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US 11,945,756 B2Granted
Protective internal coatings for porous substrates
AssigneeApplied Thin Films, Inc.
InventorsSankar Sambasivan, Vikram S. Kaul, Francis R. Chapman
Life of this patent
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Abstract
A material contains open pores in which the channels and pores that are internally coated with at least one layer of phosphorus-containing alumina. Such material is formed by infiltrating a porous material one or more times with a non-colloidal, low-viscosity liquid coating precursor, drying, and curing the coating precursor to form a phosphorus-containing alumina layer within pores of the material.
Claims29
A coated material, comprising:
- a porous inorganic substrate having an internal pore system comprising internal pores and interconnected interior channels in open communication with an exterior surface of the porous substrate, and having an initial open porosity with a mean pore diameter of up to 5 micrometers prior to coating;
- and
- a cured phospho-alumina coating having a thickness of 1 nm to 500 nm that conformally coats walls of the internal pores and the interconnected interior channels, the phosphor-alumina coating having an aluminum-to-phosphorous atomic ratio of 0.5:1 to 20:1;
- wherein the internal pore system is substantially maintained such that the coated material comprises internal pores and interconnected interior channels in open communication with an exterior surface of the coated material, and
- wherein the coated material has an open porosity that is at least 50% of the initial open porosity of the porous substrate prior to coating.
2 more elements
A coated material, comprising:
- a porous inorganic substrate having an internal pore system comprising internal pores and interconnected interior channels in open communication with an exterior surface of the porous substrate, and having an initial open porosity that is an open pore network of mesopores or macropores with a mean pore diameter of up to 5 micrometers prior to coating;
- and
- a cured phospho-alumina coating having a thickness of 1 nm to 50 nm that conformally coats walls of the internal pores and the interconnected interior channels, the phospho-alumina coating having an aluminum-to-phosphorous atomic ratio of 0.5:1 to 20:1;
- wherein the internal pore system is substantially maintained such that the coated material comprises internal pores and interconnected interior channels in open communication with an exterior surface of the coated material, and
- wherein the coated material has an open porosity that is at least 50% of the initial open porosity of the porous substrate prior to coating.
2 more elements
A coated material, comprising:
- a porous inorganic substrate having an internal pore system comprising internal pores and interconnected interior channels in open communication with an exterior surface of the porous substrate, and having an initial open porosity that is an open pore network of mesopores and macropores with a mean pore diameter of up to 5 micrometers prior to coating;
- a cured phospho-alumina coating having a thickness of 1 nm to 50 nm that conformally coats walls of the internal pores and the interconnected interior channels, the phospho-alumina coating having an aluminum-to-phosphorous atomic ratio of 0.5:1 to 20:1,
- wherein the internal pore system is substantially maintained such that the coated material comprises internal pores and interconnected interior channels in open communication with an exterior surface of the coated material, and
- wherein the coated material has an open porosity of that is at least 50% of the initial open porosity of the porous substrate prior to coating.
1 more element
Dependencies are inferred from the claim text.