unknown

Abstract

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.