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US 10,501,378 B2Granted
Conformal composite coatings and methods
AssigneeUnited Technologies Corporation
InventorsWayde R. Schmidt, Sonia Tulyani
Life of this patent
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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.
Claims19
An article comprising:
- an individual fiber substrate;
- and
- a conformal coating disposed over an outer surface of the individual fiber substrate, the conformal coating comprising:
- a first matrix layer including primarily a ceramic matrix material disposed on the outer surface of the individual fiber substrate;
- a second matrix layer including primarily the ceramic matrix material;
- 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, thereby defining an individually reinforced fiber;
- and
- a second particulate layer disposed adjacent to the second matrix layer, 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 matrix layer.
6 more elements
A composite article comprising:
- a bulk binder;
- and
- a first plurality of individually coated fibers distributed throughout the bulk binder, the first plurality of individually coated fibers each comprising:
- an individual fiber substrate;
- and
- an individual conformal coating disposed over an outer surface of each individual fiber substrate, each conformal coating comprising:
- a plurality of particulate layers, each layer including a plurality of ordered inorganic particles spaced and distributed substantially uniformly throughout each particulate 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.
6 more elements
A method comprising:
- applying a preceramic composition to a receiving surface of each of a plurality of individual fiber substrates;
- applying a plurality of inorganic particles to each receiving surface;
- and
- curing the combination of the preceramic composition and the ceramic particles to form a conformal coating disposed over an outer surface of each of the individual fiber substrates, each conformal coating comprising:
- at least a particulate layer and a matrix layer on the receiving surface of each of the plurality of individual fiber substrates;
- an individual fiber substrate;
- and
- a conformal coating disposed over an outer surface of the individual fiber substrate, the conformal coating comprising:
- a first matrix layer including primarily a ceramic matrix material disposed on the outer surface of the individual fiber substrate;
- 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, thereby defining an individually reinforced fiber;
- and
- a second particulate layer disposed adjacent to the second matrix layer, 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 matrix layer.
12 more elements
Dependencies are inferred from the claim text.