Conformal composite coatings and methods

Patent metadata

Field	Value
Publication number	US-2016244372-A1
Application number	US-201514629829-A
Country	US
Kind code	A1
Filing date	Feb 24, 2015
Priority date	Feb 24, 2015
Publication date	Aug 25, 2016
Grant date	—

Abstract

An embodiment of an article includes a substrate and a conformal coating. The conformal coating includes a first particulate layer between a first matrix layer and a second matrix layer. The first particulate layer includes a first plurality of ordered inorganic particles spaced and distributed substantially uniformly throughout the first particulate layer, and a ceramic matrix material disposed between individual ones of the first plurality of particles.

First claim

1 . An article comprising:
a substrate; and a conformal coating comprising:
a first matrix layer including primarily a ceramic matrix material;
a second matrix layer including primarily the ceramic matrix material; and
a first particulate layer disposed between the first and second matrix layers, the first particulate layer including a plurality of ordered inorganic particles spaced and distributed substantially uniformly throughout the first particulate layer, and the ceramic matrix material disposed between individual ones of the first plurality of particles.

2 . The article of claim 1 , wherein the substrate comprises a fiber formed from one of a group consisting of: oxide ceramic fibers, carbide ceramic fibers, nitride ceramic fibers, boride ceramic fibers, phosphide ceramic fibers, glass-ceramic fibers, oxycarbide fibers, oxynitride fibers, metal fibers, glass fibers, and carbon fibers.

3 . The article of claim 2 , wherein the fiber comprises silicon carbide (SiC).

4 . The article of claim 1 , wherein the first plurality of inorganic particles is selected from glass, carbides, oxides, nitrides, borides, phosphides, sulfides, and combinations thereof.

5 . The article of claim 1 , wherein the ceramic matrix material comprises silicon carbide (SiC).

6 . The article of claim 1 , further comprising:
a second particulate layer disposed adjacent to one of the first and second matrix layers, the second particulate layer including a second plurality of ordered inorganic particles spaced and distributed substantially uniformly throughout the second particulate layer, and the ceramic matrix material disposed between individual ones of the second plurality of particles; wherein less than 10% of the particles in the first particulate layer protrude into the second particulate layer.

7 . A composite article comprising:
a binder; and a first plurality of fibers distributed throughout the binder, the first plurality of fibers comprising:
a substrate; and
a coating comprising:
a plurality of particulate layers, each layer including a plurality of ordered inorganic particles spaced and distributed substantially uniformly throughout each layer, and a ceramic matrix material disposed between individual ones of the plurality of particles; and
a plurality of matrix layers including primarily the ceramic matrix material disposed between individual ones of the plurality of particulate layers.

8 . The article of claim 7 , wherein the substrate is selected from one or more of a group consisting of: oxide ceramic fibers, carbide ceramic fibers, nitride ceramic fibers, boride ceramic fibers, phosphide ceramic fibers, glass-ceramic fibers, oxycarbide fibers, oxynitride fibers, metal fibers, glass fibers, and carbon fibers.

9 . The article of claim 8 , wherein the substrate comprises silicon carbide (SiC).

10 . The article of claim 7 , wherein the plurality of ceramic particles comprises boron nitride (BN) and the ceramic matrix material comprises silicon carbide (SiC).

11 . The article of claim 7 , further comprising:
a second plurality of fibers intermingled with the first plurality of fibers, wherein the second plurality of fibers do not include the conformal coating.

12 . A method comprising:
applying a preceramic composition to a receiving surface; applying a plurality of inorganic particles to the receiving surface; and curing the combination of the preceramic composition and the ceramic particles to form at least a particulate layer and a matrix layer on the receiving surface.

13 . The method of claim 12 , further comprising:
prior to at least one of the applying steps, treating a surface of a substrate to form the receiving surface.

14 . The method of claim 13 , wherein the treating step comprises:
applying an electrostatic charge to the surface of the substrate.

15 . The method of claim 12 , further comprising:
iteratively performing the steps of claim 12 to form a plurality of alternating particulate layers and matrix layers arranged into a conformal layer-by-layer (LBL) coating, wherein:
each particulate layer includes a plurality of ordered inorganic particles spaced and distributed substantially uniformly throughout the particulate layer, and a ceramic matrix material disposed between individual ones of the plurality of particles; and
each matrix layer alternates with individual ones of the plurality of particulate layers, each matrix layer including primarily the ceramic matrix material.

16 . The method of claim 12 , wherein the preceramic composition comprises a compound adapted to dissociate into a plurality of electrostatically charged ceramic precursors in a first solution.

17 . The method of claim 16 , wherein the compound is a polymer which includes a plurality of functional groups adapted to dissociate from the polymer in the first solution.

18 . The method of claim 17 , wherein the preceramic composition is selected from one or more of a group consisting of: polycarbosilane, polysiloxane, polysilazane, polycarbosiloxane, polysilane and polycarbosilazane.

19 . The method of claim 17 , wherein the preceramic composition comprises a plurality of electrostatically charged ceramic particles in a second solution.

20 . The method of claim 19 , wherein the first solution and the second solution are a common solution containing both the electrostatically charged ceramic precursors and the electrostatically charged inorganic particles.

Assignees

• United Technologies Corp

Inventors

• Schmidt Wayde R
• Tulyani Sonia

Classifications

• B05D1/36

  Successively applying liquids or other fluent materials, e.g. without intermediate treatment · CPC title

• C04B35/571

  obtained from {Si-containing} polymer precursors {or organosilicon monomers} · CPC title

• C04B35/62868

  Boron nitride · CPC title

• C04B35/62863 Primary

  Silicon carbide · CPC title

• C04B35/583

  based on boron nitride · CPC title