# US 12,005,610 B2 · Polymer powder and article made from the same

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- Number: US 12,005,610 B2
- Document ID: US12005610B2
- Status: Granted
- Kind: B2
- Application number: 17/151,637
- Filed: 2021-01-18
- Published: 2021-05-13
- Granted: 2024-06-11
- Earliest claimed: 2017-01-15
- Assignees: Hexcel Corporation
- Applicants: Hexcel Corporation
- Inventors: Scott DeFelice; Anthony DeCarmine
- Web page: https://patentgrep.com/patent/US12005610B2

## CPC

- B29B 9/16: Auxiliary treatment of granules
- B02C 23/10: with separator arranged in discharge path of crushing or disintegrating zone
- B29B 7/16: with paddles or arms
- B29B 7/90: Fillers or reinforcements {, e.g. fibres}
- B29B 9/14: fibre-reinforced
- B29C 64/153: using layers of powder being selectively joined, e.g. by selective laser sintering or melting
- B33Y 10/00: Processes of additive manufacturing
- B33Y 70/10: Composites of different types of material, e.g. mixtures of ceramics and polymers or mixtures of metals and biomaterials
- C08G 65/4012: {Other compound (II) containing a ketone group, e.g. X-Ar-C(=O)-Ar-X for polyetherketones}
- C08G 65/46: Post-polymerisation treatment, e.g. recovery, purification, drying
- C08J 3/12: Powdering or granulating
- C08J 5/042: {with carbon fibres}
- C08L 71/12: Polyphenylene oxides
- B29B 7/005: {for mixing in batches}
- B29B 2009/125: {Micropellets, microgranules, microparticles}
- B29B 2009/168: {Removing undesirable residual components, e.g. solvents, unreacted monomers; Degassing}
- B29K 2071/00: Use of polyethers {, e.g. PEEK, i.e. polyether-etherketone or PEK, i.e. polyetherketone or derivatives thereof}, as moulding material
- C08G 2650/40: containing ketone groups, e.g. polyarylethylketones, PEEK or PEK
- C08J 2371/10: from phenols
- B29B: PREPARATION OR PRETREATMENT OF THE MATERIAL TO BE SHAPED; MAKING GRANULES OR PREFORMS; RECOVERY OF PLASTICS OR OTHER CONSTITUENTS OF WASTE MATERIAL CONTAINING PLASTICS
- B02C: CRUSHING, PULVERISING, OR DISINTEGRATING IN GENERAL; MILLING GRAIN ({household tools and machines for pulverising foodstuffs, e.g. coffee and spice mills A47J42/00; pharmaceutical mortars A61J3/02; mechanical processing of refuse and garbage B03B9/06; dressing mould materials by grinding B22C5/04}; obtaining metallic powder by crushing, grinding or milling B22F9/04; {recovery of plastics by disintegrating B29B17/00; crushing raw materials in starch making C08B30/02; beaters for papermaking D21D1/02; crushing devices specially for transport in mines E21F13/002; slag crushing devices F23J1/00; fuel milling devices in combustion apparatus F23K1/00; household devices for crushing coal F24B15/02; ice disintegrating devices F25C5/02})
- B29C: SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING (making preforms B29B11/00; making laminated products by combining previously unconnected layers which become one product whose layers will remain together B32B37/00 - B32B41/00)
- B33Y: ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
- C08G: MACROMOLECULAR COMPOUNDS OBTAINED OTHERWISE THAN BY REACTIONS ONLY INVOLVING UNSATURATED CARBON-TO-CARBON BONDS
- C08J: WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H (working, e.g. shaping, of plastics B29)
- C08L: COMPOSITIONS OF MACROMOLECULAR COMPOUNDS (compositions based on polymerisable monomers C08F, C08G; artificial filaments or fibres D01F; textile treating compositions D06)
- B29K: INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR {MOULDS, } REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS

## Abstract

A powder composition suitable for laser sintering for printing a three-dimensional object obtained by pre-heating a raw PEKK to evaporate a liquid solvent in the raw PEKK and the grinding the raw PEKK to form a PEKK powder, the powder composition having a first fraction comprising a polyetherketoneketone (PEKK) powder having a plurality of particles, the plurality of particles having a mean diameter D50 in the range of 30 μm to 150 μm. The plurality of particles of the first fraction are substantially non-spherical.

## Claims

### Claim 1

A powder composition suitable for laser sintering for printing a three-dimensional object obtained by pre-heating a raw PEKK to evaporate a liquid solvent in the raw PEKK and then grinding the raw PEKK to form a PEKK powder, the powder composition comprising:
a first fraction comprising a polyetherketoneketone (PEKK) powder having a plurality of particles, the plurality of particles having a mean diameter D50 in the range of 60 μm to 70 μm;
a second fraction comprising a plurality of carbon fiber;
wherein the plurality of particles of the first fraction are irregularly shaped and substantially non-spherical due to the particle-on-particle contact impacts during a jet milling process,
wherein the temperature of the raw PEKK during the pre-heating is greater than 200 C and is less than a temperature at which raw PEKK begins to melt;
wherein after the pre-heating the PEKK powder of the first fraction has a purity greater than 99.50% as determined by the ASTM E1868 loss-on-drying test method;
wherein the plurality of particles of the first fraction is sieved to reduce the particles less than 30 μm in diameter and greater than 150 μm in diameter so that the powder is configured for use in selective laser sintering.

### Claim 2 (depends on 1)

The powder composition of claim 1, wherein the plurality of PEKK particles are angular.

### Claim 3 (depends on 2)

The powder composition of claim 2, wherein the PEKK powder of the first fraction has a purity greater than 99.75% as determined by the ASTM E1868 loss-on-drying test method.

### Claim 4

A powder composition suitable for laser sintering for printing a three-dimensional object obtained by pre-heating a raw PEKK to evaporate a liquid solvent in the raw PEKK and then grinding the raw PEKK to form a PEKK powder, the powder composition comprising:
a first fraction comprising a polyetherketoneketone (PEKK) powder having a plurality of particles, the plurality of particles having a mean diameter D50 in the range of 60 μm to 70 μm;
a second fraction comprising a plurality of carbon fiber;
wherein the plurality of particles of the first fraction are irregularly shaped and substantially angular due to the particle-on-particle contact impacts during a jet milling process,
wherein the PEKK powder of the first fraction has purity greater than 99.50% as determined by the ASTM E1868 loss-on-drying test method as a result of subjecting the raw PEKK to a heat treatment that is greater than 200 C. and is less than a temperature at which raw PEKK begins to melt.

### Claim 5 (depends on 4)

The powder composition of claim 4, wherein the plurality of PEKK particles are angular.

### Claim 6 (depends on 5)

The powder composition of claim 5, wherein the PEKK powder of the first fraction has a purity greater than 99.75% as determined by the ASTM E1868 loss-on-drying test method.

### Claim 7 (depends on 6)

The powder composition of claim 6, wherein the plurality of particles of the first fraction is sieved to reduce the particles less than 30 μm in diameter.

### Claim 8 (depends on 4)

The powder composition of claim 4, wherein the second fraction comprises between 5% and 30% of the powder composition by weight.

### Claim 9 (depends on 8)

The powder composition of claim 8, wherein the second fraction comprises 15% of the powder composition by weight.