Method for Producing a Population of Particles of Polyvinylidene Difluoride or of Particles of a Copolymer Comprising Polyvinylidene Difluoride

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This patent describes a method for producing highly uniform, nearly spherical particles of polyvinylidene difluoride (PVDF) or its copolymers. The process involves dissolving PVDF in a specific organic solvent at elevated temperatures and then carefully cooling the solution to induce the formation of polymer particles. These particles are then separated from the solution. The resulting powder has a very narrow particle size distribution, making it ideal for powder-based manufacturing techniques.

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• Manufacturing of high-performance powders for selective laser sintering (SLS) and selective laser melting (SLM) in additive manufacturing (3D printing) processes.
• Production of PVDF-based powders for use in powder bed fusion or laser beam melting of polymers.
• Preparation of specialty coatings or films where spherical, narrowly distributed polymer particles are required.
• Formulation of advanced battery separator or membrane materials using PVDF particles with controlled morphology.
• Development of composites, paints, or adhesives where uniform particle size and shape improve material properties.

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• Creates highly uniform and spherical polymer particles, improving powder flowability and packing density over traditional grinding methods.
• Eliminates the need for additional particle size selection (like sieving), simplifying the manufacturing process.
• Enables precise control over particle size distribution and sphericity, which is crucial for additive manufacturing and other advanced applications.
• Produced particles yield improved performance in powder-based processing (e.g., smoother surfaces, higher resolution, and structural integrity in 3D printed parts).
• Process allows for incorporation of various additives, pigments, or functional agents for customizing end-use properties.

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Patent Abstract

The invention concerns a method for producing a population of particles of a polymer, wherein the polymer is polyvinylidene difluoride (= PVDF) or a copolymer comprising polyvinylidene difluoride, wherein the polymer is dissolved in an organic solvent which solvent is selected such that it completely solubilizes the polymer only at a temperature of the solvent above 25 °C, wherein the method comprises the following steps:a) heating the solvent and the solid polymer immersed in the solvent at least to a first temperature, at which first temperature the polymer completely dissolves,b) cooling the solution to a second temperature or temperature range, at which second temperature or temperature range polymer particles are formed, andc) separating the particles formed during step b) from the solution or from a gel formed from the solution during step b).