# US 10,501,378 B2 · Conformal composite coatings and methods > Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt - Number: US 10,501,378 B2 - Document ID: US10501378B2 - Status: Granted - Kind: B2 - Application number: 14/629,829 - Filed: 2015-02-24 - Published: 2016-08-25 - Granted: 2019-12-10 - Earliest claimed: 2015-02-24 - Assignees: United Technologies Corporation - Applicants: United Technologies Corporation - Inventors: Wayde R. Schmidt; Sonia Tulyani - Web page: https://patentgrep.com/patent/US10501378B2 ## CPC - C04B 35/62863: {Silicon carbide} - B05D 1/007: {using an electrostatic field (B05D1/02 - B05D1/16 take precedence)} - B05D 1/36: Successively applying liquids or other fluent materials, e.g. without intermediate treatment - B32B 18/00: Layered products essentially comprising ceramics, e.g. refractory products - C04B 35/571: obtained from {Si-containing} polymer precursors {or organosilicon monomers} - C04B 35/583: based on boron nitride - C04B 35/62868: {Boron nitride} - C04B 35/80: Fibres, filaments, whiskers, platelets, or the like - 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 - B05D: PROCESSES FOR APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL (conveying articles or workpieces through baths of liquid B65G, e.g. B65G49/02) - B32B: LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM ## 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. ## Claims ### Claim 1 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. ### Claim 2 (depends on 1) The article of claim 1, wherein the individual fiber substrate is 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. ### Claim 3 (depends on 2) The article of claim 2, wherein the individual fiber substrate comprises silicon carbide (SiC). ### Claim 4 (depends on 1) 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. ### Claim 5 (depends on 1) The article of claim 1, wherein the ceramic matrix material comprises silicon carbide (SiC). ### Claim 6 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. ### Claim 7 (depends on 6) The article of claim 6, wherein each individual fiber 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. ### Claim 8 (depends on 7) The article of claim 7, wherein each individual fiber substrate comprises silicon carbide (SiC). ### Claim 9 (depends on 6) The article of claim 6, wherein the plurality of ceramic particles comprises boron nitride (BN) and the ceramic matrix material comprises silicon carbide (SiC). ### Claim 10 (depends on 6) The article of claim 6, further comprising: a second plurality of individual fibers intermingled in the binder with the first plurality of individual fibers, wherein the second plurality of individual fibers do not include the conformal coating. ### Claim 11 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. ### Claim 12 (depends on 11) The method of claim 11, further comprising: prior to at least one of the applying steps, treating an outer surface of each of the plurality of individual fiber substrates to form each receiving surface. ### Claim 13 (depends on 12) The method of claim 12, wherein the treating step comprises: applying an electrostatic charge to the surface of each of the plurality of individual fiber substrates. ### Claim 14 (depends on 11) The method of claim 11, further comprising: iteratively performing the steps of claim 11 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. ### Claim 15 (depends on 11) The method of claim 11, wherein the preceramic composition comprises a compound adapted to dissociate into a plurality of electrostatically charged ceramic precursors in a first solution. ### Claim 16 (depends on 15) The method of claim 15, wherein the compound is a polymer which includes a plurality of functional groups adapted to dissociate from the polymer in the first solution. ### Claim 17 (depends on 16) The method of claim 16, wherein the preceramic composition is selected from one or more of a group consisting of: polycarbosilane, polysiloxane, polysilazane, polycarbosiloxane, polysilane and polycarbosilazane. ### Claim 18 (depends on 16) The method of claim 16, wherein the preceramic composition comprises a plurality of electrostatically charged ceramic particles in a second solution. ### Claim 19 (depends on 18) The method of claim 18, 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.