# US 12,214,548 B2 · Processes for producing a shaped body using polyamide blends containing a polyarylether

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- Number: US 12,214,548 B2
- Document ID: US12214548B2
- Status: Granted
- Kind: B2
- Application number: 16/321,079
- Filed: 2017-07-21
- Published: 2019-06-06
- Granted: 2025-02-04
- Earliest claimed: 2016-07-29
- Assignees: BASF SE
- Applicants: BASF SE
- Inventors: Claus Gabriel; Martin Weber; Philipp Kloke; Thomas Meier
- Web page: https://patentgrep.com/patent/US12214548B2

## CPC

- 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 70/00: Materials specially adapted for additive manufacturing
- B33Y 80/00: Products made by additive manufacturing
- C08L 71/12: Polyphenylene oxides
- C08L 77/02: Polyamides derived from omega-amino carboxylic acids or from lactams thereof (C08L77/10 takes precedence)
- B29K 2071/00: Use of polyethers {, e.g. PEEK, i.e. polyether-etherketone or PEK, i.e. polyetherketone or derivatives thereof}, as moulding material
- B29K 2077/00: Use of {PA, i.e.} polyamides, e.g. polyesteramides {or derivatives thereof}, as moulding material
- B29K 2081/06: {PSU, i.e. polysulfones; PES, i.e. polyethersulfones or derivatives thereof}
- C08L 81/06: Polysulfones; Polyethersulfones
- 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
- 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

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 (WSP) of the sinter powder (SP).

## Claims

### Claim 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—(CH2)m—NH— units where m is 4, 5, 6, 7 or 8, —CO—(CH2)n—NH— units where n is 3, 4, 5, 6 or 7, and —CO—(CH2)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—, —SO2—, S═O, C═O, —N═N— and —CRaRb— where Ra and Rb are each independently a hydrogen atom or a C1-C12-alkyl, C1-C12-alkoxy or C6-C18-aryl group and where at least one of Q, T and Y is-SO2— and
Ar, Ar1: 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).

### Claim 2 (depends on 1)

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.

### Claim 3 (depends on 1)

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

### Claim 4 (depends on 1)

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

### Claim 5 (depends on 1)

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

### Claim 6 (depends on 1)

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.

### Claim 7 (depends on 1)

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.

### Claim 8 (depends on 1)

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

### Claim 9 (depends on 1)

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.

### Claim 10

A process for broadening the sintering window (WSP) of a sinter powder (SP) compared to the sintering window (WAB) 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—(CH2)m—NH— units where m is 4, 5, 6, 7 or 8, —CO—(CH2)n—NH— units where n is 3, 4, 5, 6 or 7, and —CO—(CH2)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 (WSP; WAB) in each case is the difference between the onset temperature of melting (TMonset) and the onset temperature of crystallization (TConset), 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—, —SO2—, S═O, C═O, —N═N— and —CRaRb— where Ra and Rb are each independently a hydrogen atom or a C1-C12-alkyl, C1-C12-alkoxy or C6-C18-aryl group and where at least one of Q, T and Y is-SO2— and
Ar, Ar1: 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).