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    • 1. 发明公开
    • POLYMER-CERAMIC CORE-SHELL PARTICLE POWDERS, AND PROCESSES FOR MAKING AND ARTICLES COMPRISING SUCH POWDERS
    • EP3797863A1
    • 2021-03-31
    • EP20157486.0
    • 2020-02-14
    • SHPP Global Technologies B.V.
    • KALYANARAMAN, ViswanathanBAJAJ, Devendra NarayandasEVANS, Thomas Lane
    • B01J13/04
    • Ceramic-polymer composites and methods. The ceramic-polymer composites, in powder and/or pellet forms, comprise a plurality of core-shell particles, where: each of the core-shell particles comprises a core and a shell around the core; the core comprises a ceramic selected from the group of ceramics consisting of: Al 2 O 3 , Fe 2 O 3 , ZnO , ZrO 2 , and SiO 2 ; and the shell comprises a polymer selected from the group of polymers consisting of: PC copolymers, polyetherimide (PEI), polyetherimide (PEI) copolymers, polyphenylsulfone (PPSU), polyarylethersulfone (PAES), and polyether sulfones (PES). In powder form, the core-shell particles are in a substantially dry powder form having a moisture content of less than 2% by weight. In pellet form, shells of adjacent core-shell particles are joined to resist separation of the adjacent core-shell particles and deformation of a respective pellet. Methods of forming a ceramic-polymer composite comprise: superheating a mixture of polymer, solvent, and ceramic, to dissolve the polymer in the solvent; agitating the superheated mixture while substantially maintaining the mixture at an elevated temperature and pressure; and cooling the mixture to cause the polymer to precipitate on the particles of the ceramic and thereby form a plurality of the present polymer-ceramic core-shell particles. Methods of molding a part comprise subjecting a powder of the present polymer-ceramic core-shell particles that substantially fills a mold to a first pressure while the powder is at or above a first temperature above a melting temperature (T m ) of the polymer.
    • 2. 发明公开
    • SEMI-CRYSTALLINE POLYMER-CERAMIC CORE-SHELL PARTICLE POWDERS, AND PROCESSES FOR MAKING AND ARTICLES COMPRISING SUCH POWDERS
    • EP3797862A1
    • 2021-03-31
    • EP20157482.9
    • 2020-02-14
    • SHPP Global Technologies B.V.
    • KALYANARAMAN, ViswanathanBAJAJ, Devendra NarayandasEVANS, Thomas Lane
    • B01J13/04
    • Semi-crystalline polymer-ceramic composites and methods. The ceramic-polymer composites, in powder and/or pellet forms, comprise a plurality of core-shell particles, where: each of the core-shell particles comprises a core and a shell around the core; the core comprises a ceramic that is selected from the group of ceramics consisting of: Al 2 O 3 , ZrO 2 , and combinations of Al 2 O 3 and ZrO 2 ; and the shell comprises a semi-crystalline polymer selected from the group of semi-crystalline polymers consisting of: polyphenylene sulfide (PPS), polyaryl ether ketone (PAEK), polybutylene terephthalate (PBT), polypropylene (PP), polyethylene (PE), semi-crystalline polyimide (SC PI), and semi-crystalline polyamide (SC Polyamide). The core-shell particles can be in a powder form (e.g., a dry powder). In pellet form, shells of adjacent core-shell particles are joined to resist separation of the adjacent core-shell particles and deformation of a respective pellet. Methods of forming a ceramic-polymer composite comprise: superheating a mixture of the semi-crystalline polymer (PPS, PAEK, PBT, PP, PE, SC PI, and SC Polyamide), solvent, and the ceramic (Al 2 O 3 and/or ZrO 2 ), to dissolve the semi-crystalline polymer in the solvent; agitating the superheated mixture while substantially maintaining the mixture at an elevated temperature and pressure; and cooling the mixture to cause the semi-crystalline polymer to precipitate on the particles of the ceramic and thereby form a plurality of the present semi-crystalline polymer-ceramic core-shell particles. Methods of molding a part comprise subjecting a powder of the present semi-crystalline polymer-ceramic core-shell particles that substantially fills a mold to a first pressure while the powder is at or above a first temperature above a melting temperature (T m ) of the semi-crystalline polymers.
    • 3. 发明公开
    • POLYMER-CERAMIC COMPOSITE HOUSINGS AND HOUSING COMPONENTS FOR PORTABLE ELECTRONIC DEVICES
    • EP3805300A1
    • 2021-04-14
    • EP20157480.3
    • 2020-02-14
    • SHPP Global Technologies B.V.
    • BAJAJ, Devendra NarayandasLEENDERS, Chiel AlbertusHOOGLAND, Gabriel Julianus MariaKALYANARAMAN, ViswanathanYOUNGSTROM, Cameron
    • C08K3/22C08K3/36B29B9/12G06F1/16G06F15/02H04M1/02B29B7/00B29B7/10B29B7/90
    • Housing parts for a portable electronic devices, and methods of molding such housing parts for portable electronic devices. Such housing parts comprise: a housing component comprising ceramic particles in a polymer matrix, the ceramic particles comprising from 50% to 90% by volume of the housing component, and the polymer matrix comprising from 10% to 50% by volume of the housing component; the ceramic particles have a Dv50 of from 50 nanometers to 100 micrometers; the ceramic particles are substantially free of agglomeration; the housing component has a relative density greater than 90%; and the housing component is configured to cover a portion of a portable electronic device. The present methods of molding such housing parts comprise: disposing polymer-ceramic core-shell particles in a working portion of a cavity in a mold, each of the core-shell particles comprising a ceramic core comprising a particle of a ceramic, and a polymer shell around the core, the shell comprising a polymer, where the ceramic cores comprise from 50% to 90% by volume of the powder, and the polymer shells comprising from 10% to 50% by volume of the powder; heating the mold to a first temperature that exceeds a melting temperature (Tm) of the first polymer; subjecting the powder in the mold to a first pressure while maintaining the temperature of the mold to or above the first temperature to define a housing component in which the ceramic particles are substantially free of agglomeration; cooling the housing component to a temperature below the Tg or Tm of the first polymer; and removing the housing component from the mold. In such housing parts and methods, the ceramic particles comprise Al 2 O 3 , Fe 3 O 4 , Fe 2 O 3 , ZnO, ZrO 2 , SiO 2 , and/or a combination of any two or more of these ceramics; and the polymer comprises PPE, PPS, PC copolymers, PEI, PEI copolymers, PPSU, PAES, PES, PAEK, PBT, PP, PE, semi-crystalline PI, or semi-crystalline polyamide.