Processes for increasing density of polymer flakes and powders

Patent metadata

Field	Value
Publication number	US-2017306075-A1
Application number	US-201515523439-A
Country	US
Kind code	A1
Filing date	Oct 29, 2015
Priority date	Nov 3, 2014
Publication date	Oct 26, 2017
Grant date	—

Abstract

The present disclosure is directed to improved poly(arylene ether ketone) powders for use in laser sintering, powder coating, compression molding, or transfer molding.

First claim

1 . A method comprising:
comminuting a sheet, the sheet formed by compacting a first poly(arylene ether ketone) (PAEK) powder or a first mixture of PAEK powders, to form a second PAEK powder or second mixture of PAEK powders; wherein the second PAEK powder or second mixture of PAEK powders has a median particle diameter of between about 10 microns and about 2000 microns and a bulk density that is at least 9% greater, as compared to an uncompacted PAEK powder or mixture of PAEK powders having a median particle diameter of between about 10 microns and about 2000 microns.

2 . The method of claim 1 , wherein the particle size of the second powder or mixture of powders is between about 250 microns and about 2000 microns.

3 . The method of claim 1 , wherein the particle size of the second powder or mixture of powders is between about 10 microns and 150 microns.

4 . The method of claim 1 , wherein the sheet is compacted at a pressure of about 500 psi or greater.

5 . The method of claim 1 , wherein the PAEK is polyetherketoneketone (PEKK).

6 . The method of claim 1 , wherein the bulk density of the second powder or mixture of powders is 0.30 g/cm 3 or greater.

7 . The method of claim 1 , wherein the bulk density of the second powder or mixture of powders is 0,32 g/cm 3 or greater.

8 . The method of claim 1 , wherein the bulk density of the second powder or mixture of powders is 0.36 g/cm 3 or greater.

9 . The method of claim 1 , wherein the compacting is by roll compacting.

10 . A powder comprising PAEK or a mixture of PAEKs and having a median particle diameter of between 250 microns and about 2000 microns and a bulk density of greater than 0.3 g/cm 3 .

11 . The powder of claim 10 , having a bulk density of greater than 0.3 g/cm 3 and less than 0.90 g/cm 3 .

12 . The powder of claim 10 , having a bulk density of 0.32 g/cm 3 or greater.

13 . The powder of claim 10 , wherein the PAEK is PEKK.

14 . The powder of claim 10 , substantially free of additional flow aids or additives.

15 . A powder comprising PAEK or a mixture of PAEKs and having a median particle diameter of between 10 microns and about 150 microns and a bulk density of 0.3 g/cm 3 or greater.

16 . The powder of claim 15 , having a median particle diameter of between about 45 microns and about 55 microns.

17 . The powder of claim 15 , wherein the PAEK is PEKK.

18 . The powder of claim 15 , substantially free of additional flow aids or additives.

19 . A method of preparing a powder of claim 15 , comprising comminuting a powder of claim 10 .

20 . A method comprising
laser sintering, powder coating, compression molding, or transfer molding a PAEK powder or mixture of PAEK powders having a median particle diameter of between 10 microns to 150 microns and a bulk density of 0.30 g/cm 3 or greater; to produce an article.

21 . The method of claim 20 , wherein the bulk density is greater than 0.32 g/cm 3 .

22 . The method of claim 20 , wherein the median particle diameter is between 45 microns and 55 microns.

23 . The method of claim 20 , wherein the method comprises laser sintering.

24 . An article prepared by the method of claim 20 .

Assignees

• Arkema Inc

Inventors

• Spahr Timothy A
• Pedicini Angelo

Classifications

• B33Y70/00 Primary

  Materials specially adapted for additive manufacturing · CPC title

• C08G2650/40

  containing ketone groups, e.g. polyarylethylketones, PEEK or PEK · CPC title

• C08G4/00 Primary

  Condensation polymers of aldehydes or ketones with polyalcohols; Addition polymers of heterocyclic oxygen compounds containing in the ring at least once the grouping —O—C—O— (of cyclic oligomers of aldehydes C08G2/00) · CPC title

• B29C64/314

  Preparation · CPC title

• B29B9/12

  characterised by structure or composition · CPC title