Dense coating formation by reactive deposition
First Claim
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1. A method for coating a substrate, the method comprising:
- reacting a flowing reactant stream by directing a radiation beam at the reactant stream to produce a product stream downstream from the radiation beam, wherein the reaction is driven by photon energy from the radiation beam; and
directing the product stream at a substrate selectively positioned in the flow to coat the substrate with a coating material from the product stream at a density of at least about 65 percent of the density of the fully densified coating material.
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Abstract
Methods for forming coated substrates can be based on depositing material from a flow onto a substrate in which the coating material is formed by a reaction within the flow. In some embodiments, the product materials are formed in a reaction driven by photon energy absorbed from a radiation beam. In additional or alternative embodiments, the flow with the product stream is directed at the substrate. The substrate may be moved relative to the flow. Coating materials can be formed with densities of 65 percent to 95 percent of the fully densified coating material with a very high level of coating uniformity.
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Citations
23 Claims
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1. A method for coating a substrate, the method comprising:
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reacting a flowing reactant stream by directing a radiation beam at the reactant stream to produce a product stream downstream from the radiation beam, wherein the reaction is driven by photon energy from the radiation beam; and
directing the product stream at a substrate selectively positioned in the flow to coat the substrate with a coating material from the product stream at a density of at least about 65 percent of the density of the fully densified coating material. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17)
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18. A method for coating a substrate, the method comprising:
depositing a non-porous coating by directing flow of a product stream to a suitably positioned substrate to deposit the coating on the substrate, wherein the product stream is formed by reacting a reactant stream within the flow to form the product stream, the reaction being driven with photon energy absorbed from a radiation beam.
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19. A method for coating a substrate, the method comprising:
depositing a coating material to form a coating having a density of at least about 65 percent of the density of the fully densified coating material, wherein the coating is deposited from a product composition in a reactor, wherein product composition is within a product stream is formed by reacting a reactant stream in which the reaction is driven with photon energy absorbed from a radiation beam, and wherein the depositing of the coating comprises moving the product stream relative to the substrate. - View Dependent Claims (20, 21, 22, 23)
Specification