Abstract: A polyaryletherketone, PAEK, in the form of particles is a copolymer with at least 95 mole % repeat units of formula I, and repeat units of formula II, and a molar ratio I:II from 55:45 to 80:20. The PAEK has a melt viscosity, MV, from 0.35 to 0.55 kNsm?2 at 1000 s?1. The PAEK is of use in formation of components having high elongation at break when formed by selective sintering and melt-bonding of sequentially deposited layers of powder comprising the PAEK particles. Also provided are processes for making the PAEK particles, powders including them and their use and methods of their use in component formation.

Abstract: A method for manufacture of PEEK-PEDEK copolymers is described herein, along with copolymers formed by the method and their use. The method includes a nucleophilic polycondensation of a mixture of dihydroxybenzene and dihydroxybiphenyl with 4,4?-dihalobenzophenone in a reaction mixture comprising sodium carbonate and potassium carbonate, in an aromatic sulfone solvent, at a reaction temperature rising to a temperature from 280° C. to 330° C. immediately prior to the addition of a reaction-stopping salt, such as LiCl or Li2SO4, to the reaction mixture. Further organic dihalide is subsequently added to the reaction mixture for end-capping of the copolymer. The resulting copolymer has reduced chain branching and reduced melt viscosity at low shear rate compared to prior art copolymer of comparable molecular mass.

Abstract: The disclosure relates to polymer-containing composite materials and to unusually low-pressure consolidation methods for forming composite parts from such materials. More specifically, for example, the disclosure relates to use of a certain “PEEK-PEDEK” copolymer in low-pressure consolidation methods, using as little as 1 bar pressure (or using atmospheric pressure acting on a consolidation that is held under vacuum) to provide composite parts that are substantially void-free.

Abstract: A polyetheretherketone pipe of length greater than 250 meters and a residual stress of less than 5 MPa may be made using a calibrator device 2 which includes a cone shaped opening 6 arranged to receive a molten extruded pipe shaped polymer. Attached to the front member 4 is a vacuum plate 14a and successive vacuum plates 14b-14h are attached to one another to define an array of vacuum plates, the vacuum plates being arranged to allow a vacuum to be applied to a pipe precursor passing through opening 16. The vacuum plates 14 also include temperature control means for heating or cooling the plates and therefore heating or cooling a pipe precursor passing through the openings.

Abstract: A polymeric material has a repeat unit of formula —O-Ph-O-Ph-CO-Ph- I and a repeat unit of formula —O-Ph-Ph-O-Ph-CO-Ph- II wherein Ph represents a phenylene moiety; wherein the repeat units I and II are in the relative molar properties I:II of from 65:35 to 95:5; wherein log10 (X %)>1.50-0.26 MV; wherein X % refers to the % crystallinity measured as described in Example 31 and MV refers to the melt viscosity measured as described in Example 30. A process for making the polymeric material comprises polycondensing a mixture of at least one dihydroxybenzene compound and at least one dihydroxybiphenyl compound in the molar proportions 65:35 to 95:5 with at least one dihalobenzophenone in the presence of sodium carbonate and potassium carbonate wherein: (i) the mole % of said potassium carbonate is at least 2.

Abstract: A component comprises a first part and a second part, wherein said second part is in contact with said first part, wherein: (i) said first part comprises a polymer having a repeat unit of formula —O-Ph-O-Ph-CO-Ph-??I and a repeat unit of formula —O-Ph-Ph-O-Ph-CO-Ph??II wherein Ph represents a phenylene moiety; and (ii) said second part comprises a metal.

Abstract: A process for manufacturing an object, the process comprising steps: a) selecting a feedstock material comprising one or more polymeric material selected from i) a polymeric material (A) having a repeat unit of formula I and a repeat unit of formula II wherein Ph represents a phenylene moiety; and/or ii) a polymeric material (B) having a repeat unit of formula III and a repeat unit of formula IV wherein Ph represents a phenylene moiety; each X independently represents an oxygen or suphur atom; n represents an integer of 1 or 2; Y is selected from a phenylene moiety, a Ph-Ph moiety and a naphthalenyl moiety; W is a carbonyl group, an oxygen or sulphur atom, Z is selected from —X-Ph-S02-Ph- —X-Ph-S02-Y-S02-Ph- and —CO-Ph-; b) melting the feedstock material; and c) extruding the feedstock material to form a plurality of parts that define the object.

Abstract: A component comprising a first part and a second part, wherein a third part is positioned between the first and second parts, wherein: (iv) said first part comprises a polymeric material (A) which comprises a repeat unit of formula (XI) wherein t1, and w1 independently represent 0 or 1 and v1 represents 0, 1 or 2; (v) said second part comprises a polymeric material (B) which comprises a repeat unit of formula (XI) wherein t1, and w1 independently represent 0 or 1 and v1 represents 0, 1 or 2; and (vi) said third part comprises a polymeric material (C) which comprises a polymer having a repeat unit of formula —O-Ph-O-Ph-CO-Ph-??I and a repeat unit of formula —O-Ph-Ph-O-Ph-CO-Ph-??II wherein Ph represents a phenylene moiety.

Abstract: This anti-backlash gear includes a gear wheel and gear teeth. Each gear tooth comprises first and second flanks, a top face and a bottom face, wherein for each gear tooth each flank extends from the top face to the bottom face, wherein the gear teeth comprise a polymeric material which comprises a repeat unit of form I wherein t1, and w1 independently represent 0 or 1 and v1 represents 0, 1 or 2. For each gear tooth, at least one of said flanks comprises two or more surfaces arranged to form a single protrusion extending along the at least one said flank such that a tooth thickness of each gear tooth varies between the top face and the bottom face of said gear tooth in a direction parallel to an axis of rotation of the gearwheel in operation. In use, the single protrusion is elastically deformable so as to absorb backlash.

Abstract: Polyaryletherketones are produced which are end-capped with a phenylethynyl-containing moiety.

Abstract: An assembly or apparatus for use in relation to an assembly, wherein said assembly is subjected to a temperature of less than ?50° C. in use, wherein said assembly or apparatus includes a component which comprises a polymeric material (A) having a repeat unit of formula —O-Ph-O-Ph-CO-Ph- (I) wherein Ph represents a phenylene moiety; and wherein said polymeric material (A) has a melt viscosity of at least 0.50 kNsm?2.

Abstract: A composite pipe comprises a polyetheretherketone innermost pipe around which a reinforcing overwrap is arranged. A protective sheath surrounds the overwrap. Such a composite pipe may be made by selecting a polyetheretherketone pipe having an outer region having a crystallinity of less than 25%; overlaying the selected pipe with overwrap; and subjecting the combination to heat, thereby causing the crystallinity of the outer region of the polyetheretherketone pipe to increase. The method reduces the risk of pipe failure.

Abstract: A polymeric material has a repeat unit of formula —O-Ph-O-Ph-CO-Ph-I and a repeat unit of formula —O-Ph-Ph-O-Ph-CO-Ph-II wherein Ph represents a phenylene moiety; wherein the repeat units I and II are in the relative molar properties I:II of from 65:35 to 95:5; wherein log10 (X %)>1.50-0.26 MV; wherein X % refers to the % crystallinity and MV refers to the melt viscosity. A process for making the polymeric material is also disclosed.

Abstract: A composition comprising: (i) a polymeric material (A) having a repeat unit of formula —(O-Ph)n-O-Ph-O-Ph-CO-Ph-??I and a repeat unit of formula —O-Ph-Ph-O-Ph-CO-Ph-??II wherein Ph represents a phenylene moiety and n represents 0 or 1; and (ii) a polymeric additive comprising one or more of: (a) a polycarbonate; and/or (b) a polymeric material (B) which includes a repeat unit of general formula wherein R1 and R2 independently represent a hydrogen atom or an optionally-substituted (preferably un-substituted) alkyl group, and R3 and R4 independently represent a hydrogen atom or an optionally-substituted alkyl group, an anhydride-containing moiety or an alkyloxycarbonyl-containing moiety.

Abstract: This anti-backlash gear includes a gear wheel and gear teeth. Each gear tooth comprises first and second flanks, a top face and a bottom face, wherein for each gear tooth each flank extends from the top face to the bottom face, wherein the gear teeth comprise a polymeric material which comprises a repeat unit of form I wherein t1, and w1 independently represent 0 or 1 and v1 represents 0, 1 or 2. For each gear tooth, at least one of said flanks comprises two or more surfaces arranged to form a single protrusion extending along the at least one said flank such that a tooth thickness of each gear tooth varies between the top face and the bottom face of said gear tooth in a direction parallel to an axis of rotation of the gearwheel in operation. In use, the single protrusion is elastically deformable so as to absorb backlash.

Abstract: An insulated conductor has an elongate conductor provided with an insulating layer which comprises a polymeric material. The polymeric material has a crystallinity of at least 25% and includes a repeat unit of general formula wherein t1 and w1 independently represent 0 or 1 and v1 represents 0, 1 or 2. The insulating layer has a thickness in the range 2 ?m-300 ?m.

Abstract: A process for manufacturing an object by laser sintering comprises: (i) selecting a powder comprising a polymeric material having a repeat unit of formula —O—Ph—O—Ph—CO—Ph—??I and a repeat unit of formula —O—Ph—Ph—O—Ph—CO—Ph—??II wherein Ph represents a phenylene moiety; and (ii) selectively sintering the powder to produce the object. It is found that the polymer used can be advantageously recycled and blended with virgin material to produce a blend which has very similar mechanical properties and crystallinity compared to the virgin material. Thus, the polymer may be cost-effectively used in laser sintering.

Abstract: A component comprises a first part and a second part, wherein said second part is in contact with said first part, wherein: (i) said first part comprises a first polymer which is semi-crystalline and includes phenylene moieties, carbonyl moieties and ether moieties; (ii) said second part comprises a second polymer which is semi-crystalline and includes phenylene moieties, carbonyl moieties and ether moieties; (iii) the melting temperature (Tm) of the second polymer is less than the melting temperature (Tm) of the first polymer. In a preferred embodiment, said first polymer is polyetheretherketone and said second polymer is a copolymer having a repeat unit of formula VIII and a repeat unit of formula IX.

Abstract: A polyetheretherketone pipe of length greater than 250 meters and a residual stress of less than 5 MPa may be made using a calibrator device (2) which includes a cone shaped opening (6) arranged to receive a molten extruded pipe shaped polymer. Attached to the front member (4) is a vacuum plate (14a) and successive vacuum plates (14b-14h) are attached to one another to define an array of vacuum plates, the vacuum plates being arranged to allow a vacuum to be applied to a pipe precursor passing through opening (16). The vacuum plates (14) also include (10) temperature control means for heating or cooling the plates and therefore heating or cooling a pipe precursor passing through the openings.

Abstract: A process for manufacturing an object, the process comprising steps: a) selecting a feedstock material comprising one or more polymeric material selected from i) a polymeric material (A) having a repeat unit of formula I and a repeat unit of formula II wherein Ph represents a phenylene moiety; and/or ii) a polymeric material (B) having a repeat unit of formula III and a repeat unit of formula IV wherein Ph represents a phenylene moiety; each X independently represents an oxygen or suphur atom; n represents an integer of 1 or 2; Y is selected from a phenylene moiety, a Ph-Ph moiety and a naphthalenyl moiety; W is a carbonyl group, an oxygen or sulphur atom, Z is selected from —X-Ph-S02-Ph- —X-Ph-S02-Y-S02-Ph- and —CO-Ph-; b) melting the feedstock material; and c) extruding the feedstock material to form a plurality of parts that define the object.