Additively manufactured article and method

Patent metadata

Field	Value
Publication number	US-11306221-B2
Application number	US-202017418907-A
Country	US
Kind code	B2
Filing date	Mar 25, 2020
Priority date	May 7, 2019
Publication date	Apr 19, 2022
Grant date	Apr 19, 2022

Abstract

An article includes at least two contiguous layers containing a composition that includes a branched polycarbonate, optionally a linear carbonate-containing polymer, and 0 to less than 5 weight percent filler. The composition is characterized by an average mole percent branching of 0.06 to 2.4 mole percent, which is calculated as 100 times moles of branched carbonate units in the branched polycarbonate divided by the sum of moles of linear carbonate units in the branched polycarbonate and the optional linear carbonate-containing polymer. The composition is further characterized by a melt flow rate of 1 to 20 grams per 10 minutes, determined according to ASTM D1238-13 at 300° C. and 1.2 kilogram load. Also described is a method of additive manufacturing utilizing the composition.

First claim

The invention claimed is:

1. An article, comprising:
at least two contiguous layers;
wherein the at least two contiguous layers comprise a composition comprising, based on the total weight of the composition,
10 to 100 weight percent of a branched polycarbonate;
0 to 90 weight percent of a linear carbonate-containing polymer selected from the group consisting of linear polycarbonates, linear polycarbonate-polysiloxanes, and combinations thereof; and
0 to less than 5 weight percent filler;

wherein the composition is characterized by an average mole percent branching of 0.06 to 2.4 mole percent, wherein the average mole percent branching is calculated as 100 times moles of branched carbonate units in the branched polycarbonate divided by the sum of moles of linear carbonate units in the branched polycarbonate and the linear carbonate-containing polymer;
wherein the composition comprises 70 to 100 weight percent total of the branched polycarbonate and the linear carbonate-containing polymer; and
wherein the composition has a melt flow rate of 1 to 20 grams per 10 minutes, determined according to ASTM D1238-13 at 300° C. and 1.2 kilogram load.

2. The article of claim 1 , wherein the composition comprises the branched polycarbonate and the linear carbonate-containing polymer.

3. The article of claim 1 , wherein the composition comprises 95 to 100 weight percent total of the branched polycarbonate and the linear carbonate-containing polymer.

4. The article of claim 1 , wherein the composition is characterized by an average mole percent branching of 0.06 to 2 mole percent.

5. The article of claim 1 , wherein the composition comprises 0 to 1 weight percent filler.

6. The article of claim 1 , wherein
the composition comprises the branched polycarbonate and the linear polycarbonate;
the composition comprises 95 to 100 weight percent total of the branched polycarbonate and the linear polycarbonate;
the composition is characterized by an average mole percent branching of 0.06 to 2 mole percent; and
the composition comprises 0 to 1 weight percent filler.

7. The article of claim 1 , wherein
the composition comprises the branched polycarbonate, the linear polycarbonate, and the linear polycarbonate-polysiloxane;
the composition comprises 95 to 100 weight percent total of the branched polycarbonate, the linear polycarbonate, and the linear polycarbonate-polysiloxane;
the composition is characterized by an average mole percent branching of 0.06 to 2 mole percent; and
the composition comprises 0 to 1 weight percent filler.

8. A method of additive manufacturing, the method comprising:
converting a composition from a solid form to a molten form, wherein the composition is characterized by a glass transition temperature, and the molten form has a temperature 70 to 250° C. above the glass transition temperature;
extruding the molten form to form a first molten extrusion;
depositing the first molten extrusion in a predetermined pattern to form a first layer;
further extruding the molten form to form a second molten extrusion; and
depositing the second molten extrusion in a predetermined pattern to form a second layer having a lower surface in contact with an upper surface of the first layer,
wherein the composition comprises, based on the total weight of the composition,
10 to 100 weight percent of a branched polycarbonate;
0 to 90 weight percent of a linear carbonate-containing polymer selected from the group consisting of linear polycarbonates, linear polycarbonate-polysiloxanes, and combinations thereof; and
0 to less than 5 weight percent filler;

wherein the composition is characterized by an average mole percent branching of 0.06 to 2.4 mole percent, wherein the average mole percent branching is calculated as 100 times moles of branched carbonate units in the branched polycarbonate divided by the sum of moles of linear carbonate units in the branched polycarbonate and moles of linear carbonate units in the linear carbonate-containing polymer;
wherein the composition comprises 70 to 100 weight percent total of the branched polycarbonate and the linear carbonate-containing polymer; and
wherein the composition has a melt flow rate of 1 to 20 grams per 10 minutes, determined according to ASTM D1238-13 at 300° C. and 1.2 kilogram load.

9. The method of claim 8 , wherein the upper surface of the first layer has a temperature 20 to 200° C. above the glass transition temperature during the depositing the second molten extrusion.

10. The method of claim 8 , wherein the composition is characterized by an average mole percent branching of 0.06 to 2 mole percent.

11. The method of claim 8 , wherein the composition comprises 95 to 100 weight percent total of the branched polycarbonate and the linear carbonate-containing polymer.

12. The method of claim 8 , wherein the composition comprises 0 to 1 weight percent filler.

13. The method of claim 8 , wherein
the composition comprises the branched polycarbonate and the linear polycarbonate;
the composition comprises 95 to 100 weight percent total of the branched polycarbonate and the linear polycarbonate;
the composition is characterized by an average mole percent branching of 0.06 to 2 mole percent; and
the composition comprises 0 to 1 weight percent filler.

14. The method of claim 8 , wherein
the composition comprises the branched polycarbonate, the linear polycarbonate, and the linear polycarbonate-polysiloxane;
the composition comprises 95 to 100 weight percent total of the branched polycarbonate, the linear polycarbonate, and the linear polycarbonate-polysiloxane;
the composition is characterized by an average mole percent branching of 0.06 to 2 mole percent; and
the composition comprises 0 to 1 weight percent filler.

Assignees

• Shpp Global Tech Bv

Inventors

• Elleithy Rabeh Hosny
• Chellamuthu Manojkumar
• Delaney Alex R
• Sybert Paul Dean
• Ly Kim Loan Thi

Classifications

• C08L69/00 Primary

  Compositions of polycarbonates; Compositions of derivatives of polycarbonates · CPC title

• B33Y10/00

  Processes of additive manufacturing · CPC title

• C08G77/448

  containing polycarbonate sequences · CPC title

• B33Y80/00

  Products made by additive manufacturing · CPC title

• C09D169/00 Primary

  Coating compositions based on polycarbonates; Coating compositions based on derivatives of polycarbonates · CPC title