Water dispersible polymer for use in additive manufacturing

Abstract

A water dispersible sulfo-polyamide is configured as a filament for use as an extrudable support material in the additive manufacture of a part comprising a non water dispersible polymer. The water dispersible sulfo-polyamide is a reaction product of a sulfo monomer, the water dispersible sulfo-polymer being dispersible in water resulting in separation of the water dispersible polymer from the part comprising the non water dispersible polymer.

1 . A water dispersible sulfo-polyamide configured as a filament for use as an extrudable support material in the additive manufacture of a part comprising a non water dispersible polymer, wherein the water dispersible sulfo-polyamide is a reaction product of a sulfo monomer, the water dispersible sulfo-polymer being dispersible in water resulting in separation of the water dispersible polymer from the part comprising the non water dispersible polymer. 
     
     
         2 . The water dispersible sulfo-polymer of  claim 1 , wherein the water dispersible sulfo-polymer has a heat deflection temperature within ±20° C. of the heat deflection temperature of the non water dispersible polymer. 
     
     
         3 . The water dispersible sulfo-polymer of  claim 1 , wherein the water dispersible polymer has a glass transition temperature within ±20° C. of the glass transition temperature of the non water dispersible polymer. 
     
     
         4 . The water dispersible polymer of  claim 1 , and further comprising the reaction product of a condensation reaction. 
     
     
         5 . The water dispersible polymer of  claim 1 , and further comprising approximately 18 to 40% metal sulfoisophthalic monomer. 
     
     
         6 . The water dispersible polymer of  claim 6 , and further comprising approximately 20 to 30% metal sulfoisophthalic monomer. 
     
     
         7 . The water dispersible polymer of  claim 1 , wherein the metal sulfo monomer is a sodio sulfo monomer or a lithium sulfo monomer. 
     
     
         8 . The water dispersible polymer of  claim 3 , wherein the water dispersible polymer is characterized by a glass transition temperature of at least approximately 40° C. 
     
     
         9 . The water dispersible polymer of  claim 1 , wherein the water dispersible polymer is substantially amorphous. 
     
     
         10 . The water dispersible polymer of  claim 1 , wherein the water dispersible polymer is at least semi-crystalline. 
     
     
         11 . The water dispersible polymer of claim,  1  wherein the water dispersible polymer has a charge density of at least about 0.4 meq./g, suitable to exhibit water solubility or water dispersibility without the aid of any other solubility or dispersibility adjuvant. 
     
     
         12 . The water dispersible polymer of  claim 1 , wherein a sulfonated aromatic diacid or diol monomer is used in the synthesis thereof. 
     
     
         13 . The water dispersible polymer of  claim 1 , and further comprising a diacid in a range of about 15 mol % to about 50 mol % on a diamine basis. 
     
     
         14 . The water dispersible polymer of  claim 1 , and further comprising lactam ranging up to about 25 mol % of the total molar basis. 
     
     
         15 . A method of additive manufacturing a support structure for use with a part made of a non water dispersible polymer, the method comprising:
 the support structure comprising a water dispersible sulfo-polyamide comprising a reaction product of a metal sulfur monomer and the water dispersible polymer comprising a polyamide having a glass transition temperature within ±20° C. of the glass transition temperature of the non water dispersible polymer; and   separating the non water dispersible polymer from the water dispersible polymer by subjecting the water dispersible polymer to water.   
     
     
         16 . The method of  claim 15  and wherein the method further comprises the reaction product of the metal sulfur monomer and the water dispersible polymer comprises the polymer having a heat deflection temperature within ±20° C. of the heat deflection temperature of the non water dispersible polymer. 
     
     
         17 . The method of  claim 15 , wherein the water dispersible sulfo-polyamide has a charge density of at least approximately 0.4 meq./g, such that the water dispersible sulfo-polyamide is dispersible in water resulting in separation of the water dispersible polymer from the part comprising the non water dispersible polymer. 
     
     
         18 . The method of  claim 17  wherein the charge density is between approximately 0.4 meq/g and 0.9 meq./g. 
     
     
         19 . The method of  claim 15 , wherein the water dispersible sulfo-polyamide comprises a sulfoisophthalic monomer. 
     
     
         20 . The method of  claim 19 , wherein the water dispersible sulfo-polyamide comprises approximately 18 to 35 mol % sulfoisophthalic monomer on a diacid basis. 
     
     
         21 - 35 . (canceled)