# US 2014/0193661 A1 · Sinter Bonded Porous Metallic Coatings

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- Number: US 2014/0193661 A1
- Document ID: US20140193661A1
- Status: Published application
- Kind: A1
- Application number: 14/149,196
- Filed: 2014-01-07
- Published: 2014-07-10
- Earliest claimed: 2006-09-29
- Assignees: Mott Corporation
- Applicants: Mott Corporation
- Inventors: James K. Steele; Wayne F. White; Alfred M. Romano; Kenneth L. Rubow
- Web page: https://patentgrep.com/patent/US20140193661A1

## CPC

- B01D 39/2034: {sintered or bonded by inorganic agents}
- B01D 39/201: {sintered or bonded by inorganic agents}
- B01D 39/2027: {Metallic material}
- B01J 2/006: {Coating of the granules without description of the process or the device by which the granules are obtained (to prevent the granules sticking together B01J2/30)}
- B01J 2/04: in a gaseous medium {(if combined with suspending the material in a gas, e.g. fluidised beds B01J2/16)}
- B01J 2/18: using a vibrating apparatus
- B01J 23/42: Platinum
- B22F 1/054: Nanosized particles
- B22F 1/056: {Submicron particles having a size above 100 nm up to 300 nm}
- B22F 3/1103: {with particular physical characteristics}
- B22F 5/106: {Tube or ring forms}
- B22F 7/002: {of porous nature}
- B22F 7/02: of composite layers {(B22F7/002 takes precedence)}
- B82Y 30/00: Nanotechnology for materials or surface science, e.g. nanocomposites
- C22C 1/02: by melting {(C22C1/1036 takes precedence)}
- C22C 5/04: Alloys based on a platinum group metal
- C22C 14/00: Alloys based on titanium
- C22C 19/056: {with the maximum Cr content being at least 10% but less than 20%}
- C22C 38/00: Ferrous alloys, e.g. steel alloys (cast-iron alloys C22C37/00)
- C23C 18/06: Coating on selected surface areas, e.g. using masks
- C23C 24/04: Impact or kinetic deposition of particles
- C23C 24/08: by application of heat or pressure and heat (C23C24/04 takes precedence)
- B01D 2239/0258: comprising nanoparticles
- B01D 2239/0478: on a layer of the filter
- B01D 2239/0654: Support layers
- B01D 2239/083: Binders between layers of the filter
- B01D 2239/10: Filtering material manufacturing
- B01D 2239/1216: Pore size
- B01D 2239/1241: Particle diameter
- Y10T 428/12042: Porous component
- Y10T 428/12479: Porous [e.g., foamed, spongy, cracked, etc.]
- Y10T 428/13: Hollow or container type article [e.g., tube, vase, etc.]
- Y10T 428/249981: Plural void-containing components
- B01D: SEPARATION (separating solids from solids by wet methods B03B, B03D; by pneumatic jigs or tables B03B; by other dry methods B07; magnetic or electrostatic separation of solid materials from solid materials or fluids, separation by high-voltage electric fields B03C; centrifuges, vortex apparatus B04; presses per se for squeezing-out liquid from liquid-containing material B30B9/02; treatment of water C02F, e.g. softening by ion-exchange C02F1/42; {arrangements of air intake cleaners in gas turbine plants F02C7/05} ; arrangements or mounting of filters in air-conditioning, air-humidification or ventilation F24F13/28)
- B01J: CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
- B22F: WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER (making alloys by powder metallurgy C22C); APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
- B82Y: SPECIFIC USES OR APPLICATIONS OF NANOSTRUCTURES; MEASUREMENT OR ANALYSIS OF NANOSTRUCTURES; MANUFACTURE OR TREATMENT OF NANOSTRUCTURES
- C22C: ALLOYS (treatment of alloys C21D, C22F)
- 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 composite structure includes a substrate with pores of a first mean pore size and a coating on at least one surface of that substrate. This coating has pores of a second mean pore size where the first mean pore size is equal to or greater than said second mean pore size. When the pore size of the coating is effective to capture particulate greater than 0.2 micron, the composite may be formed into a filter effective to remove microbes from a fluid medium. One method to form the porous coating on the substrate includes the steps of: (a) forming a suspension of sinterable particles in a carrier fluid and containing the suspension in a reservoir; (b) maintaining the suspension by agitation in the reservoir; (c) immersing the substrate in the reservoir; (c) applying a first coating of the suspension to the substrate; (d) removing the substrate with the applied first coating from the reservoir; and (e) sintering the sinterable particles to the substrate thereby forming a coated substrate.

## Claims

### Claim 1

A composite structure, comprising:
a substrate having pores with a first mean pore size; and
a coating on at least one surface of said substrate, said coating having pores with a second mean pore size wherein said first mean pore size is equal to or greater than said second mean pore size.

### Claim 2 (depends on 1)

The composite structure of claim 1 wherein said substrate is selected from materials having a Media Grade of between 0.2 and 5.

### Claim 3 (depends on 2)

The composite structure of claim 2 wherein said second mean pore size is less than 0.2 micron.

### Claim 4 (depends on 3)

The composite structure of claim 3 wherein said coating pores are effective to capture particulate greater than 0.2 micron.

### Claim 5 (depends on 4)

The composite structure of claim 4 wherein said coating has a thickness of from 20 microns to 250 microns.

### Claim 6 (depends on 5)

The composite structure of claim 5 wherein said coating has a thickness of from 30 microns to 75 microns.

### Claim 7 (depends on 4)

The composite structure of claim 4 wherein said coating if a mass of particles having an average particle size of 50 nanometers to 350 nanometers.

### Claim 8 (depends on 7)

The composite structure of claim 7 wherein said coating if a mass of particles having an average particle size of 60 nanometers to 200 nanometers.

### Claim 9 (depends on 7)

The composite structure of claim 7 wherein said substrate and said mass of particles are both predominantly stainless steel.

### Claim 10 (depends on 7)

The composite structure of claim 7 wherein said substrate and said mass of particles are both predominantly titanium.

### Claim 11 (depends on 7)

The composite structure of claim 7 wherein said substrate and said mass of particles are sintered.

### Claim 12 (depends on 11)

The composite structure of claim 11 formed into a filter effective to remove microbes from a fluid medium.

### Claim 13 (depends on 12)

The composite structure of claim 12 formed into a flat disk.

### Claim 14 (depends on 13)

The composite structure of claim 13 formed into a tube.

### Claim 15 (depends on 14)

The composite structure of claim 14 wherein said coating is on an outward facing surface of said tube.

### Claim 16

A method for forming a porous coating on a substrate, comprising the steps of:
(a) forming a suspension of sinterable particles in a carrier fluid and containing said suspension in a reservoir;
(b) maintaining said suspension by agitation in said reservoir;
(c) immersing said substrate in said reservoir;
(c) applying a first coating of said suspension to said substrate;
(d) removing said substrate with applied first coating from said reservoir; and
(e) sintering said sinterable particles to said substrate thereby forming a coated substrate.

### Claim 17 (depends on 16)

The method of claim 16 including forming said substrate as a tube having an interior bore and applying a vacuum to said interior bore during said applying step.

### Claim 18 (depends on 17)

The method of claim 17 including applying ultrasonic energy to said suspension.

### Claim 19 (depends on 18)

The method of claim 18 wherein a ratio of said sinterable particles to said carrier fluid in said suspension is less than or equal to 15 grams of sinterable particles to 1 liter of carrier fluid.

### Claim 20 (depends on 18)

The method of claim 18 wherein said first coating has a thickness of about 10 to 25 microns, whereby shrinkage cracks during step (e) are avoided.