Ceramic component

Patent metadata

Field	Value
Publication number	US-11878944-B2
Application number	US-201816650116-A
Country	US
Kind code	B2
Filing date	Sep 28, 2018
Priority date	Sep 28, 2017
Publication date	Jan 23, 2024
Grant date	Jan 23, 2024

Abstract

A ceramic component containing silicon carbide and to the use of the component. The method for producing the ceramic component includes the following steps: a) providing a green body based on SiC, which has been produced by means of a 3D-printing method, b) impregnating the green body with a solution selected from the group consisting of a sugar solution, a starch solution or a cellulose solution, or a resin system comprising a mixture containing at least one resin, at least one solvent and at least one curing agent, the at least one resin and the at least one solvent being different, c) drying or curing the impregnated green body, d) carbonising the dried or cured green body, wherein a fine-pored, foam-like carbon skeleton is produced from the dried solution or a fine-pored, sponge-like carbon skeleton is produced from the cured resin system.

First claim

The invention claimed is:

1. A ceramic component containing silicon carbide (SiC) obtainable by a method comprising the following steps:
a) providing a green body based on SiC, which has been produced by means of a 3D-printing method,
b) impregnating the green body with a solution selected from the group consisting of a sugar solution, a starch solution or a cellulose solution, or a resin system comprising a mixture containing at least one resin, at least one solvent and at least one curing agent, the at least one resin and the at least one solvent being different,
c) drying or curing the impregnated green body,
d) carbonising the dried or cured green body, wherein a fine-pored, foam-like carbon skeleton is produced from the dried solution or a fine-pored, sponge-like carbon skeleton is produced from the cured resin system, and
e) siliconising the carbonised green body by infiltrating with liquid silicon; wherein the obtained ceramic component contains 90 to 95 wt. % SiC, 2 to 9 wt. % free silicon and less than 1 wt. % free carbon, and the obtained ceramic component has a universal hardness of at least 8000 MPa.

2. The ceramic component according to claim 1 , wherein in order to produce the green body an SiC powder having a grain size (d50) between 50 and 500 μm is used.

3. The ceramic component according to claim 1 , wherein the at least one resin in step b) is a phenol resin, a furan resin, or any mixture of a phenol resin with a furan resin.

4. The ceramic component according to claim 1 , wherein the at least one solvent is selected from the group consisting of water, a monovalent or polyvalent alcohol, a mixture of at least two of monovalent or polyvalent alcohols, a mixture of water with at least one monovalent and/or polyvalent alcohol or naphthalene.

5. The ceramic component according to claim 1 , wherein the curing agent in step b) is an inorganic or organic acid.

6. The ceramic component according to claim 1 , wherein the at least one solvent is replaced by at least one propellant.

7. The ceramic component according to claim 6 , wherein the at least one resin is a two-component resin.

8. The ceramic component according to claim 1 , wherein the curing in step c) is performed at room temperature or under application of a temperature which is lower than the boiling point of the at least one solvent.

9. The ceramic component according to claim 1 , wherein the sponge-like carbon skeleton of the carbonised green body from step d) has a mean pore size of less than 50 μm.

10. The ceramic component according to claim 1 , wherein, after the carbonising according to step d), the steps of the impregnation according to step b), of the curing according to step c), and of the carbonisation according to step d) are repeated at least once in the stated order, before the siliconisation according to step e) is performed.

11. The ceramic component according to claim 1 , wherein the density of the component is greater than 2.85 g/cm 3 .

12. The ceramic component according to claim 1 , wherein the component has a heat conductivity of at least 80 W/(m·K).

13. The ceramic component according to claim 1 , wherein the open porosity of the component is at most 1.0%.

14. A device comprising the component according to claim 1 , wherein the device is selected from an impeller and separating or rotary vane in pumps and compressors, a pump housing, fittings in columns, static mixer elements, turbulators, an electrical heating element, an electrical contact, a classifier wheel, a heat exchanger or element for heat exchangers, heat sink in electronics, a cooling housing for light-emitting diodes and camera, highly rigid precise optical structures or measurement gauges, a sliding element in bearings or hinges comprising plan bearings and mechanical seals, a cam in transmissions, a gearwheel, a slide plate and a guide pipe of flexible shafts, a piston and piston sleeve, a lining element against wear and in corrosive applications, a friction element for clutches and brakes, a machining tool in the form of milling tools, drills, drill heads and indexable inserts, hot pressing tools and a device for ballistic protection.

15. The ceramic component according to claim 1 , wherein the obtained ceramic component has a 3-point flexural strength of 120 MPa to 180 MPa.

Assignees

• Sgl Carbon Se

Inventors

• Kienzle Andreas
• Rivola Dominik
• Oettinger Oswin
• Hell Blasius
• Modlmeir Philipp

Classifications

• C04B35/565 Primary

  based on silicon carbide · CPC title

• B28B1/001

  Rapid manufacturing of 3D objects by additive depositing, agglomerating or laminating of material (selective deposition modelling of metallic powder B22F10/00; rapid manufacturing of 3D objects in general and in particular of plastics B29C64/00) · CPC title

• B33Y70/00

  Materials specially adapted for additive manufacturing · CPC title

• B33Y80/00

  Products made by additive manufacturing · CPC title

• C04B2235/3821

  Boron carbides · CPC title