Coprecipitated Polyamide Powder for Laser Sintering
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Solution Overview
Problem
Current rapid prototyping methods using polymer powders face challenges in achieving optimal toughness and heat resistance, particularly in layer-by-layer processing, where the mechanical properties of sintered parts are not fully satisfactory, and the use of ABBB polyamides with AB polyamides results in inhomogeneous structures due to different melting points.
Innovation Solution
The development of coprecipitated polymer powders combining AB and AABB polyamides, specifically coprecipitating polyamides with 10-12 carbon atoms in the monomer unit, which melt uniformly and can be processed to produce impact-resistant moldings with increased heat resistance, improved powder-flow properties, and reduced need for powder-flow aids.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If ABBB polyamides are used to increase heat resistance, then heat resistance is improved, but toughness deteriorates
Solution Approach 1:
The patent changes the chemical composition parameters of the polyamide by incorporating specific ratios of AB-type (50-90 mol%) and AABB-type (10-50 mol%) polyamides with controlled monomer unit structures (10-14 carbon atoms), thereby achieving both high heat resistance and toughness simultaneously
Solution Approach 2:
The patent creates a composite polyamide material by combining AB-type and AABB-type polyamides in specific proportions, where each component contributes different properties: AB-type provides toughness while AABB-type enhances heat resistance, resulting in a synergistic effect
2Temperature
If polyamides with different melting points are mixed, then heat resistance can be adjusted, but structural homogeneity deteriorates
Solution Approach 1:
The patent carefully controls the melting point parameters of both AB-type and AABB-type polyamides by selecting monomers with 10-14 carbon atoms, ensuring that both components have compatible melting ranges (170-210°C) that maintain structural homogeneity during sintering
Solution Approach 2:
The patent ensures that local regions within the sintered part have uniform composition and melting behavior by selecting polyamides with similar melting characteristics, preventing phase separation and maintaining consistent local properties throughout the material
3Productivity
If conventional polyamide powders are used for rapid prototyping, then manufacturing speed is improved, but mechanical property quality deteriorates
Solution Approach 1:
The patent optimizes particle size parameters (10-250 μm) and surface characteristics of the coprecipitated polyamide powder to ensure rapid and uniform laser sintering while achieving mechanical properties comparable to injection-molded parts, thus maintaining both high productivity and quality
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 coprecipitated polymer powders exhibit enhanced mechanical properties, including higher toughness and heat resistance, better dimensional accuracy, and surface quality, comparable to conventional polyamide powders, with reduced curl tendency and improved processability.
Implementation Method 1
the coprecipitated polymer powders exhibit enhanced mechanical properties, including higher toughness and heat resistance
Implementation Method 2
The introduction of energy is achieved by way of electromagnetic radiation
Implementation Method 3
plastics powders are briefly irradiated selectively with light from a laser beam in a chamber, and the powder particles encountered by the laser beam therefore melt. The molten particles coalesce and rapidly solidify again to give a solid mass
Implementation Method 4
The molten particles coalesce and rapidly solidify again to give a solid mass
Implementation Method 5
The development of coprecipitated polymer powders combining AB and AABB polyamides, specifically coprecipitating polyamides with 10-12 carbon atoms in the monomer unit, which melt uniformly
Data Source
AI summary
Disclosed herein is a polymer powder containing a polyamide of AB type, produced by polymerizing at least one lactam having from 10 to 12 carbon atoms in a monomer unit or by polycondensing at least one corresponding ω-aminocarboxylic acid having from 10 to 12 carbon atoms in a monomer unit, and a polyamide of AABB type, produced by polycondensing at least one diamine and at least one dicarboxylic acid having respectively from 10 to 14 carbon atoms in monomer units. The polyamide of the AB type and the polyamide of the AABB type are prepared separately and then coprecipitated to form the polymer powder, and the polymer powder is a physical mixture of the polyamide of the AB type and the polyamide of the AABB type. Also disclosed herein is a method for producing the polymer powder.