SUMIKAEXCEL PES Powder Grades

Introduction

SUMIKAEXCEL PES powder grades are suitable for usage in the following applications:

  • Adhesives and paint / coating compounds in solvent solutions
  • Hollow-fiber membranes and cast films (flat films) in solvent solutions
  • Compounds and epoxy reinforcing applications

Table 1 shows PES powder grades and their applications.

Table 1 PES Powder Grades

Powder Grades RV (Reduced Viscosity) Main Applications
3600P 0.36 Compounds
4100P 0.41 Paint / coating compounds, adhesives
4800P 0.48 Flat films and hollow-fiber membranes, adhesives
5003P 0.50 Paint / coating compounds, adhesives, impact modifier for epoxy compounds
5200P 0.52 Flat films and hollow-fiber membranes

* Viscosity measured with 1(W/V)% SUMIKAEXCEL PES dissolved in DMF.

Physical Properties of SUMIKAEXCEL Powder Grades

Characteristics of 3600P, 4100P, 4800P and 5200P

To obtain the physical properties for the following grades: 3600P, 4100P, 4800P, please refer to the physical properties for pellet-type grades: 3600G, 4100G, 4800G (Table 2).

Table 2 Physical Properties of 3600G, 4100G, 4800G, 5200G

Test Method
(ASTM)
Units 3600G/4100G
4800G/5200G
Physical Properties Specific gravity D792 - 1.37
Mold shrinkage MD
                             TD
D955
D955
%
%
0.6
0.6
Water absorption(23 deg C,24hr) D570 % 0.43
Refractive index - - 1.65
Mechanical Properties Tensile strength(23 deg C) D638 MPa 85
Elongation at break D638 % 40~80
Flexural strength D790 MPa 130
Flexural modulus(23 deg C) D790 GPa 2.6
Compressive strength D695 MPa 109
Compressive modulus D695 MPa 1.625
Izod impact strength(6.4 mm. notched)
                                     (6.4 mm. without notch)
D256
-
J/m
J/m
85
Did not break
Rockwell hardness
            
D785
-
-
-
M88
R120
Taber abrasion(Load of 1 kg, CS17 Wheel) D1044 mg/1000rev 20
Thermal Properties Deflection temperature under load(0.46MPa) D648 deg C 210
Deflection temperature under load(1.82MPa) D648 deg C 203
Vicat softening point(1kg) D1525 deg C 226
Vicat softening point(5kg) D1525 deg C 222
Coefficient of linear expansion MD
                                                        TD
D696
D696
10-5/K
10-5/K
5.5
5.7
Thermal conductivity C177 W/(m・K) 0.18
Specific heat - J/(kg・K) 1.121
Temperature index UL746 deg C 180
Electrical Properties Dielectric constant(23 deg C. 60Hz) D150 - 3.5
Dielectric constant(23 deg C. 106Hz) D150 - 3.5
Dielectric constant(23 deg C. 2.5×109Hz) D150 - 3.4
Dielectric dissipation factor(23 deg C. 60Hz) D150 - 0.001
Dielectric dissipation factor(23 deg C. 106Hz) D150 - 0.0035
Dielectric dissipation factor(23 deg C. 2.5×109Hz) D150 - 0.004
Volume resistivity D257 Ω・m 1015
Dielectric breakdown voltage D149 kV/mm 16
Track resistance DIN53480 V 150
Arc resistance(tungsten electrode) D495 sec 70
High voltage arc ignition UL746 sec 300
High current arc ignition UL746 sec 200
Flammability Flame resistance UL94 - V-O
Limiting oxygen index(1.6m/m) D286 - 38
Hot wire ignition UL746 sec 80

Characteristics of SUMIKAEXCEL 5003P

  • SUMIKAEXCEL 5003P is an amorphous resin that has a glass transition temperature of 225 deg C.
  • It possesses excellent adhesive properties due to the large number of terminal hydroxyl groups, which range from 0.6 - 1.4 per 100 polymer repeating units.
  • Its other physical properties are similar to those of other grades.

Paint / Coating Applications

SUMIKAEXCEL 4100P and 5003P grades are utilized as paints and as coating compounds. The following characteristics have been specially enhanced in the 5003P grade: hardness after heating, chemical resistance and adhesion toward metals.
This section describes the paints and coating compounds that utilize 5003P.

Features of Paints and Coating Compounds of SUMIKAEXCEL 5003P

  • Stable even after long periods of usage in air at a temperature of 250 deg C, and when used under conditions of repetitive heating and cooling cycles (0 deg C - 250 deg C).
  • Adhesive Properties and Bonding : Demonstrates outstanding adhesion to glass, ceramic, iron, stainless steel, aluminum and aluminum alloys.
  • Solvent Resistance : Demonstrates the highest solvent resistance among most amorphous resins.
  • Resistance to Hydrolysis : Polyethersulfone resin itself has outstanding hydrolysis resistance, yet 5003P possesses even greater resistance to hydrolysis.
  • Film Formation Properties : Has superior film formation properties and provides effective protection against base materials.
  • Flame Resistance : Has high flame resistance without utilizing any flame retardant components.
  • Transparency : Has excellent transparency and does not change the appearance of the base material, even after application.
  • Hygienic Properties : Does not contain additives, such as plasticizers, thus making it highly hygienic.

Coating Procedures for SUMIKAEXCEL 5003P (Example of Solution Method)

  • Remove all oil and grease from the base material. If necessary, sandblast or etch the surface.
  • Dissolve 5003P in a solution of solvent.
  • Apply this solution to the base material, using any of the following methods: immersion; brush application or spraying. Allow to air dry.
  • Heat-treat the material in hot air at a temperature of 350 - 400 deg C for 30 minutes.

Heat Resistance of SUMIKAEXCEL 5003P Coating on Aluminum Plate (Example)

Table 3 Heat Resistance Under Continuous Service (in air at a temperature of 250 deg C)

Item Evaluated Time (Hr)
0 115 235
Change in Appearance - No change No change
Cross-cut Adhesion Test (*1) 100/100 100/100 100/100
Corrosion Resistance Test (*2) No corrosion No corrosion No corrosion

Table 4 Repetitive Heating and Cooling Cycle Test (2 minutes in ice water at 0 deg C ⇔ 2 minutes in oven at 250 deg C)

Item Evaluated Number of Cycles (Repetitions)
0 25 50
Change in Appearance - Minimal changes Slight occurrence of foam around edges
Cross-cut Adhesion Test (*1) 100/100 100/100 100/100
Corrosion Resistance Test (*2) No corrosion/td> No corrosion No corrosion

(*1) The test procedure for cross-cut adhesion is as follows: Using a safety razor, create a mesh of intersecting cuts (the shape of lines on a Checker board) into a base material that has been coated with SUMIKAEXCEL 5003P. The cuts must be deep enough to reach the base material and should be spaced 1 mm apart, to form a series of 1 mm x 1 mm squares, over an area of 100 mm2. Place adhesive tape over the area of the cuts and apply pressure, then remove the tape. Check the squares to determine the number of squares that still contain the PES coating.
(*2) The test procedure for corrosion resistance is as follows: Place several drops of a solution containing 15% (vol) nitric acid onto the test surface that has been coated with SUMIKAEXCEL 5003P. Cover the surface with a glass plate and let it stand for 24 hours. Observe any changes in the surface appearance.

Applications as Impact Modifier for Epoxy based systems

SUMIKAEXCEL 5003P is utilized in the creation of epoxy-based composite materials. The advantages of adding SUMIKAEXCEL 5003P to epoxy-based composites are as follows:

  • Improves the toughness of epoxy.
  • Has an extremely high Tg (230 deg C).
  • Possesses outstanding mechanical properties.

Enhancing the Plasticity of Epoxy Resins

SUMIKAEXCEL 5003P is essentially plastic in behavior, thus has both a high Tg and flexural modulus. Therefore, it has the ability to add plasticity to epoxy resins without degrading the overall performance of the composite itself.

Table 5 Effects when Blended with TGDDM / 4, 4'-DDS

Concentration of 5003P (%) Flexural modulus (GPa) Tg (deg C) G1c (kJ/m2)
0 3.34 205 0.28
10 3.21 205 0.41
15 3.07 200 0.47

(Note)
1)G11c values were measured under flat surface distortion conditions at -65 deg C.
2)Tg values were measured using torsion DMA.

The table above indicates a large increase in fracture toughness (G1c). It is also apparent that Tg does not decrease as significantly.

Table 6 Comparison of 5003P and PEI

Results of Comparing Epoxy Resin and As4CF at a Polymer Concentration of 30% (wt)

PEI 5003P
CAI(Compressive strength after impact)
                                                     MPa
194 223
Compressive Strength            MPa
        (Room Temp.)
       (82 deg C)
       (82 deg C)/Wet

1697
1434
N/A

1731
1648
1076
8 deg C Viscosity (Cps)       (Pa・s) 130 100

N /A: no data available

5003P for Aircraft and Sporting Equipment Applications

Epoxy thermosetting resins are utilized as the resin matrix in CFRPs (Carbon Fiber Reinforced Polymers). Although epoxy resins possess excellent mechanical and thermal properties, it is more susceptible to fracture than thermoplastic resins. For applications in the area of aircraft and sporting equipment, it is mandatory that its fracture toughness (residual compressive strength : CAI = Compressive Strength After Impact) is improved. If 5003P is added to epoxy resin, a reaction occurs, which increases the resin’s plasticity, toughening it against impact fractures that may cause delamination within the resin matrix.

  • Procedures for SUMIKAEXCEL 5003P

    The 5003P is dissolved directly in the epoxy base resin and mixed until a homogeneous solution is obtained. Next, the hardener is mixed into the solution. As the epoxy mixture hardens, it reacts with the hydroxyl radicals in the 5003P, forming a special morphology that contains an "ocean and islands structure" (matrix and discontinuous phase), thus providing improved impact resistance. Either of the two following procedures can be utilized in order to obtain a homogeneous solution of 5003P in epoxy base resin: the 5003P can be ground finely and dissolved directly in the epoxy base resin in an N2 atmosphere at a temperature of approximately 150 deg C. Alternately, the 5003P can first be dissolved uniformly in a solvent, then the solvent is later removed. The epoxy base resin is then mixed into this remaining compound to obtain a homogeneous solution.

  • Amounts of 5003P for Usage in Composites (Example)
    • Per unit of matrix range
      Epoxy base resin (100 phr) : hardening agent (30 - 40 phr) : 5003P (30 phr)
    • Per unit of prepreg
      ~10wt%
  • Usage in Aircraft Structural Composites

    In order to utilize 5003P in structural composites for aircraft, precisely-sized fine particles of 5003P (tough balls), are sprinkled onto the surface of CF prepreg, which has been produced according to the above section entitled "Procedures for SUMIKAEXCEL 5003P". Next, several dozen of these CF prepreg layers are laminated together. This process improves the impact resistance, due to the PES particles that are located on the boundaries of each surface. Furthermore, a variety of creative laminating methods have also been invented thus far.

    (Example : structural composite standards for Boeing aircraft)
    • CAI (Compression After Impact) value must be 310 MPa or greater.
    • CS (Compressive Strength under hot / wet conditions) value must be 1,100 MPa (at 82 deg C) or greater.

Adhesive Applications

PES can be utilized as a heat resistant adhesive. It possesses particularly outstanding adhesive strength toward metals.

Features

  • Bonded surfaces possess high tensile adhesive shear strength and T-peel adhesive strength. Its characteristics are well balanced, as it also possesses both rigidity and flexibility.
  • PES possesses the highest heat resistance of most commercial thermoplastic resin adhesives. It possesses an extremely high, tensile fracture adhesion strength of 20 MPa, even at a temperature of 200 deg C. As well, for short periods of time, it can be utilized repeatedly at temperatures of up to 250 deg C.
  • PES has outstanding chemical resistant and heat resistant properties.
  • PES does not contain any solvents or volatile components and demonstrates excellent adhesion toward a variety of materials, including unprimed metals such as aluminum, stainless steel, steel and brass.

Bonding Methods

Hot Melt Bonding Using PES Film

  • Cut the film to the size of the objects being bonded (adherends).
  • Roughen the adherend surfaces using sandpaper or a disc sander, then clean the surfaces with acetone or toluene.
  • Sandwich the film between the adherends, apply a small amount of pressure using a jig, then heat the joint for 10 - 30 minutes at a temperature of 300 - 360 deg C. An adequate level of pressure will be achieved if the melted resin just begins to ooze out from between the adherends, as flash.
  • A strong bond will be obtained if the joint is left to stand in cold conditions.

Bonding With Adhesive Solutions

5003P Solvent Solutions
5003P is unstable when dissolved in a single solvent, resulting in some deposition of the PES. Therefore, a solution of mixed solvents (examples shown in Table 7) is usually utilized. (Solution stability is low in a single solvent, thus causing gelation.)

Table 7 Examples of Mixed Solvent Solutions for SUMIKAEXCEL 5003P

Solvent Solution Solvent Mixing ratio (volumetric ratio)
A 1,1,2-trichloroethane
Dichloromethane
1
1(by weight)
B Dimethylformamide
Cychlohexanone
Methyl ethyl ketone
20
80
25
C N-methyl-2-pyrrolidone
Toluene or xylene
2
1
D N-methyl-2-pyrrolidone
Dichloromethane
1
1
E N-methyl-2-pyrrolidone
Toluene or xylene
Silicone flow modifier
Methyl ethyl ketone
60
30
0.5~1
35

Bonding Method
As the strength of PES adhesives will vary depending upon the thermal treatment conditions, it is necessary to determine the appropriate conditions in accordance with each particular application.
(Condition Example 1) : Dry for 2 hours at a temperature of 130 deg C
(Condition Example 2) : Dry for 1 hour at a temperature of 100 deg C, then continue drying for 15 minutes at a temperature of 350 deg C

Characteristics of SUMIKAEXCEL 5003P Adhesives

SUMIKAEXCEL 5003P has outstanding adhesive strength at high temperatures. For example, when bonding chrome/nickel stainless steel (18/8 W/W) using 5003P adhesive, changes to the adhesive strength as the temperature rises to 220 deg C are shown in Table 8. As well, the adhesive retention of bonded materials during aging at a temperature of 150 deg C is shown in Table 9.

Table 8 The Effects of Temperature on Peel Strength

Temperature (deg C) Peel Strength (MPa)
23 37
150 26
220 14

Peel strength was measured at a peel rate of 12.5 mm/min.

Table 9 The Effects of High Temperatures on Retention Time and Peel Strength

1Retention Time
at 150 deg C (hr)
Peel Strength
at 150 deg C (MPa)
No retention 26
1000 21

Even after a temperature of 150 deg C has been maintained for 1,000 hours, 81% of initial adhesive strength was retained.

Cartridge Filters Utilizing PES Membranes (Courtesy of ADVANTEC MFS, INC.)

This cartridge filter is composed of a polyethersulfone (PES) membrane filter and polypropylene. It possesses superior resistance to both heat and chemicals.

Features

  • Minimal amounts of eluted substances are produced, thus minimizing the amount of cartridge cleaning required as a pretreatment process.
  • As it utilizes asymmetric media and incorporates a pre-membrane filter having a different aperture size, it possesses high filtration efficiency and a high flow rate, thus has a long filtration life.
  • Both autoclave sterilization and in-line steam sterilization can be performed.
  • As the media itself is inert, sample constituent absorption is very minimal.

Applications

  • Precision filtration of ultrapure water in the electronics industry
  • Particle removal and disinfecting of process gases and vented air
PES membrane filter and polypropylene
Inquiries about SUMIKAEXCEL PES