Amorphous polyaryletherketone and blends thereof for use in additive manufacturing

a polyaryletherketone and polymer technology, applied in the direction of additive manufacturing processes, manufacturing tools, instruments, etc., can solve the problems of inferior mechanical properties, poor heat resistance, relative poor chemical resistance, etc., and achieve high viscosity and melt flow, desirable rheological effect, and high pressur

Inactive Publication Date: 2018-10-25
AREVO INC
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  • Summary
  • Abstract
  • Description
  • Claims
  • Application Information

AI Technical Summary

Benefits of technology

This patent is about using a combination of semi-crystalline and amorphous PAEK to create better-performing materials for 3D printing. The semi-crystalline PAEK requires high pressure to print, while the amorphous PAEK has lower viscosity and requires less pressure to print. Additionally, the amorphous PAEK has lower shrinkage and warping, which allows for tighter geometrical tolerances and better adhesion to the build surface. Adding amorphous PAEK to the mix also increases heat resistance and maximum operating temperature compared to conventional materials used for 3D printing.

Problems solved by technology

Unfortunately, these polymers tend to have relatively poor chemical resistance, poor heat resistance, and inferior mechanical properties such that the parts formed therefrom using material extrusion are often not suitable for production (as opposed to prototyping) applications.
Although parts formed from PEEK have been printed using material extrusion, this polymer introduces challenges to the 3D-printing process due to its semi-crystalline morphology.
Furthermore, this semi-crystalline polymer has a longer cooling time compared to lower temperature amorphous materials, which increases the minimum layer time and requires the use of cooling to speed up solidification.
PEEK parts printed via material extrusion also experience more significant shrinkage and warpage compared to parts printed from amorphous materials.
This leads to decreased dimensional accuracy and larger tolerances for PEEK parts printed in this fashion.
The increased warpage can also result in part separation from the build surface unless high build-chamber temperatures (c.a.
Additionally, PEEK has higher melt flows requiring higher pressures during extrusion and printing compared to amorphous materials.
Although easier to process than neat semi-crystalline PEEK, these PEEK blends do not exhibit the superior mechanical, thermal, and chemical resistivity properties of neat PEEK.

Method used

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  • Amorphous polyaryletherketone and blends thereof for use in additive manufacturing

Examples

Experimental program
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Embodiment Construction

references PEEK or any other specific PAEK, such as those mentioned above, it is to be understood that these teachings apply generally to any PAEK compound unless otherwise specified. In various embodiments, the resin comprises:[0015]one amorphous PAEK compound (e.g., PEEK, etc.);[0016]one type of amorphous PAEK (e.g., PEEK, etc.) but at least two versions thereof, each having a different measure of amorphousness (i.e., one relatively less amorphous, one relatively more amorphous) from the other;[0017]two or more different amorphous PAEKs (e.g., PEEK and PEKK, etc.);[0018]at least one PAEK compound in amorphous form and at least one amorphous compound that is not a PAEK compound;[0019]at least one amorphous PAEK and at least one semi-crystalline PAEK, wherein the PAEK compound is the same (e.g., amorphous PEEK and semi-crystalline PEEK, etc.);[0020]at least one amorphous PAEK and at least one semi-crystalline PAEK, wherein each PAEK compound is different (e.g., amorphous PEEK and se...

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Abstract

A material for use with a 3D printer comprises a polyaryletherketone (PAEK) having an amorphous morphology. In some embodiments, the material also includes one or more further compounds having an amorphous morphology. In some further embodiments, the material includes, in addition to an amorphous PAEK, a compound having a semi-crystalline morphology.

Description

CROSS-REFERENCE[0001]The present application is a continuation of International Application No. PCT / US2016 / 055505, filed Oct. 5, 2016, which is a continuation of U.S. patent application Ser. No. 14 / 874,963, filed Oct. 5, 2015, each of which is entirely incorporated herein by reference.FIELD OF THE INVENTION[0002]The present invention generally relates to compositions for use in additive manufacturing, more commonly known as “3D printing.”BACKGROUND OF THE INVENTION[0003]The additive manufacturing process is widely known as the three-dimensional (“3D”) printing of objects. There are a variety of 3D-printing processes, VAT polymerization, material jetting, binder jetting, material extrusion, powder bed fusion, sheet lamination, and directed energy deposition.[0004]Extrusion-based 3D printing involves the deposition of thermoplastic materials. This process fabricates a three-dimensional object from a mathematical model of the object using materials such as thermoplastics and metals tha...

Claims

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Application Information

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Patent Type & AuthorityApplications(United States)
IPC IPC(8): C09D161/16B33Y70/00B29C64/106C08L71/10G03G15/00C08L71/00G03G15/22B33Y10/00B29K71/00B29K105/16
CPCB29C64/106G03G15/00C08L71/10C08L71/00B29K2105/16B33Y70/00G03G15/224C09D161/16B29K2105/162B29K2995/0039B29K2995/004B33Y10/00G03G15/225B29K2071/00B29C64/118B33Y70/10
InventorBHEDA, HEMANTREESE, RILEY
OwnerAREVO INC