US 12,145,312 B2
Additive manufacturing method for making a three-dimensional object using selective laser sintering
Chantal Louis, Alpharetta, GA (US); Christopher Ward, Sandy Springs, GA (US); and Craig Swanson, Roswell, GA (US)
Assigned to SOLVAY SPECIALTY POLYMERS USA, LLC, Alpharetta, GA (US)
Appl. No. 17/292,764
Filed by SOLVAY SPECIALTY POLYMERS USA, LLC, Alpharetta, GA (US)
PCT Filed Nov. 12, 2019, PCT No. PCT/EP2019/081082
§ 371(c)(1), (2) Date May 11, 2021,
PCT Pub. No. WO2020/099444, PCT Pub. Date May 22, 2020.
Claims priority of provisional application 62/760,271, filed on Nov. 13, 2018.
Claims priority of application No. 19151955 (EP), filed on Jan. 15, 2019.
Prior Publication US 2021/0394438 A1, Dec. 23, 2021
Int. Cl. B29C 64/153 (2017.01); B29K 71/00 (2006.01); B29K 105/00 (2006.01); B29K 105/26 (2006.01); B33Y 10/00 (2015.01); B33Y 70/00 (2020.01); C08G 65/40 (2006.01); C08J 11/16 (2006.01); C09D 5/03 (2006.01); C09D 171/00 (2006.01)
CPC B29C 64/153 (2017.08) [B33Y 70/00 (2014.12); C08G 65/4012 (2013.01); C08J 11/16 (2013.01); C09D 5/031 (2013.01); C09D 171/00 (2013.01); B29K 2071/00 (2013.01); B29K 2105/0094 (2013.01); B29K 2105/26 (2013.01); B33Y 10/00 (2014.12); C08J 2371/10 (2013.01)] 10 Claims
 
1. A method for manufacturing a three-dimensional (3D) object, comprising:
a) depositing successive layers of a powdered material (M), at least partially recycled, comprising at least one a poly (ether ketone ketone) (PEKK), wherein the at least one PEKK has a phosphorus content of more than 30 ppm, which is obtained by a step of contacting a PEKK powder with a solution of alkali metal phosphate, this phosphorus content being measured by Inductively Coupled Plasma Optical Emission Spectrometry (ICP-OES), wherein the alkali metal phosphate is at least one of sodium dihydrogen phosphate (NaH2PO4), disodium hydrogen phosphate (Na2HPO4), potassium dihydrogen phosphate (KH2PO4), dipotassium hydrogen phosphate (K2HPO4) or mixtures thereof, and
b) selectively sintering each of the successive layers prior to deposition of a subsequent successive layer,
wherein the at least one PEKK is a polymer comprising at least 95 mol % of a first recurring unit (RM) and a second recurring unit (RP), respectively represented by formulae (M′) and (P′), the mol % being based on a total number of moles in the polymer:

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wherein the at least one PEKK has a residual acidity ≤9 μeq/g as measured by the Residual Acidity Test and a residual basicity ≤20 μeq/g as measured by the Residual Basicity Test;
and wherein the at least one PEKK is prepared by the synthesis method further comprising:
i) polycondensing in a solvent, in the absence of a Lewis acid or in the presence of an amount of Lewis acid of less than 2 wt. %, based on the total weight of the monomers, the following monomers (P′—OH), (M′-OH), (P′—F) and/or (M′-F):

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wherein the molar ratio of moles of (P′—OH) and (M′-OH) to moles of (P′—F) and (M′-F) is such that:

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ii) extracting the solvent and salts, in order to obtain the PEKK powder.