US4738896A
Expired / Lapsed
US
⏱️ 0.0 years remaining
Sol gel formation of polysilicate, titania, and alumina interlayers for enhanced adhesion of metal films on substrates
Assignee: Advanced Technology Materials Inc
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Filing: 1986-09-26
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Granted: 1988-04-19
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Expires: 2006-09-26
Abstract
Abstract A metal-coated substrate, e.g., of glass, ceramic, or a hydroxy-functionalized material, wherein the improvement comprises a polysilicate, titania, or alumina interlayer between the substrate and the metal coating. The interlayer may have a porous microstructure, e.g., a polysilicate interlayer with an average pore size on the order of 50-150 Angstroms. Such articles, e.g., in the form of metal-coated fibers, may suitably be employed as reinforcing media in material composites having utility in structural applications, such as EMI shielding elements. Also disclosed is a corresponding method for forming a metal coating on a substrate by the provision of an interlayer of the above type. The interlayer may suitably be formed by applying to the substrate a sol gel dispersion of the polysilicate, titania, or alumina material, followed by drying of the applied dispersion.
Inventors
- 👤 Ward C. Stevens
Bibliographic Details
Application Number
—
Jurisdiction
US
Data Source
google_patents
Last Synchronized
2026-10-31 02:47
CPC Classifications
C; C03; C03C; C03C17/00; C03C17/34; C03C17/36; C03C17/3602; C03C17/3607; C03C17/3642; C04; C04B; C04B41/00; C04B41/009; C04B41/45; C04B41/4582; C04B41/4584; C04B41/52; C04B41/80; C04B41/81; C04B41/89; C03C2217/00; C03C2217/40; C03C2217/425; C03C2217/43; C03C2217/46; C03C2217/48; C03C2217/485; C03C2217/90; C03C2217/93; Y; Y10; Y10T; Y10T428/00; Y10T428/249921; Y10T428/249953; Y10T428/249978; Y10T428/24998; Y10T428/249982; Y10T428/29; Y10T428/2913; Y10T428/2933; Y10T428/2938; Y10T428/294; Y10T428/2942; Y10T428/2944; Y10T428/2949; Y10T428/2956; Y10T428/2958; Y10T428/296
Claims Analysis
Total Claims: 16
Claim 1
Independent Claim
128 words
A metal-coated substrate with an interlayer of porous microstructure between the substrate and the metal coating, comprising a material selected from the group consisting of polysilicate, titania, and alumina, and formed on the substrate by application thereto of a sol gel dispersion comprising said material, and drying of the applied sol gel dispesion to form the porous microstructure, under selected temperature and drying conditions to partially collapse the pores of the microstructure and provide the interlayer with an average pore size of between about 20 and about 300 Angstroms and render it adherent to the substrate and scratch-resistant in character, the thickness of the interlayer being from about 30 to about 2500 Angstroms, and the thickness of the metal coating being from about 0.01 to about 3.0 microns.
Claim 2
Dependent Claim
128 words
A metal-coated substrate with an interlayer of porous microstructure between the substrate and the metal coating, comprising a material selected from the group consisting of polysilicate, titania, and alumina, and formed on the substrate by application thereto of a sol gel dispersion comprising said material, and drying of the applied sol gel dispesion to form the porous microstructure, under selected temperature and drying conditions to partially collapse the pores of the microstructure and provide the interlayer with an average pore size of between about 20 and about 300 Angstroms and render it adherent to the substrate and scratch-resistant in character, the thickness of the interlayer being from about 30 to about 2500 Angstroms, and the thickness of the metal coating being from about 0.01 to about 3.0 microns.
Claim 3
Dependent Claim
26 words
A metal-coated substrate according to claim 1, wherein the microstructure of the interlayer has an average pore size of between about 30 and about 250 Angstroms.
Claim 4
Dependent Claim
24 words
A metal-coated substrate according to claim 1, wherein the substrate comprises a material selected from the group consisting of glasses, ceramics, and hydroxy-functionalized materials.
Claim 5
Dependent Claim
26 words
A metal-coated substrate according to claim 3, wherein the substrate comprises a ceramic selected from the group consisting of mullite, alumina, silicon carbide, and silicon nitride.
Claim 6
Dependent Claim
26 words
A metal-coating substrate according to claim 1, wherein the substrate consists essentially of a material selected from the group consisting of glasses, ceramics, and hydroxy-functionalized materials.
Claim 7
Dependent Claim
31 words
A metal-coated substrate according to claim 1, wherein the interlayer is formed of a polysilicate, with a microstructure having an average pore size of from about 50 to about 150 Angstroms.
Claim 8
Dependent Claim
8 words
A nickel-coated glass substrate according to claim 1.
Claim 9
Dependent Claim
23 words
A nickel-coated glass substrate according to claim 1, wherein the thickness of the nickel coating is from about 0.1 to about 1.0 micron.
Claim 10
Dependent Claim
15 words
A nickel-coated glass substrate according to claim 1, wherein the interlayer comprises a polysilicate material.
Claim 11
Dependent Claim
43 words
A metal-coated substrate according to claim 1, wherein: the interlayer is formed from a sol gel dispersion of a material comprising a polysilicate; the polysilicate is a condensation product of a silanol; and the silanol is a hydrolysis reaction product of a tetraalkylorthosilicate.
Claim 12
Dependent Claim
35 words
A metal-coated substrate according to claim 1, wherein the interlayer is formed from a sol gel dispersion of a material comprising an alkoxide of a metal selected from the group consisting of titanium and aluminum.
Claim 13
Dependent Claim
25 words
A metal-coating substrate according to claim 1, wherein the metal coating is applied by chemical vapor deposition from a thermally decomposable compound comprising the metal.
Claim 14
Dependent Claim
8 words
A metal-coated fiber substrate according to claim 1.
Claim 15
Dependent Claim
53 words
A metal-coated substrate according to claim 1, wherein the interlayer has been dried at elevated temperature, and wherein the metal coating is applied by a chemical vapor deposition from a thermally decomposable compound comprising the metal, while the substrate and the interlayer formed thereon are still at elevated temperature from the drying step.
Claim 16
Dependent Claim
23 words
A metal-coated substrate according to claim 1 additionally comprising a pigment enabling visual detection of discontinuities in the metal coated over the interlayer.
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USPTO Annuity & Maintenance Windows
| Annuity Stage | Window Opens | Payment Deadline | Surcharge Period Until | Estimated Fee | Status |
|---|---|---|---|---|---|
| 3.5 Years (Year 4) | 1991-04-19 | 1991-10-19 | 1992-04-19 | $2000.00 | Window Closed / Lapsed |
| 7.5 Years (Year 8) | 1995-04-19 | 1995-10-19 | 1996-04-19 | $3760.00 | Window Closed / Lapsed |
| 11.5 Years (Year 12) | 1999-04-19 | 1999-10-19 | 2000-04-19 | $7700.00 | Window Closed / Lapsed |