)-polysiloxanes and polyamides are described above.
  • the poly(phenylene ether) -poly siloxane/polyamide blend can include the poly(phenylene ether)- polysiloxane and the polyamide in a weight ratio of 10:90 to 70:30.
  • the first polymer can comprise a poly(phenylene ether)- polysiloxane/polypropylene blend. Poly(phenylene ether)-polysiloxanes and polypropylenes are described above.
  • the poly(phenylene ether)-polysiloxane/polypropylene blend can include the poly(phenylene ether) -polysiloxane and the polypropylene in a weight ratio of 10:90 to 70:30.
  • the first composition comprises the first polymer in an amount of 50 to 100 weight percent, based on the total weight of the first composition. Within this range, the first polymer amount can be 80 to 100 weight percent, or 90 to 100 weight percent, or 95 to 100 weight percent.
  • the first composition comprises, based on the total weight of the first composition, 96 to 99.8 weight percent of the first polymer and further comprises 0.2 to 4 weight percent of a nucleating agent.
  • the nucleating agent content of the first composition can be 0.5 to 2 weight percent.
  • Suitable nucleating agents include metallic oxides (including titanium dioxide), clays, talcs, silicates, silica, aluminates, barites, titanates, borates, nitrides, and combinations thereof.
  • the nucleating agent comprises talc.
  • the closed cell content of the thermoplastic foam can range from 0 to 100 percent, as determined according to ASTM D6226-15. In some embodiments, the thermoplastic foam has a closed cell content of 50 to 100 percent, or 65 to 100 percent, or 80 to 100 percent.
  • the thermoplastic foam can be prepared in a continuous foam extrusion process.
  • a suitable foam extrusion apparatus can include a primary extruder for melt blending an expandable composition that includes the first polymer, and a secondary extruder for cooling and extruding the expandable composition.
  • the first polymer comprises a polyetherimide
  • illustrative foam extrusion conditions are as follows:
  • the first polymer comprises a block polyestercarbonate-polysiloxane
  • illustrative foam extrusion conditions are as follows:
  • the composite comprises a secondary structure in contact with and at least partially embedded in the primary structure.
  • the secondary structure has a density of 0.8 to 4 grams per centimeter 3 determined at 23 °C according to ASTM D792-13. Within this range, the secondary structure density can be 0.9 to 3.5 grams per centimeter 3 , or 1 to 3 grams per centimeter 3 .
  • the secondary structure comprises a second composition comprising a second polymer selected from the group consisting of polyimides (including polyetherimides), acrylonitrile -butadiene -styrene copolymers, polycarbonates (including linear and branched polycarbonates, carbonate homopolymers, carbonate copolymers, block polycarbonate- polysiloxanes, block polyestercarbonates, and block polyestercarbonate-polysiloxanes), poly(phenylene ether)s, poly(aryl ether sulfone)s (including polysulfones (PSU), polyethersulfones (PES), and polyphenylsulfones (PPSU)), polyamides (including polyamide- 1,1, polyamide-6, polyamide-6,6, and polyphthalamides), polyetheretherketones (PEEK), poly(phenylene sulfide)s (PPS), and combinations thereof.
  • a second polymer selected from the group consisting of polyimides (including polyetherimides
  • the second polymer can comprise a polyimide.
  • Polyimides are described above in the context of the first polymer.
  • the second polymer can comprise an acrylonitrile-butadiene-styrene copolymer.
  • Acrylonitrile-butadiene-styrene copolymers are polymers comprising repeat units derived from acrylonitrile, butadiene, and styrene. Typical monomer contents are 15 to 35% acrylonitrile, 5 to 30% butadiene, and 40 to 60% styrene.
  • the second polymer can comprise a polycarbonate.
  • Polycarbonates are described above in the context of the first polymer.
  • the second polymer can comprise a poly(phenylene ether).
  • Poly(phenylene ether)s are described above in the context of the first polymer.
  • the second polymer can comprise a poly(aryl ether sulfone).
  • Poly(aryl ether sulfone)s are described above in the context of the first polymer.
  • the second polymer can comprise a polyamide.
  • Polyamides are described above in the context of the first polymer.
  • the second polymer comprises a polyamide selected from the group consisting of polyamide- 1,1, polyamide-6, polyamide-6,6, polyphthalamides, and combinations thereof.
  • the second can comprise a polyetheretherketone (PEEK).
  • PEEK polyetheretherketone
  • a polyetheretherketone is a polymer comprising etheretherketone units having the structure
  • the second can comprise a poly(phenylene sulfide).
  • a poly(phenylene sulfide) is a polymer comprising 70 to 100 mole percent of phenylene sulfide units having the structure
  • the poly(phenylene sulfide) comprises less than 100 mole percent of the phenylene sulfide units above, the remaining units can have a structure selected from the group consisting of
  • first polymer and the second polymer fall within the same structural class, their chemical structures can be the same or different.
  • first polymer and the second polymer are both polyimides, each can be a poly [ 2.2- A/.s(4-(3.4- dicarboxyphenoxy)phenyl)propane)-l,3-phenylene bisimide].
  • first polymer and the second polymer are both polycarbonates, the first polymer can be a block polyestercarbonate-polysiloxane, and the second polymer can be a bisphenol A polycarbonate.
  • the second polymer comprises a polyimide
  • the polyimide comprises a polyetherimide
  • the second composition comprises the second polymer in an amount of 30 to 100 weight percent, based on the total weight of the second composition.
  • the second polymer content of the second composition can be 50 to 100 weight percent, or 50 to 90 weight percent, or 60 to 80 weight percent.
  • the first composition exhibits a glass transition temperature and/or melting point within 20 °C of a glass transition temperature and/or melting point of the second composition.
  • the glass transition temperature and/or melting point of the first composition can be within 10 °C of the glass transition temperature and/or melting point of the second composition.
  • the volume of the secondary structure is less than or equal to 50% of the volume of the primary structure.
  • the volume of the secondary structure can be less than or equal to 40% of the volume of the primary structure, or be less than or equal to 40% of the volume of the primary structure.
  • the composite exhibits a normalized peak load at least 50% greater than the normalized peak load of the primary structure, wherein normalized peak load is determined by three-point bend testing at 23 °C according to ASTM D790-17.
  • the composition can exhibit a normalized peak load at least 100% greater than the normalized peak load of the primary structure, or at least 150% greater than the normalized peak load of the primary structure. Determination of normalized peak load is described in the working examples below.
  • the secondary structure can serve other functions.
  • the secondary structure can contribute electrical conductivity (e.g., conduction of static electricity), electrical insulation, electromagnetic shielding, acoustic insulation, mechanical reinforcement of a portion of the composite (e.g., when the primary structure has a honeycomb structure with through channels, the secondary structure can occupy one or more of the through channels), system modularity (e.g., the secondary structure can include fasteners or brackets to facilitate combination of the composite with another component), light conduction (e.g., an illuminant can be combined with a transparent secondary structure and a light-diffusing primary structure to provide diffuse lighting), dimensional stabilization (i.e., warpage reduction), and fluid channeling (e.g., in combination with the primary structure to form a fdtration device), among other functionalities.
  • electrical conductivity e.g., conduction of static electricity
  • electrical insulation e.g., electromagnetic shielding, acoustic insulation, mechanical reinforcement of a portion of the composite
  • the secondary structure can
  • the second composition comprises, based on the total weight of the second composition, 50 to 95 weight percent of the second polymer and further comprises 5 to 50 weight percent of a filler selected from the group consisting of reinforcing fillers (including metal fibers, metallized inorganic fibers, metallized synthetic fibers, glass fibers, graphite fibers, carbon fibers, ceramic fibers, mineral fibers, and combinations thereof), electrically conductive fillers (including carbon fibers, carbon nanotubes, and metal fibers), antimicrobial fillers (including silver sulfate and copper sulfate), damping fillers (including epoxy resins and borax), thermally conductive fillers (including aluminum fibers, graphite fibers, boron nitride, and aluminum nitride), and combinations thereof.
  • the filler comprises glass fibers.
  • the external (exposed) surface of the composite comprises at least a portion of a surface of the primary structure and at least a portion of a surface of the secondary structure.
  • the present composite is distinguished from reinforced foam-based composites in which a reinforcing structure is internal and therefore not exposed on the external surface of the composite.
  • the composite has a primary structure and the secondary structure can adhere to each other without the need for an adhesive or any other intermediate layer or structure.
  • the composite excludes adhesives.
  • the composite consists of the primary structure and the secondary structure.
  • the first composition comprises, based on the total weight of the first composition, 96 to 99.8 weight percent of the first polymer and further comprises 0.2 to 4 weight percent of a nucleating agent;
  • the first polymer comprises a polyimide that comprises a first polyetherimide;
  • the second composition comprises, based on the total weight of the second composition, 50 to 95 weight percent of the second polymer and further comprises 5 to 50 weight percent of glass fibers;
  • the second polymer comprises a polyimide that comprises a second polyetherimide; and the first polyetherimide and the second polyetherimide are the same or different.
  • the first polyetherimide can, optionally, have a weight average molecular weight of 30,000 to 80,000 grams per mole and a dispersity of 2.7 to 4.5, determined by gel permeation chromatography using polystyrene standards.
  • the thermoplastic foam can, optionally, have a density of 20 to 60 kilograms per meter 3 .
  • Another embodiment is an article comprising the composite in any of its above- described variations. Such articles include components employed in the interiors of vehicles including automobiles, aircraft, ships, trains, and subway cars. A specific article is aerospace interior paneling.
  • the first composition comprises, based on the total weight of the first composition, 96 to 99.8 weight percent of a polyimide and further comprises 0.2 to 4 weight percent of a nucleating agent; wherein the polyimide comprises a first polyetherimide; the second composition comprises, based on the total weight of the second composition, 50 to 95 weight percent of a polyimide and further comprises 5 to 50 weight percent of glass fibers; wherein the polyimide comprises a second polyetherimide; and wherein the first polyetherimide and the second polyetherimide are the same or different.
  • the first polyetherimide can, optionally, have a weight average molecular weight of 30,000 to 80,000 grams per mole and a dispersity of 2.7 to 4.5, determined by gel permeation chromatography using polystyrene standards.
  • the thermoplastic foam can, optionally, have a density of 20 to 60 kilograms per meter 3 .
  • Another embodiment is a method of forming a composite, comprising: additively manufacturing a secondary structure in contact with and at least partially embedded in a primary structure; wherein the primary structure comprises a thermoplastic foam having a density of 20 to 150 kilograms per meter 3 determined at 23 °C according to ASTM D1622-14; wherein the thermoplastic foam comprises a first composition comprising a first polymer selected from the group consisting of polyethylene terephthalate)s, polypropylenes, polycarbonates, polyimides, poly(aryl ether sulfone)s, thermoplastic polyurethanes, poly(phenylene ether)/polystyrene blends, poly(phenylene ether)/polyamide blends, poly(phenylene ether)/polypropylene blends, poly(phenylene ether) -poly siloxane/poly styrene blends, poly(phenylene ether)- polysiloxane/polyamide blends, poly((pheny
  • the method includes additively manufacturing a secondary structure in contact with and at least partially embedded in a primary structure.
  • this is accomplished by depositing the second composition onto the thermoplastic foam of the primary structure under conditions such that on deposition the second composition partially melts the underlying thermoplastic foam.
  • This partial melting causes the thermoplastic foam to be deformed and causes the secondary structure to adhere to and become partially embedded in the thermoplastic foam.
  • the viscosity of the second composition is low enough during deposition that it at least partially flows into foam cells of the thermoplastic foam.
  • the thermoplastic foam before deposition of the second composition, can comprise open cells, closed cells (some of which are disrupted and penetrated by the deposited second composition), or a combination of open cells and closed cells.
  • the surface of the thermoplastic foam can be selectively textured in areas to which the second composition is subsequently applied, thereby facilitating adhesion and embedding of the secondary structure to the primary structure.
  • a powder form of the second composition can be applied to a surface of the thermoplastic foam, during which application the powder flows into open cells of the foam. The powder is then selectively sintered by a powder bed fusion technique (e.g., selective laser sintering) to form the secondary structure in contact with and partially embedded in the primary structure, and excess powder is removed.
  • a powder bed fusion technique e.g., selective laser sintering
  • a small amount of a good solvent for the first composition and the second composition can be selectively sprayed onto areas of the thermoplastic foam to which the second composition is subsequently applied, thereby facilitating adhesion and embedding of the secondary structure to the primary structure.
  • a good solvent for the first composition and the second composition can be selectively sprayed onto areas of the thermoplastic foam to which the second composition is subsequently applied, thereby facilitating adhesion and embedding of the secondary structure to the primary structure.
  • acetone can be used as the good solvent for a first composition based on polyetherimide. Combinations of the above-described adhesion and embedding techniques can be used.
  • Additive manufacturing methods suitable for forming the secondary structure include fused filament fabrication, large format additive manufacturing, and powder bed fusion. In some embodiments, large format additive manufacturing is employed. Specific conditions for additively manufacturing the secondary structure depend on factors including the second composition and in particular on the identity of the second polymer.
  • the various second polymers used herein are known for use in additive manufacturing, and the skilled person can determine conditions for additive manufacturing with a second composition comprising them.
  • the working examples below include illustrative additive manufacturing conditions for a second composition comprising a polyetherimide.
  • the first composition comprises, based on the total weight of the first composition, 96 to 99.8 weight percent of a polyimide and further comprises 0.2 to 4 weight percent of a nucleating agent; wherein the polyimide comprises a first polyetherimide; the second composition comprises, based on the total weight of the second composition, 50 to 95 weight percent of a polyimide and further comprises 5 to 50 weight percent of glass fibers; wherein the polyimide comprises a second polyetherimide; and wherein the first polyetherimide and the second polyetherimide are the same or different.
  • Polyetherimide foam sheets having densities of 40 kilograms/meter 3 (kg/m 3 ) and 110 kg/m 3 were prepared by foam extrusion.
  • the 40 kg/m 3 foam sheet had a thickness of 16 millimeters, and a closed-cell content of 95 percent determined according to ASTM D6226-15.
  • the 110 kg/m 3 foam sheet had a thickness of 16 millimeters, and a closed-cell content of 5 percent determined according to ASTM D6226-15.
  • the polyetherimide present in both foam sheets was a poly
  • Foam sheets were produced by a continuous extrusion process using polyetherimide as a base resin, talc as a nucleating agent, and a mixture of acetone and methanol as a blowing agent.
  • the polyetherimide (“PEI”; 99.15 parts by weight) was pre-blended with talc (0.85 parts by weight) in an extruder to form a PEEtalc blend.
  • PEI polyetherimide
  • talc 0.85 parts by weight
  • acetone acetone
  • FIG. 1 is a schematic illustration of foam extrusion apparatus 1.
  • the foam extrusion apparatus 1 includes primary extruder 10, in which PEEtalc blend is melted and mixed with blowing agent (e.g., acetone and methanol) at a temperature of about 390 °C to form a melt blend.
  • the PEEtalc blend is added to primary extruder 10 via feed throat 20.
  • Blowing agent is added to primary extruder 10 via a port (not shown) just downstream of feed throat 20.
  • the melt blend produced in primary extruder 10 is transferred to secondary extruder 30, where it is cooled to a temperature of about 210 °C.
  • the cooled melt blend is then transferred to die 40, maintained at a temperature of about 232 °C, where expansion (foam formation) begins.
  • the still-expanding foam 50 continues to expand in all directions until that expansion is constrained by calibrator plates 60 above and below the major plane of the foam (only the lower calibrator plate is shown in Figure 1) and constrained on the sides by edges 70 parallel to the machine direction and within the plane of Figure 1.
  • the foam After emerging from calibrator plates 60, the foam is fully expanded and in the form of foam sheet 80.
  • Foam sheet 80 passes between a series of rollers 90 which pull the sheet through the line at a line speed of 0.97 meters/minute (Figure 1 shows only the set of rollers 90 below foam sheet 80). At the left end of Figure 1, an arrow indicates the machine direction.
  • FIG. 1 is a schematic illustration of a cross section of the outlet portion of die 40. Before exiting the die through an opening having height 110, the expanding material encounters a restriction characterized by die lip angle 120. In the present experiments, the die lip angle was about 31°, and the opening had a width of about 800 millimeters and a height of about 3 millimeters.
  • the secondary structure was created by additive manufacturing using a blend of 30 weight percent glass fiber and 70 weight percent polyetherimide (poly
  • polyetherimide poly
  • Figure 3 is a photographic image of a primary structure 10 (i.e., an unreinforced foam sheet).
  • the number “1” on primary structure 10 is an arbitrary sample identifier.
  • Figure 4 is a photographic image of a composite 100 comprising a primary structure 10 and a secondary structure 20.
  • the number “5” on primary structure 10 is an arbitrary sample identifier.
  • Figure 5 is a photographic image of a composite 100 having an edge produced by breaking in a three-point bend test according to ASTM D790- 17. Breaking created a rough edge on primary structure 10 and a clean edge on secondary structure 20.
  • the number “4” on primary structure 10 is an arbitrary sample identifier.
  • peak load values expressed in units of Newtons, were determined by three-point bend testing at 23 °C according to ASTM D790-17.
  • the invention includes at least the following aspects.
  • a composite comprising: a primary structure comprising a thermoplastic foam; wherein the thermoplastic foam has a density of 20 to 150 kilograms per meter 3 determined at 23 °C according to ASTM D1622-14 and comprises a first composition comprising a first polymer selected from the group consisting of polyethylene terephthalate)s, polypropylenes, polycarbonates, polyimides, poly(aryl ether sulfone)s, thermoplastic polyurethanes, poly(phenylene ether)/polystyrene blends, poly(phenylene ether)/polyamide blends, poly(phenylene ether)/polypropylene blends, poly(phenylene ether)- polysiloxane/polystyrene blends, poly(phenylene ether)-polysiloxane/polyamide blends, poly(phenylene ether)-polysiloxane/polypropylene blends, and combinations thereof; and
  • Aspect 2 The composite of aspect 1, wherein the first composition comprises, based on the total weight of the first composition, 96 to 99.8 weight percent of the first polymer and further comprises 0.2 to 4 weight percent of a nucleating agent.
  • Aspect 3 The composite of aspect 1 or 2, wherein the first polymer comprises a polycarbonate, and wherein the polycarbonate comprises a block polyestercarbonate- polysiloxane.
  • Aspect 4 The composite of aspect 1 or 2, wherein the first polymer comprises a polyimide, and wherein the polyimide comprises a polyetherimide.
  • Aspect 5 The composite of any one of aspects 1-4, wherein the thermoplastic foam has a closed cell content of 80 to 100 percent, determined according to ASTM D6226-15.
  • Aspect 6 The composite of any one of aspects 1-5, wherein the second polymer comprises a polymide, and the polyimide comprises a polyetherimide.
  • Aspect 7 The composite of any one of aspects 1-6, wherein the second composition comprises, based on the total weight of the second composition, 50 to 95 weight percent of the second polymer and further comprises 5 to 50 weight percent of a filler selected from the group consisting of reinforcing fillers, electrically conductive fillers, antimicrobial fillers, damping fillers, thermally conductive fillers, and combinations thereof.
  • a filler selected from the group consisting of reinforcing fillers, electrically conductive fillers, antimicrobial fillers, damping fillers, thermally conductive fillers, and combinations thereof.
  • Aspect 8 The composite of aspect 7, wherein the filler comprises glass fibers.
  • Aspect 9 The composite of aspect 1, wherein the first composition comprises, based on the total weight of the first composition, 96 to 99.8 weight percent of the first polymer and further comprises 0.2 to 4 weight percent of a nucleating agent; wherein the first polymer comprises a polyimide that comprises a first polyetherimide; wherein the second composition comprises, based on the total weight of the second composition, 50 to 95 weight percent of the second polymer and further comprises 5 to 50 weight percent of glass fibers; wherein the second polymer comprises a polyimide that comprises a second polyetherimide; and wherein the first polyetherimide and the second polyetherimide are the same or different.
  • Aspect 10 An article comprising the composite of any one of aspects 1-9.
  • Aspect 11 The article of aspect 10, wherein the first composition comprises, based on the total weight of the first composition, 96 to 99.8 weight percent of the first polymer and further comprises 0.2 to 4 weight percent of a nucleating agent; wherein the first polymer comprises a polyimide that comprises a first polyetherimide; wherein the second composition comprises, based on the total weight of the second composition, 50 to 95 weight percent of the second polymer and further comprises 5 to 50 weight percent of glass fibers; wherein the second polymer comprises a polyimide that comprises a second polyetherimide; and wherein the first polyetherimide and the second polyetherimide are the same or different.
  • a method of forming a composite comprising: additively manufacturing a secondary structure in contact with and at least partially embedded in a primary structure; wherein the primary structure comprises a thermoplastic foam having a density of 20 to 150 kilograms per meter 3 determined at 23 °C according to ASTM D1622-14; wherein the thermoplastic foam comprises a first composition comprising a first polymer selected from the group consisting of polyethylene terephthalate)s, polypropylenes, polycarbonates, polyimides, poly(aryl ether sulfone)s, thermoplastic polyurethanes, poly(phenylene ether)/polystyrene blends, poly(phenylene ether)/polyamide blends, poly(phenylene ether)/polypropylene blends, poly(phenylene ether) -poly siloxane/poly styrene blends, poly(phenylene ether)- polysiloxane/polyamide blends, poly((phenylene ether)-
  • Aspect 13 The method of aspect 12, wherein the additively manufacturing comprises using an additive manufacturing method selected from the group consisting of fused filament fabrication, large format additive manufacturing, and powder bed fusion.
  • Aspect 14 The method of aspect 12 or 13, wherein the first composition comprises, based on the total weight of the first composition, 96 to 99.8 weight percent of the first polymer and further comprises 0.2 to 4 weight percent of a nucleating agent; wherein the first polymer comprises a polyimide that comprises a first polyetherimide; wherein the second composition comprises, based on the total weight of the second composition, 50 to 95 weight percent of the second polymer and further comprises 5 to 50 weight percent of glass fibers; wherein the second polymer comprises a polyimide that comprises a second polyetherimide; and wherein the first polyetherimide and the second polyetherimide are the same or different.

Landscapes

  • Chemical & Material Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • Materials Engineering (AREA)
  • Organic Chemistry (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Medicinal Chemistry (AREA)
  • Polymers & Plastics (AREA)
  • Health & Medical Sciences (AREA)
  • Manufacturing & Machinery (AREA)
  • Mechanical Engineering (AREA)
  • Composite Materials (AREA)
  • Physics & Mathematics (AREA)
  • Optics & Photonics (AREA)
  • Ceramic Engineering (AREA)
  • Civil Engineering (AREA)
  • Inorganic Chemistry (AREA)
  • Structural Engineering (AREA)
  • Laminated Bodies (AREA)

Abstract

Un composite comprend une structure primaire et une structure secondaire en contact avec la structure primaire et au moins partiellement incorporée dans celle-ci. La structure primaire comprend une mousse thermoplastique. La structure secondaire comprend l'un quelconque de plusieurs types de polymère et a une densité supérieure à celle de la structure primaire. La structure secondaire est avantageusement formée par impression tridimensionnelle de la structure secondaire sur la structure primaire.
PCT/US2020/064429 2019-12-11 2020-12-11 Composite à base de mousse et procédé et article associés Ceased WO2021119385A1 (fr)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
EP19215257 2019-12-11
EP19215257.7 2019-12-11

Publications (1)

Publication Number Publication Date
WO2021119385A1 true WO2021119385A1 (fr) 2021-06-17

Family

ID=68886846

Family Applications (1)

Application Number Title Priority Date Filing Date
PCT/US2020/064429 Ceased WO2021119385A1 (fr) 2019-12-11 2020-12-11 Composite à base de mousse et procédé et article associés

Country Status (1)

Country Link
WO (1) WO2021119385A1 (fr)

Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN115806738A (zh) * 2023-02-02 2023-03-17 成都思立可科技有限公司 一种低温降噪助剂和含其的pc/abs合金、及其制备方法

Citations (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2010008683A2 (fr) 2008-06-24 2010-01-21 Sabic Innovative Plastics Ip B.V. Composition de poly(éther d’arylène)-polysiloxane et procédé
US7790292B2 (en) 1999-05-18 2010-09-07 Sabic Innovative Plastics Ip B.V. Polysiloxane copolymers, thermoplastic composition, and articles formed therefrom
US20180194917A1 (en) 2015-12-23 2018-07-12 Sabic Global Technologies, B.V. Reinforced foam structure, and associated method of forming, and article
WO2018130668A2 (fr) 2017-01-12 2018-07-19 Sabic Global Technologies B.V. Feuille de construction pour fabrication additive

Patent Citations (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US7790292B2 (en) 1999-05-18 2010-09-07 Sabic Innovative Plastics Ip B.V. Polysiloxane copolymers, thermoplastic composition, and articles formed therefrom
WO2010008683A2 (fr) 2008-06-24 2010-01-21 Sabic Innovative Plastics Ip B.V. Composition de poly(éther d’arylène)-polysiloxane et procédé
US20180194917A1 (en) 2015-12-23 2018-07-12 Sabic Global Technologies, B.V. Reinforced foam structure, and associated method of forming, and article
WO2018130668A2 (fr) 2017-01-12 2018-07-19 Sabic Global Technologies B.V. Feuille de construction pour fabrication additive

Cited By (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN115806738A (zh) * 2023-02-02 2023-03-17 成都思立可科技有限公司 一种低温降噪助剂和含其的pc/abs合金、及其制备方法
CN115806738B (zh) * 2023-02-02 2023-04-21 成都思立可科技有限公司 一种低温降噪助剂和含其的pc/abs合金、及其制备方法

Similar Documents

Publication Publication Date Title
KR102398481B1 (ko) 우수한 유전 특성을 갖는 열 전도성 열가소성 조성물 및 이의 성형품
KR101846522B1 (ko) 개선된 내연성을 갖는 폴리이미드 폴리페닐설폰 블렌드
EP2238196B1 (fr) Compositions ignifugeantes de polyimide/polyester-polycarbonate, procédés de fabrication et articles formés à partir de ces compositions
US20080248278A1 (en) Fiber reinforced thermoplastic sheets with surface coverings and methods of making
KR102050410B1 (ko) 고모듈러스 레이저 직접 구조화 복합체
CN113613878B (zh) 纤维强化塑料层叠成形体及其制造方法
CN105026472A (zh) 聚合物片材、其制造和使用方法、以及包括聚合物片材的制品
KR20140133933A (ko) 강화된 열가소성 물품, 상기 물품 제조용 조성물, 제조 방법, 및 이로부터 형성된 물품
JP6359453B2 (ja) ポリエーテルイミド／ポリ（ビフェニルエーテルスルホン）発泡材
WO2016028960A1 (fr) Compositions thermoplastiques, procédés pour leur préparation et objets correspondants
CN107532041A (zh) 聚(醚酰亚胺‑硅氧烷)‑芳香族聚酮组合物及由其制造的制品
WO2021119385A1 (fr) Composite à base de mousse et procédé et article associés
WO2020109970A1 (fr) Composite thermoplastique conforme à l'intérieur d'un rail
US10590240B2 (en) Thermoplastic composition with balanced chemical resistance and impact properties
JP2016519190A (ja) 熱成形発泡体物品
EP3237542B1 (fr) Compositions de polycarbonate, procédé de fabrication associé, et articles formés à partir de ces compositions
CN110114216B (zh) 包含聚亚苯基化物和聚丙烯的多层片材及其制造方法
JP6907764B2 (ja) 積層発泡断熱シート、成形体及び積層発泡断熱シートの製造方法
CN114466897A (zh) 树脂组合物、膜、复合材料、移动体和三维造型用材料
US20220025145A1 (en) Closed cell foam and associated expandable composition, foam-forming process, and article
JP2008205158A (ja) プリント回路基板用フィルム
WO2019092229A1 (fr) Compositions de polysulfone comprenant un copolymère polycarbonate-polysiloxane
JP2008205159A (ja) 自動車用平板型配線板用ベースフィルム

Legal Events

Date Code Title Description
121 Ep: the epo has been informed by wipo that ep was designated in this application

Ref document number: 20830467

Country of ref document: EP

Kind code of ref document: A1

NENP Non-entry into the national phase

Ref country code: DE

122 Ep: pct application non-entry in european phase

Ref document number: 20830467

Country of ref document: EP

Kind code of ref document: A1