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The invention describes powders for use in the production of spatial structures, i.e. molded bodies, using layer build-up methods, as well as methods for their efficient production. The powders have the special feature that they have good flow behavior, for one thing, and at the same time, have such a composition that the molded body that can be produced with the powder, using rapid prototyping, has significantly improved mechanical and/or thermal properties. According to a particularly advantageous embodiment, the powder has a first component that is present in the form of essentially spherical powder particles, which is formed by a matrix material, and at least one further component in the form of stiffening and/or reinforcing fibers, which are preferably embedded in the matrix material.
1 - 30 . (canceled)
31 . A powder comprising essentially spherical particles of an aromatic polyether ketone plastic.
32 . The powder of claim 31 , wherein the aromatic polyether ketone plastic is a polyaryl ether ketone plastic comprising polymerized units of oxy-1,4-phenylene-oxy-1,4-phenylene-carbonyl-1,4-phenylene of formula (I)
33 . The powder of claim 31 , wherein the particles are spherical.
34 . The power according to claim 1 , further comprising one or more of a stiffening fiber or a reinforcing fiber, and a matrix material in the form of essentially spherical powder particles.
35 . The powder according to claim 34 , wherein the total amount of the stiffening fibers and reinforcing fibers is up to 25% by volume.
36 . The powder according to claim 34 , wherein the total amount of the stiffening fibers and reinforcing fibers is up to 15% by volume.
37 . The powder of claim 34 , wherein the total amount of the stiffening fibers and reinforcing fibers is up to 10% by volume.
38 . The powder according to claim 34 , wherein the fibers are embedded in the aromatic polyether ketone plastic.
39 . The powder according to claim 34 , wherein the fibers are essentially completely surrounded by the aromatic polyether ketone plastic.
40 . The powder according to claim 34 , wherein the reinforcing fibers and stiffening fibers are completely surrounded by the aromatic polyether ketone plastic.
41 . The powder according to claim 38 , wherein the reinforcing fibers and stiffening fibers are present in a volume proportion of greater than 15%.
42 . The powder according to claim 38 , wherein the stiffening fibers and reinforcing fibers are present in a volume proportion of greater than 25%.
43 . The powder according to claim 34 , wherein the matrix material comprises a thermoplastic material.
44 . The powder according to claim 43 , wherein the matrix material comprises a crosslinked polyamide.
45 . The powder according to claim 44 , wherein the crosslinked polyamide is at least one selected from the group consisting of PA11 and PA12.
46 . The powder according to claim 43 , wherein at least one of the stiffening fibers or reinforcing fibers comprises at least one of carbon or glass fibers.
47 . The powder according to claim 31 , wherein the spherical particles have an average grain sized d 50 of from 20 to 150 μm.
48 . The powder according to claim 31 , wherein the spherical powder particles have an average grain size d 50 of from 40 to 70 μm.
49 . The powder according to claim 34 , wherein the matrix material comprises a metallic material.
50 . The powder according to claim 51 , wherein the fibers are selected from the group consisting of ceramic fibers and boron fibers.
51 . The powder according to claim 49 , wherein the spherical powder particles have an average grain size d 50 in the range of 10 to 100 μm.
52 . The powder according to claim 49 , wherein the spherical powder particles have an average grain size d 50 of from 10 to 80 μm.
53 . The powder according to claim 34 , wherein the average length L50 of the fibers is no greater than the average grain size d 50 of the spherical powder particles.
54 . A powder comprising a first component in the form of essentially spherical powder particles and at least one of a stiffening fiber or a reinforcing fiber, wherein the first component comprises a matrix material.
55 . The powder according to claim 54 , wherein the total amount of the stiffening fibers and reinforcing fibers is up to 25% by volume.
56 . The powder according to claim 54 , wherein the total amount of the stiffening fibers and reinforcing fibers is up to 15% by volume.
57 . The powder of claim 54 , wherein the total amount of the stiffening fibers and reinforcing fibers is up to 10% by volume.
58 . The powder according to claim 54 , wherein the fibers are embedded in the aromatic polyether ketone plastic.
59 . The powder according to claim 54 , wherein the fibers are essentially completely surrounded by the aromatic polyether ketone plastic.
60 . The powder according to claim 54 , wherein the reinforcing fibers and stiffening fibers are completely surrounded by the aromatic polyether ketone plastic.
61 . The powder according to claim 58 , wherein the reinforcing fibers and stiffening fibers are present in a volume proportion of greater than 15%.
62 . The powder according to claim 58 , wherein the stiffening fibers and reinforcing fibers are present in a volume proportion of greater than 25%.
63 . The powder according to claim 54 , wherein the matrix material comprises a thermoplastic material.
64 . The powder according to claim 63 , wherein the thermoplastic material comprises a crosslinked polyamide.
65 . The powder according to claim 64 , wherein the crosslinked polyamide is at least one selected from the group consisting of PA11 and PA12.
66 . The powder according to claim 63 , wherein at least one of the stiffening fibers or reinforcing fibers comprises at least one of carbon or glass fibers.
67 . The powder according to claim 54 , wherein the spherical particles have an average grain sized d 50 of from 20 to 150 μm.
68 . The powder according to claim 54 , wherein the spherical powder particles have an average grain size d 50 of from 40 to 70 μm.
69 . The powder according to claim 54 , wherein the matrix material comprises a metallic material.
70 . The powder according to claim 69 , wherein the fibers are selected from the group consisting of ceramic fibers and boron fibers
71 . The powder according to claim 69 , wherein the spherical powder particles have an average grain size d 50 in the range of 10 to 100 μm.
72 . The powder according to claim 69 , wherein the spherical powder particles have an average grain size d 50 of from 10 to 80 μm.
73 . A method for the production of a powder comprising essentially spherical particles of an aromatic polyether ketone plastic, comprising:
mixing a matrix micropowder into a liquid phase to form a suspension wherein the particle size of the matrix micropowder is less than the particle size of the powder;
spraying the suspension through a nozzle to form droplets comprising the matrix micropowder; and
vaporizing or evaporating a liquid component from the droplets to form the powder in the form of essentially spherical agglomerates.
74 . The method according to claim 73 , wherein the liquid phase is further mixed with at least one of a reinforcing fiber or a stiffening fiber having a length less than the particle size of the powder.
75 . The method according to claim 73 , wherein the matrix micropowder has an average grain size d 50 between 3 and 10 μm.
76 . The method according to claim 73 , wherein the matrix micropowder has an average grain size d 50 of 5 μm.
77 . The method of claim 74 , wherein the fibers have an average length L50 of 20 to 150 μm.
78 . The method according to claim 74 , wherein the fibers have an average length L50 of 40 to 70 μm.
79 . The method according to claim 74 , wherein the matrix micropowder has an average grain size d 50 between 3 and 10 μm and the fibers have an average length L50 of 10 to 100 μm.
80 . The method according to claim 74 , wherein the matrix micropowder has an average grain size d 50 of 5 μm and the fibers have an average length L50 of 10 to 80 μm.
81 . The method according to claim 73 , wherein the droplets have an average diameter d 50 of 10 to 70 μm.
82 . The method according to claim 73 , wherein the vaporizing or evaporating is carried out while the droplets are moving through a heating segment.
83 . A method for the production of a powder comprising a first component in the form of essentially spherical powder particle and at least one of a stiffening fiber or a reinforcing fiber, wherein the first component comprises a matrix material, and the fibers are embedded in the powder particles, comprising:
mixing a matrix micropowder with a liquid phase to form a suspension wherein the particle size of the matrix micropowder is less than the particle size of the powder;
spraying the suspension through a nozzle to form droplets comprising the matrix micropowder; and
vaporizing or evaporating a liquid component from the droplets to form the powder in the form of essentially spherical agglomerates.
84 . The method according to claim 83 , wherein the liquid phase is further mixed with at least one of a reinforcing fiber or a stiffening fiber having a length less than the particle size of the powder.
85 . The method according to claim 83 , wherein the matrix micropowder has an average grain size d 50 between 3 and 10 μm.
86 . The method according to claim 83 , wherein the matrix micropowder has an average grain size d 50 of 5 μm.
87 . The method of claim 83 , wherein the fibers have an average length L50 of 20 to 150 μm.
88 . The method according to claim 83 , wherein the fibers have an average length L50 of 40 to 70 μm.
89 . The method according to claim 84 , wherein the matrix micropowder has an average grain size d 50 between 3 and 10 μm and the fibers have an average length L50 of 10 to 100 μm.
90 . The method according to claim 84 , wherein the matrix micropowder has an average grain size d 50 of 5 μm and the fibers have an average length L 50 of 10 to 80 μm.
91 . The method according to claim 83 , wherein the droplets have an average diameter d 50 of 10 to 70 μm.
92 . The method according to claim 83 , wherein the vaporizing or evaporating is carried out while the droplets are moving through a heating segment.
93 . A method for the production of a powder comprising essentially spherical particles of an aromatic polyether ketone plastic, comprising:
cooling a coarse granulate comprising a plastic matrix material to form brittle, coarse granulates;
grinding the brittle, coarse granulates; and
separating the ground granulate into a fraction spectrum.
94 . The method according to claim 93 , wherein the coarse granulate is a fiber-reinforced plastic matrix material.
95 . The method according to claim 93 , wherein the grinding is carried out with a pinned disk mill.
96 . The method according to claim 93 , wherein the grinding is carried out with cooling.
97 . The method according to claim 93 , wherein the separating is carried out with an air separator.
98 . The method according to claim 93 , further comprising:
smoothing the ground granulate.
99 . The method according to claim 98 , wherein the smoothing is carried out by embedding or accumulating at least one of microparticles or nanoparticles.
100 . A method for producing a powder comprising a first component in the form of essentially spherical powder particles and at least one of a stiffening fiber or a reinforcing fiber, wherein the first component comprises a matrix material, comprising:
cooling a coarse granulate comprising a plastic matrix material to form brittle, coarse granulates;
grinding the brittle, coarse granulates; and
separating the ground granulate into a fraction spectrum.
101 . The method according to claim 100 , wherein the coarse granulate is a fiber-reinforced plastic matrix material.
102 . The method according to claim 100 , wherein the grinding is carried out with a pinned disk mill.
103 . The method according to claim 100 , wherein the grinding is carried out with cooling.
104 . The method according to claim 100 , wherein the separating is carried out with an air separator.
105 . The method according to claim 100 , further comprising:
smoothing the ground granulate.
106 . The method according to claim 105 , wherein the smoothing is carried out by embedding or accumulating at least one of microparticles or nanoparticles.
107 . A method for producing a powder comprising essentially spherical particles of an aromatic polyether ketone plastic, comprising:
melting a matrix material;
blowing the melted matrix material through a nozzle to form droplets; and
passing the droplets through a cooling segment.
108 . The method according to claim 107 , further comprising:
stirring at least one of stiffening fibers or reinforcing fibers into the melted matrix material before blowing the melted matrix material.
109 . The method according to claim 107 , wherein the droplets are formed in a hot gas jet.
110 . The method according to claim 107 , further comprising:
separating the cooled droplets into a fraction spectrum.
111 . A method for producing a powder comprising a first component in the form of essentially spherical powder particles and at least one of a stiffening fiber or a reinforcing fiber, wherein the first component comprises a matrix material, comprising:
melting a matrix material;
blowing the melted matrix material through a nozzle to form droplets; and
passing the droplets through a cooling segment.
112 . The method according to claim 111 , further comprising:
stirring at least of stiffening or reinforcing fibers into the melted matrix material before blowing the melted matrix material.
113 . The method according to claim 111 , wherein the droplets are formed in a hot gas jet.
114 . The method according to claim 111 , further comprising:
separating the cooled droplets into a fraction spectrum.
115 . A method for producing a spatial structure, comprising:
melting the powder according to claim 31 .
116 . The method according to claim 115 , wherein melting includes powder-based generative rapid prototyping, selective laser sintering or laser melting.
117 . A method for producing a spatial structure, comprising:
melting the powder according to claim 34 .
118 . The method according to claim 117 , wherein melting includes powder-based generative rapid prototyping, selective laser sintering or laser melting.
119 . A molded body obtained by powder-based generative rapid prototyping of the powder according to claim 31 .
120 . The molded body of claim 119 , wherein the powder-based generative rapid prototyping is selective laser sintering or laser melting.
121 . A molded body obtained by powder-based generative rapid prototyping of the powder according to claim 34 .
122 . The molded body of claim 121 , wherein the powder-based generative rapid prototyping is selective laser sintering or laser melting.
123 . The molded body according to claim 119 , comprising one or more interior reinforcements.
124 . The molded body according to claim 119 , comprising a three-dimensional framework reinforcement.
125 . The molded body according to claim 121 , comprising one or more interior reinforcements.
126 . The molded body according to claim 121 , comprising a three-dimensional framework reinforcement.
127 . A molded body obtained by powder-based generative rapid prototyping of the powder according to claim 54 .
128 . The molded body of claim 127 , wherein the powder-based generative rapid prototyping is selective laser sintering or laser melting.
129 . The molded body according to claim 128 , comprising one or more interior reinforcements.