Method for forming an oxide coated substrate

Patent metadata

Field	Value
Publication number	US-9555406-B2
Application number	US-201414759610-A
Country	US
Kind code	B2
Filing date	Jan 3, 2014
Priority date	Jan 7, 2013
Publication date	Jan 31, 2017
Grant date	Jan 31, 2017

Abstract

A method for forming an oxide coated substrate comprising heating a pre-coating mixture in the presence of a substrate to synthesize an oxide coating on the substrate. The pre-coating mixture comprises a solubilized reducing additive, a solubilized oxidizing additive, and the substrate. The heating is conducted at a temperature sufficiently high enough to exothermically react the solubilized reducing additive and solubilized oxidizing additive and low enough to control the phase and composition of the oxide.

First claim

What is claimed is:

1. A method for forming an oxide coated substrate comprising:
heating a pre-coating mixture in the presence of a substrate to synthesize an oxide coating on the substrate;
wherein the pre-coating mixture comprises Titanium(IV) bis(ammonium lactato)dihydroxide and a solubilized oxidizing additive; and
wherein heating is conducted at a temperature high enough to exothermically react the Titanium(IV) bis(ammonium lactato)dihydroxide and the solubilized oxidizing additive and low enough to control the phase and composition of the oxide.

2. The method of claim 1 , wherein the oxide coated substrate surface product is annealed.

3. The method of claim 1 , wherein the oxide coated substrate surface product is not annealed.

4. The method of claim 1 , wherein the solubilized oxidizing additive comprises a metal or non-metal precursor.

5. The method of claim 1 , wherein the solubilized oxidizing additive comprises ammonium perchlorate (NH 4 CIO 4 ), ammonium nitrate, ammonium chlorate, ammonium peroxide, hydrogen peroxide or an organic peroxide.

6. The method of claim 1 , wherein the solubilized oxidizing additive is ammonium nitrate.

7. The method of claim 1 , wherein the substrate is porous.

8. The method of claim 1 , wherein the substrate is substantially non-porous.

9. The method of claim 1 , wherein the porous substrate comprises mullite, pumice or concrete.

10. The method of claim 1 , wherein, prior to the addition of the substrate to the pre-coating mixture, the solubilized oxidizing additive and the Titanium(IV) bis(ammonium lactato)dihydroxide are preheated together at about 100° C. to about 200° C. for about 10 minutes to about 30 minutes.

11. The method of claim 1 , wherein the substrate comprises a mullite ceramic.

12. The method of claim 1 , wherein the substrate is immersed in the pre-coating mixture and heated at about 350° C. for about 40 minutes in a preheated furnace.

13. The method of claim 1 , wherein the atmosphere and pressure conditions are ambient.

14. The method of claim 1 , wherein the coated substrate is removed from the reaction vessel and the coated substrate is then placed into a preheated furnace and annealed at about 400° C. for about 20 minutes.

15. The method of claim 1 , wherein the coated substrate is then rotated along its longest axis to expose the second surface, and then annealed at about 400° C. for about an additional 20 minutes.

16. The method of claim 1 , wherein the pre-coating mixture is doped with a metal or non-metal precursor.

17. The method of claim 16 , wherein the dopant comprises titanium, tungsten, cerium, tin, zinc, zirconium, bismuth, copper, indium, iron, silver, strontium, lithium, calcium, carbon, nitrogen, or a combination thereof.

18. The method of claim 16 , wherein the oxide coating on the substrate comprises TiSn(C,N,O) 2 .

19. The method of claim 16 , wherein the oxide coating on the substrate comprises Ti(C,N,O) 2 .

20. The method of claim 16 , wherein the oxide coating on the substrate comprises TiM(C,N,O) 2 , where M is tungsten, cerium, tin, zinc, zirconium, bismuth, copper, indium, iron, silver, strontium, lithium, calcium, carbon, or nitrogen, or a combination thereof.

Assignees

• Nitto Denko Corp

Inventors

• Sambandan Ekambaram
• Mukherjee Rajesh
• Fukumura Takuya
• Mochizuki Amane

Classifications

• C04B35/185

  Mullite {3Al2O3-2SiO2} · CPC title

• C04B41/009

  characterised by the material treated · CPC title

• B01J27/25

  Nitrates · CPC title

• C04B2111/00827

  Photocatalysts · CPC title

• C01P2002/30

  Three-dimensional structures · CPC title