High strength additive manufactured articles

Patent metadata

Field	Value
Publication number	US-11447630-B2
Application number	US-201917049363-A
Country	US
Kind code	B2
Filing date	Apr 29, 2019
Priority date	Apr 30, 2018
Publication date	Sep 20, 2022
Grant date	Sep 20, 2022

Abstract

A composition including, based on a total weight of the composition: 30 to 60 wt % of polycarbonate; 20 to 40 wt % of polybutylene terephthalate; 5 to 40 wt % of carbon fiber; 1 to 10 wt % of an ethylene acrylic ester terpolymer; and less than 5 wt % of glass fiber.

First claim

The invention claimed is:

1. A composition comprising, based on a total weight of the composition:
30 to 60 wt % of polycarbonate;
20 to 40 wt % of polybutylene terephthalate;
5 to 40 wt % of carbon fiber having a diameter of 3 micrometers to 12 micrometers;
1 to 10 wt % of an ethylene acrylic ester terpolymer; and
less than 5 wt % of glass fiber;
wherein the total weight of the composition is 100 wt %.

2. The composition of claim 1 , comprising less than 3 wt % of glass fiber, based on the total weight of the composition.

3. The composition of claim 1 , wherein the composition is free of glass fiber.

4. The composition of claim 1 , comprising polycarbonate in an amount of 35 to 50 wt %, based on the total weight of the composition.

5. The composition of claim 1 , comprising polybutylene terephthalate in an amount of 25 to 35 wt %, based on the total weight of the composition.

6. The composition of claim 1 , comprising carbon fiber in an amount of 15 to 25 wt %, based on the total weight of the composition.

7. The composition of claim 1 , comprising ethylene acrylic ester terpolymer in an amount of 5 to 7 wt %, based on the total weight of the composition.

8. The composition of claim 1 , comprising, based on the total weight of the composition, carbon fiber in an amount of 10 to 30 wt %, and ethylene acrylic ester terpolymer in an amount of 5 to 7 wt %.

9. The composition of claim 1 , wherein the carbon fiber has a length of 0.1 millimeters to 6 millimeters.

10. The composition of claim 1 , wherein the carbon fiber has a diameter of 3 micrometers to 10 micrometers.

11. The composition of claim 1 , wherein the composition comprises carbon fibers having a tensile modulus of 28 to 48 megapounds per square inch (193 to 331 gigapascals).

12. The composition of claim 1 , wherein the composition comprises carbon fibers having a tensile strength of 400 to 1,200 kilopounds per square inch (2,758 to 8,274 megapascals).

13. A method of forming an article, the method comprising three dimensional printing using the composition of claim 1 .

14. An additively manufactured article formed using the composition of claim 1 .

15. The additively manufactured article of claim 14 , wherein the article exhibits a tensile strength in the z direction of at least 15 megapascals, as determined by a modified ASTM D 638 test method, wherein the z direction is the direction in which layers are added during an additive manufacturing process.

Assignees

• Sabic Global Technologies Bv
• Shpp Global Tech Bv

Inventors

• Moniruzzaman Mohammad
• Elleithy Rabeh
• Delaney Alex
• Chellamuthu Manojkumar

Classifications

• C08L69/00 Primary

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

• C08L67/02

  Polyesters derived from dicarboxylic acids and dihydroxy compounds (C08L67/06 takes precedence) · CPC title

• C08K7/06

  Elements · CPC title

• C08L23/0884

  Epoxide-containing esters · CPC title