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Abstract

Polymer-ceramic composite particles, molded parts, and methods. The composites, in powder form, comprise a plurality of composite particles each comprising an agglomeration of polybutylene terephthalate (PBT) particle physically bonded to a plurality of aluminum oxide (AI₂O₃) particles, where at least some of the AI₂O; particles are exposed to an exterior of the agglomeration of PBT particles. Such composite powders comprises between 50% and 90% by volume of AI₂O₃, and between 10% and 50% by volume of PBT. In pellet form, PBT particles of adjacent composite particles are joined to resist separation of the adjacent composite particles and deformation of a respective pellet. Methods of forming a ceramic-polymer composite comprise: heating a mixture of PBT particles, organic solvent, and AI₂O₃ particles to a first temperature that is between the glass transition temperature and the melting point of the PBT, while maintaining the mixture at a first pressure at which the solvent remains substantially liquid, to at least partially dissolve the PBT particles in the solvent; agitating the heated mixture for a period of minutes; and cooling the mixture to or below the glass transition temperature of the PBT to precipitate at least some of the PBT to form agglomerations of PBT particles and bond at least some of the AI₂O₃ particles to to PBT particles to thereby form a plurality of composite particles each comprising an agglomeration of PBT particles physically bonded to a plurality of AI₂O₃ particles, at least some of which being exposed to an exterior of the agglomeration.

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