Processes for producing a shaped body using polyamide blends containing a polyarylether

Patent metadata

Field	Value
Publication number	US-12214548-B2
Application number	US-201716321079-A
Country	US
Kind code	B2
Filing date	Jul 21, 2017
Priority date	Jul 29, 2016
Publication date	Feb 4, 2025
Grant date	Feb 4, 2025

Abstract

The present invention relates to a process for producing a shaped body by selective laser sintering of a sinter powder (SP). The sinter powder (SP) comprises at least one semicrystalline polyamide, at least one nylon-6I/6T and at least one polyaryl ether. The present invention further relates to a shaped body obtainable by the process of the invention and to the use of a polyaryl ether in a sinter powder (SP) for broadening the sintering window (W SP ) of the sinter powder (SP).

First claim

The invention claimed is:

1. A process for producing a shaped body by selective laser sintering of a sinter powder (SP), wherein the sinter powder (SP) comprises the following components:
(A) at least one semicrystalline polyamide comprising at least one unit selected from the group consisting of —NH—(CH 2 ) m —NH— units where m is 4, 5, 6, 7 or 8, —CO—(CH 2 ) n —NH— units where n is 3, 4, 5, 6 or 7, and —CO—(CH 2 ) o —CO— units where o is 2, 3, 4, 5 or 6,
(B) at least one nylon-6I/6T,
(C) at least one polyaryl ether,
wherein
component (C) is a polyaryl ether containing units of the general formula (I)

with the following definitions:
t, q: each independently 0, 1, 2 or 3,
Q, T, Y: each independently a chemical bond or group selected from —O—, —S—, —SO 2 —, S═O, C═O, —N═N— and —CR a R b — where R a and R b are each independently a hydrogen atom or a C 1 -C 12 -alkyl, C 1 -C 12 -alkoxy or C 6 -C 18 -aryl group and where at least one of Q, T and Y is-SO 2 — and
Ar, Ar 1 : each independently an arylene group having from 6 to 18 carbon atoms, and wherein a first layer of the sinter powder (SP) is arranged in a powder bed and locally exposed to a laser beam, and wherein the sinter powder (SP) comprises in the range from 20% to 90% by weight of component (A), in the range from 5% to 40% by weight of component (B) and in the range from 5% to 40% by weight of component (C), based in each case on the sum total of the percentages by weight of components (A), (B) and (C).

2. The process according to claim 1 , wherein the sinter powder (SP) has
a D10 in the range from 10 to 30 μm,
a D50 in the range from 25 to 70 μm and
a D90 in the range from 50 to 150 μm,
wherein the particle sizes of the sinter powder (SP) are determined by a laser diffraction.

3. The process according to claim 1 , wherein the sinter powder (SP) has a melting temperature (T M ) in the range from 180 to 270° C., wherein the melting temperature (T M ) is determined by means of dynamic differential calorimetry.

4. The process according to claim 1 , wherein the sinter powder (SP) has a crystallization temperature (T C ) in the range from 120 to 190° C., wherein the crystallization temperature (T C ) is determined by means of dynamic differential calorimetry.

5. The process according to claim 1 , wherein the sinter powder (SP) has a sintering window (W SP ), where the sintering window (W SP ) is the difference between the onset temperature of melting (T M onset ) and the onset temperature of crystallization (T C onset ) and where the sintering window (W SP ) is in the range from 18 to 45 K.

6. The process according to claim 1 , wherein the sinter powder (SP) is produced by grinding components (A), (B) and (C) at a temperature in the range from −210 to −195° C.

7. The process according to claim 1 , wherein component (A) is selected from the group consisting of PA 6, PA 6.6, PA 6.10, PA 6.12, PA 6.36, PA 6/6.6, PA 6/6I6T, PA 6/6I and PA 6/6T.

8. The process according to claim 1 , wherein component (C) is selected from the group consisting of PSU, PESU and PPSU.

9. The process according to claim 1 , wherein the sinter powder (SP) additionally comprises at least one additive selected from the group consisting of antinucleating agents, stabilizers, end group functionalizers and dyes.

10. A process for broadening the sintering window (W SP ) of a sinter powder (SP) compared to the sintering window (W AB ) of a mixture of components (A) and (B) which comprises incorporating into the sinter powder at least one polyaryl ether in the sinter powder (SP) comprising the following components:
(A) at least one semicrystalline polyamide comprising at least one unit selected from the group consisting of —NH—(CH 2 ) m —NH— units where m is 4, 5, 6, 7 or 8, —CO—(CH 2 ) n —NH— units where n is 3, 4, 5, 6 or 7, and —CO—(CH 2 ) o —CO— units where o is 2, 3, 4, 5 or 6,
(B) at least one nylon-6I/6T,
(C) at least one polyaryl ether,
where the sintering window (W SP ; W AB ) in each case is the difference between the onset temperature of melting (T M onset ) and the onset temperature of crystallization (T C onset ), wherein
the polyaryl ether contains units of the general formula (I)

with the following definitions:
t, q: each independently 0, 1, 2 or 3,
Q, T, Y: each independently a chemical bond or group selected from —O—, —S—, —SO 2 —, S═O, C═O, —N═N— and —CR a R b — where R a and R b are each independently a hydrogen atom or a C 1 -C 12 -alkyl, C 1 -C 12 -alkoxy or C 6 -C 18 -aryl group and where at least one of Q, T and Y is-SO 2 — and
Ar, Ar 1 : each independently an arylene group having from 6 to 18 carbon atoms, wherein the sinter powder (SP) comprises in the range from 20% to 90% by weight of component (A), in the range from 5% to 40% by weight of component (B) and in the range from 5% to 40% by weight of component (C), based in each case on the sum total of the percentages by weight of components (A), (B) and (C).

Assignees

• Basf Se

Inventors

• Gabriel Claus
• Weber Martin
• Kloke Philipp
• Meier Thomas

Classifications

• C08L81/06

  Polysulfones; Polyethersulfones · CPC title

• C08L71/12

  Polyphenylene oxides · CPC title

• B29K2081/06

  PSU, i.e. polysulfones; PES, i.e. polyethersulfones or derivatives thereof · 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

• B33Y70/00

  Materials specially adapted for additive manufacturing · CPC title