# US 11,910,494 B2 · High-temperature component and method for the production thereof

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- Number: US 11,910,494 B2
- Document ID: US11910494B2
- Status: Granted
- Kind: B2
- Application number: 16/648,927
- Filed: 2018-09-12
- Published: 2020-08-06
- Granted: 2024-02-20
- Earliest claimed: 2017-09-26
- Assignees: Schunk Kohlenstofftechnik GmbH
- Applicants: Schunk Kohlenstofftechnik GmbH
- Inventors: Gotthard Nauditt
- Web page: https://patentgrep.com/patent/US11910494B2

## CPC

- H05B 3/145: {Carbon only, e.g. carbon black, graphite}
- H05B 3/48: heating conductor embedded in insulating material
- B33Y 10/00: Processes of additive manufacturing
- B33Y 40/20: Post-treatment, e.g. curing, coating or polishing
- B33Y 80/00: Products made by additive manufacturing
- C04B 35/66: Monolithic refractories or refractory mortars, including those whether or not containing clay {(making or repairing of linings F27D1/16)}
- C04B 35/78: containing non-metallic materials
- C04B 41/009: {characterised by the material treated}
- C04B 41/4531: {by C.V.D.}
- C04B 41/5059: {Silicon carbide}
- C04B 41/87: Ceramics
- H05B 3/08: having electric connections specially adapted for high temperatures
- H05B 3/286: {the insulating material being an organic material, e.g. plastic}
- H05B 3/46: heating conductor mounted on insulating base
- B29C 64/118: using filamentary material being melted, e.g. fused deposition modelling [FDM]
- C04B 2235/3826: Silicon carbides
- C04B 2235/422: Carbon
- C04B 2235/48: Organic compounds becoming part of a ceramic after heat treatment, e.g. carbonising phenol resins
- C04B 2235/6026: Computer aided shaping, e.g. rapid prototyping
- C23C 16/325: {Silicon carbide}
- H05B 2203/002: Heaters using a particular layout for the resistive material or resistive elements
- H05B 2203/017: Manufacturing methods or apparatus for heaters
- H05B 2214/04: Heating means manufactured by using nanotechnology
- H05B: ELECTRIC HEATING; ELECTRIC LIGHT SOURCES NOT OTHERWISE PROVIDED FOR; CIRCUIT ARRANGEMENTS FOR ELECTRIC LIGHT SOURCES, IN GENERAL
- B33Y: ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
- C04B: LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE {(roofing granules E04D7/005)}; CERAMICS (devitrified glass-ceramics C03C10/00); REFRACTORIES; TREATMENT OF NATURAL STONE
- B29C: SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING (making preforms B29B11/00; making laminated products by combining previously unconnected layers which become one product whose layers will remain together B32B37/00 - B32B41/00)
- C23C: COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL (making metal-coated products by extrusion B21C23/22; covering with metal by connecting pre-existing layers to articles, see the relevant places, e.g. B21D39/00, B23K; metallising of glass C03C; metallising mortars, concrete, artificial stone, ceramics or natural stone C04B41/00; enamelling of, or applying a vitreous layer to, metals C23D; treating metal surfaces or coating of metals by electrolysis or electrophoresis C25D; single-crystal film growth C30B; by metallising textiles D06M11/83; decorating textiles by locally metallising D06Q1/04)

## Abstract

A method for producing a high-temperature includes forming a dimensionally stable green body of the high-temperature component from a matrix material and pyrolizing the matrix material. A material mixture of the matrix material with a carbon material is used to form the high-temperature component, and a thermoplastic is used as the matrix material. The green body is formed by additive manufacturing.

## Claims

### Claim 1

A method for producing a high-temperature component comprising the following steps:
forming a dimensionally stable green body from a matrix material comprising a material mixture of thermoplastic mixed with a carbon material using additive manufacturing; and
pyrolizing the green body to form a high-temperature component, wherein the high-temperature component is a resistance heating element, wherein the resistance heating element comprises a heating conductor formed from the material mixture, and wherein the matrix material further comprises another material mixture, and the step of forming a dimensionally stable green body further comprises the step of forming an electrically non-conductive conductor support accommodating the heating conductor from the other material mixture.

### Claim 2 (depends on 1)

The method according to claim 1, wherein the other material mixture of the matrix material comprises a silicon material.

### Claim 3 (depends on 2)

The method according to claim 2, wherein the step of forming a dimensionally stable green body comprises forming the green body with the material mixture embedded in the other material mixture.

### Claim 4 (depends on 2)

The method according to claim 2, wherein the other material mixture comprises a stoichiometric mixture of matrix material and silicon material, and the step of pyrolyzing the other material mixture forms silicon carbide from the other material mixture.

### Claim 5 (depends on 2)

The method according to claim 2, wherein the step of pyrolyzing the green body converts the material mixture forming the heating conductor into carbon and the other material mixture forming the conductor support into silicon carbide.

### Claim 6 (depends on 2)

The method according to claim 2, wherein silicon fibers or silicon particles are used as the silicon material.

### Claim 7 (depends on 6)

The method according to claim 6, wherein the fibers are discharged from a nozzle together with the matrix material and are spatially arranged.

### Claim 8 (depends on 6)

The method according to claim 6, wherein the high-temperature component is realized with a fiber content of 10 vol % to 60 vol %.

### Claim 9 (depends on 1)

The method according to claim 1, wherein carbon fibers, carbon black, graphite, graphene and/or carbon nanotubes are used as the carbon material.

### Claim 10 (depends on 1)

The method according to claim 1, wherein the green body is formed by fused deposition modeling (FDM).

### Claim 11 (depends on 1)

The method according to claim 1, wherein polyetherimide (PEI), polyether ether ketone (PEEK), polysulfone (PSU) or polyphenylene sulfone (PPSU) is used as the matrix material.

### Claim 12 (depends on 1)

The method according to claim 1, wherein, after the step of pyrolyzing the green body, the high-temperature component is CVD-coated with silicon carbide after pyrolysis.

### Claim 13 (depends on 1)

The method according to claim 1, further comprising the step of applying a high-temperature heat treatment after the step of pyrolyzing the green body.