# US 2021/0171709 A2 · Poly(aryl–ether–ketone) (paek) powder suitable for multiple use in sintering methods

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- Number: US 2021/0171709 A2
- Document ID: US20210171709A2
- Status: Published application
- Kind: A2
- Application number: 16/080,261
- Filed: 2017-02-28
- Published: 2021-06-10
- Earliest claimed: 2016-03-04
- Assignees: Arkema France
- Applicants: Arkema France
- Inventors: Benoît BRULE; Jérome Pascal
- Web page: https://patentgrep.com/patent/US20210171709A2

## CPC

- C08G 65/4012: {Other compound (II) containing a ketone group, e.g. X-Ar-C(=O)-Ar-X for polyetherketones}
- B29C 64/153: using layers of powder being selectively joined, e.g. by selective laser sintering or melting
- B29C 64/264: Arrangements for irradiation
- B33Y 70/00: Materials specially adapted for additive manufacturing
- 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 2271/00: Use of polyethers {, e.g. PEEK, i.e. polyether-etherketone or PEK, i.e. polyetherketone or derivatives thereof,} as reinforcement
- B33Y 10/00: Processes of additive manufacturing
- C08G 2650/40: containing ketone groups, e.g. polyarylethylketones, PEEK or PEK
- C08G: MACROMOLECULAR COMPOUNDS OBTAINED OTHERWISE THAN BY REACTIONS ONLY INVOLVING UNSATURATED CARBON-TO-CARBON BONDS
- 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
- 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 invention relates to a poly(aryl-ether-ketone) (PAEK) powder, for use in a method for building objects layer-by-layer by electromagnetic radiation-generated sintering, said powder being characterized in that it is obtained from a thermal pretreatment at a temperature comprised between 260° C. and 290° C., preferably between 280° C. and 290° C., and in that it has a melting temperature which is stable, at the build temperature, and below or equal to 330° C., preferably below or equal to 320° C., and more preferably below or equal to 310° C.

## Claims

### Claim 1

A poly(aryl-ether-ketone) (PAEK) powder for use in a method for building objects layer-by-layer by electromagnetic radiation-generated sintering, said powder being characterized in that it is obtained from a thermal pretreatment at a temperature comprised between 260° C. and 290° C., preferably between 280° C. and 290° C., and in that it has a melting temperature which is stable, at the build temperature, and below or equal to 330° C., preferably below or equal to 320° C., and more preferably below or equal to 310° C.

### Claim 2 (depends on 1)

The powder according to claim 1, characterized in that its thermal pretreatment is carried out for a period comprised between 5 min and 120 min, preferably between 5 min and 60 min, and more preferably between 5 min and 30 min.

### Claim 3 (depends on 1, 2)

The powder according to any one of claim 1 or 2, characterized in that it comprises a mixture of several polymers belonging to the PAEK family, the melting temperature Tm of which is below or equal to 330° C., preferably below or equal to 320° C., and more preferably below or equal to 310° C.

### Claim 4 (depends on 1, 2, 3)

The powder according to any one of claims 1 to 3, characterized in that it comprises at least one poly(ether-ketone-ketone) (PEKK) powder which represents more than 60% by weight, preferably more than 70% by weight of the powder, bounds included.

### Claim 5 (depends on 1, 2)

The powder according to any one of claim 1 or 2, characterized in that the powder is a poly(ether-ketone-ketone) (PEKK) powder.

### Claim 6 (depends on 4, 5)

The powder according to claim 4 or 5, characterized in that the PEKK powder has a percentage by weight of terephthalic units relative to the sum of terephthalic and isophthalic units comprised between 55% and 65%.

### Claim 7 (depends on 1, 2, 3, 4, 5, 6)

The powder according to one of claims 1 to 6, characterized in that it comprises a mixture of recycled or non-recycled powders, said recycled powders having been used an identical and/or different number of cycles.

### Claim 8 (depends on 1, 2, 3, 4, 5, 6, 7)

The powder according to one of claims 1 to 7, characterized in that its molecular weight remains stable during the sintering fabrication method.

### Claim 9 (depends on 1, 2, 3, 4, 5, 6, 7, 8)

The powder according to one of claims 1 to 8, characterized in that its melting temperature does not increase by more than 2° C. after each sintering run.

### Claim 10 (depends on 1, 2, 3, 4, 5, 6, 7, 8)

The powder according to one of claims 1 to 8, characterized in that its melting temperature does not increase by more than 1° C. after each sintering run.

### Claim 11 (depends on 1, 2, 3, 4, 5, 6, 7, 8, 9, 10)

Use of the powder according to one of claims 1 to 10, in a method for building an object layer-by-layer by laser sintering, said powder being reusable in several successive runs.

### Claim 12 (depends on 1, 2, 3, 4, 5, 6, 7, 8, 9, 10)

A method for building a three-dimensional object layer-by-layer by electromagnetic radiation-generated sintering of powder, characterized in that the powder used conforms to one of claims 1 to 10.

### Claim 13 (depends on 12)

The method according to claim 12, wherein successive sintering is carried out while keeping the sintering machine parameters unchanged.

### Claim 14 (depends on 13)

The method according to claim 13, wherein the sintering machine parameters include laser power and/or powder bed temperature.

### Claim 15 (depends on 1, 2, 3, 4, 5, 6, 7, 8, 9, 10)

A three-dimensional article obtained by sintering a powder layer-by-layer using electromagnetic radiation, said powder being characterized in that it conforms to one of claims 1 to 10.