Transition metal oxide coated substrates

• US 5,756,207 A
• Filed: 06/06/1995
• Issued: 05/26/1998
• Est. Priority Date: 03/24/1986
• Status: Expired due to Fees

• Current Assignee: Ensci, Inc.
• Original Assignee: Ensci, Inc.
• Inventors: Clough, Thomas J., Pinsky, Naum, Grosvenor, Victor L.
• Primary Examiner(s): LE, HOA T
• Application Number:
  US08/470,259
• Time in Patent Office: 1,085 Days
• Field of Search: 428/357, 428/375, 428/379, 428/388, 428/389, 428/402, 428/403, 428/701, 428/702
• US Class Current: 428/375
• CPC Class Codes: C04B 14/4631 Silica
• CPC Class Codes: C04B 2235/5224 Alumina or aluminates
• CPC Class Codes: C04B 2235/5232 Silica or silicates other than aluminosilicates, e.g. quartz
• CPC Class Codes: C04B 2235/5252 having a specific pre-form
• CPC Class Codes: C04B 30/02 containing fibrous materials
• CPC Class Codes: C04B 35/56 based on carbides or oxycarbides containing free metal binder C22C29/00
• CPC Class Codes: C04B 35/62847 with oxide ceramics
• CPC Class Codes: C04B 35/62892 with a coating layer consisting of particles
• CPC Class Codes: C04B 35/62897 Coatings characterised by their thickness
• CPC Class Codes: C04B 41/009 characterised by the material treated
• CPC Class Codes: C04B 41/4523 applied from the molten state vitreous materials C04B41/5022; Thermal spraying, e.g. plasma spraying
• CPC Class Codes: C04B 41/4545 applied as a powdery material
• CPC Class Codes: C04B 41/455 the coating or impregnating process including a chemical conversion or reaction
• CPC Class Codes: C04B 41/5036 Ferrites
• CPC Class Codes: C04B 41/87 Ceramics
• CPC Class Codes: Y10T 428/2933 Coated or with bond, impregnation or core
• CPC Class Codes: Y10T 428/294 including metal or compound thereof [excluding glass, ceramic and asbestos]
• CPC Class Codes: Y10T 428/2956 Glass or silicic fiber or filament with metal coating
• CPC Class Codes: Y10T 428/2958 Metal or metal compound in coating
• CPC Class Codes: Y10T 428/2991 Coated

Abstract

Processes for coating substrates, in particular substrates including shielded surfaces, with transition metal oxide-containing coatings are disclosed. Such processes comprise contacting a substrate with a transition metal oxide precursor, preferably maintaining the precursor coated substrate at conditions to equilibrate the coating, and then oxidizing the precursor to form a substrate containing transition metal oxide. Also disclosed are substrates coated with transition metal oxide-containing coatings for use in various applications.

Claims

1. An article comprising a three-dimensional inorganic particulate substrate and at least one of an electrically conductive or magnetic interacting component containing transition metal oxide containing coating on at least a portion of all three dimensions of said substrate, said substrate including external surfaces and shielded surfaces which are at least partially shielded by other portions of said substrate and having at least one of the electronically conductive or magnetic transition metal oxide containing coating on at least a portion of said external surfaces and said shielded surfaces, provided that said substrate has substantially nonelectronically conductive and nonmagnetic properties derived from a transition metal oxide contained in said substrate which is the same as the transition metal oxide of the coating;

said coating being formed from the oxidation of a liquidus transition metal oxide precursor on said substrate, said coated substrate being adapted for use, alone or in combination with one or more articles or elements selected from the group consisting of an inorganic matrix element, an organic matrix element, a porous polymer matrix element, a porous inorganic matrix element, a fluid matrix element, a structural element, a catalyst component element, a porous membrane element, an electrostatic dissipation element, an electromagnetic interference shielding element, a heating element and a mechanical electrical element.

2. The article of claim 1 wherein the article is adapted for use as an electrostatic-dissipation/electromagnetic interference shielding element.

3. The article of claim 2 wherein a matrix material is in contact with said coated substrate.

4. The article of claim 3 wherein said matrix material is an organic polymer material.

5. The article of claim 4 wherein said coated substrate is in a form selected from the group consisting of spheres, flakes, irregularly shaped particles, fibers, and porous substrates.

6. The article of claim 1 wherein the article is adapted for use as a heating element.

7. The article of claim 6 wherein said coated substrate is in a form selected from the group consisting of spheres, extrudes, flakes, single fibers, chopped fibers, porous substrates, irregular shaped particles and multi-channel monoliths.

8. The article of claim 7 wherein said coated substrate is in the form of a multi-channel monolith.

9. The article of claim 1 wherein the article is adapted for use as a catalyst element.

10. The article of claim 9 wherein the substrate is selected from the group consisting of a porous substrate and a monolith.

11. The article of claim 10 wherein said catalyst element includes at least one catalyst metal selected from the group consisting of gold, silver, copper, vanadium, chromium, tungsten, zinc, indium, antimony, the platinum group metals, iron, nickel, manganese, cesium and titanium.

12. An article comprising at least one of an electrically conductive or magnetic transition metal oxide coated inorganic three dimensional substrate produced by a process comprising:

contacting said inorganic three dimensional substrate which includes external surfaces and shielded surfaces which are at least partially shielded by other portions of said substrate with a composition comprising a transition metal oxide forming compound having a melting point of from about 100°

C. to about 650°

C. at conditions effective to form a transition metal oxide forming compound containing coating on at least a portion of said three dimensional substrate, including at least a portion of the shielded surfaces of said substrate;

forming a liquidus coating from said transition metal oxide forming compound on at least a portion of the three dimensions of said substrate including the shielded surfaces of said substrate under substantially nondeleterious conditions effective to do at least one of the following;

(1) coat a larger portion of said substrate with the said transition metal oxide forming compound coating;

(2) distribute said transition metal oxide forming compound coating over said substrate; and

(3) make the transition metal oxide forming compound coating more uniform in thickness, contacting said substrate having liquidus transition metal oxide forming compound containing coating thereon with an oxidizing agent at conditions effective to convert the transition metal oxide forming compound to a transition metal oxide and form a transition metal oxide on at least a portion of said three dimensions of said coated substrate including the shield surfaces and recovering at least one of an electrically conductive or magnetic transition metal oxide coated three dimensional substrate, provided that said substrate has substantially nonelectronically conductive and nonmagnetic properties derived from a transition metal oxide contained in said substrate which is the same as the transition metal oxide of the coating.

13. The article of claim 12 wherein the transition metal of said transition metal oxide is selected from the group consisting of chromium, tungsten, indium, molybdenum, titanium and mixtures thereof.

14. The article of claim 12 wherein said transition metal oxide forming compound is selected from the group consisting of a transition metal chloride, a transition metal organic salt, a transition metal organic complex and mixtures thereof.

15. The article of claim 14 wherein said transition metal oxide forming compound is a transition metal chloride.

16. The article of claim 15 wherein said substrate is an inorganic oxide and in a form selected from the group consisting of spheres, extrudates, flakes, fibers, porous substrates, irregularly shaped particles and multi-channel monoliths.

17. The article of claim 12 wherein said substrate is contacted with an additional coating property modifying interacting component in any one or more of said process steps and forming a coated substrate having one or more interacting components on at least a portion of said substrate including at least a portion of the shielded surfaces of said substrate.

18. The article of claim 17 wherein said substrate is an inorganic oxide and in a form selected from the group consisting of spheres, extrudates, flakes, fibers, fiber rovings, chopped fibers, fiber mats, porous substrates, irregularly shaped particles and multi-channel monoliths.

19. The article of claim 12 wherein the substrate is an inorganic oxide and the thickness of the coating is in the range of from about 0.1 micron to about 10 microns.

20. The article of claim 19 wherein said substrate is in a form selected from the group consisting of spheres, extrudates, flakes, fibers, fiber rovings, chopped fibers, fiber mats, porous substrates, irregularly shaped particles and multi-channel monoliths.

21. The article of claim 12 wherein said substrate is in a form selected from the group consisting of spheres, extrudates, flakes, fibers, fiber rovings, chopped fibers, fiber mats, porous substrates, irregularly shaped particles and multi-channel monoliths.

22. An article comprising at least one of an electrically conductive or magnetic transition metal oxide coated inorganic three dimensional substrate produced by a process comprising;

contacting said inorganic three dimensional substrate which includes external surfaces and shielded surfaces which are at least partially shielded by other portions of said substrates, with a composition comprising a transition metal oxide precursor powder at conditions effective to form a coating containing transition metal oxide precursor on at least a portion of the substrate;

forming a liquidus coating from said transition metal oxide precursor on at least a portion of the three dimensions of said substrate including the shielded surfaces of said substrate and at conditions effective to do at least one of the following;

(1) coat a larger portion of said substrate with said coating;

(2) distribute said coating over said substrate; and

(3) make said coating more uniform in thickness and contacting said liquidus coated substrate with an oxidizing agent at conditions effective to convert the coating to a transition metal oxide and form a transition metal oxide coating on at least a portion of said three dimensions of said substrate including shielded surfaces and recovering at least one of an electrically conductive or magnetic transition metal oxide coated three dimensional substrate, provided that said substrate has substantially nonelectronically conductive and nonmagnetic properties derived from a transition metal oxide contained in said substrate which is the same as the transition metal oxide of the coating.

23. The article of claim 22 wherein the transition metal of said transition metal oxide is selected from the group consisting of chromium, tungsten, indium, molybdenum, titanium and mixtures thereof.

24. The article of claim 22 wherein said transition metal oxide precursor powder is selected from the group consisting of a transition metal chloride, a transition metal organic salt, a transition metal organic complex and mixtures thereof.

25. The article of claim 22 wherein said transition metal oxide precursor powder is a transition metal chloride.

26. The process of claim 22 wherein said substrate is contacted with an additional coating property modifying interacting component in any one or more of said process steps and forming a coated substrate having one or more interacting components on at least a portion of said substrate including at least a portion of the shielded surfaces of said substrate.

27. The article of claim 26 wherein said substrate is an inorganic and in a form selected from the group consisting of spheres, extrudates, flakes, fibers, fiber rovings, chopped fibers, fiber mats, porous substrates, irregularly shaped particles and multi-channel monoliths.

28. The article of claim 26 wherein any one or more of said contacting steps and forming steps are conducted under at least one or both of said precursor powder and said substrate being fluidized.

29. The article of claim 26 wherein the substrate is an inorganic oxide and in a form selected from the group consisting of spheres, extrudates, flakes, fibers, porous substrates, and irregularly shaped particles and the transition metal oxide forming compound is a transition metal chloride.

30. The article of claim 26 wherein said substrate is in a form selected from the group consisting of spheres, extrudates, flakes, fibers, fiber rovings, chopped fibers, fiber mats, porous substrates, irregularly shaped particles and multi-channel monoliths.

31. The article of claim 22 wherein any one or more of said contacting steps and forming steps are conducted under at least one or both of said precursor powder and said substrate being fluidized.