Method for producing spherical thermoplastic polymer particles

A process for producing particles of a thermoplastic polymer in spherical form, the process comprising:

• (i) providing at least one thermoplastic polymer in a molten state;
• (ii) providing an aqueous solution of at least one surface-active substance, wherein the aqueous solution of the at least one surface-active substance is at a temperature in a range from 100 to 300° C.;
• (iii) dispersing the at least one thermoplastic polymer from (i) in the aqueous solution of the at least one surface-active substance from (ii), to obtain an aqueous solution comprising dispersed thermoplastic polymer;
• (iv) cooling down the aqueous solution comprising dispersed thermoplastic polymer to a temperature below a solidification point of the at least one thermoplastic polymer, to obtain a suspension comprising an aqueous solution and particles of the at least one thermoplastic polymer suspended therein in a solid state, wherein the particles are in spherical form;
• (v) separating the particles of the at least one thermoplastic polymer in spherical form from the suspension obtained in (iv);
• and
• (vi) optionally, drying the particles of the at least one thermoplastic polymer in spherical form that have been separated off in (v);
• wherein the particles of the at least one thermoplastic polymer in spherical form that have been separated off in (v) and optionally dried in (vi) have a particle size distribution having a d[4,3] value of more than 10 μm and a d90.3 value of more than 20 μm.