Electrophoretically active sol-gel processes to backfill, seal, and/or densify porous, flawed, and/or cracked coatings on electrically conductive material
First Claim
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1. A method to seal a porous coating on an electrically conductive substrate with sol-gel ceramic by electrophoretically active sol-gel processes, comprising:
- cleaning the coating on the electrically conductive substrate;
electrophoretically depositing, preferentially at locally high electric-field sites associated with pores, cracks, and flaws, a prescribed amount of ceramic-precursor compounds from sol-gel ceramics onto and into the coating, comprising immersing the coating and its substrate, electrically biased, spaced adjacent an oppositely biased electrode, in an electrophoretically active sol-gel solution; and
heating the coating and substrate to cause a chemical reaction to form a ceramic from the ceramic-precursor compounds to penetrate into and seal the coating, said ceramic being inseparably bound to the coating and the substrate.
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Abstract
Electrophoretically active sol-gel processes to fill, seal, and/or density porous, flawed, and/or cracked coatings on electrically conductive substrates. Such coatings may be dielectrics, ceramics, or semiconductors and, by the present invention, may have deposited onto and into them sol-gel ceramic precursor compounds which are subsequently converted to sol-gel ceramics to yield composite materials with various tailored properties.
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Citations
27 Claims
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1. A method to seal a porous coating on an electrically conductive substrate with sol-gel ceramic by electrophoretically active sol-gel processes, comprising:
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cleaning the coating on the electrically conductive substrate; electrophoretically depositing, preferentially at locally high electric-field sites associated with pores, cracks, and flaws, a prescribed amount of ceramic-precursor compounds from sol-gel ceramics onto and into the coating, comprising immersing the coating and its substrate, electrically biased, spaced adjacent an oppositely biased electrode, in an electrophoretically active sol-gel solution; and heating the coating and substrate to cause a chemical reaction to form a ceramic from the ceramic-precursor compounds to penetrate into and seal the coating, said ceramic being inseparably bound to the coating and the substrate. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, 20, 21, 22, 23, 24, 25, 26, 27)
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Specification