# US 10,119,585 B2 · Carbon-carbon composite including hydrophobic coating

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- Number: US 10,119,585 B2
- Document ID: US10119585B2
- Status: Granted
- Kind: B2
- Application number: 14/990,564
- Filed: 2016-01-07
- Published: 2017-07-13
- Granted: 2018-11-06
- Earliest claimed: 2016-01-07
- Assignees: Honeywell International Inc.
- Applicants: Honeywell International Inc.
- Inventors: Richard George Rateick, Jr.; Stephen Frederic Yates
- Web page: https://patentgrep.com/patent/US10119585B2

## CPC

- F16D 65/126: {the material being of low mechanical strength, e.g. carbon, beryllium; Torque transmitting members therefor}
- C04B 41/009: {characterised by the material treated}
- C04B 41/52: Multiple coating or impregnating {multiple coating or impregnating with the same composition or with compositions only differing in the concentration of the constituents, is classified as single coating or impregnation}
- C04B 41/89: for obtaining at least two superposed coatings having different compositions
- C23C 16/045: {Coating cavities or hollow spaces, e.g. interior of tubes; Infiltration of porous substrates}
- C23C 16/26: Deposition of carbon only
- F16D 69/023: {Composite materials containing carbon and carbon fibres or fibres made of carbonizable material}
- C04B 2111/00362: {Friction materials, e.g. used as brake linings, anti-skid materials}
- C04B 2111/27: Water resistance, i.e. waterproof or water-repellent materials
- F16D 2200/0052: Carbon
- F16D 2200/0082: Production methods therefor
- F16D 2250/0046: Coating
- F16D: COUPLINGS FOR TRANSMITTING ROTATION; CLUTCHES; BRAKES
- C04B: LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE {(roofing granules E04D7/005)}; CERAMICS (devitrified glass-ceramics C03C10/00); REFRACTORIES; TREATMENT OF NATURAL STONE
- C23C: COATING 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 (making metal-coated products by extrusion B21C23/22; covering with metal by connecting pre-existing layers to articles, see the relevant places, e.g. B21D39/00, B23K; metallising of glass C03C; metallising mortars, concrete, artificial stone, ceramics or natural stone C04B41/00; enamelling of, or applying a vitreous layer to, metals C23D; treating metal surfaces or coating of metals by electrolysis or electrophoresis C25D; single-crystal film growth C30B; by metallising textiles D06M11/83; decorating textiles by locally metallising D06Q1/04)

## Abstract

In some examples, an article may include a carbon-carbon composite, an antioxidant in pores in a surface of the carbon-carbon composite, and a hydrophobic coating on the surface. The hydrophobic coating includes an oxide of a metal. The metal has a Pauling electronegativity of less than about 1.7. In some examples, the article may be a carbon-carbon composite brake disk that includes a carbon-carbon composite substrate defining a friction surface and a non-friction surface. The antioxidant may be a phosphate-based antioxidant, and the antioxidant may be in pores in the non-friction surface. In some examples, the hydrophobic coating is on the non-friction surface over the phosphate-based antioxidant. In some examples, the hydrophobic coating may include a majority of at least one of yttrium oxide, scandium oxide, or zirconium oxide.

## Claims

### Claim 1

An article comprising:
a carbon-carbon composite brake disk defining a friction surface and a non-friction surface, wherein the non-friction surface comprises a sub-surface region;
a phosphate-based antioxidant in pores in the sub-surface region of the non-friction surface of the carbon-carbon composite brake disk; and
a hydrophobic coating on the non-friction surface of the carbon-carbon composite brake disk, the hydrophobic coating comprising a majority by weight of an oxide of a first metal, wherein the first metal has a Pauling electronegativity of less than about 1.7, and wherein the hydrophobic coating excludes oxides of second metals, the second metals having a Pauling electronegativity of greater than 1.7.

### Claim 2 (depends on 1)

The article of claim 1, wherein the hydrophobic coating consists essentially of the oxide of the first metal having the Pauling electronegativity of less than about 1.7.

### Claim 3 (depends on 1)

The article of claim 1, wherein the oxide of the first metal has a standard free energy of formation that is less than the standard free energy of formation of carbon monoxide at all temperatures below 1000° C.

### Claim 4 (depends on 1)

The article of claim 1, wherein the first metal comprises at least one of Y, Sc, or Zr.

### Claim 5 (depends on 1)

The article of claim 1, wherein the first metal is Y.

### Claim 6 (depends on 1)

The article of claim 1, wherein the first metal and the oxide of the first metal do not promote oxidation of the carbon.

### Claim 7 (depends on 1)

A method of forming the article of claim 1, the method comprising:
infiltrating the phosphate-based antioxidant into pores in the sub-surface region of the non-friction surface of the carbon-carbon composite brake disk, wherein the carbon-carbon composite brake disk defines the non-friction surface and the friction surface; and
forming the hydrophobic coating on the non-friction surface of the carbon-carbon composite brake disk over the sub-surface region, wherein the hydrophobic coating comprises a majority by weight of the oxide of the first metal, wherein the first metal has a Pauling electronegativity of less than about 1.7, and wherein the hydrophobic coating excludes oxides of second metals, the second metals having a Pauling electronegativity of greater than 1.7.

### Claim 8 (depends on 7)

The method of claim 7, wherein forming the hydrophobic coating comprises applying a solution or slurry comprising a solvent and the oxide of the first metal or the solvent and a precursor of the oxide of the first metal to the non-friction surface of the carbon-carbon composite brake disk to form a coated carbon-carbon composite brake disk.

### Claim 9 (depends on 8)

The method of claim 8, further comprising:
heating the coated carbon-carbon composite brake disk to evaporate substantially all of the solvent and form a dried carbon-carbon composite brake disk.

### Claim 10 (depends on 9)

The method of claim 9, wherein the solution or slurry comprising the oxide of the first metal or the precursor of the oxide of the first metal and the solvent comprises a solution comprising a salt precursor of the oxide of the first metal and the solvent, the method further comprising:
heating the dried carbon-carbon composite at a temperature that facilitates decomposition of the salt precursor of the oxide of the first metal to the oxide of the first metal.

### Claim 11 (depends on 7)

The method of claim 7, wherein forming the hydrophobic coating comprises applying the hydrophobic coating using sol-gel processing or from a colloidal suspension.

### Claim 12

A carbon-carbon composite brake disk comprising:
a carbon-carbon composite substrate defining a friction surface and a non-friction surface;
a phosphate-based antioxidant in pores in a sub-surface region below the non-friction surface; and
a hydrophobic coating on the non-friction surface over the phosphate-based antioxidant, wherein the hydrophobic coating comprises a majority by weight of at least one of yttrium oxide, scandium oxide, or zirconium oxide, and wherein the hydrophobic coating excludes metal oxides of metals that have a Pauling electronegativity of greater than 1.7.

### Claim 13 (depends on 12)

The carbon-carbon composite brake disk of claim 12, wherein the hydrophobic coating consists essentially of the at least one of yttrium oxide, scandium oxide, or zirconium oxide.

### Claim 14 (depends on 12)

The carbon-carbon composite brake disk of claim 12, wherein the hydrophobic coating is substantially free of materials that catalyze carbon oxidation.