# US 2013/0157004 A1 · Method for sealing pores of ceramic layer and article manufactured by the same

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- Number: US 2013/0157004 A1
- Document ID: US20130157004A1
- Status: Published application
- Kind: A1
- Application number: 13/441,303
- Filed: 2012-04-06
- Published: 2013-06-20
- Earliest claimed: 2011-12-16
- Assignees: FIH (Hong Kong) Limited; Shenzhen Futaihong Precision Industry Co., Ltd.
- Inventors: YONG-GANG ZHU
- Web page: https://patentgrep.com/patent/US20130157004A1

## CPC

- C23C 4/10: Oxides, borides, carbides, nitrides or silicides; Mixtures thereof
- C23C 4/11: Oxides
- C23C 4/18: After-treatment
- C23C 28/00: Coating for obtaining at least two superposed coatings either by methods not provided for in a single one of groups C23C2/00 - C23C26/00 or by combinations of methods provided for in subclasses C23C and C25C or C25D
- Y10T 428/24339: Keyed
- Y10T 428/249921: Web or sheet containing structurally defined element or component
- Y10T 428/269: including synthetic resin or polymer layer or component
- 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)
- Y10T: TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION

## Abstract

An article comprises a metal substrate, a ceramic layer formed on the metal substrate, and a sealing layer formed on the ceramic layer. The ceramic layer defines pores. The sealing layer comprises filling portions filling the ceramic pores. The filling portions contain thermosetting resins. A method for sealing pores of ceramic layer is also provided.

## Claims

### Claim 1

An article, comprising:
a metal substrate;
a ceramic layer formed on the ceramic layer, the ceramic layer defining ceramic pores therein; and
a sealing layer formed on the ceramic layer, the sealing layer comprising filling portions filling the ceramic pores, the filling portions containing thermosetting resins.

### Claim 2 (depends on 1)

The article as claimed in claim 1, wherein the porosity of the ceramic layer is about 15% to about 30%.

### Claim 3 (depends on 1)

The article as claimed in claim 1, wherein the ceramic pores comprise a plurality of through pores and a plurality of blind pores.

### Claim 4 (depends on 1)

The article as claimed in claim 1, wherein in the ceramic pores, the percentage of the through pores exceeds 50%.

### Claim 5 (depends on 1)

The article as claimed in claim 1, wherein the ceramic layer has a thickness of about 0.12 mm to about 0.3 mm.

### Claim 6 (depends on 1)

The article as claimed in claim 1, wherein the ceramic layer mainly consists of metal oxidate, metal carbide and/or metal nitride.

### Claim 7 (depends on 6)

The article as claimed in claim 6, wherein the ceramic layer is made of materials selected from a group consisting of titanium oxide, iron oxide, aluminium oxide, and zirconium dioxide.

### Claim 8 (depends on 1)

The article as claimed in claim 1, wherein the sealing layer is made of materials selected from a group consisting of epoxy resin, a mixture of epoxy resin and polyester, a mixture of polyurethane and polyurethane, and a mixture of saturated hydroxyl polyester resin and polyurethane.

### Claim 9 (depends on 1)

The article as claimed in claim 1, wherein the sealing layer further comprises a covering portion coated on the ceramic layer and a filling portion.

### Claim 10

A method for sealing pores of ceramic layer comprising:
providing a metal substrate;
flame spraying a ceramic layer on the metal substrate, the ceramic layer defining ceramic pores therein;
electrostatic powder spraying a sealing layer on the ceramic layer, the sealing layer comprising filling portions filling the ceramic pores, a sealing powder used to form the filling portions containing thermosetting resins.

### Claim 11 (depends on 10)

The method of claim 10, wherein the sealing layer is formed by the following steps: the sealing powder is adsorbed on the surface of the metal substrate and the ceramic pores; the metal substrate is baked at a temperature about 170° C. to about 190° C. for about 10 min to about 15 min.

### Claim 12 (depends on 10)

The method of claim 10, wherein the particles of sealing powder has a diameter of about 32 μm to about 100 μm.

### Claim 13 (depends on 10)

The method of claim 10, wherein the sealing powder is made of materials selected from a group consisting of epoxy resin, a mixture of epoxy resin and polyester, a mixture of polyurethane and polyurethane, and a mixture of saturated hydroxyl polyester resin and polyurethane.

### Claim 14 (depends on 10)

The method of claim 10, wherein the method further comprises a step of roughening the metal substrate before forming the ceramic layer.

### Claim 15 (depends on 14)

The method of claim 14, wherein the surface roughness (Ra) of the metal substrate is about 1.3 μm to about 2.0 μm.

### Claim 16 (depends on 10)

The method of claim 10, wherein the sealing layer further comprises a covering portion coated on the ceramic layer and a filling portion.

### Claim 17 (depends on 10)

The method of claim 10, wherein the method further comprises a step of polishing the sealing layer to remove the covering portion and exposes the ceramic layer.