Block Polyetheramide Powder for Selective Laser Sintering
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Solution Overview
Problem
Existing polymer powders used in layer-by-layer manufacturing processes, such as selective laser sintering, suffer from poor impact resistance and grindability issues, making them unsuitable for applications requiring mechanical strength, especially at low temperatures.
Innovation Solution
Development of a polymer powder comprising block polyetheramide based on oligoamide dicarboxylic acids and polyetheramines, which can be processed to produce moldings with improved impact resistance and mechanical properties through a layer-by-layer process using electromagnetic energy.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conventional polyamide powders are used in layer-by-layer manufacturing processes, then processing reliability is maintained, but impact resistance is poor
Solution Approach 1:
The patent employs block copolymer composition comprising hard segments (polyamide) and soft segments (polyether or polyester) to create a composite material system. This composite structure combines the processing reliability of polyamide with the impact resistance of elastomeric segments, resolving the contradiction between strength and reliability.
Solution Approach 2:
The patent modifies the chemical composition parameters of the polymer by incorporating specific ratios of hard and soft segments (e.g., 70-30 to 90-10 weight ratios). This parameter change enables the material to achieve both high impact resistance and reliable processing characteristics that conventional polyamides cannot provide alone.
2Strength
If block copolymers with soft segments containing ester units are used, then impact resistance is improved, but grindability becomes poor
Solution Approach 1:
The patent changes the chemical composition parameter by replacing ester-containing soft segments with ether-containing soft segments (e.g., polytetramethylene oxide, polyethylene glycol). This parameter change maintains impact resistance while significantly improving grindability, as ether-based soft segments do not exhibit the same grindability problems as ester-based ones.
3Strength
If polyether block amides with defined structure are prepared, then mechanical properties are improved, but transamidation reactions occur causing random monomer distribution
Solution Approach 1:
The patent changes the chemical structure parameter by using ether linkages instead of ester linkages in the soft segments. This parameter change prevents transamidation reactions that would otherwise occur with conventional polyamide-ester block copolymers, thereby maintaining the defined block structure and mechanical properties.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The block polyetheramide powder exhibits enhanced impact resistance, easier grindability, and comparable processing reliability to conventional polyamide powders, with improved notched impact resistance and tensile strain at break, while maintaining adjustable modulus of elasticity for flexible or stiff components.
Implementation Method 1
selectively melted via introduction of electromagnetic energy
Implementation Method 2
plastics powders in a chamber are selectively and briefly irradiated with light from a laser beam, the result being that the powder particles impacted by the laser beam are melted
Data Source
AI summary
Moldings can be produced from a polymer powder containing at least one block polyetheramide containing an oligoamide dicarboxylic acid and a polyetheramine; wherein the powder is suitable for use in a layer-by-layer process in which regions of a powder layer are selectively melted via introduction of electromagnetic energy.