Semi-crystalline build materials

Patent metadata

Field	Value
Publication number	US-10807302-B2
Application number	US-201715783711-A
Country	US
Kind code	B2
Filing date	Oct 13, 2017
Priority date	Nov 21, 2012
Publication date	Oct 20, 2020
Grant date	Oct 20, 2020

Abstract

A polymeric material includes a semi-crystalline polymer and a secondary material wherein when the secondary material is combined with the semi-crystalline polymer to form a blend having an enthalpy that is between about 2 J/g heat of fusion and about 80% of the heat of fusion of the neat semi-crystalline material, as measured by differential scanning calorimetry (DSC) when cooling from a melting temperature to a hot crystalline temperature at a rate of 10° C./min.

First claim

The invention claimed is:

1. A filament for use as a build material for printing parts in an extrusion based additive manufacturing system, the filament comprising:
a semi-crystalline polyetherketoneketone (PEKK);
a polyetheretherketone (PEEK) configured to accelerate crystallization of the PEKK; and
antioxidants;
wherein when the PEEK and antioxidants are combined with the PEKK to form a homogenous blend having a glass transition temperature and a cold crystallization temperature, wherein the PEKK comprises between 90 wt % and about 99 wt % of the blend and the antioxidants comprise between 0.1 wt % and 5 wt % of the weight of the blend, and wherein the blend is substantially homogenous and configured to be extruded in a series of roads in a plurality of layers to print a part in a layer-wise manner, wherein as the blend used to print the part exhibits partial crystallinity, wherein adjacent roads within a layer (interlayer) and in consecutive layers (intralayer) contact one another at extrudate interfaces and molecular reptation occurs at the extrudate interfaces due to a crystallization reaction before the molten material supercools to an annealing temperature, thereby increasing bonding of the roads in the x-y build plane and also between layers prior to being supercooled.

2. The filament of claim 1 and wherein the PEEK comprises about 5 wt % of the blend and the PEKK comprises about 95% of the blend.

3. The filament of claim 1 and further comprising fillers in the range of 1 wt % and about 45 wt % of a total weight of the blend.

4. The filament of claim 3 and wherein the fillers comprise glass or carbon fibers.

5. A filament for use as a build material for printing parts in an extrusion based additive manufacturing system, the filament comprising:
a semi-crystalline polyetherketoneketone (PEKK);
a polyetheretherketone (PEEK) configured to accelerate crystallization of the PEKK; and
antioxidants;
wherein when the PEEK and antioxidants are combined with the PEKK to form a homogenous blend having a glass transition temperature and a cold crystallization temperature, wherein the PEKK comprises between 90 wt % and about 99 wt % of the blend and the antioxidants comprise between 0.1 wt % and 5 wt % of the weight of the blend, and wherein the blend is substantially homogenous and configured to be extruded in a series of roads in a plurality of layers to print a part in a layer-wise manner, wherein the blend used to print the part exhibits a heat of fusion upon cooling of about 33% to about 61% relative to neat PEEK and/or neat PEKK.

6. The filament of claim 5 and wherein the PEEK comprises about 5 wt % of the blend and the PEKK comprises about 95% of the blend.

7. The filament of claim 5 and further comprising fillers in the range of 1 wt % and about 45 wt % of a total weight of the blend.

8. The filament of claim 7 and wherein the fillers comprise glass or carbon fibers.

9. A filament for use as a build material for printing parts in an extrusion based additive manufacturing system, the filament comprising:
a semi-crystalline polyetherketoneketone (PEKK);
a polyetheretherketone (PEEK) configured to accelerate crystallization of the PEKK; and
antioxidants;
wherein when the PEEK and antioxidants are combined with the PEKK to form a homogenous blend having a glass transition temperature and a cold crystallization temperature, wherein the PEKK comprises between 90 wt % and about 99 wt % of the blend and the antioxidants comprise between 0.1 wt % and 5 wt % of the weight of the blend, and wherein the blend is substantially homogenous and wherein the addition of the PEEK to the PEKK increases the relative crystallinity of the PEKK from 3% to up to 30%.

10. The filament of claim 9 and wherein the PEEK comprises about 5 wt % of the blend and the PEKK comprises about 95% of the blend.

11. The filament of claim 9 and further comprising fillers in the range of 1 wt % and about 45 wt % of a total weight of the blend.

12. The filament of claim 11 and wherein the fillers comprise glass or carbon fibers.

Assignees

• Stratasys Inc

Inventors

• Rodgers Luke M B
• Jaker Vittorio L

Classifications

• B33Y70/10

  Composites of different types of material, e.g. mixtures of ceramics and polymers or mixtures of metals and biomaterials · CPC title

• B33Y70/00

  Materials specially adapted for additive manufacturing · CPC title

• B29C64/336

  of two or more materials · CPC title

• B29K2071/00

  Use of polyethers {, e.g. PEEK, i.e. polyether-etherketone or PEK, i.e. polyetherketone or derivatives thereof}, as moulding material · CPC title

• B29C64/112

  using individual droplets, e.g. from jetting heads · CPC title