PROTECTIVE COATINGS FOR SUBSTRATES HAVING AN ACTIVE SURFACE

• US 20130065066A1
• Filed: 05/10/2011
• Published: 03/14/2013
• Est. Priority Date: 05/27/2010
• Status: Abandoned Application

• Current Assignee: Applied Thin Films, Inc.
• Original Assignee: Applied Thin Films, Inc.
• Inventors: Sambasivan, Sankar, Kaul, Vikram Sharad
• Application Number:
  US13/699,561
• Publication Number:
  US 20130065066A1
• Time in Patent Office: Days
• US Class Current: 428/432
• CPC Class Codes: C03C 1/008 for the production of films or coatings
• CPC Class Codes: C04B 35/00 Shaped ceramic products characterised by their composition porous ceramic products C04B38/00; ceramic articles characterised by particular shape, see the relevant classes, e.g. linings for casting ladles, tundishes, cups or the like B22D41/02; ceramic substrates for microelectronic semi-conductors H01L23/15; Ceramics compositions containing free metal bonded to carbides, diamond, oxides, borides, nitrides, silicides, e.g. cermets, or other metal compounds, e.g. oxynitrides or sulfides other than as macroscopic reinforcing agents C22C; shaping of ceramics B28B; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products chemical preparation of powders of inorganic compounds C01; infiltration of sintered ceramic preforms with molten metal C04B41/51
• CPC Class Codes: C04B 41/009 characterised by the material treated
• CPC Class Codes: C04B 41/4537 by the sol-gel process
• CPC Class Codes: C04B 41/508 Aluminous cements
• CPC Class Codes: C04B 41/5092 Phosphate cements
• CPC Class Codes: C04B 41/52 Multiple coating or impregnating multiple coating or impregnating with the same composition or with compositions only differing in the concentration of the constituents, is classified as single coating or impregnation
• CPC Class Codes: C04B 41/85 with inorganic materials
• CPC Class Codes: C09D 1/00 Coating compositions, e.g. paints, varnishes or lacquers, based on inorganic substances
• CPC Class Codes: C23C 18/1225 Deposition of multilayers of inorganic material
• CPC Class Codes: C23C 22/74 for obtaining burned-in conversion coatings
• CPC Class Codes: C23C 22/83 Chemical after-treatment
• CPC Class Codes: C23C 26/00 Coating not provided for in groups C23C2/00 - C23C24/00

Abstract

A coated substrate having a surface containing at least one active species such as an oxide to which is bonded at least one amorphous phospho-alumina layer containing an aluminum to phosphorus atomic ratio of about 0.2 to about 0.8 is bonded to at least one further amorphous phospho-alumina layer containing an aluminum to phosphorus atomic ratio of at least about 1.

Claims

1. :

A coated substrate having a surface containing at least one active species to which is bonded at least one amorphous phospho-alumina layer containing an aluminum to phosphorus atomic ratio of about 0.2 to about 0.8 which is bonded to at least one further amorphous phospho-alumina layer containing an aluminum to phosphorus atomic ratio of at least about 1.

2. :

A coated substrate of claim 1 in which the active species is an active oxide.

3. :

A coated substrate of claim 1 in which the substrate is a metal or a metal alloy.

4. :

A coated substrate of claim 1 which the substrate is a ceramic, a ceramic composite, a glass, a porcelain enamel, or a glass-ceramic.

5. :

A coated substrate of claim 1 in which an active oxide is formed by partially oxidizing the substrate surface.

6. :

A coated substrate of claim 1 in which the substrate is chemically milled to form a surface containing an active oxide.

7. :

A coated substrate of claim 2 in which the active oxide is selected from a Group 2-14 oxide that is thermodynamically less stable than aluminum oxide.

8. :

A coated substrate of claim 2 in which at least one active oxide is an oxide of zinc, copper, cobalt, iron, manganese, molybdenum, tungsten, vanadium, titanium, tin, niobium, nickel, tantalum, antimony, zirconium, yttrium, chromium, hafnium, magnesium, calcium, strontium, or combinations thereof.

9. :

A coated substrate of claim 8 in which the active oxide surface has oxides of molybdenum, manganese, or combinations thereof.

10. :

A coated substrate of claim 8 in which the substrate surface contains an active oxide of titanium, aluminum, molybdenum, tin, and zirconium.

17. :

A coated substrate of claim 1 in which the substrate is a titanium-aluminum-molybdenum-tin-zirconium alloy substrate or a titanium-aluminum-vanadium alloy having a surface containing at least one active oxide to which is bonded at least one amorphous phospho-alumina layer containing an aluminum to phosphorus atomic ratio of about 0.2 to about 0.8.

18. :

A coated substrate of claim 1 in which the surface containing at least one active species to which is bonded at least one primary amorphous phospho-alumina layer containing an aluminum to phosphorus atomic ratio of about 0.3 to about 0.6.

11. :

A method to produce a protective coating on a substrate surface containing at least one active species comprising applying an alcoholic solution of a phosphate oxide or ester and an aluminum salt in which the Al/P atomic ratio is 0.2 to 0.8 to a substrate having an active species surface, drying and curing the applied solution to form a primary layer and further applying to the primary layer an alcoholic solution of a phosphorus oxide or ester and an aluminum salt in which the Al/P atomic ratio is at least 1 and drying and curing the applied solution to form a secondary layer.

12. :

A method of claim 11 in which in which each layer is cured at a temperature of at least 400°

C.

13. :

A method of claim 11 in which more than one primary or secondary layer is applied.

19. :

A method of claim 11 in which in which the primary layer has an Al/P atomic ratio of about 0.3 to 0.6.

14. :

A shaped article having a surface containing at least one active oxide to which is bonded at least one amorphous phospho-alumina layer containing an aluminum to phosphorus atomic ratio of about 0.2 to about 0.8 which is bonded to at least one further amorphous phospho-alumina layer containing an aluminum to phosphorus atomic ratio of at least about 1.

15. :

An article of claim 14 formed from an iron-chromium-aluminum alloy.

16. :

An article of claim 14 formed from a titanium alloy.

20. :

An article of claim 16 formed from a titanium-aluminum-molybdenum-tin-zirconium alloy.