# US 2013/0157047 A1 · Carbon material and method of manufacturing the same > Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt - Number: US 2013/0157047 A1 - Document ID: US20130157047A1 - Status: Published application - Kind: A1 - Application number: 13/820,583 - Filed: 2011-07-15 - Published: 2013-06-20 - Earliest claimed: 2010-09-06 - Assignees: Toyo Tanso Co., Ltd. - Inventors: Akiyoshi Takeda; Hiroaki Matsunaga; Kaoru Setani - Web page: https://patentgrep.com/patent/US20130157047A1 ## CPC - B05D 1/38: with intermediate treatment (intermediate treatment per se B05D3/00) - B32B 9/041: {of metal} - 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 41/90: at least one coating being a metal - C23C 10/58: more than one element being diffused in more than one step - Y10T 428/26: Web or sheet containing structurally defined element or component, the element or component having a specified physical dimension - Y10T 428/265: 1 mil or less - Y10T 428/31678: Of metal - 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 - 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) - Y10T: TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION ## Abstract A carbon material and a method of manufacturing the same are provided that make it possible to form a layer of a metal that is highly reactive with carbon, such as tungsten, on a carbon substrate while at the same time inhibiting an increase in manufacturing cost and a degradation of processing accuracy. The carbon material has a carbon substrate 2, a first layer 12, and a second layer 13. The first layer contains a carbide of a transition metal. The second layer contains a second metal and/or a carbide of the second metal and a carbide of the transition metal, the second metal being at least one metal selected from the group of metals consisting of Group 4 elements, Group 5 elements, and Group 6 elements. The first and second layers are formed on a surface of the carbon substrate in that order. ## Claims ### Claim 1 A carbon material characterized by comprising: a carbon substrate, a first layer, and a second layer, and characterized in that: the first layer contains a carbide of a transition metal; the second layer contains a second metal and/or a carbide of the second metal and a carbide of the transition metal, the second metal being at least one metal selected from the group consisting of Group 4 metals, Group 5 metals, and Group 6 metals; and the first and second layers are formed on a surface of the carbon substrate in that order. ### Claim 2 (depends on 1) The carbon material according to claim 1, wherein the second layer comprises a layer containing the carbide of the transition metal in a greater amount than that of the carbide of the second metal, and a layer containing the carbide of the second metal in a greater amount than that of the carbide of the transition metal. ### Claim 3 (depends on 1) The carbon material according to claim 1, wherein the second layer comprises a layer having, as determined by an EPMA measurement, a higher intensity of the carbide of the transition metal than that of the carbide of the second metal and a layer having a higher intensity of the carbide of the second metal than that of the carbide of the transition metal. ### Claim 4 (depends on 1) The carbon material according to claim 1, wherein the second layer has a thickness of 20 μm or less. ### Claim 5 (depends on 1) The carbon material according to claim 1, wherein the second metal is tungsten. ### Claim 6 (depends on 1) The carbon material according to claim 1, wherein the transition metal is chromium. ### Claim 7 (depends on 1) The carbon material according to claim 1, wherein the first layer has a thickness of from 1 μm to 10 μm. ### Claim 8 (depends on 1) The carbon material according to claim 1, wherein the second layer has a thickness of 0.5 μm or greater. ### Claim 9 A method of manufacturing a carbon material, characterized by comprising: a first layer formation step of forming a first layer containing a carbide of a transition metal on a carbon substrate; and a second layer formation step of contacting and heating the carbon substrate on which the first layer has been formed, with a treatment agent containing at least one metal selected from the group of metals consisting of Group 4 elements, Group 5 elements, and Group 6 elements, to form a second layer on a surface of the first layer, the second layer containing the at least one metal selected from the group of metals consisting of Group 4 elements, Group 5 elements, and Group 6 elements and/or a carbide of the at least one metal. ### Claim 10 (depends on 9) The method of manufacturing a carbon material according to claim 9, wherein the heating temperature in the second layer formation step is from 800° C. to 1300° C. ### Claim 11 (depends on 10) The method of manufacturing a carbon material according to claim 10, wherein the heating temperature in the second layer formation step is from 800° C. to 1,000° C. . ### Claim 12 (depends on 9) The method of manufacturing a carbon material according to claim 9, further comprising a heat treatment step of performing a heat treatment after the first layer formation step. ### Claim 13 (depends on 9) The method of manufacturing a carbon material according to claim 9, wherein the at least one metal is tungsten. ### Claim 14 (depends on 9) The method of manufacturing a carbon material according to claim 9, wherein the first layer is formed by contacting and heating the carbon substrate with a treatment agent containing a transition metal.