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1. WO2000039358 - COLLOIDAL SPRAY METHOD FOR LOW COST THIN COATING DEPOSITION

Publication Number WO/2000/039358
Publication Date 06.07.2000
International Application No. PCT/US1999/029104
International Filing Date 08.12.1999
Chapter 2 Demand Filed 23.02.2000
IPC
C23C 4/12 2006.01
CCHEMISTRY; METALLURGY
23COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
CCOATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
4Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge
12characterised by the method of spraying
C23C 24/08 2006.01
CCHEMISTRY; METALLURGY
23COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
CCOATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
24Coating starting from inorganic powder
08by application of heat or pressure and heat
CPC
C23C 24/08
CCHEMISTRY; METALLURGY
23COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
CCOATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
24Coating starting from inorganic powder
08by application of heat or pressure and heat
C23C 4/123
CCHEMISTRY; METALLURGY
23COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
CCOATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
4Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge
12characterised by the method of spraying
123Spraying molten metal
Y10T 428/24942
YSECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
10TECHNICAL SUBJECTS COVERED BY FORMER USPC
TTECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
428Stock material or miscellaneous articles
24Structurally defined web or sheet [e.g., overall dimension, etc.]
24942including components having same physical characteristic in differing degree
Y10T 428/249961
YSECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
10TECHNICAL SUBJECTS COVERED BY FORMER USPC
TTECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
428Stock material or miscellaneous articles
249921Web or sheet containing structurally defined element or component
249953Composite having voids in a component [e.g., porous, cellular, etc.]
249961With gradual property change within a component
Y10T 428/249967
YSECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
10TECHNICAL SUBJECTS COVERED BY FORMER USPC
TTECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
428Stock material or miscellaneous articles
249921Web or sheet containing structurally defined element or component
249953Composite having voids in a component [e.g., porous, cellular, etc.]
249967Inorganic matrix in void-containing component
Y10T 428/24997
YSECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
10TECHNICAL SUBJECTS COVERED BY FORMER USPC
TTECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
428Stock material or miscellaneous articles
249921Web or sheet containing structurally defined element or component
249953Composite having voids in a component [e.g., porous, cellular, etc.]
249967Inorganic matrix in void-containing component
24997Of metal-containing material
Applicants
  • THE REGENTS OF THE UNIVERSITY OF CALIFORNIA [US/US]; 1111 Franklin Street Oakland, CA 94607-5200, US
Inventors
  • PHAM, Ai-Quoc; US
  • GLASS, Robert, S.; US
  • LEE, Tae, H.; US
Agents
  • THOMPSON, Alan, H.; P.O. Box 808, L-703 Livermore, CA 94551, US
Priority Data
09/293,44616.04.1999US
60/113,26823.12.1998US
Publication Language English (EN)
Filing Language English (EN)
Designated States
Title
(EN) COLLOIDAL SPRAY METHOD FOR LOW COST THIN COATING DEPOSITION
(FR) PROCEDE DE PULVERISATION COLLOIDALE POUR LE DEPOT DE COUCHES MINCES A BAS PRIX
Abstract
(EN)
A dense or porous coating of material is deposited onto a substrate by forcing a colloidal suspension through an ultrasonic nebulizer and spraying a fine mist of particles in a carrier medium onto a sufficiently heated substrate. The spraying rate is essentially matched to the evaporation rate of the carrier liquid from the substrate to produce a coating that is uniformly distributed over the surface of the substrate. Following deposition to a sufficient coating thickness, a single sintering step may be used to produce a dense ceramic coating. Using this method, coatings ranging in thickness from about one to several hundred microns can be obtained. By using a plurality of compounds in the colloidal suspension, coatings of mixed composition can be obtained. By using a plurality of solutions and separate pumps and a single or multiple ultrasonic nebulizer(s), and varying the individual pumping rates and/or the concentrations of the solutions, a coating of mixed and discontinuously graded (e.g., stepped) or continuously graded layers may be obtained. This method is particularly useful for depositing ceramic coatings. Dense ceramic coating materials on porous substrates are useful in providing improved electrode performance in devices such as high power density solid oxide fuel cells. Dense ceramic coatings obtained by the invention are also useful for gas turbine blade coatings, sensors, steam electrolyzers, etc. The invention has general use in preparation of systems requiring durable and chemically resistant coatings, or coatings having other specific chemical or physical properties.
(FR)
Selon ce procédé, un revêtement dense ou poreux d'un matériau est déposé sur un substrat en forçant une suspension colloïdale à passer à travers un nébuliseur ultrasonique et en vaporisant une fine brume de particules, dans un support, sur un substrat suffisamment chauffé. Le taux de vaporisation correspond sensiblement au taux d'évaporation du support liquide sur le substrat, et ce afin de produire un revêtement distribué sur la surface du substrat de manière homogène. Suite à un dépôt jusqu'à l'obtention d'une épaisseur du revêtement suffisante, on peut procéder à une étape de frittage unique pour produire un revêtement en céramique dense. Avec ce procédé, il est possible d'obtenir des revêtements d'une épaisseur allant d'environ un à plusieurs centaines de microns. Avec l'utilisation de plusieurs composés dans la suspension colloïdale, il est possible d'obtenir des revêtements de compositions différentes. En utilisant plusieurs solutions, des pompes séparées avec un ou plusieurs nébuliseurs et en faisant varier les taux de pompage individuels et/ou les concentrations des solutions, il est possible d'obtenir un revêtement constitués de couches mélangées et à gradient discontinu (à gradins) ou continu. Ce procédé convient particulièrement au dépôt de revêtements céramiques. Les matériaux de revêtement céramiques sur des substrats poreux permettent d'améliorer les performances des électrodes dans des dispositifs tels que des piles à combustible oxyde solide à haute densité de puissance. Les revêtements céramiques denses de l'invention conviennent également pour les aubes, les capteurs et les électrolyseurs à vapeurs de turbines à gaz. L'invention est utile, de manière générale, à la préparation de systèmes qui nécessitent des revêtements durables et résistants d'un point de vue chimique, ou des revêtements présentant d'autres propriétés chimiques ou physiques spécifiques.
Also published as
Latest bibliographic data on file with the International Bureau