# US 2022/0033593 A1 · Thermoplastic polymer powders and use thereof for selective laser sintering > Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt - Number: US 2022/0033593 A1 - Document ID: US20220033593A1 - Status: Published application - Kind: A1 - Application number: 17/277,484 - Filed: 2019-09-18 - Published: 2022-02-03 - Earliest claimed: 2018-09-21 - Assignees: Ineos Styrolution Group GmbH - Applicants: Ineos Styrolution Group GmbH - Inventors: Bianca WILHELMUS; Norbert NIESSNER - Web page: https://patentgrep.com/patent/US20220033593A1 ## CPC - C08J 3/12: Powdering or granulating - B29C 64/153: using layers of powder being selectively joined, e.g. by selective laser sintering or melting - C08J 3/005: {Processes for mixing polymers} - C08K 3/36: Silica - C08L 23/06: Polyethylene - C08L 23/0815: {with aliphatic 1-olefins containing one carbon-to-carbon double bond} - C08L 23/12: Polypropene - C08L 23/16: Ethylene-propylene or ethylene-propylene-diene copolymers - C08L 25/10: with conjugated dienes - C08L 25/12: with unsaturated nitriles - C08L 25/14: with unsaturated esters - C08L 53/00: Compositions of block copolymers containing at least one sequence of a polymer obtained by reactions only involving carbon-to-carbon unsaturated bonds; Compositions of derivatives of such polymers - C08L 55/02: ABS [Acrylonitrile-Butadiene-Styrene] polymers - B33Y 70/00: Materials specially adapted for additive manufacturing - B33Y 80/00: Products made by additive manufacturing - C08K 2201/011: Nanostructured additives - C08L 2205/03: containing three or more polymers in a blend - C08L 2207/066: LDPE (radical process) - 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) - 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) - C08K: Use of inorganic or non-macromolecular organic substances as compounding ingredients (paints, inks, varnishes, dyes, polishes, adhesives C09) - C08L: COMPOSITIONS OF MACROMOLECULAR COMPOUNDS (compositions based on polymerisable monomers C08F, C08G; artificial filaments or fibres D01F; textile treating compositions D06) - 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 ## Abstract The invention relates to a thermoplastic polymer powder and to the use thereof as material for selective laser sintering (SLS). The polymer powder contains a semi-crystalline polyolefin, an amorphous styrene-polymer and a selected polymeric compatibilizer, in addition to optionally further additives and/or auxiliary agents. The semi-crystalline polymer, amorphous polymer and selected polymeric compatibilizer are present in the polymer powder in the form of a polymer blend. The invention also relates to a method for producing the thermoplastic polymer powder and to a method for selective laser sintering (SLS) using the polymer powder according to the invention. ## Claims ### Claim at position 1 1-15. (canceled) ### Claim 16 A thermoplastic polymer powder P comprising: (A) 10% to 89.9% by weight, based on the overall polymer powder P, of at least one semicrystalline polyolefin A; (B) 10% to 89.9% by weight, based on the overall polymer powder P, of at least one amorphous styrene polymer B; (C) 0.1% to 20% by weight, based on the overall polymer powder P, of at least one compatibilizer C selected from the group consisting of styrene-butadiene block copolymers, styrene-polyolefin copolymers, acrylonitrile-styrene-polyolefin copolymers, and acrylonitrile-styrene-butadiene-polyolefin copolymers; (D) optionally 0% to 5% by weight, based on the overall polymer powder P, of at least one additive and/or auxiliary; wherein the sum total of the percentages by weight of components A, B, C, and, optionally, D together is 100% by weight; wherein the semicrystalline polymer A, the amorphous styrene polymer B, and the compatibilizer C are in the form of a polymer blend; and wherein the thermoplastic polymer powder P has a median particle diameter D50 in the range from 5 to 200 μm. ### Claim 17 (depends on 16) The thermoplastic polymer powder P of claim 16, wherein the semicrystalline polyolefin A is at least one polymer selected from the group consisting of polyethylene, polypropylene, and polypropylene-polyethylene copolymers. ### Claim 18 (depends on 16) The thermoplastic polymer powder P of claim 16, wherein the amorphous styrene polymer B is at least one polymer selected from the group consisting of styrene-acrylonitrile copolymers, acrylonitrile-butadiene-styrene copolymers, acrylate-styrene-acrylonitrile copolymers, methyl methacrylate-acrylonitrile-butadiene-styrene copolymers, methyl methacrylate-butadiene-styrene copolymers, α-methylstyrene-acrylonitrile copolymers, styrene-methyl methacrylate copolymers, amorphous polystyrene, and impact-modified polystyrene. ### Claim 19 (depends on 16) The thermoplastic polymer powder P of claim 16, wherein the amorphous styrene polymer B is at least one styrene polymer or styrene copolymer having a melt volume flow rate, measured to ISO 1133, in the range from 2 to 60 cm3/10 min. ### Claim 20 (depends on 16) The thermoplastic polymer powder P of claim 16, wherein the compatibilizer C is a styrene-butadiene block copolymer or the combination of a styrene-butadiene block copolymer and a further polymer selected from the group consisting of styrene-polyolefin copolymers, acrylonitrile-styrene-polyolefin copolymers, and acrylonitrile-styrene-butadiene-polyolefin copolymers. ### Claim 21 (depends on 16) The thermoplastic polymer powder P of claim 16, wherein the polymer powder P has a particle diameter D90 of less than 200 μm. ### Claim 22 (depends on 16) The thermoplastic polymer powder P of claim 16, comprising: (A) 20% to 79.9% by weight, based on the overall polymer powder P, of at least one polyolefin selected from the group consisting of polyethylene (PE), polypropylene (PP), and polypropylene-polyethylene copolymers as semicrystalline polyolefin A; (B) 20% to 79.9% by weight, based on the overall polymer powder P, of at least one polymer selected from the group consisting of styrene-acrylonitrile copolymers, acrylonitrile-butadiene-styrene copolymers, acrylate-styrene acrylonitrile copolymers, methyl methacrylate-acrylonitrile-butadiene-styrene copolymers, methyl methacrylatebutadiene-styrene copolymers, α-methylstyrene-acrylonitrile copolymers, styrene-methyl methacrylate copolymers, amorphous polystyrene, and impact-modified polystyrene as amorphous styrene polymer B; (C) 0.1% to 20% by weight, based on the overall polymer powder P, of a polymer selected from the group consisting of styrene-butadiene block copolymers, styrene-polyolefin copolymers, acrylonitrile-styrene-polyolefin copolymers, and acrylonitrile-styrenebutadiene-polyolefin copolymers as compatibilizer C; (D1) 0% to 3% by weight, based on the overall polymer powder P, of at least one silicon dioxide nanoparticle powder or silicone additive as free-flow aid; and (D2) optionally 0% to 3% by weight, based on the overall polymer powder P, of at least one further additive and/or auxiliary as further component D. ### Claim 23 (depends on 16) A process for producing a thermoplastic polymer powder P of claim 16, comprising the following steps: i) providing a solid-state mixture comprising components A, B, C, and, optionally, D; ii) mechanically comminuting the solid-state mixtures to obtain a thermoplastic polymer powder P having a median particle diameter D50 in the range from 5 to 200 μm. ### Claim 24 (depends on 23) The process for producing a thermoplastic polymer powder P of claim 23, wherein step i) comprises the mixing of components A, B, and C in the liquid state at a temperature in the range from 200 to 250° C. ### Claim 25 (depends on 23) The process for producing a thermoplastic polymer powder P of claim 23, wherein the mechanical comminution of the solid-state mixtures in step ii) is effected by grinding, micronizing, cryogenic grinding, or jet grinding. ### Claim 26 (depends on 16) A process for producing a three-dimensional component by selective laser sintering, comprising the steps of: x) setting a processing temperature Tx in a build chamber and providing a powder layer consisting of the thermoplastic polymer powder P of claim 16 in the build chamber; xi) spatially resolved melting by a directed beam of electromagnetic radiation, followed by solidification of the thermoplastic polymer powder P in a defined region; wherein steps x) and xi) are performed repeatedly, such that binding of the regions of the melted and resolidified polymer forms a three-dimensional component layer by layer. ### Claim 27 (depends on 26) The process for producing a three-dimensional component of claim 26, wherein the powder layer has a thickness in the range from 10 to 400 μm. ### Claim 28 (depends on 26) The process for producing a three-dimensional component of claim 26, wherein the processing temperature Tx is in the range from 80 to 250° C., wherein the temperature during the performance of the individual steps x) and xi) varies by not more than +/−10% from the processing temperature Tx set. ### Claim 29 (depends on 26) The process for producing a three-dimensional component of claim 26, wherein volume shrinkage and/or warpage during production of the three-dimensional component is reduced by at least 10% by selective laser sintering using the polymer powder P of the invention compared to the volume shrinkage or warpage when using a polymer powder comprising the corresponding semicrystalline polyolefin A as the sole polymeric component. ### Claim 30 (depends on 26) The process for producing a three-dimensional component of claim 26, wherein the semicrystalline polyolefin A is at least one polymer selected from the group consisting of polyethylene, polypropylene, and polypropylene-polyethylene copolymers. ### Claim 31 (depends on 26) The process for producing a three-dimensional component of claim 26, wherein the amorphous styrene polymer B is at least one polymer selected from the group consisting of styrene-acrylonitrile copolymers, acrylonitrile-butadiene-styrene copolymers, acrylate-styrene-acrylonitrile copolymers, methyl methacrylate-acrylonitrile-butadiene-styrene copolymers, methyl methacrylatebutadiene-styrene copolymers, α-methylstyrene-acrylonitrile copolymers, styrene-methyl methacrylate copolymers, amorphous polystyrene, and impact-modified polystyrene. ### Claim 32 (depends on 26) The process for producing a three-dimensional component of claim 26, wherein the compatibilizer C is a styrene-butadiene block copolymer or the combination of a styrene-butadiene block copolymer and a further polymer selected from the group consisting of styrene-polyolefin copolymers, acrylonitrile-styrene-polyolefin copolymers, and acrylonitrile-styrene-butadiene-polyolefin copolymers. ### Claim 33 (depends on 26) The process for producing a three-dimensional component of claim 26, wherein the polymer powder P has a particle diameter D90 of less than 200 μm. ### Claim 34 (depends on 26) The process for producing a three-dimensional component of claim 26, wherein the polymer powder P comprises: (A) 20% to 79.9% by weight, based on the overall polymer powder P, of at least one polyolefin selected from the group consisting of polyethylene (PE), polypropylene (PP), and polypropylene-polyethylene copolymers as semicrystalline polyolefin A; (B) 20% to 79.9% by weight, based on the overall polymer powder P, of at least one polymer selected from the group consisting of styrene-acrylonitrile copolymers, acrylonitrile-butadiene-styrene copolymers, acrylate-styrene acrylonitrile copolymers, methyl methacrylate-acrylonitrile-butadiene-styrene copolymers, methyl methacrylatebutadiene-styrene copolymers, α-methylstyrene-acrylonitrile copolymers, styrene-methyl methacrylate copolymers, amorphous polystyrene, and impact-modified polystyrene as amorphous styrene polymer B; (C) 0.1% to 20% by weight, based on the overall polymer powder P, of a polymer selected from the group consisting of styrene-butadiene block copolymers, styrene-polyolefin copolymers, acrylonitrile-styrene-polyolefin copolymers, and acrylonitrile-styrenebutadiene-polyolefin copolymers as compatibilizer C; (D1) 0% to 3% by weight, based on the overall polymer powder P, of at least one silicon dioxide nanoparticle powder or silicone additive as free-flow aid; and (D2) optionally 0% to 3% by weight, based on the overall polymer powder P, of at least one further additive and/or auxiliary as further component D. ### Claim 35 (depends on 16) A three-dimensional component produced from the thermoplastic polymer powder P of claim 16 by selective laser sintering or related methods of additive manufacture.