Patent US4921723A successfully refreshed from Google Patents.
US4921723A
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Process for applying a composite insulative coating to a substrate
Assignee: MISSOURI COLUMBIA MISSOURI, University of, Curators of
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Filing: 1987-10-16
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Granted: 1990-05-01
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Expires: 2007-10-16
Abstract
Abstract A process for applying an adherent electrically insulative moisture-resistant composite coating to a substrate. A thin, adherent, highly cross-linked, substantially liquid moisture-impervious primer coating is provided on the substrate by glow discharge polymerization of a low molecular weight hydrocarbon monomer in a low pressure chamber containing the substrate, the monomer being selected from among methane, ethane, propane, ethylene, and propylene. A second polymeric coating layer is provided over the primer coating by glow discharge polymerization of a second precursor comprising a hydrocarbon or substituted hydrocarbon. The precursor exhibits a hydrogen yield of not greater than about 0.75 hydrogen atoms per molecule under the glow discharge polymerization conditions under which the second layer is deposited, whereby the second polymeric coating layer is substantially resilient and strongly bonded to the primer coating and the second layer comprises a high concentration of surface and bulk free radicals.
Inventors
- 👤 Michael F. Nichols
- 👤 Allen W. Hahn
Bibliographic Details
Application Number
—
Jurisdiction
US
Data Source
google_patents
Last Synchronized
2026-10-23 17:30
CPC Classifications
B; B05; B05D; B05D1/00; B05D1/62; H; H10; H10W; H10W72/00; H10W72/30; H10W99/00; B05D7/00; B05D7/50; B05D7/52; H05; H05K; H05K3/00; H05K3/22; H05K3/28; H05K3/284; H10W72/071; H10W72/073; H10W72/07331; H10W72/07337
Claims Analysis
Total Claims: 30
Claim 1
Independent Claim
161 words
A process for applying an adherent electrically insulative moisture-resistant composite coating to a substrate, the process comprising the steps of: providing a thin, adherent, highly cross-linked, substantially liquid moisture-impervious primer coating on said substrate by glow discharge polymerization of a low molecular weight hydrocarbon monomer in a low pressure chamber containing said substrate, said monomer being selected from the group consisting of methane, ethane, propane, ethylene, and propylene; and providing a second polymeric coating layer over said primer coating by glow discharge polymerization of a second precursor compound in a low pressure chamber, said second precursor comprising a hydrocarbon or substituted hydrocarbon, said precursor exhibiting a hydrogen yield of not greater than about 0.75 hydrogen atoms per molecule under the glow discharge polymerization conditions under which said second layer is deposited, whereby said second polymeric coating layer is substantially resilient and strongly bonded to said primer coating and said second layer comprises a high concentration of surface and bulk free radicals.
Claim 2
Dependent Claim
161 words
A process for applying an adherent electrically insulative moisture-resistant composite coating to a substrate, the process comprising the steps of: providing a thin, adherent, highly cross-linked, substantially liquid moisture-impervious primer coating on said substrate by glow discharge polymerization of a low molecular weight hydrocarbon monomer in a low pressure chamber containing said substrate, said monomer being selected from the group consisting of methane, ethane, propane, ethylene, and propylene; and providing a second polymeric coating layer over said primer coating by glow discharge polymerization of a second precursor compound in a low pressure chamber, said second precursor comprising a hydrocarbon or substituted hydrocarbon, said precursor exhibiting a hydrogen yield of not greater than about 0.75 hydrogen atoms per molecule under the glow discharge polymerization conditions under which said second layer is deposited, whereby said second polymeric coating layer is substantially resilient and strongly bonded to said primer coating and said second layer comprises a high concentration of surface and bulk free radicals.
Claim 3
Dependent Claim
26 words
A process as set forth in claim 1 wherein said glow discharge zone is established by reactance coupling without the presence of electrodes inside the chamber.
Claim 4
Dependent Claim
28 words
A process as set forth in claim 1 wherein said glow discharge zone is established by inductive coupling via a coil outside of and surrounding said polymerization chamber.
Claim 5
Dependent Claim
36 words
A process as set forth in claim 1 wherein said second layer is provided over said primer coating by glow discharge polymerization in the same chamber in which the formation of said primer coating is provided.
Claim 6
Dependent Claim
26 words
A process as set forth in claim 4 wherein the provision of said second coating layer immediately follows, or overlaps, the provision of said primer coating.
Claim 7
Dependent Claim
29 words
A process as set forth in claim 5 wherein oxygen is substantially excluded from the glow discharge zone during the provision of said primer coating and second coating layer.
Claim 8
Dependent Claim
26 words
A process as set forth in claim 1 wherein the provision of said second coating layer immediately follows, or overlaps, the provision of said primer coating.
Claim 9
Dependent Claim
29 words
A process as set forth in claim 1 wherein oxygen is substantially excluded from the glow discharge zone during the provision of said primer coating and second coating layer.
Claim 10
Dependent Claim
39 words
A process as set forth in claim 1 wherein the thickness of said primer coating is between about 30 and about 100 angstroms and the thickness of said second coating layer is between about 50 and about 500 angstroms.
Claim 11
Dependent Claim
36 words
A process as set forth in claim 1 which further comprises providing a third polymeric coating layer over said second layer, said third layer being substantially impervious to moisture and strongly bonded to said second layer.
Claim 12
Dependent Claim
102 words
A process as set forth in claim 10 wherein said third coating layer is provided by a vapor deposition process, said vapor deposition process comprising: vaporizing a precursor compound which may be pyrolyzed in the vapor state to form free radicals condensable to a polymer; passing the vapor deposition precursor through a pyrolysis zone and heating the vapor deposition precursor within said zone to a temperature sufficient to form free radicals; and depositing a vapor deposition polymer over said second layer, the surface of said second layer being at a temperature at which a condensed polymer is formed from said pyrolyzed vapor.
Claim 13
Dependent Claim
61 words
A process as set forth in claim 11 wherein said second layer is provided over said primer coating by glow discharge polymerization in the same chamber in which said primer coating is provided, and said outer coating layer is provided by deposition of said condensed polymer from said pyrolyzed vapor in the same chamber in which said primer coating is provided.
Claim 14
Dependent Claim
44 words
A process as set forth in claim 11 wherein the provision of said second coating layer immediately follows, or overlaps, the provision of said primer coating, and the provision of said outer coating immediately follows, or overlaps, the provision of said second coating layer.
Claim 15
Dependent Claim
51 words
A process as set forth in claim 11 wherein the thickness of said primer coating is between about 30 and about 100 angstroms, the thickness of said second coating layer is between about 50 and about 500 angstroms, and the thickness of said outer coating is at least about 1/2 micron.
Claim 16
Dependent Claim
16 words
A process as set forth in claim 1 wherein said low molecular weight monomer comprises methane.
Claim 17
Dependent Claim
30 words
A process as set forth in claim 1 wherein said second precursor compound is selected from the group consisting of aromatic hydrocarbons, substituted aromatic hydrocarbons, heterocyclic compounds, and acetylenic compounds.
Claim 18
Dependent Claim
19 words
A process as set forth in claim 16 wherein the second precursor compound comprises an aromatic or heterocyclic compound.
Claim 19
Dependent Claim
31 words
A process as set forth in claim 17 wherein said second precursor compound is selected from the group dichloro (Parylene D) consisting of di(p-xylylene), di(monochloro-p-xylylene), di(dichloro-p-xylylene), benzene, toluene, xylene, and acetylene.
Claim 20
Dependent Claim
15 words
A process as set forth in claim 18 wherein said second precursor compound is acetylene.
Claim 21
Dependent Claim
15 words
A process as set forth in claim 18 wherein said second precursor compound comprises di(chloro-p-xylylene).
Claim 22
Dependent Claim
27 words
A process as set forth in claim 16 wherein the second coating layer is threadlike in character and comprises fibrils contacting and extending into said primer coating.
Claim 23
Dependent Claim
17 words
A process as set forth in claim 16 wherein said second precursor compound is an acetylenic compound.
Claim 24
Dependent Claim
72 words
A process as set forth in claim 1 wherein the glow discharge polymerization for formation of said second coating layer is carried out under conditions such that the value of W/FM is between about 2×10 9 and about 60×10 9 joules per kg where W=the power input flux to the glow discharge zone F=the flow rate of monomer into the glow discharge zone M=the average molecular weight of the glow discharge plasma.
Claim 25
Dependent Claim
37 words
A process as set forth in claim 23 wherein the power input to the glow discharge zone during the deposition of said second coating layer is between about 1.5×10 -2 and about 15×10 -2 watts/cm 3 .
Claim 26
Dependent Claim
30 words
A process as set forth in claim 23 wherein the glow discharge polymerization deposition rate of said second coating layer is between about 5 and about 7 angstroms per minute.
Claim 27
Dependent Claim
47 words
A process as set forth in claim 23 wherein a fraction of argon is included in the gas fed to said glow discharge zone during the deposition of said second coating layer, whereby the value of W/FM is increased at constant power input and total flow rate.
Claim 28
Dependent Claim
74 words
A process as set forth in claim 23 wherein the glow discharge polymerization for formation of said primer coating layer is carried out under conditions such that the value of W/FM is between about 5×10 9 and about 500×10 9 joules per kg where W=the power input per unit volume of the glow discharge zone F=the flow rate of monomer into the glow discharge zone M=the average molecular weight of the glow discharge plasma.
Claim 29
Dependent Claim
37 words
A process as set forth in claim 27 wherein the power input to the glow discharge zone during the deposition of said primer coating layer is between about 1.5×10 -2 and about 15×10 -2 watts/cm 3 .
Claim 30
Dependent Claim
30 words
A process as set forth in claim 27 wherein the glow discharge polymerization deposition rate of said primer coating layer is between about 5 and about 9 angstroms per minute.
References Cited (Backward Citations)
USPTO Annuity & Maintenance Windows
| Annuity Stage | Window Opens | Payment Deadline | Surcharge Period Until | Estimated Fee | Status |
|---|---|---|---|---|---|
| 3.5 Years (Year 4) | 1993-04-30 | 1993-10-30 | 1994-05-01 | $2000.00 | Window Closed / Lapsed |
| 7.5 Years (Year 8) | 1997-04-30 | 1997-10-30 | 1998-05-01 | $3760.00 | Window Closed / Lapsed |
| 11.5 Years (Year 12) | 2001-04-30 | 2001-10-30 | 2002-05-01 | $7700.00 | Window Closed / Lapsed |