THERMAL SPRAY METHOD FOR THE FORMATION OF NANOSTRUCTURED COATINGS

• US 20010004473A1
• Filed: 06/04/1999
• Published: 06/21/2001
• Est. Priority Date: 11/13/1995
• Status: Active Grant

• Current Assignee: Bernard H. Kear, Peter R. Strutt, Ross F. Boland
• Original Assignee: Bernard H. Kear, Peter R. Strutt, Ross F. Boland
• Inventors: KEAR, BERNARD H., STRUTT, PETER R., BOLAND, ROSS F.
• Granted Patent: US 6,277,448 B2
• Time in Patent Office: Days
• US Class Current: 427/446
• CPC Class Codes: B01J 13/02 Making microcapsules or microballoons for medical preparations A61K9/50
• CPC Class Codes: C01B 21/0687 After-treatment, e.g. grinding, purification
• CPC Class Codes: C01B 25/32 Phosphates of magnesium, calcium, strontium, or barium
• CPC Class Codes: C01G 25/02 Oxides
• CPC Class Codes: C01G 45/02 Oxides; Hydroxides
• CPC Class Codes: C01P 2002/02 Amorphous compounds
• CPC Class Codes: C01P 2004/03 obtained by SEM
• CPC Class Codes: C01P 2004/10 extending in one dimension, e.g. needle-like
• CPC Class Codes: C01P 2004/32 Spheres
• CPC Class Codes: C01P 2004/50 Agglomerated particles
• CPC Class Codes: C01P 2004/61 Micrometer sized, i.e. from 1-100 micrometer
• CPC Class Codes: C01P 2004/80 Particles consisting of a mixture of two or more inorganic phases
• CPC Class Codes: C04B 35/62222 obtaining ceramic coatings coating of mortars, concrete, artificial or natural stone or ceramics C04B41/45; laminated ceramic products B32B18/00; coating metallic materials C23; coating of glass C03C17/00, applying ceramic coatings on silicon for semi-conductor purposes H01L
• CPC Class Codes: C23C 4/04 characterised by the coating material
• CPC Class Codes: C23C 4/06 Metallic material
• CPC Class Codes: C23C 4/10 Oxides, borides, carbides, nitrides or silicides; Mixtures thereof
• CPC Class Codes: C23C 4/11 Oxides
• CPC Class Codes: C23C 4/123 Spraying molten metal
• CPC Class Codes: Y10S 977/892 Liquid phase deposition

Abstract

This invention relates to methods whereby nanoparticle precursor solutions are used in conventional thermal spray deposition for the fabrication of high-quality nanostructured coatings. The method allows combining nanoparticle synthesis, melting, and quenching into a single operation.

Claims

1. A method of forming a nanostructured coating comprising

(a) delivering a solution of a liquid precursor to a thermal spray device;

(b) forming nanaostructured particles from the liquid precursor solution within the thermal spray device; and

(c) delivering the formed nanostructured particles from the thermal spray device to a substrate, thereby forming a nanostructured coating on the substrate.

2. The method of

claim 2

, wherein the solution of liquid precursor is a metalorganic feedstock solution.

3. The method of

claim 2

, wherein the metalorganic feedstock is hexamethyldisilazane.

4. The method of

claim 2

, wherein the coating is SiC_xN_y.

5. A method of forming a nanostructured coating comprising

(a) atomizing a precurosr solution;

(b) delivering the atomized solution to a plasma flame of a thermal spray device, thereby forming nanostructured particles; and

(c) delivering the formed nanostructured particles from the thermal spray device to a substrate, thereby forming a nanostructured coating on the substrate.

6. The method of

claim 5

, wherein the solution of liquid precursor is a metalorganic feedstock solution.

7. The method of

claim 6

, wherein the metalorganic feedstock is hexamethyldisilazane.

8. The method of

claim 6

, wherein the coating is SiC_xN_y.

9. A method of forming a nanostructured coating comprising

(a) atomizing a solution of a liquid precursor;

(b) delivering the atomized solution to a plasma flame in a thermal spray device;

(c) forming nanostructured particles from the liquid precursor solution within the plasma flame; and

(d) delivering the formed nanostructured particles from the thermal spray device to a substrate, thereby forming a nanostructured coating on the substrate.

10. The method of

claim 9

, wherein the solution of liquid precursor is a metalorganic feedstock solution.

11. The method of

claim 10

, wherein the metalorganic feedstock is hexamethyldisilazane.

12. The method of

claim 9

, wherein the formed coating is SiC_xN_y.