US 12,258,446 B2
Polyketone powder for laser sintering
Steven Kubiak, Edina, MN (US); Zachary Peterson, New Hope, MN (US); Nicholas John Dippel, Burnsville, MN (US); Mathew Artin Torosian, Highlands Ranch, CO (US); and Thomas Fry, Victoria, MN (US)
Assigned to LUMAS Polymers LLC, Chaska, MN (US)
Appl. No. 18/289,857
Filed by LUMAS Polymers LLC, Chaska, MN (US)
PCT Filed May 16, 2022, PCT No. PCT/US2022/029422
§ 371(c)(1), (2) Date Nov. 7, 2023,
PCT Pub. No. WO2022/245721, PCT Pub. Date Nov. 24, 2022.
Claims priority of provisional application 63/217,451, filed on Jul. 1, 2021.
Claims priority of provisional application 63/189,609, filed on May 17, 2021.
Prior Publication US 2024/0247103 A1, Jul. 25, 2024
Int. Cl. C08G 67/02 (2006.01); B29B 9/02 (2006.01); B29B 13/02 (2006.01); B29C 64/153 (2017.01); B29C 64/314 (2017.01); B33Y 40/10 (2020.01); B33Y 70/00 (2020.01); C08J 3/12 (2006.01); C08J 3/14 (2006.01); C08J 9/00 (2006.01); C08J 9/36 (2006.01); C08L 73/00 (2006.01); C09D 5/03 (2006.01); C09D 173/00 (2006.01); B29K 61/00 (2006.01); B29K 71/00 (2006.01)
CPC C08G 67/02 (2013.01) [B29B 9/02 (2013.01); B29B 13/021 (2013.01); B29C 64/314 (2017.08); B33Y 40/10 (2020.01); B33Y 70/00 (2014.12); C08J 3/12 (2013.01); C08J 3/14 (2013.01); C08J 9/0004 (2013.01); C08J 9/36 (2013.01); C08L 73/00 (2013.01); C09D 5/031 (2013.01); C09D 173/00 (2013.01); B29C 64/153 (2017.08); B29K 2061/00 (2013.01); B29K 2071/00 (2013.01); B29K 2995/004 (2013.01); C08G 2140/00 (2013.01); C08G 2150/20 (2013.01); C08J 2201/054 (2013.01); C08J 2361/02 (2013.01); C08J 2373/00 (2013.01); C08L 2205/025 (2013.01)] 17 Claims
 
15. A method for forming an aliphatic polyketone powder useful for making an additive manufactured article comprising:
(i) reacting carbon monoxide, alkene monomer in the presence of a group 8 through 10 transition metal catalyst to form a raw polyketone powder,
(ii) recovering the raw polyketone powder, and
(iii) separating the raw polyketone powder to form the polyketone powder having a D90 particle size of at most 300 micrometers and D50 particle size of 10 micrometer to 125 micrometers equivalent spherical diameter and an oversized polyketone powder, wherein the aliphatic polyketone powder is a copolymer of ethylene, carbon monoxide and at least one other alkene monomer and has a bimodal melt peak determined by an initial differential scanning calorimetry (DSC) scan at 20° C./min, wherein the polyketone powder, raw polyketone powder or oversized polyketone powder is subjected to conditions further crystallizing said polyketone powder.