IP Library › Granted Patent US 12,473,400
Granted Patent B2
US 12,473,400 · App. 17/745,169 · Granted Nov 18, 2025

Polyketone powder for laser sintering

Inventors: Steven Kubiak (Edina, MN); Zachary Peterson (New Hope, MN); Nicholas John Dippel (Burnsville, MN); Mathew Artin Torosian (Highlands Ranch, CO); Thomas Fry (Victoria, MN)
Assignee: LUMAS Polymers LLC
C08G67/02B29B9/02B29B13/021B29C64/314B33Y40/10B33Y70/00C08J3/12C08J3/14C08J9/0004C08J9/36C08L73/00C09D5/031C09D173/00B29C64/153B29K2061/00B29K2071/00B29K2995/004C08G2140/00C08G2150/20C08J2201/054C08J2361/02C08J2373/00C08L2205/025
View Patent ↗
Loading inventors, assignments & file history…
Monitor This Case
Get email alerts when status or documents change.
Order Certified Copies
Most orders are placed with the USPTO same day — all within 24 business hours.
Order via The Patent Place →
Pre-filled with this patent's details
Quick Facts
Patent No.
US 12,473,400
App. No.
17/745,169
Granted
Nov 18, 2025
Kind
B2
Abstract

In one instance a semicrystalline polyketone powder useful for additive manufacturing is comprised of a bimodal melt peak determined by an initial differential scanning calorimetry (DSC) scan at 20° C./min and a D 90 particle size of at most 300 micrometers and average particle size of 1 micrometer to 150 micrometers equivalent spherical diameter. In another instance, A composition is comprised of a semicrystalline polyketone powder having a melt peak and a recrystallization peak, wherein the melt peak and recrystallization peak fail to overlap.

Claims (19)

1 . A method of forming an additive manufactured article comprising selectively fusing by directed melting of a composition comprising a semicrystalline polyketone powder having a bimodal melt peak determined by an initial differential scanning calorimetry (DSC) scan at 20° C./min and a D 90 particle size of at most 300 micrometers and average particle size of 1 micrometer to 150 micrometers equivalent spherical diameter.

2 . The method of claim 1 , wherein at least 90% by number of the particles of the semicrystalline polyketone powder has a circularity of at least about 0.9.

3 . The method of claim 1 , wherein the polyketone is comprised of repeating units represented by:

where A is the residue of an alkene monomer converted to a saturated hydrocarbon group, m is from about 1 to 6 and n is at least about 2 to 10,000.

4 . The method of claim 3 , wherein the semicrystalline polyketone powder is a copolymer of ethylene, carbon monoxide and at least one other alkene containing monomer.

5 . The method of claim 4 , wherein the other alkene containing monomer is propylene.

6 . The method of claim 3 , wherein the semicrystalline polyketone powder has a flowability of at least about 0.5 g/s as determined by ASTM D 1895 using a 15 mm nozzle.

7 . The method of claim 1 , wherein the semicrystalline polyketone has a recrystallization peak that overlaps a portion of the bimodal melt peak during an initial heating and cooling DSC scan.

8 . The method of claim 7 , wherein upon a subsequent DSC scan, the polyketone has a monomodal melt peak.

9 . The method of claim 8 , wherein the subsequent DSC scan has a recrystallization peak that overlaps a portion of the monomodal melt peak.

10 . The method of claim 8 , wherein the melt peak and recrystallization peak fail to overlap.

11 . The method of claim 10 , wherein melt peak has a melt peak onset temperature and a recrystallization onset temperature that are at least separated by 10° C.

12 . The method of claim 11 , wherein the semicrystalline polyketone has a crystallinity of at least 15%, by volume.

13 . The method of claim 8 , wherein each of the melt and crystallization peaks are monomodal.

14 . The method of claim 1 , wherein the composition is essentially free of a solvent.

15 . The method of claim 1 , wherein the melt peak has a melt enthalpy of a least 5 joules/gram of the semicrystalline polyketone powder.

16 . The method of claim 15 , wherein the melt enthalpy is at least 20 joules/gram of the semicrystalline polyketone powder.

17 . The method of claim 1 , wherein the semicrystalline polyketone powder is without a flow aid.

18 . The method of claim 17 , wherein the semicrystalline polyketone powder is without a filler.

Assignments (2)
ASSIGNMENT OF ASSIGNOR'S INTEREST Recorded Oct 18, 2024
From: JABIL INC.
To: LUMAS POLYMERS LLC
Reel/Frame 069208/0334 →
ASSIGNMENT OF ASSIGNOR'S INTEREST Recorded May 26, 2022
From: KUBIAK, STEVEN; PETERSON, ZACHARY; DIPPEL, NICHOLAS JOHN; TOROSIAN, MATHEW ARTIN; FRY, THOMAS
To: JABIL INC.
Reel/Frame 060022/0895 →
Continuity (3)
Provisional Application 63217451 · Jul 1, 2021
Provisional Application 63189609 · May 17, 2021
Related Publication 20220363825A1 · Nov 17, 2022
References Cited (88)
US 3065205A · Bonner, Jr. · 1962 [cited by applicant]
US 3179631A · Endry · 1965 [cited by applicant]
US 3214407A · Butterworth · 1965 [cited by applicant]
US 3249588A · Gall · 1966 [cited by applicant]
US 3441538A · Marks · 1969 [cited by applicant]
US 3442857A · Thornton · 1969 [cited by applicant]
US 3516966A · Berr · 1970 [cited by applicant]
US 4704448A · Brugel · 1987 [cited by applicant]
US 4755555A · Manwiller et al. · 1988 [cited by applicant]
US 4816556A · Gay et al. · 1989 [cited by applicant]
US 4824720A · Malone · 1989 [cited by applicant]
US 4835250A · Drent · 1989 [cited by applicant]
US 4853462A · Hostetler et al. · 1989 [cited by applicant]
US 4894435A · Drent · 1990 [cited by applicant]
US 4895689A · Gerlowski · 1990 [cited by applicant]
US 4985278A · George · 1991 [cited by applicant]
US 5138032A · Mastenbroek et al. · 1992 [cited by applicant]
US 5169928A · van Doorn et al. · 1992 [cited by applicant]
US 5391640A · Akkapeddi et al. · 1995 [cited by applicant]
US 5395055A · Shutov et al. · 1995 [cited by applicant]
US 5527877A · Dickens, Jr. et al. · 1996 [cited by applicant]
US 5597589A · Deckard · 1997 [cited by applicant]
US 5670102A · Perman et al. · 1997 [cited by applicant]
US 5698663A · Kinneberg · 1997 [cited by applicant]
US 5952066A · Schmidt et al. · 1999 [cited by applicant]
US 5955019A · Ash · 1999 [cited by applicant]
US 5977231A · Ash · 1999 [cited by applicant]
US 6136948A · Dickens, Jr. et al. · 2000 [cited by applicant]
US 6177518B1 · Lahijani · 2001 [cited by applicant]
US 6213540B1 · Tusim et al. · 2001 [cited by applicant]
US 6284810B1 · Burnham et al. · 2001 [cited by applicant]
US 7267534B2 · Xu · 2007 [cited by applicant]
US 10364349B1 · Bertelo et al. · 2019 [cited by applicant]
US 10479733B2 · Diekmann et al. · 2019 [cited by applicant]
US 11851526B2 · Louis et al. · 2023 [cited by applicant]
US 12187847B2 · Fry et al. · 2025 [cited by applicant]
US 20030181538A1 · Martel et al. · 2003 [cited by applicant]
US 20050276967A1 · Prasad · 2005 [cited by applicant]
US 20080058494A1 · Shim et al. · 2008 [cited by applicant]
US 20120077010A1 · Manesis et al. · 2012 [cited by applicant]
US 20120114848A1 · M Ller et al. · 2012 [cited by applicant]
US 20130323416A1 · Bertelo et al. · 2013 [cited by applicant]
US 20150011815A1 · Ma et al. · 2015 [cited by applicant]
US 20170282430A1 · Baldwin et al. · 2017 [cited by applicant]
US 20170326790A1 · Lee et al. · 2017 [cited by applicant]
US 20180200922A1 · DeFelice et al. · 2018 [cited by applicant]
US 20200247012A1 · DeFelice et al. · 2020 [cited by applicant]
US 20200247041A1 · Katzenstein · 2020 [cited by examiner]
US 20210277180A1 · Gardner et al. · 2021 [cited by applicant]
US 20210277192A1 · Gardner et al. · 2021 [cited by applicant]
US 20220169866A1 · Zekriardehani · 2022 [cited by examiner]
US 20220363825A1 · Kubiak et al. · 2022 [cited by applicant]
US 20220363826A1 · Fry et al. · 2022 [cited by applicant]
CN 110655666A · 2020 [cited by applicant]
EP 121965B1 · 1989 [cited by applicant]
EP 0431924A2 · 1991 [cited by applicant]
KR 1020160108820A · 2016 [cited by applicant]
NL 8801276A · 1989 [cited by applicant]
WO 199606881A2 · 1996 [cited by applicant]
WO 199618686A1 · 1996 [cited by applicant]
WO 200138061A1 · 2001 [cited by applicant]
WO 2017033146A1 · 2017 [cited by applicant]
WO 2021137086A1 · 2021 [cited by applicant]
Groenewoud, Wim et al., “Characterization of Polyketone Copolymer by High Speed DSC.” Application Note; PerkinElmer product information (6 pages), 2011. [cited by applicant]
International Search Report and Written Opinion in co-pending International Application PCT/US2022/029422 mailed Jul. 25, 2022 (20 pages). [cited by applicant]
Klop, E.A., et al., “Polymorphism in alternative polyketones studied by x-ray diffraction and calorimetry.” Journal of Polymer Science Part B: Polymer Physics / vol. 33, Issue 2. (2 pages), Jan. 30, 1995. [cited by applicant]
Naitove, Matthew, “A Rare ‘Resurrection’ in Engineering Plastics.” Plastics Technology, Published Oct. 27, 2014. [cited by applicant]
Wikipedia: Polyketone definition (4 pages), Mar. 24, 2021. [cited by applicant]
Industrial Specialties Mfg. & IS Med Specialties; Mesh and Micron Sizes, Mar. 11, 2020, pp. 1-7. [cited by applicant]
International Search Report and Written Opinion in co-pending application PCT/US2022/029424 mailed Sep. 1, 2022 (14 pages). [cited by applicant]
Database WPI Week 202001, Thomson Scientific, Long, GB; AN 2020-05446X, 2020. [cited by applicant]
Migliore, Nicola et al., “Effect of the Polyketone Aromatic Pendent Groups on the Electrical Conductivity of the Derived MWCNTs-Based Nanocomposities . . . .” Polymers 2018, 10, 618; doi: 10.3390/polym10060618 (16 pages… [cited by applicant]
Toncelli, Claudio, “Functional Polymers from Alternating Aliphatic Polyketones: Synthesis and Applications.” Publication date 2013, University of Groningen (136 pages). [cited by applicant]
“Hydrocerol and Colormatrix Excelite Chemical Foaming Additives.” Product Selection Guide, Avient (6 pages). 2022. [cited by applicant]
Altan, M., “Thermoplastic Foams: Processing, Manufacturing, and Characterization.” DOI: 10.5772/intechopen.71083. (23 pages), Dec. 20, 2017. [cited by applicant]
Bhamidipati, M., MS et al., “The Future of Carbon Dioxide for Polymer Processing in Tissue Engineering.” Tissue Engineering: Part B, vol. 19, No. 3, 2013. DOI: 10.1089/ten.teb.2012.0361. (12 pages). [cited by applicant]
Gendron, R. et al., “Supercritical Fluids in Thermoplastics Foaming: Facts or Fallacies?” Rapra Technology, 2006, Cellular Polymers. vol. 25, No. 4, 2006 (24 pages). [cited by applicant]
Jimenez, J. et al., “Foaming of PLA Composites by Supercritical Fluid-Assisted Processes: A Review.” Molecules 2020, 25, 3408; doi: 10.3390/molecule25153408 (39 pages). [cited by applicant]
Jin, Fan-Long et al., “Recent Trends of Foaming in Polymer Processing: A Review.” Polymers 2019, 11, 953; DOI: 10.3390/polym11060953 (23 pages). [cited by applicant]
Nalawade, S. et al., “Supercritical carbon dioxide as a green solvent for processing polymer melts: Processing aspects and applications.” Prog. Polym. Sci. 31 (2006) 19-43 (25 pages). [cited by applicant]
Olson, Eric, “Particle Shape Factors and Their use in Image Analysis Part II: Practical Applications.” Journal of GXP Compliance, Autumn 2011 vol. 15 No. 4 (13 pages). [cited by applicant]
Sauceau, M. et al., “New challenges in polymer foaming: A review of extrusion processes assisted by supercritical carbon dioxide.” Progress in Polymer Science, (2011) 36: 749-766 (30 pages). [cited by applicant]
Sichina, W.J., “Measurement of Tg by DSC.” Perkin Elmer™ instruments. 2000 PerkinElmer, Inc., PETech-09 Thermal Analysis (5 pages). [cited by applicant]
Maloo et al.,“A Sneak Peek Toward Polyaryletherketone (PAEK) Polymer: A review”, Cureus, vol. 14, No. 11, Nov. 3, 2022. (9 pages). [cited by applicant]
Schmid et al.,“Materials perspective of polymers for additive manufacturing with selective laser sintering”, Journal of Materials Research, vol. 29, No. 17, Sep. 14, 2014. (1824-1832 pages). [cited by applicant]
Chen, Youming et al., “Effects of Cell Size and Cell Wall Thickness Variations on the Strength of Closed-Cell Foams Using Laguerre Tessellation.” 21st International Conference on Composite Materials, Aug. 2017 (15 pages… [cited by applicant]
Waddon et al.,“On the Crystalline Structure and Morphology of Aliphatic Ketone Terpolymer”, Macromolecules 1999, vol. 32, pp. 423-428. [cited by applicant]
Taminco technical data sheet for Dimethylacetamide, 2018, pp. 1-5. [cited by applicant]