US5418003A
Expired / Lapsed
US
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Vapor deposition of ceramic materials
Assignee: General Electric Co
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Filing: 1993-09-10
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Granted: 1995-05-23
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Expires: 2013-09-10
Abstract
Abstract Evaporated ceramic coatings are prepared by furnishing an ingot of a ceramic material, treating the ingot to reduce sources of gas within the ingot, and evaporating the ceramic material in the ingot by melting the surface of the ingot with an intense heat source. The evaporated ceramic is deposited upon a substrate as the ceramic coating. The reduced gas content of the ingot decreases the incidence of spitting and eruptions from the molten surface of the ingot, thereby improving the quality of the deposited coating, and facilitating increases in evaporation rates and coatings process production rates.
Inventors
- 👤 Robert W. Bruce
- 👤 David W. Skelly
- 👤 William P. Minnear
- 👤 Richard A. Nardi, Jr.
- 👤 David J. Wortman
- 👤 Antonio F. Maricocchi
- 👤 Rudolfo Viguie
- 👤 David V. Rigney
Bibliographic Details
Application Number
—
Jurisdiction
US
Data Source
google_patents
Last Synchronized
2026-11-09 03:09
CPC Classifications
C; C23; C23C; C23C14/00; C23C14/06; C23C14/08; C23C14/083; C23C14/22; C23C14/24; Y; Y02; Y02T; Y02T50/00; Y02T50/60
Claims Analysis
Total Claims: 21
Claim 1
Independent Claim
73 words
A method for depositing evaporated ceramic coatings, comprising the steps of: furnishing an ingot of a ceramic material, the ingot having porosity therein; next, treating the ingot to reduce sources of gas trapped within the porosity of the ingot; followed by evaporating the ceramic material in the previously treated ingot by melting the surface of the ingot with an intense heat source; and depositing the evaporated material upon a substrate as a coating.
Claim 2
Independent Claim
73 words
A method for depositing evaporated ceramic coatings, comprising the steps of: furnishing an ingot of a ceramic material, the ingot having porosity therein; next, treating the ingot to reduce sources of gas trapped within the porosity of the ingot; followed by evaporating the ceramic material in the previously treated ingot by melting the surface of the ingot with an intense heat source; and depositing the evaporated material upon a substrate as a coating.
Claim 3
Dependent Claim
35 words
The method of claim 1, wherein the step of treating is accomplished by heating the ingot to a temperature at which substantially all entrapped gas is evolved from the ingot before the step of evaporating.
Claim 4
Dependent Claim
17 words
The method of claim 2, wherein the step of heating the ingot is performed in a vacuum.
Claim 5
Dependent Claim
38 words
The method of claim 2, wherein the temperature to which the ingot is heated during the step of heating is at least about 750° C. (1382° F.) but less than about 1400° C. (2552° F.) in a vacuum.
Claim 6
Dependent Claim
36 words
The method of claim 1 further including the step of protecting the ingot against reintroduction of gas prior to the evaporating step and after the treating step by sealing the ingot in a vacuum sealed container.
Claim 7
Dependent Claim
19 words
The method of claim 1 wherein the step of treating to remove gases includes treating to remove water vapor.
Claim 8
Dependent Claim
51 words
The method of claim 6 further including the step of protecting the ingot against reintroduction of water vapor prior to the evaporating step and after the heating step by sealing the ingot in a hermetically sealed container backfilled with a gas selected from the group consisting of oxygen and inert gases.
Claim 9
Dependent Claim
35 words
The method of claim 1, wherein the step of furnishing an ingot includes providing an ingot having a length and a diameter, and the length is from about one to about four times the diameter.
Claim 10
Dependent Claim
18 words
The method of claim 1, wherein the step of furnishing an ingot includes furnishing a modified zirconium oxide.
Claim 11
Independent Claim
80 words
A method for depositing evaporated ceramic coatings, comprising the steps of, in sequence: furnishing an ingot of a porous yttria-stabilized zirconia ceramic material having a density of less than 3.6 grams per milliliter; treating the ingot to increase the density of the ingot to at least 3.6 grams per milliliter; evaporating the ceramic material in the ingot by melting the surface of the ingot with an intense heat source; and depositing the evaporated material upon a substrate as a coating.
Claim 12
Independent Claim
80 words
A method for depositing evaporated ceramic coatings, comprising the steps of, in sequence: furnishing an ingot of a porous yttria-stabilized zirconia ceramic material having a density of less than 3.6 grams per milliliter; treating the ingot to increase the density of the ingot to at least 3.6 grams per milliliter; evaporating the ceramic material in the ingot by melting the surface of the ingot with an intense heat source; and depositing the evaporated material upon a substrate as a coating.
Claim 13
Independent Claim
119 words
A method for depositing evaporated ceramic coatings, comprising the steps of, in sequence: furnishing an ingot of a ceramic material having a chemical composition of a gas-forming impurity element and oxides thereof sufficiently low that a negligible amount of gas is evolved during surface melting of the ingot, the gas-forming impurity element including at least one element selected from the group consisting of carbon, aluminum, silicon, phosphorus, iron, chlorine, and titanium, and wherein the total weight of the gas forming impurity elements is no greater than 0.05% by weight; evaporating the ceramic material in the ingot by melting the surface of the ingot with an intense heat source; and depositing the evaporated material upon a substrate as a coating.
Claim 14
Independent Claim
119 words
A method for depositing evaporated ceramic coatings, comprising the steps of, in sequence: furnishing an ingot of a ceramic material having a chemical composition of a gas-forming impurity element and oxides thereof sufficiently low that a negligible amount of gas is evolved during surface melting of the ingot, the gas-forming impurity element including at least one element selected from the group consisting of carbon, aluminum, silicon, phosphorus, iron, chlorine, and titanium, and wherein the total weight of the gas forming impurity elements is no greater than 0.05% by weight; evaporating the ceramic material in the ingot by melting the surface of the ingot with an intense heat source; and depositing the evaporated material upon a substrate as a coating.
Claim 15
Dependent Claim
22 words
The method of claim 11, wherein the gas forming impurity element is carbon present in the amount of 500 ppm or less.
Claim 16
Dependent Claim
22 words
The method of claim 11, wherein the gas forming impurity element is aluminum present in the amount of 100 ppm or less.
Claim 17
Dependent Claim
22 words
The method of claim 11, wherein the gas forming impurity element is phosphorus present in the amount of 300 ppm or less.
Claim 18
Dependent Claim
22 words
The method of claim 11, wherein the gas forming impurity element is iron present in the amount of 1000 ppm or less.
Claim 19
Dependent Claim
22 words
The method of claim 11, wherein the gas forming impurity element is silicon present in the amount of 500 ppm or less.
Claim 20
Dependent Claim
22 words
The method of claim 11, wherein the gas forming impurity element is chlorine present in the amount of 500 ppm or less.
Claim 21
Dependent Claim
22 words
The method of claim 11 wherein the gas forming impurity element is titanium present in the amount of 1000 ppm or less.
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) | 1998-05-22 | 1998-11-21 | 1999-05-23 | $2000.00 | Window Closed / Lapsed |
| 7.5 Years (Year 8) | 2002-05-22 | 2002-11-21 | 2003-05-23 | $3760.00 | Window Closed / Lapsed |
| 11.5 Years (Year 12) | 2006-05-22 | 2006-11-21 | 2007-05-23 | $7700.00 | Window Closed / Lapsed |