U.S. patent application number 13/581085 was filed with the patent office on 2012-12-13 for polyamide-based polymer powder, use thereof in a molding method, and molded articles made from said polymer powder.
This patent application is currently assigned to Evonik Degussa GmbH. Invention is credited to Franz-Erich Baumann, Wolfgang Diekmann, Maik Grebe, Harald Haeger, Beatrice Kueting, Sylvia Monsheimer, Heike Stemmer, Kristiane Warnke.
Application Number | 20120315483 13/581085 |
Document ID | / |
Family ID | 43920982 |
Filed Date | 2012-12-13 |
United States Patent
Application |
20120315483 |
Kind Code |
A1 |
Baumann; Franz-Erich ; et
al. |
December 13, 2012 |
POLYAMIDE-BASED POLYMER POWDER, USE THEREOF IN A MOLDING METHOD,
AND MOLDED ARTICLES MADE FROM SAID POLYMER POWDER
Abstract
The invention relates to a polymer powder for use in a
layer-by-layer method in which areas of each powder layer are
selectively fused by introducing electromagnetic energy. Said
polymer powder contains: at least one AB-type polyamide produced by
polymerizing lactams comprising 10 to 12 carbon atoms in the
monomer unit or polycondensing the corresponding .omega.-amino
carboxylic acids comprising 10 to 12 carbon atoms in the monomer
unit and at least one AABB-type polyamide produced by
polycondensing diamines and dicarboxylic acids, each of which
comprises 10 to 14 carbon atoms in the monomer units, the AB-type
polyamide containing up to 20 mole % of the AABB comonomer units
and the AABB-type polyamide containing up to 20 mole % of the AB
monomer units. The invention also relates to a method for producing
such a powder, a layer-by-layer method for producing a molded
article from such a powder in which areas of each layer are
selectively fused by introducing electromagnetic energy, the
selectivity being obtained using masks or by applying inhibitors,
absorbers or susceptors or focusing the applied energy, and molded
articles produced in said manner.
Inventors: |
Baumann; Franz-Erich;
(Duelmen, DE) ; Diekmann; Wolfgang; (Waltrop,
DE) ; Kueting; Beatrice; (Marl, DE) ; Stemmer;
Heike; (Haltern am See, DE) ; Grebe; Maik;
(Bochum, DE) ; Warnke; Kristiane; (Recklinghausen,
DE) ; Monsheimer; Sylvia; (Haltern am See, DE)
; Haeger; Harald; (Luedinghausen, DE) |
Assignee: |
Evonik Degussa GmbH
Essen
DE
|
Family ID: |
43920982 |
Appl. No.: |
13/581085 |
Filed: |
April 6, 2011 |
PCT Filed: |
April 6, 2011 |
PCT NO: |
PCT/EP2011/055316 |
371 Date: |
August 24, 2012 |
Current U.S.
Class: |
428/402 ;
264/482; 524/538; 525/432 |
Current CPC
Class: |
C08L 77/06 20130101;
B33Y 70/00 20141201; C08L 2205/02 20130101; B29C 64/153 20170801;
Y10T 428/2982 20150115; C09D 5/03 20130101; B29C 64/106 20170801;
C08L 77/02 20130101; C08L 77/02 20130101; C08L 77/06 20130101; C08L
77/06 20130101; C08L 77/02 20130101 |
Class at
Publication: |
428/402 ;
525/432; 524/538; 264/482 |
International
Class: |
C08L 77/06 20060101
C08L077/06; B29C 35/08 20060101 B29C035/08 |
Foreign Application Data
Date |
Code |
Application Number |
Apr 9, 2010 |
DE |
10 2010 014 443.6 |
Dec 2, 2010 |
DE |
10 2010 062 347.4 |
Claims
1. A polymer powder, comprising: a polyamide of the 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 .omega.-aminocarboxylic acid having from 10 to 12
carbon atoms in a monomer unit; and a polyamide of the AABB type,
produced by polycondensing at least one diamine and at least one
dicarboxylic acid having respectively from 10 to 14 carbon atoms in
a monomer units, wherein: the polyamide of the AB type optionally
comprises up to 20 mol % of AABB comonomer units; and the polyamide
of the AABB type optionally comprises up to 20 mol % of AB monomer
units.
2. The polymer powder of claim 1, wherein the powder is obtained by
coprecipitation of at least one polyamide of the AB type and of at
least one polyamide of the AABB type.
3. The polymer powder of claim 1, comprising at least nylon-11 or
nylon-12 and at least one homopolyamide based on PA1010, PA1012,
PA1212 or PA1013.
4. The polymer powder of claim 1, wherein the polyamide of the AB
type optionally comprises up to 10 mol % of the AABB comonomer
units and the polyamide of the AABB type optionally comprises up to
10 mol % of the AB monomer units.
5. The polymer powder of claim 1, comprising the polyamide of the
AB type and the polyamide of the AABB type in a ratio by mass of
from 98:2 to 2:98.
6. The polymer powder of claim 1, wherein a relative solution
viscosity of the powder is from 1.4 to 2.1, measured in a 0.5% by
weight solution in m-cresol in accordance with ISO 307.
7. The polymer powder of claim 1, wherein an average particle size
of the powder is from 10 to 250 .mu.m.
8. The polymer powder of claim 1, further comprising a auxiliary, a
filler, or both.
9. A process for producing the polymer powder of claim 1, the
process comprising: codissolving the polyamide of the AB type and
the polyamide of the AABB type by heating in an alcohol having from
1 to 3 carbon atoms; lowering the temperature in one or more stages
to a temperature at which a copolyamide precipitates; isolating the
copolyamide from the solvent, drying the copolyamide, or both
isolating and drying, to form a powder; and optionally mixing an
auxiliary, a filler, or both, into the powder.
10. The process of claim 9, comprising: codissolving the polyamide
of the AB type and the polyamide of the AABB type under an
autogenous pressure at a temperature of from 130.degree. C. to
180.degree. C.; and then lowering the temperature in one or more
stages to from 90.degree. C. to 128.degree. C.
11. The process of claim 9, wherein, after the codissolving, the
temperature is maintained at from 110.degree. C. to 128.degree. C.
for 10 minutes to 3 hours and then the temperature is lowered in
one or more further stages to from 90.degree. C. to 118.degree.
C.
12. A process for producing moldings by a layer-by-layer process,
the process comprising selectively melting regions of a respective
polymer powder layer by introducing electromagnetic energy, wherein
the respective polymer powder layer comprises the polymer powder of
claim 1.
13. The process of claim 12, wherein selective melting is achieved
by applying susceptors, inhibitors, or absorbers, or by masks, or
by focusing a laser beam.
14. A molding obtained from the polymer powder of claim 1 by a
direct progressive construction process.
15. The molding of claim 14, wherein the molding is produced by a
layer-by-layer process in which regions of a respective powder
layer are melted selectively by introducing electromagnetic energy,
and the selectivity is achieved by applying susceptors, inhibitors,
or absorbers, or by masks, or by focusing a laser beam.
16. The polymer powder of claim 1, comprising a polyamide of the AB
type, produced by polymerizing at least one lactam having from 10
to 12 carbon atoms in a monomer unit.
17. The polymer powder of claim 1, comprising a polyamide of the AB
type, produced by polycondensing at least one
.omega.-aminocarboxylic acid having from 10 to 12 carbon atoms in a
monomer unit.
18. The polymer powder of claim 1, wherein the polyamide of the AB
type comprises up to 20 mol % of AABB comonomer units.
19. The polymer powder of claim 1, wherein the polyamide of the
AABB type comprises up to 20 mol % of AB monomer units.
20. The polymer powder of claim 2, wherein the polyamide of the AB
type optionally comprises up to 10 mol % of the AABB comonomer
units and the polyamide of the AABB type optionally comprises up to
10 mol % of the AB monomer units.
Description
[0001] The rapid provision of prototypes is a task frequently
encountered in very recent times. Particularly suitable processes
use operations based on pulverulent materials, where the desired
structures are produced layer-by-layer by selective melting and
hardening. Supportive structures for overhangs and undercuts can be
omitted here, since the powder bed surrounding the molten regions
provides sufficient support. The subsequent operation of removing
supports is likewise omitted. The processes are also suitable for
producing small runs. In the latter case, the mechanical properties
of the sintered parts are increasingly required to be as close as
possible to those of injection molded parts; in particular, there
is not yet complete satisfaction with the toughness of the sintered
parts made of powders of the prior art. Heat resistance is also
subject to increasingly stringent requirements. The powders
obtainable as in DE102004020453, based on ABBB polyamides, permit
production of moldings that have higher heat resistance, but the
toughness of these is not yet fully satisfactory.
[0002] The invention relates to coprecipitated polymer powders
based on a polyamide of the AABB type, produced by polycondensing
diamines with dicarboxylic acids, with polyamides of the AB type,
produced from lactams and/or aminocarboxylic acids, the use of said
powder in shaping processes, and moldings produced by a
layer-by-layer process which melts regions of a powder layer
selectively by introducing electromagnetic energy, with use of said
powder. Once the regions previously melted layer-by-layer have been
cooled and hardened, the molding can be removed from the powder
bed.
[0003] The selectivity of the layer-by-layer process here can be
achieved, for example, by way of susceptors, inhibitors, or masks,
or by way of focused introduction of energy, for example by a laser
beam, or by way of glass fibers. The introduction of energy is
achieved by way of electromagnetic radiation.
[0004] Some processes which can produce moldings of the invention
from the powder of the invention are described below, but without
any intention that the invention be restricted thereto.
[0005] A process which has particularly good suitability for the
purposes of rapid prototyping is selective laser sintering. In this
process, 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. This
process can produce three-dimensional products simply and rapidly
by using light for repeated irradiation of a succession of freshly
applied layers.
[0006] The patent specifications U.S. Pat. No. 6,136,948 and WO
96/06881 (both DTM Corporation) provide a detailed description of
the laser sintering (rapid prototyping) process for producing
moldings from pulverulent polymers. A wide variety of polymers and
copolymers is claimed for said application, e.g. polyacetate,
polypropylene, polyethylene, ionomers, and polyamide.
[0007] Other processes with good suitability are the SIB process as
described in WO 01/38061 and a process described in EP 1 015 214.
Both processes operate with large-surface-area infrared heating to
melt the powder. The selectivity of the melting process is achieved
in the first process by applying an inhibitor and in the second
process it is achieved by a mask. DE 103 56 193 describes another
process. In this, the energy needed for the fusion process is
introduced by a microwave generator and the selectivity is achieved
by applying a susceptor.
[0008] The rapid prototyping or rapid manufacturing processes (RP
or RM processes) mentioned can use pulverulent substrates, in
particular polymers, preferably selected from polyester, polyvinyl
chloride, polyacetal, polypropylene, polyethylene, polystyrene,
polycarbonate, poly(N-methylmethacrylimide) (PMMI), polymethyl
methacrylate (PMMA), ionomer, polyamide, or a mixture thereof.
[0009] WO 96/30195 describes a polymer powder which is suitable for
the laser sintering process and which exhibits no overlap of the
melt peak and recrystallization peak when melting behavior is
determined by differential scanning calorimetry at a scanning rate
of from 10 to 20 C/min, and which has a degree of crystallinity of
from 10 to 90%, likewise determined by DSC, and has a
number-average molecular weight Mn of from 30 000 to 500 000 and a
quotient M.sub.w/M.sub.n in the region from 1 to 5.
[0010] DE 197 47 309 describes the use of a nylon-12 powder which
has an elevated melt peak and elevated enthalpy of fusion and which
is obtained by reprecipitating a polyamide previously produced by
ring-opening and subsequent polycondensation of laurolactam. A
polyamide of the AB type is involved here. However, the heat
resistance of the moldings formed therefrom by a sintering process
is not substantially above that of injection-molded PA12 parts. The
powders obtainable as in DE102004020453 and based on ABBB
polyamides permit production of moldings that have high heat
resistance; their use in a mixture with separately produced powders
based on precipitated powders made of AB polyamides generally
encounters problems, because the different melting point of these
leads to inhomogeneous structure of the sintered parts, the
toughness of which is therefore not entirely satisfactory.
[0011] It was therefore an object of the present invention to
provide a polymer power which permits production of moldings which
have maximum toughness and which have increased heat resistance and
which can be used in any of the layer-by-layer processing
methods.
[0012] Surprisingly, it has now been found that by using
precipitative crystallization to coprecipitate suitably selected
polyamides it is possible to produce polymer powders which avoid
the problems mentioned and which have mechanical properties like
those of a polymer powder of the prior art, for example as in DE
197 47 309 or else DE102004020453. Coprecipitation of AB polyamides
having from 10 to 12 carbon atoms in the monomer unit and of AABB
polyamides based on diamines and dicarboxylic acids respectively
having from 10 to 14 carbon atoms in the respective monomer unit is
successful in producing powders which melt uniformly and which can
be processed to give impact-resistant moldings with increased heat
resistance.
[0013] When the powders produced by coprecipitation are compared
with powders of the prior art they moreover have better powder-flow
properties and, respectively, application properties. The amount
needed of powder-flow aid can therefore be reduced, or powder-flow
aid can be entirely omitted. This is advantageous for processing,
in particular in the laser sintering process. There is less
tendency toward what is known as curl.
[0014] Particularly suitable coprecipitates are those of: PA11 with
PA1010, PA11 with PA1012, PA12 WITH PA1012, PA12 with PA1212, and
PA12 with PA1013.
[0015] The present invention therefore provides a polymer powder
for use in a layer-by-layer process in which regions of the
respective powder layer are melted selectively by introducing
electromagnetic energy, comprising: [0016] at least one polyamide
of the AB type, produced by polymerizing lactams having from 10 to
12 carbon atoms in the monomer unit or by polycondensing the
corresponding .omega.-aminocarboxylic acids having from 10 to 12
carbon atoms in the monomer unit and [0017] at least one polyamide
of the AABB type, produced by polycondensing diamines and
dicarboxylic acids having respectively from 10 to 14 carbon atoms
in the monomer units, where the polyamide of the AB type can
comprise up to 20 mol % of the AABB comonomer units and the
polyamide of the AABB type can comprise up to 20 mol % of the AB
monomer units.
[0018] AB polyamide used preferably comprises PA11 or PA12, and
AABB polyamide used preferably one from the group PA1010, PA1012,
PA1212, and PA1013. It is particularly preferable to coprecipitate
PA11 with PA1010, PA11 with PA1012, PA12 with PA1012, PA12 with
PA1212, and PA12 with PA1013. The proportion of the AABB polyamide
here is from 2 to 98% by mass, preferably from 10 to 90% by mass,
and particularly preferably from 30 to 70% by mass. The melting
point of the coprecipitated polymer powder of the invention here,
determined by means of DSC, is at least 175.degree. C., preferably
at least 180.degree. C., and particularly preferably at least
185.degree. C.
[0019] Suitability for the coprecipitation process is further
exhibited by copolyamides of the AABB type in which up to 20 mol %
of the molar-equivalent diamines and dicarboxylic acids have been
replaced by a lactam and, respectively, an .omega.-aminocarboxylic
acid having from 10 to 12 carbon atoms, and also by copolyamides of
the AB type in which up to 20 mol % of the lactams and,
respectively, .omega.-aminocarboxylic acids having from 10 to 12
carbon atoms have been replaced by molar-equivalent diamines and
dicarboxylic acids having from 10 to 14 carbon atoms. The use of
said coprecipitates comprising copolyamide is advantageous by way
of example when the intention is to construct parts with low
shrinkage. It is preferable that the respective proportion of
comonomer in one or both polyamides to be coprecipitated is
restricted to 10 mol %, and it is very preferable that the
proportion of comonomer is at most 5 mol %, with a view to higher
heat resistance.
[0020] A feature of the polyamides to be used in the invention is
that the powder comprises at least one AABB polyamide and at least
one AB polyamide. Homopolymers involved here respectively have the
general formula:
(NH--(CH.sub.2).sub.x--NH--CO--(CH.sub.2).sub.y--CO).sub.n/2--
and
(NH--(CH.sub.2).sub.z--NH--CO).sub.n
and copolyamides involved here respectively comprise up to 20 mol %
of monomers of the respective other type.
[0021] Not only the AB component but also the AABB component here
can have entirely linear structure or can have a small degree of
branching, and the number of acid end groups can be greater, the
same as, or less than the number of amino end groups. Specific
regulators of the prior art can be added for this purpose during
the polycondensation process. Particular preference is given to a
balanced ratio of acid end groups to amino end groups, and very
particular preference is given to an excess of acid with an
acid:amine ratio of from 1.2:1 to 5:1. In another preferred sector,
there is an excess of the amino end groups with an amine:acid ratio
of from 1.2:1 to 5:1.
[0022] ISO 1874-1 regulates the nomenclature of the polyamides. In
particular, Annex A describes the definition and characterization
of aliphatic linear polyamides. Polyamides of the type XY, the use
of which accords with the invention, are obtained from
polycondensation of diamines with dicarboxylic acids. x is the
number of C atoms in the diamine, and y is the number of C atoms in
the dicarboxylic acid. The preferred powder comprises not only
diamines but also dicarboxylic acids of aliphatic (linear) type.
Examples of monomer units used here are diamines from the following
group: decanediamine, undecanediamine, and 1,12-diaminododecane.
Examples of monomers for the dicarboxylic acids are sebacic acid
(decanedioic acid, b=8), dodecanedioic acid (b=10), brassylic acid
(b=11), and tetradecanedioic acid (b=12).
[0023] Examples of suitable monomers of the AB type are
.omega.-aminoundecanoic acid, .omega.-aminododecanoic acid, and
.omega.-laurolactam.
[0024] The present invention also provides processes for producing
a polymer powder of the invention, where the respective polyamide
components are codissolved by heating in an alcohol having from 1
to 3 carbon atoms, the temperature is lowered in one or more stages
to a temperature at which a copolyamide precipitates, the
copolyamide is isolated from the solvent and/or is dried, and
auxiliaries or fillers are optionally mixed into the powder.
[0025] In one embodiment, the polyamide components are dissolved
under autogenous pressure at a temperature of from 130.degree. C.
to 180.degree. C., and then the temperature is lowered in one or
more stages to from 90.degree. C. to 128.degree. C.
[0026] The powders of the invention are preferably produced by
coprecipitating the AB polyamides and AABB polyamides from
alcoholic solution under pressure as in DE-A 3510689. It is
preferable to use ethanol as solvent. The dissolution temperatures
are kept in the range from 135 to 175.degree. C., preferably from
140 to 165.degree. C., and the cooling rates are kept in the range
from 0.1 to 2.0 K/min, preferably in the range from 0.4 to 1.0
K/min. The precipitation temperatures are in the range from 90 to
130.degree. C., preferably in the range from 105 to 125.degree. C.
After the dissolution process, the temperature is preferably kept
at from 110.degree. C. to 128.degree. C. for from 10 minutes to 3
hours, and then the temperature is lowered in one or more further
stages to from 90.degree. C. to 118.degree. C.
[0027] Manual experiments can be used in a specific individual case
to determine the dissolution conditions and precipitation
conditions that are advantageous for the respective polyamide
mixture. The polyamide concentrations to be selected are from 5 to
30% by weight, based on the entirety of all of the polyamides used,
preferably from 10 to 25% by weight, particularly preferably from
13 to 22% by weight. Preliminary experiments are to be used to
determine the dissolution temperatures required in order to obtain
a polyamide solution that is optically clear, and it is also
necessary here that the polyamide with the respectively highest
melting point dissolves completely.
[0028] In order to obtain polyamide powder with relatively narrow
grain size distribution, it is possible to precede the actual
precipitation process with a nucleation phase as in DE19708946, in
which the PA solution remains optically clear and no exothermic
crystallization is observed. For this, the alcoholic solution is
stirred isothermally at from 2 K to 20 K, preferably from 5 K to 15
K, above the subsequent precipitation temperature, for the time
previously mentioned, and the temperature is then lowered at the
cooling rates above to the precipitation temperature, which is to
be kept as constant as possible.
[0029] Suitable assemblies are stirred tanks, and blade stirrers
are preferably used, but it is readily possible to carry out the
precipitation process in other pressure-tight apparatuses and/or to
use other stirrer units. One or more of the polyamides to be
reprecipitated can be subjected to a prior extraction process in
order to remove any residual monomers and, respectively, oligomers
that might possibly disrupt subsequent processing.
[0030] The invention further provides coprecipitated powders made
of AB polyamides having from 10 to 12 carbon atoms in the monomer
unit and of AABB polyamides based on diamines and dicarboxylic
acids respectively having from 10 to 14 carbon atoms in the
respective monomer unit, and also the abovementioned coprecipitates
which melt uniformly and which are based on one or more
copolyamides, which comprise up to 20 mol % of comonomers of the
respective other type, which can be processed to give
impact-resistant moldings with increased heat resistance.
Particularly suitable coprecipitates are those of PA11 with PA1010,
PA11 with PA1012, PA12 with PA1012, PA12 with PA1212, and PA12 with
PA1013.
[0031] The present invention also provides moldings produced by a
layer-by-layer process which melts regions of the respective layer
selectively by introducing electromagnetic energy, where these are
characterized in that the powders are coprecipitates of AB
polyamides having from 10 to 12 carbon atoms in the monomer unit
and of AABB polyamides based on diamines and dicarboxylic acids
having respectively from 10 to 14 carbon atoms, and also the
abovementioned coprecipitates which melt uniformly and which are
based on one or more copolyamides which comprise up to 20 mol % of
comonomers of the respective other type. Particularly suitable
moldings are those based on coprecipitates of PA11 with PA1010,
PA11 with PA1012, PA12 with PA1012, PA12 with PA1212, and PA12 with
PA1013.
[0032] An advantage of the polymer powders of the invention is that
they are used in a layer-by-layer process in which regions of the
respective layer are melted selectively to give moldings with
increased heat resistance, higher toughness values, better
dimensional accuracy, and better surface quality, when comparison
is made with moldings made of conventional polyamide powders.
[0033] The mechanical properties exhibited by the moldings produced
from the powders of the invention here are good and similar to
those of moldings produced from conventional powders. The
processability of the powder of the invention is also comparable
with that of conventional polyamide powders.
[0034] The polymer powder of the invention is described below,
without any intention of resultant restriction of the
invention.
[0035] Powder of the invention is obtained for example by a process
based on DE 29 06 647 B1 or through DE 19708946, where a polyamide
of the AB type is used as starting material. The polyamide mixture
made of AABB polyamide and AB polyamide is dissolved in ethanol and
precipitated in crystalline form under certain conditions. A
precautionary sieving process and further classification or cold
grinding optionally follows. The person skilled in the art can
easily discover the conditions through exploratory preliminary
experiments.
[0036] The melting point of the coprecipitated polymer powder of
the invention here, determined by means of DSC, is at least
175.degree. C., preferably at least 180.degree. C., and
particularly preferably at least 185.degree. C.
[0037] Another feature of the powder of the invention is good
powder-flow properties and, respectively, good application
properties. The amount to be used of the powder-flow aid can be
reduced, or powder-flow aid can be omitted entirely.
[0038] Solution viscosity in 0.5% m-cresol solution in accordance
with ISO 307 is preferably from 1.4 to 2.1 for the polyamide
powders of the invention, particularly preferably from 1.5 to 1.9,
and very particularly preferably from 1.6 to 1.7.
[0039] The polymer powder of the invention preferably comprises
polyamide powder of the AB type, and also of the AABB type, with an
average particle size of from 10 to 250 .mu.m, preferably from 45
to 150 .mu.m, and particularly preferably from 50 to 125 .mu.m.
[0040] The quantitative ratio of AABB polyamide to AB polyamide in
the invention is from 1:99 to 99:1, preferably from 10:90 to 90:10,
very preferably from 30:70 to 70:30, parts by mass of the
respective polyamides. If copolyamides are used, the ratios by mass
mentioned apply to the individual AABB--and, respectively, AB-based
copolyamides as an entirety; it is of no great importance here that
the proportions of the other monomer type are respectively
identical.
[0041] The bulk densities of the polymer powder of the invention,
measured in accordance with DIN 53468, are from 300 to 700 g/l,
preferably from 400 to 600 g/l.
[0042] The polymer powder of the invention moreover preferably has
BET surface areas of from 1 to 15 m.sup.2/g, measured with nitrogen
gas in accordance with DIN ISO 9277:2003-05 (volumetric method),
particularly preferably from 2 to 10 m.sup.2/g, and very
particularly preferably from 2.5 to 7 m.sup.2/g.
[0043] The starting pellets for processing to give powders of the
invention are marketed by way of example by Evonik-Degussa, Marl,
Germany (nylon-12, trade name VESTAMID L product line, nylon-10,10,
VESTAMID Terra DS product line, nylon-10,12, VESTAMID Terra DD
product line), or by ARKEMA, Serquigny, France (RILSAN B, nylon-11,
RILSAN A, nylon-12).
[0044] Polymer powder of the invention can moreover comprise
auxiliaries and/or fillers, and/or further organic or inorganic
pigments. Examples of auxiliaries of this type can be powder-flow
aids, e.g. precipitated and/or fumed silicas. Fumed silicas are
marketed by way of example with trademark Aerosil.RTM., with
various specifications, by Evonik-Degussa GmbH. It is preferable
that polymer powder of the invention comprises less than 3% by
weight, preferably from 0.001 to 2% by weight, and very
particularly preferably from 0.05 to 1% by weight, of auxiliaries
of this type, based on the entirety of the polymers present. The
fillers can by way of example be glass particles, metal particles,
or ceramic particles, e.g. glass beads, steel shot, or metal
granules, or foreign pigments, e.g. transition metal oxides. The
pigments can by way of example be titanium dioxide particles based
on rutile or anatase, or carbon black particles.
[0045] The average particle size of the filler particles here is
preferably smaller than or approximately equal to that of the
particles of the polyamides. The d.sub.50 median particle size of
the fillers should preferably not exceed the d.sub.50 median
particle size of the polyamides by more than 20%, preferably 15%,
and very particularly preferably 5%. A particular restriction on
particle size results from the permissible overall height or layer
thickness in the rapid prototyping/rapid manufacturing system.
[0046] Polymer powder of the invention preferably comprises less
than 75% by weight, with preference from 0.001 to 70% by weight,
with particular preference from 0.05 to 50% by weight, and with
very particular preference from 0.5 to 25% by weight, of fillers of
this type, based on the entirety of the polyamides present.
[0047] If the stated maximum limits for auxiliaries and/or fillers
are exceeded, the result, depending on the filler or auxiliary
used, can be marked impairment of the mechanical properties of
moldings produced by means of these polymer powders.
[0048] It is likewise possible to mix conventional polymer powders
with polymer powders of the invention. This method can produce
polymer powders with another combination of surface properties. The
process for producing these mixtures can be found by way of example
in DE 34 41 708.
[0049] In order to improve melt flow during the production of the
moldings, a leveling agent can be added to the precipitated
polyamide powder, examples being metal soaps, preferably the alkali
metal or alkaline earth metal salts of the underlying
alkanemonocarboxylic acids or dimer acids. The metal soap particles
can be incorporated into the polymer particles, but mixtures of
fine metal soap particles and polymer particles are also
possible.
[0050] The amounts used of the metal soaps are from 0.01 to 30% by
weight, preferably from 0.5 to 15% by weight, based on the entirety
of the polyamides present in the powder. It is preferable to use,
as metal soaps, the sodium or calcium salts of the underlying
alkanemonocarboxylic acids or dimer acids. Examples of products
commercially available are Licomont NaV 101 and Licomont CaV 102
from Clariant.
[0051] The following can be added to the polymer powder in order to
improve processability or for further modification of said powder:
inorganic foreign pigments, e.g. transition metal oxides,
stabilizers, e.g. phenols, in particular sterically hindered
phenols, leveling agents and powder-flow aids, e.g. fumed silicas,
and also filler particles. The amount of said substances added to
the polymers, based on the total weight of polymers in the polymer
powder, is preferably such as to comply with the concentrations
stated for fillers and/or auxiliaries for the polymer powder of the
invention.
[0052] The present invention also provides processes for producing
moldings via layer-by-layer processes in which regions are melted
selectively by introducing electromagnetic energy, which use
polymer powder of the invention obtained by coprecipitation of at
least one polyamide of the AB type, produced by polymerizing
lactams having from 10 to 12 carbon atoms in the monomer unit or by
polycondensing the corresponding .omega.-aminocarboxylic acids
having from 10 to 12 carbon atoms in the monomer unit and at least
one polyamide of the AABB type, produced by polycondensing diamines
and dicarboxylic acids having respectively from 10 to 14 carbon
atoms in the monomer units.
[0053] The invention further provides processes for producing
moldings by layer-by-layer processes which use copolyamides of the
AABB type in which up to 20 mol % of the molar-equivalent diamines
and dicarboxylic acids have been replaced by a lactam and,
respectively, an .omega.-aminocarboxylic acid having from 10 to 12
carbon atoms, and also by copolyamides of the AB type in which up
to 20 mol % of the lactams and, respectively,
.omega.-aminocarboxylic acids having from 10 to 12 carbon atoms
have been replaced by molar-equivalent diamines and dicarboxylic
acids having from 10 to 14 carbon atoms. The use of said
coprecipitates comprising copolyamide is advantageous by way of
example when the intention is to construct parts with low
shrinkage. It is preferable that the respective proportion of
comonomer in one or both polyamides to be coprecipitated is
restricted to 10 mol %, and it is very preferable that the
proportion of comonomer is at most 5 mol %, with a view to higher
heat resistance.
[0054] It is preferable that the layer-by-layer process uses a
coprecipitate made of PA11 or PA12, and as AABB polyamide, a
polyamide from the group of PA1010, PA1012, PA1212, and PA1013. It
is particularly preferable that the layer-by-layer shaping process
uses a powder obtained by coprecipitation from PA11 with PA1010,
PA11 with PA1012, PA12 with PA1012, PA12 with PA1212, or of PA12
with PA1013. The proportion of the AABB polyamide here is from 2 to
98% by mass, preferably from 10 to 90% by mass, and particularly
preferably from 30 to 70% by mass. The melting point of the
coprecipitated polymer powder of the invention here, determined by
means of DSC, is at least 175.degree. C., preferably at least
180.degree. C., and particularly preferably at least 185.degree.
C.
[0055] The energy is introduced by electromagnetic radiation, and
the selectivity is introduced, for example, through masks,
application of inhibitors, absorbers, or susceptors, or else by
focusing the radiation. Once all of the layers have cooled, the
molding of the invention can be removed.
[0056] The examples of these processes below serve for
illustration, but there is no intention that the invention be
restricted thereto.
[0057] Laser sintering processes are well known and are based on
the selective sintering of polymer particles, where layers of
polymer particles are briefly exposed to laser light and the
polymer particles exposed to the laser light thus become bonded to
one another. Three-dimensional objects are produced by successive
sintering of layers of polymer particles. Details of the selective
laser sintering process can be found by way of example in the
documents U.S. Pat. No. 6,136,948 and WO 96/06881.
[0058] Other processes with good suitability are the SIB process as
described in WO 01/38061 and a process described in EP 1 015 214.
Both processes operate with large-surface-area infrared heating to
melt the powder. The selectivity of the melting process is achieved
in the first process by applying an inhibitor and in the second
process it is achieved by a mask. DE 103 11 438 describes another
process. In this, the energy needed for the fusion process is
introduced by a microwave generator and the selectivity is achieved
by applying a susceptor.
[0059] A feature of the moldings of the invention which are
produced by a layer-by-layer process in which regions are melted
selectively is that they comprise at least one polyamide of the AB
type, produced by polycondensing diamines and dicarboxylic acids,
preferably a polyamide of the AB type from the group of AB
polyamides having from 10 to 12 carbon atoms in the monomer unit,
and at least one polyamide from the group of AABB polyamides based
on diamines and dicarboxylic acids having respectively from 10 to
14 carbon atoms in the respective monomer unit. Particular
preference is given to moldings of PA11 in a mixture with PA1010,
PA11 with PA1012, PA12 with PA1012, PA12 with PA1212, and PA12 with
PA1013.
[0060] It is particularly preferable that the moldings of the
invention comprise, as polyamide of the AABB type, PA1010, PA1012,
PA1013, or PA1212.
[0061] The moldings can moreover comprise fillers and/or
auxiliaries, e.g. heat stabilizers, e.g. sterically hindered phenol
derivatives. Fillers can by way of example be glass particles,
ceramic particles, and also metal particles, for example aluminum
granules, iron shot, or appropriate hollow beads. It is preferable
that the moldings of the invention comprise glass particles, very
particularly glass beads. It is preferable that moldings of the
invention comprise less than 3% by weight, preferably from 0.001 to
2% by weight, and very particularly preferably from 0.05 to 1% by
weight, of these auxiliaries, based on the entirety of the polymers
present. It is likewise preferable that moldings of the invention
comprise less than 75% by weight, preferably from 0.001 to 70% by
weight, particularly preferably from 0.05 to 50% by weight, and
very particularly preferably from 0.5 to 25% by weight, of these
fillers, based on the entirety of the polymers present.
[0062] The examples below are intended to describe the polymer
powder of the invention and use of said powder, without restricting
the invention to the examples.
EXAMPLES
[0063] The values measured were determined by the following
methods, and the measurement methods here can be used both for the
starting materials required and for the respective products.
Particle Size Determination
[0064] Average particle size and particle size distribution are
determined by means of laser scattering. The measurements are made
with a Malvern Mastersizer 2000. This is a dry measurement. For
each measurement, from 20 to 40 g of powder were metered into the
system with the aid of Scirocco dry-dispersion equipment. The feed
rate used to operate the vibrating trough was 70%. The pressure of
the dispersion air was 3 bar. Each measurement involved a
background measurement (10 seconds/10 000 individual measurements).
The measurement time for the sample was 5 seconds (5000 individual
measurements). The refractive index, and also the blue-light value,
was defined as 1.52. Evaluation was based on the Mie theory.
[0065] Relative solution viscosity is obtained in 0.5% by weight
m-cresol solution in accordance with ISO 307.
[0066] BET surface area is determined by means of nitrogen gas
adsorption (volumetric, continuous gas supply) in accordance with
DIN ISO 9277:2003-05 with gas-adsorption equipment from
Micromeritics TriStar 3000 (Software Win 3000, V6.03), thus giving
the specific surface area by the BET method. The purity of the
nitrogen is 99.996% by volume. A plurality of measurement points
(seven) are defined here at relative pressures p/p.sub.0 from about
0.05 to about 0.20.
[0067] He (purity at least 99.996%) was used for dead volume
calibration. The samples were devolatilized respectively for one
hour at 25.degree. C. and for 16 hours at 80.degree. C. in vacuo.
The specific surface area is based on the devolatilized sample. The
evaluation used multipoint determination in accordance with DIN ISO
9277:2003-05, section 7.2.
[0068] Bulk densities are measured in accordance with DIN
53468.
[0069] Crystallite melting point T.sub.m and enthalpy of fusion are
determined by means of DSC (Perkin Elmer Diamond; heating rate 20 K
per min.), by a method based on ISO 11357 and DIN 53765.
[0070] Powder-flowability is measured by a method based on method A
of DIN EN ISO 6186. Powder-flowability is characterized by the
powder-flow time. This is the discharge time t.sub.R for a defined
amount of powder through a funnel with defined dimensions.
[0071] The equipment used for the test is as follows: 500 ml glass
beaker, balance with accuracy .+-.0.5 g, test funnel in accordance
with DIN EN ISO 6186 with 10 mm, 15 mm, and 25 mm nozzles,
stopwatch readable down to 0.1 second.
[0072] 150 g of powder are accurately weighed into the glass
beaker. Any clumps present are carefully crushed. The aperture of
the clean discharge funnel is kept closed while the sample is
charged thereto. The time determined then starts from the
vibration-free opening of the funnel and ends when all of the
powder has been discharged. Dust adhering to the funnel walls is
ignored. The discharge nozzle generally selected is nozzle 2 with
diameter 15.+-.0.01 mm. However, it is also possible to use
discharge nozzle 1 with diameter 10.+-.0.01 mm or discharge nozzle
3 with diameter 25.+-.0.01 mm in accordance with the nature of the
powder.
[0073] The diameter of the discharge nozzle is recorded as
index.
t.sub.R10, t.sub.R15, t.sub.R25
[0074] The powder-flow time t.sub.R is determined by calculating
the average of 3 measurements. The time is stated in whole
seconds.
[0075] Modulus of elasticity and tensile strength are determined in
accordance with DIN/EN/ISO 527, and impact resistance values are
determined in accordance with ISO 179/1eA. Vicat temperatures are
measured in accordance with ISO 306/2008, in oil.
Example 1
[0076] The following starting materials were supplied to a 200 l
stirred autoclave to produce a PA 1010:
TABLE-US-00001 34.957 kg of 1,10-decanediamine (as 98,5,5% aqueous
solution), 40.902 kg of sebacic and, and 8.6 g of a 50% aqueous
solution of hypophosphorous acid (corresponding to 0.006% by
weight) with 25.3 kg of deionized water
[0077] The starting materials are melted under nitrogen and heated
to about 220.degree. C., with stirring, in the closed autoclave,
the resultant internal pressure being about 20 bar. Said internal
pressure was maintained for 2 hours; the melt was then further
heated to 270.degree. C. with continuous depressurization to
atmospheric pressure, and was then kept at said temperature for 1.5
hours in the stream of nitrogen. The system was then depressurized
to atmospheric pressure within 3 hours, and nitrogen was passed
over the melt for a further 3 hours until the torque indicated no
further rise of melt viscosity. The melt was then discharged by
means of a gear pump and the melt strand was granulated. The
granulated material was dried at 80.degree. C. under nitrogen for
24 hours. [0078] Yield: 65 kg
[0079] The properties of the product were as follows: [0080]
Crystallite melting point T.sub.m: 192.degree. C. and 204.degree.
C. [0081] Enthalpy of fusion: 78 J/g [0082] Relative solution
viscosity .eta..sub.rel: 1.76
Example 2
Production of PA1012
[0083] The following starting materials were reacted with one
another by a method based on example 1:
TABLE-US-00002 34.689 kg of 1,10-decanediamine (98.7%), 46.289 kg
of dodecanedioic acid and 9.2 g of a 50% aqueous solution of
hypophosphorous acid (corresponding to 0.006% by weight) with 20.3
kg of deionized water
[0084] The properties of the product--yield 73.6 kg--were as
follows: [0085] Crystallite melting point T.sub.m: 191.degree. C.
[0086] Enthalpy of fusion: 74 J/g [0087] Relative solution
viscosity .eta..sub.rel: 1.72
Example 3
Production of PA1013
[0088] The following starting materials were reacted with one
another by a method based on example 1:
TABLE-US-00003 33.521 kg of 1,10-decanediamine (98.7%), 47.384 kg
of brassylic acid and 9.5 g of a 50% aqueous solution of
hypophosphorous acid (corresponding to 0.006% by weight) with 20.5
kg of deionized water
[0089] The properties of the product were as follows: [0090]
Relative solution viscosity .eta..sub.rel: 1.66 [0091] Crystallite
melting point T.sub.m: 183.degree. C. [0092] Enthalpy of fusion: 71
J/g
Example 4
Production of PA1212
[0093] The following starting materials were reacted with one
another by a method based on example 1:
TABLE-US-00004 33.366 kg of 1,12-dodecanediamine (as 97.5% aqueous
solution), 37.807 kg of dodecanedioic acid and 8.1 g of a 50%
aqueous solution of hypophosphorous acid (corresponding to 0.006%
by weight) with 20.5 kg of deionized water
[0094] The properties of the product were as follows: [0095]
Crystallite melting point T.sub.m: 183.degree. C. [0096] Enthalpy
of fusion: 75 J/g [0097] Relative solution viscosity .eta..sub.rel:
1.81
Example 5
Production of CoPA1012/12 (92:8)
[0098] The following starting materials were reacted with one
another by a method based on example 1:
TABLE-US-00005 29.774 kg of 1,10-decanediamine (as 99.3% aqueous
solution), 39.532 kg of dodecanedioic acid, 5.891 kg of
laurolactam, and 7.9 g of a 50% aqueous solution of hypophosphorous
acid (corresponding to 0.006% by weight) with 25.5 kg of deionized
water
[0099] The properties of the product were as follows: [0100]
Crystallite melting point T.sub.m: 186.degree. C. [0101] Enthalpy
of fusion: 75 J/g [0102] Relative solution viscosity .eta..sub.rel:
1.72
Example 6
Reprecipitation of Nylon-12 (PA 12) (Not in the Invention)
[0103] 40 kg of unregulated PA 12 produced by hydrolytic
polymerization with a relative solution viscosity of 1.62 and an
end group content of 75 mmol/kg of COOH and 69 mmol/kg of NH.sub.2
are heated to 145.degree. C. in an 800 l stirred tank within 2.5
hours with 2500 l of ethanol, denatured with 2-butanone and 1%
water content, and the mixture is kept at said temperature for 1
hour, with stirring. The jacket temperature is then reduced to
124.degree. C., and the internal temperature is brought to
125.degree. C. with continuous removal of the ethanol by
distillation with a cooling rate of 25 K/h, at the same stirrer
rotation rate. From now on, the jacket temperature is kept at from
2 K to 3 K below the internal temperature, at the same cooling
rate. The internal temperature is brought to 117.degree. C. at the
same cooling rate, and then is kept constant for 60 minutes.
Further material is then removed by distillation at a cooling rate
of 40 K/h, and the internal temperature is thus brought to
111.degree. C. Precipitation, discernible from heat generation,
begins at this temperature. The distillation rate is increased to
the extent required to prevent the internal temperature from rising
above 111.3.degree. C. After 25 minutes, the internal temperature
falls, indicating that precipitation has ended. The temperature of
the suspension is brought to 45.degree. C. through further removal
of material by distillation and cooling by way of the jacket, and
then the suspension is transferred to a paddle dryer. The ethanol
is removed by distillation at 70.degree. C./400 mbar, and the
residue is then further dried for 3 hours at 20 mbar/86.degree.
C.
[0104] This gives a precipitated PA 12 with an average grain
diameter of 55 .mu.m. Bulk density was 435 g/l.
Example 7
Reprecipitation of Nylon-11 (PA 11) (Not in the Invention)
[0105] By analogy with example 6, 40 kg of a commercially available
granulated PA11 material (RILSAN.RTM. BMNO TL from ARKEMA) are
reprecipitated to give a powder with the following properties:
[0106] Crystallite melting point T.sub.m: 192.degree. C. and
200.degree. C. [0107] Enthalpy of fusion: 128 J/g [0108] Relative
solution viscosity .eta..sub.rel: 1.66 [0109] Bulk density: 391 g/l
BET: 4.80 m.sup.2/g [0110] D(10%)=44 .mu.m D(50%)=59 .mu.m
D(90%)=84 .mu.m
Example 8
Reprecipitation of PA 1010 (Not in the Invention)
[0111] By a method based on example 6, 40 kg of the PA 1010 sample
obtained in example 1 were reprecipitated; the precipitation
conditions here were altered in comparison with example 10 as
follows: [0112] Dissolution temperature: 155.degree. C., nucleation
temperature/time: 128.degree. C./60 min. [0113] Precipitation
temperature: 120.degree. C., precipitation time: 1 hour, stirrer
rotation rate: 90 rpm [0114] Crystallite melting point T.sub.m:
192.degree. C. and 206.degree. C. [0115] Enthalpy of fusion: 128
J/g [0116] Relative solution viscosity .eta..sub.rel: 1.69 [0117]
Bulk density: 380 g/l BET: 6.80 m.sup.2/g [0118] D(10%)=44 .mu.m
D(50%)=69 .mu.m D(90%)=103 .mu.m
Example 9
Reprecipitation of PA 1012 (Not in the Invention)
[0119] In accordance with example 6, 40 kg of the sample of
granulated PA 1012 material obtained in example 2 were
reprecipitated, and the precipitation conditions here were altered
as follows in comparison with example 6: [0120] Dissolution
temperature: 155.degree. C., nucleation temperature: 141.degree.
C., precipitation temperature: 123.degree. C., precipitation time:
40 minutes, stirrer rotation rate: 110 rpm [0121] Crystallite
melting point T.sub.m: 191.degree. C. and 202.degree. C. [0122]
Enthalpy of fusion: 148 J/g [0123] Relative solution viscosity
.eta..sub.rel: 1.69 [0124] Bulk density: 430 g/l BET: 3.90
m.sup.2/g [0125] D(10%)=34 .mu.m D(50%)=65 .mu.m D(90%)=94
.mu.m
Example 10
Reprecipitation of PA 1212 (Not in the Invention)
[0126] In accordance with example 6, 40 kg of the sample of
granulated PA 1212 material obtained in example 4 were
reprecipitated, and the precipitation conditions here were altered
as follows: [0127] Dissolution temperature: 155.degree. C.,
nucleation temperature: 123.degree. C., nucleation time: 60 min.
[0128] Precipitation temperature: 117.degree. C., precipitation
time: 60 minutes, stirrer rotation rate: 110 rpm [0129] Bulk
density: 392 g/l BET: 5.60 m.sup.2/g [0130] D(10%)=33 .mu.m
D(50%)=75 .mu.m D(90%)=114 .mu.m [0131] Crystallite melting point
T.sub.m: 187.degree. C. and 194.degree. C. [0132] Enthalpy of
fusion: 143 J/g [0133] Relative solution viscosity .eta..sub.rel:
1.79
Example 11
Reprecipitation of PA 1013 (Not in the Invention)
[0134] In accordance with example 6, 40 kg of the sample of
granulated PA 1013 material obtained in example 3 were
reprecipitated, and the precipitation conditions here were altered
as follows: [0135] Dissolution temperature: 145.degree. C.,
nucleation temperature: 113.degree. C., nucleation time: 60 min.
[0136] Precipitation temperature: 102.degree. C., precipitation
time: 60 minutes, stirrer rotation rate: 110 rpm [0137] Bulk
density: 452 g/l BET: 4.40 m.sup.2/g [0138] D(10%)=25 .mu.m
D(50%)=59 .mu.m D(90%)=94 .mu.m [0139] Crystallite melting point
T.sub.m: 182.degree. C. and 190.degree. C. [0140] Enthalpy of
fusion: 143 J/g [0141] Relative solution viscosity .eta..sub.rel:
1.62
Example 12
Joint Reprecipitation of PA 1010 with PA 11 (In the Invention)
[0142] In accordance with example 6, 20 kg of each of the following
were reprecipitated: the sample of granulated PA 1010 material
obtained in example 1 and the RILSAN.RTM. BMNO TL (ARKEMA) used in
example 6, and the precipitation conditions here were altered as
follows: [0143] Dissolution temperature: 145.degree. C., nucleation
temperature: 118.degree. C., nucleation time: 60 min. [0144]
Precipitation temperature: 112.degree. C., precipitation time: 60
minutes, stirrer rotation rate: 110 rpm [0145] Bulk density: 498
g/l BET: 1.40 m.sup.2/g [0146] D(10%)=41 .mu.m D(50%)=66 .mu.m
D(90%)=103 .mu.m [0147] Crystallite melting point T.sub.m:
192.degree. C. and 198.degree. C. [0148] Enthalpy of fusion: 127
J/g [0149] Relative solution viscosity .eta..sub.rel: 1.72
Example 13
Joint Reprecipitation of PA 1012 with PA 11 (In the Invention)
[0150] In accordance with example 6, 20 kg of each of the following
were reprecipitated: the sample of granulated PA 1012 material
obtained in example 2 and the RILSAN.RTM. BMNO TL (ARKEMA) used in
example 7, and the precipitation conditions here were altered as
follows: [0151] Dissolution temperature: 155.degree. C., nucleation
temperature: 118.degree. C., nucleation time: 60 min. [0152]
Precipitation temperature: 108.degree. C., precipitation time: 60
minutes, stirrer rotation rate: 110 rpm [0153] Bulk density: 438
g/l BET: 7.40 m.sup.2/g [0154] D(10%)=44 .mu.m D(50%)=69 .mu.m
D(90%)=104 .mu.m [0155] Crystallite melting point T.sub.m:
192.degree. C. and 198.degree. C. [0156] Enthalpy of fusion: 127
J/g [0157] Relative solution viscosity .eta..sub.rel: 1.72
Example 14
Joint Reprecipitation of PA 1012 with PA 12 (In the Invention)
[0158] In accordance with example 6, 20 kg of each of the following
were reprecipitated: the sample of granulated PA 1012 material
obtained in example 2 and the unregulated PA 12 used in example 5,
and the precipitation conditions here were altered as follows:
[0159] Dissolution temperature: 155.degree. C., nucleation
temperature: 118.degree. C., nucleation time: 60 min. [0160]
Precipitation temperature: 111.degree. C., precipitation time: 60
minutes, stirrer rotation rate: 110 rpm [0161] Bulk density: 425
g/l BET: 8.10 m.sup.2/g [0162] D(10%)=34 .mu.m D(50%)=62 .mu.m
D(90%)=114 .mu.m [0163] Crystallite melting point T.sub.m:
198.degree. C. [0164] Enthalpy of fusion: 137 J/g [0165] Relative
solution viscosity .eta..sub.rel: 1.64
Example 15
Joint Reprecipitation of PA 1013 with PA12 (In the Invention)
[0166] In accordance with example 6, 20 kg of each of the following
were reprecipitated: the sample of granulated PA 1013 material
obtained in example 3 and the unregulated PA12 used in example 6,
and the precipitation conditions here were altered as follows:
[0167] Dissolution temperature: 145.degree. C., nucleation
temperature: 114.degree. C., nucleation time: 60 min. [0168]
Precipitation temperature: 101.degree. C., precipitation time: 60
minutes, stirrer rotation rate: 110 rpm [0169] Bulk density: 425
g/l BET: 7.20 m.sup.2/g [0170] D(10%)=23 .mu.m D(50%)=46 .mu.m
D(90%)=78 .mu.m [0171] Crystallite melting point T.sub.m:
183.degree. C. [0172] Enthalpy of fusion: 117 J/g [0173] Relative
solution viscosity .eta..sub.rel: 1.64
Example 16
Joint Reprecipitation of PA 1212 with PA12 (In the Invention)
[0174] In accordance with example 6, 20 kg of each of the following
were reprecipitated: the sample of granulated PA 1212 material
obtained in example 4 and the unregulated PA12 used in example 6,
and the precipitation conditions here were altered as follows:
[0175] Dissolution temperature: 152.degree. C., nucleation
temperature: 118.degree. C., nucleation time: 60 min. [0176]
Precipitation temperature: 111.degree. C., precipitation time: 60
minutes, stirrer rotation rate: 110 rpm [0177] Bulk density: 408
g/l BET: 8.1 m.sup.2/g [0178] D(10%)=60 .mu.m D(50%)=85 .mu.m
D(90%)=110 .mu.m [0179] Crystallite melting point T.sub.m:
186.degree. C. [0180] Enthalpy of fusion: 137 J/g [0181] Relative
solution viscosity .eta..sub.rel: 1.76
Example 17
Joint Reprecipitation of CoPA 1012/12 with PA12 (In the
Invention)
[0182] In accordance with example 6, 20 kg of each of the following
were reprecipitated: the sample of granulated 1012/12 material
obtained in example 5 and the unregulated PA12 used in example 6,
and the precipitation conditions here were altered as follows:
[0183] Dissolution temperature: 145.degree. C., nucleation
temperature: 112.degree. C., nucleation time: 45 min. [0184]
Precipitation temperature: 107.degree. C., precipitation time: 60
minutes, stirrer rotation rate: 120 rpm [0185] Bulk density: 424
g/l BET: 3.2 m.sup.2/g [0186] D(10%)=31 .mu.m D(50%)=54 .mu.m
D(90%)=89 .mu.m [0187] Crystallite melting point T.sub.m:
185.degree. C. [0188] Enthalpy of fusion: 120 J/g [0189] Relative
solution viscosity .eta..sub.rel: 1.65
Example 18
Joint Reprecipitation of CoPA 1012/12 with PA12 (In the
Invention)
[0190] In accordance with example 6, 20 kg of each of the following
were reprecipitated: the sample of granulated CoPA 1012/12 material
obtained in example 5 and the unregulated PA12 used in example 6,
and the precipitation conditions here were altered as follows:
[0191] Dissolution temperature: 145.degree. C., nucleation
temperature: 112.degree. C., nucleation time: 45 min. [0192]
Precipitation temperature: 110.degree. C., precipitation time: 60
minutes, stirrer rotation rate: 120 rpm [0193] Bulk density: 410
g/l BET: 4.8 m.sup.2/g [0194] D(10%)=29 .mu.m D(50%)=52 .mu.m
D(90%)=91 .mu.m [0195] Crystallite melting point T.sub.m:
185.degree. C. [0196] Enthalpy of fusion: 120 J/g [0197] Relative
solution viscosity .eta..sub.rel: 1.64
Example 19
Joint Reprecipitation of PA 1012 with PA12 (In the Invention)
[0198] In accordance with example 6, 2-kg of the sample of
granulated PA 1012 material obtained in example 2 and 38 kg of the
unregulated PA12 used in example 5 were reprecipitated, and the
precipitation conditions were altered as follows: [0199]
Dissolution temperature: 142.degree. C., nucleation temperature:
none, nucleation time: none [0200] Precipitation temperature:
107.degree. C., precipitation time: 120 minutes, stirrer rotation
rate: 110 rpm [0201] Bulk density: 426 g/l BET: 5.80 m.sup.2/g
[0202] D(10%)=40 .mu.m D(50%)=62 .mu.m D(90%)=96 .mu.m [0203]
Crystallite melting point T.sub.m: 184.degree. C. [0204] Enthalpy
of fusion: 119 J/g [0205] Relative solution viscosity
.eta..sub.rel: 1.61
Example 20
Joint Reprecipitation of PA 1012 with PA12 (In the Invention)
[0206] In accordance with example 6, 2-kg of the sample of
granulated PA 1012 material obtained in example 2 and 38 kg of the
unregulated PA12 used in example 5 were reprecipitated, and the
precipitation conditions were altered as follows: [0207]
Dissolution temperature: 142.degree. C., nucleation temperature:
none, nucleation time: none [0208] Precipitation temperature:
107.degree. C., precipitation time: 120 minutes, stirrer rotation
rate: 110 rpm [0209] Bulk density: 409 g/l BET: 7.50 m.sup.2/g
[0210] D(10%)=37 .mu.m D(50%)=55 .mu.m D(90%)=82 .mu.m [0211]
Crystallite melting point T.sub.m: 185.degree. C. [0212] Enthalpy
of fusion: 119 J/g [0213] Relative solution viscosity
.eta..sub.rel: 1.61
Example 21
Joint Reprecipitation of PA 1013 with PA12 (In the Invention)
[0214] In accordance with example 6, 6 kg of the sample of
granulated PA 1013 material obtained in example 3 and 34 kg of the
unregulated PA12 used in example 5 were reprecipitated, and the
precipitation conditions were altered as follows: [0215]
Dissolution temperature: 147.degree. C., nucleation temperature:
113.degree. C., nucleation time: 30 min. [0216] Precipitation
temperature: 109.degree. C., precipitation time: 120 minutes,
stirrer rotation rate: 110 rpm [0217] Bulk density: 378 g/l BET:
8.20 m.sup.2/g [0218] D(10%)=28 .mu.m D(50%)=51 .mu.m D(90%)=83
.mu.m [0219] Crystallite melting point T.sub.m: 197.degree. C.
[0220] Enthalpy of fusion: 124 J/g [0221] Relative solution
viscosity .eta..sub.rel: 1.64
[0222] The powder of the invention also features good powder-flow
properties and, respectively, good application properties. The
amount of the powder-flow aid required can be reduced, or
powder-flow aid can be omitted entirely. The table below shows the
results observed:
TABLE-US-00006 Applicable on SPro 60 Powder-flow time HDHS 3D
systems t.sub.R15 in sec. with without with without powder- powder-
powder- powder- Product flow aid flow aid flow aid flow aid Powder
from yes no 25.7 powder ex. 6 does not flow Powder from yes yes 19
28 ex. 19 Powder from yes yes 17 24 ex. 20 Powder from yes yes 32
111 (with ex. 21 tapping)
Examples 22-25
Processing of the PA12/PA1013 Powders of the Invention from Example
15 to Give Moldings by the SLS Process
[0223] Unless otherwise mentioned, the processing experiments below
were carried out in an EOSINT P380 machine from EOS, Krailing:
Example 22
Processing Conditions:
[0224] Process chamber heating: 165.degree. C. [0225] Layer
thickness: 0.15 mm [0226] Laser power rating: 19 W [0227]
Irradiation velocity: 1100 mm/s [0228] Hatch spacing: 0.3 mm
Tensile Test Results:
[0228] [0229] Modulus of elasticity: 1800 MPa [0230] Tensile
strength: 46.5 MPa [0231] Notched impact resistance at -30.degree.
C.: 5.45 kJ/m.sup.2
Example 23
Processing Conditions
[0231] [0232] Process chamber heating: 164.degree. C. [0233] Layer
thickness: 0.15 mm [0234] Laser power rating: 19 W [0235]
Irradiation velocity: 1100 mm/s [0236] Hatch spacing: 0.3 mm
Tensile Test Results:
[0236] [0237] Modulus of elasticity: 1800 MPa [0238] Tensile
strength: 48.6 MPa [0239] Notched impact resistance at -30.degree.
C.: 4.14 kJ/m.sup.2
Example 24
Processing Conditions:
[0239] [0240] Process chamber heating: 167.degree. C. [0241] Layer
thickness: 0.15 mm [0242] Laser power rating: 19 W [0243]
Irradiation velocity: 1100 mm/s [0244] Hatch spacing: 0.3 mm
Tensile Test Results:
[0244] [0245] Modulus of elasticity: 1800 MPa [0246] Tensile
strength: 47.7 MPa [0247] Notched impact resistance at -30.degree.
C.: 4.2 kJ/m.sup.2
Example 25
Processing Conditions:
[0247] [0248] Process chamber heating: 175.degree. C. [0249] Layer
thickness: 0.15 mm [0250] Laser power rating: 19 W [0251]
Irradiation velocity: 1100 mm/s [0252] Hatch spacing: 0.3 mm
Tensile Test Results:
[0252] [0253] Modulus of elasticity: 1800 MPa [0254] Tensile
strength: 51.0 MPa [0255] Vicat A--temperature: 176.degree. C.
Examples 26-28
Processing of the PA12/PA1012 Powders from Example 14 to Give
Moldings by the SLS Process
[0256] Unless otherwise mentioned, the processing experiments below
were carried out in an EOSINT P380 machine from EOS, Krailing:
Example 26
Processing Conditions
[0257] Process chamber heating: 168.degree. C. [0258] Layer
thickness: 0.15 mm [0259] Laser power rating: 19 W [0260]
Irradiation velocity: 1100 mm/s [0261] Hatch spacing: 0.3 mm
Tensile Test Results
[0261] [0262] Modulus of elasticity: 1650 MPa [0263] Tensile
strength: 49 MPa
Example 27
Processing Conditions
[0263] [0264] Process chamber heating: 169.degree. C. [0265] Layer
thickness: 0.15 mm [0266] Laser power rating: 19 W [0267]
Irradiation velocity: 1100 mm/s [0268] Hatch spacing: 0.3 mm
Tensile Test Results
[0268] [0269] Modulus of elasticity: 1600 MPa [0270] Tensile
strength: 48 MPa
Example 28
Processing Conditions:
Processing in a HiQ SLS System Machine
[0270] [0271] Processing temperature: 169.degree. C. [0272] Layer
thickness: 0.1 mm [0273] Laser power rating: 13 W [0274]
Irradiation velocity: 5 m/s [0275] Hatch spacing: 0.3 mm
Tensile Test Results
[0275] [0276] Modulus of elasticity: 1650 MPa [0277] Tensile
strength: 47 MPa
Example 29
Processing Example with Material from Example 19
Processing on 3D Systems SPro 60 HDHS
[0277] [0278] Processing temperature: 168.degree. C. [0279] Layer
thickness: 0.1 mm [0280] Laser power rating: 58 W [0281]
Irradiation velocity: 12 m/s [0282] Hatch spacing: 0.2 mm
Tensile Test Results
[0282] [0283] Modulus of elasticity: 1800 MPa [0284] Tensile
strength: 48 MPa
Example 30
Processing Example with Material from Example 20
Processing on 3D Systems SPro 60 HDHS
[0284] [0285] Processing temperature: 169.degree. C. [0286] Layer
thickness: 0.1 mm [0287] Laser power rating: 58 W [0288]
Irradiation velocity: 12 m/s [0289] Hatch spacing: 0.2 mm
Tensile Test Results
[0289] [0290] Modulus of elasticity: 1850 MPa [0291] Tensile
strength: 48 MPa
Example 31
Processing Example with Material from Example 21
Processing on 3D Systems SPro 60 HDHS
[0291] [0292] Processing temperature: 166.degree. C. [0293] Layer
thickness: 0.1 mm [0294] Laser power rating: 58 W [0295]
Irradiation velocity: 12 m/s [0296] Hatch spacing: 0.2 mm
Tensile Test Results
[0296] [0297] Modulus of elasticity: 1750 MPa [0298] Tensile
strength: 40 MPa
Example 32
Processing of the PA12/PA1212 Powder from Example 16 to Give
Moldings by the SLS Process. The Material was Processed in an
EOSINT P380
Processing Conditions:
[0298] [0299] Process chamber heating: 168.degree. C. [0300] Layer
thickness: 0.15 mm [0301] Laser power rating: 19 W [0302]
Irradiation velocity: 1100 mm/s [0303] Hatch spacing: 0.3 mm
Examples 33-34
Processing of the PA12 Powders from Example 6 to Give Moldings,
Comparative Examples, Not in the Invention
[0304] The processing experiments were carried out in an EOSINT
P380 machine from EOS, Krailing:
Example 33
Tensile Test Results:
[0305] Modulus of elasticity: 1750 MPa [0306] Tensile strength: 50
MPa [0307] Notched impact resistance at -30.degree. C.: 3.09
kJ/m.sup.2 [0308] Vicat A temperature: 165.degree. C.
Example 34
Processing Conditions:
[0308] [0309] Process chamber heating: 179.degree. C. [0310] Layer
thickness: 0.15 mm [0311] Laser power rating: 19 W [0312]
Irradiation velocity: 1100 mm/s [0313] Hatch spacing: 0.3 mm
Tensile Test Results:
[0313] [0314] Modulus of elasticity: 1750 MPa [0315] Tensile
strength: 48 MPa [0316] Notched impact resistance at -30.degree.
C.: 3.09 kJ/m.sup.2 [0317] Vicat A temperature: 165.degree. C.
Example 35
Processing of the PA1013 Powder from Example 11 to Give Moldings,
Comparative Examples, Not in the Invention
[0318] The materials were processed in an EOSINT P380 machine from
EOS, Krailing:
Processing Conditions:
[0319] Process chamber temperature: 169.degree. C. [0320] Layer
thickness: 0.15 mm [0321] Laser power rating: 24 W [0322]
Irradiation velocity: 1100 mm/s [0323] Hatch spacing: 0.3 mm
Tensile Test Results:
[0323] [0324] Modulus of elasticity: 1900 MPa [0325] Tensile
strength: 47 MPa [0326] Notched impact resistance at -30.degree.
C.: 2.92 kJ/m.sup.2
* * * * *