US5648127A
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Method of applying, sculpting, and texturing a coating on a substrate and for forming a heteroepitaxial coating on a surface of a substrate
Assignee: QQC Inc
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Filing: 1995-06-05
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Granted: 1997-07-15
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Expires: 2015-06-05
Abstract
Abstract Energy, such as from one or more lasers, is directed at the surface of a substrate to mobilize and vaporize a constituent element (e.g., carbide) within the substrate (e.g., steel). The vaporized constituent element is reacted by the energy to alter its physical structure (e.g., from carbon to diamond) to that of a composite material which is diffused back into the substrate as a composite material. An additional secondary element, which can be the same as or different from the constituent element, may optionally be directed (e.g., sprayed) onto the substrate to augment, enhance and/or modify the formation of the composite material, as well as to supply sufficient or additional material for fabricating one or more coatings on the surface of the substrate. The process can be carried out in an ambient environment (e.g., without a vacuum), and without pre-heating or post-cooling of the substrate. Articles formed by the disclosed processes are described, including three-dimensional objects.
Inventors
- 👤 Manuel C. Turchan
- 👤 Pravin Mistry
Bibliographic Details
Application Number
—
Jurisdiction
US
Data Source
google_patents
Last Synchronized
2026-11-04 17:31
CPC Classifications
C; C23; C23C; C23C14/00; C23C14/06; C23C14/0605; C23C16/00; C23C16/44; C23C14/22; C23C14/24; C23C14/28; C23C16/22; C23C16/26; C23C16/27; C23C16/4418; C23C16/48; C23C26/00; C30; C30B; C30B23/00; C30B23/02; C30B25/00; C30B25/02; C30B25/10; C30B25/105; C30B25/18; C30B29/00; C30B29/02; C30B29/04; F; F41; F41A; F41A21/00; F41A21/02; F41A21/04; F16; F16C; F16C33/00; F16C33/30; F16C33/58; F16C33/62; Y; Y10; Y10S; Y10S427/00; Y10S427/103; Y10S427/104
Claims Analysis
Total Claims: 36
Claim 1
Independent Claim
115 words
A method of applying and texturing a coating on a substrate, without masking, comprising: directing energy at a surface of a substrate, and with the energy: mobilizing one or more constituent elements in a sub-surface zone of the substrate; moving the one or more constituent elements towards the surface of the substrate; vaporizing amounts of a selected portion of the one or more constituent elements in a controlled manner; reacting the vaporized one or more constituent elements; and forming from the reacted, vaporized one or more constituent elements a material in the sub-surface zone of the substrate; and further comprising: fabricating, applying and texturing with the energy, a coating on the surface of the substrate.
Claim 2
Independent Claim
115 words
A method of applying and texturing a coating on a substrate, without masking, comprising: directing energy at a surface of a substrate, and with the energy: mobilizing one or more constituent elements in a sub-surface zone of the substrate; moving the one or more constituent elements towards the surface of the substrate; vaporizing amounts of a selected portion of the one or more constituent elements in a controlled manner; reacting the vaporized one or more constituent elements; and forming from the reacted, vaporized one or more constituent elements a material in the sub-surface zone of the substrate; and further comprising: fabricating, applying and texturing with the energy, a coating on the surface of the substrate.
Claim 3
Dependent Claim
18 words
Method, according to claim 1, further comprising: while directing the energy at the substrate, electrically biassing the substrate.
Claim 4
Dependent Claim
21 words
Method, according to claim 1, further comprising: inducing, with the energy, physical stresses in the coating being fabricated on the substrate.
Claim 5
Dependent Claim
14 words
Method, according to claim 1, further comprising: surface finishing the coating with the energy.
Claim 6
Dependent Claim
17 words
Method, according to claim 1, further comprising: fabricating the coating on a selected area of the substrate.
Claim 7
Dependent Claim
14 words
Method, according to claim 1, further comprising: fabricating a multi-layer coating on the substrate.
Claim 8
Dependent Claim
64 words
Method, according to claim 1, wherein: the coating is fabricated on a selected area of the substrate; a first portion of the coating extends in one direction from the surface of the substrate to a position above the surface of the substrate; and a second portion of the coating extends in an other direction from the position, from the first portion of the coating.
Claim 9
Dependent Claim
28 words
Method, according to claim 1, further comprising: while directing the energy at the substrate, providing a secondary element from an external source; wherein the secondary element comprises carbon.
Claim 10
Dependent Claim
12 words
Method, according to claim 1, wherein: the substrate is a cutting tool.
Claim 11
Dependent Claim
21 words
Method, according to claim 1, wherein: the coating is a material selected from the group consisting of diamond and diamond-like carbon.
Claim 12
Dependent Claim
28 words
Method, according to claim 1, wherein: providing the energy directed at the surface of the substrate by directing beams from three lasers towards the surface of the substrate.
Claim 13
Dependent Claim
15 words
Method, according to claim 1, wherein: more than one surface of the substrate is coated.
Claim 14
Dependent Claim
14 words
Method, according to claim 1, wherein: the coating is diffusion bonded to the substrate.
Claim 15
Dependent Claim
12 words
Method, according to claim 1, wherein: the substrate is a planar substrate.
Claim 16
Dependent Claim
13 words
Method, according to claim 1, wherein: the substrate is a substantially cylindrical substrate.
Claim 17
Dependent Claim
64 words
Method, according to claim 1, wherein: the substrate is an object selected from the group consisting of a valve seat, a draw tool, a can punch, a container seaming tool, a bearing, a helical travelling wave tube, a resistive heating element, an article of cookware, a replacement joint, a gun barrel, a cylinder liner, a razor, a knife, a scalpel, and a drill bit.
Claim 18
Dependent Claim
17 words
Method, according to claim 1, wherein: the coating is formed as a chip-breaker on a cutting tool.
Claim 19
Independent Claim
110 words
A method of forming a heteroepitaxial coating on a surface of a substrate, comprising: directing energy at a surface of a substrate, and with the energy: mobilizing one or more constituent elements in a sub-surface zone of the substrate; moving the one or more constituent elements towards the surface of the substrate; vaporizing amounts of a selected portion of the one or more constituent elements in a controlled manner; reacting the vaporized one or more constituent elements; and forming from the reacted, vaporized one or more constituent elements a material in the sub-surface zone of the substrate; and further comprising: fabricating a heteroepitaxial coating on the surface of the substrate.
Claim 20
Independent Claim
110 words
A method of forming a heteroepitaxial coating on a surface of a substrate, comprising: directing energy at a surface of a substrate, and with the energy: mobilizing one or more constituent elements in a sub-surface zone of the substrate; moving the one or more constituent elements towards the surface of the substrate; vaporizing amounts of a selected portion of the one or more constituent elements in a controlled manner; reacting the vaporized one or more constituent elements; and forming from the reacted, vaporized one or more constituent elements a material in the sub-surface zone of the substrate; and further comprising: fabricating a heteroepitaxial coating on the surface of the substrate.
Claim 21
Dependent Claim
18 words
Method, according to claim 18, further comprising: while directing the energy at the substrate, electrically biassing the substrate.
Claim 22
Dependent Claim
21 words
Method, according to claim 18, further comprising: inducing, with the energy, physical stresses in the coating being fabricated on the substrate.
Claim 23
Dependent Claim
14 words
Method, according to claim 18, further comprising: surface finishing the coating with the energy.
Claim 24
Dependent Claim
17 words
Method, according to claim 18, further comprising: fabricating the coating on a selected area of the substrate.
Claim 25
Dependent Claim
14 words
Method, according to claim 18, further comprising: fabricating a multi-layer coating on the substrate.
Claim 26
Dependent Claim
64 words
Method, according to claim 18, wherein: the coating is fabricated on a selected area of the substrate; a first portion of the coating extends in one direction from the surface of the substrate to a position above the surface of the substrate; and a second portion of the coating extends in an other direction from the position, from the first portion of the coating.
Claim 27
Dependent Claim
28 words
Method, according to claim 18, further comprising: while directing the energy at the substrate, providing a secondary element from an external source; wherein the secondary element comprises carbon.
Claim 28
Dependent Claim
12 words
Method, according to claim 18, wherein: the substrate is a cutting tool.
Claim 29
Dependent Claim
21 words
Method, according to claim 18, wherein: the coating is a material selected from the group consisting of diamond and diamond-like carbon.
Claim 30
Dependent Claim
28 words
Method according to claim 18, wherein: providing the energy directed at the surface of the substrate by directing beams from three lasers towards the surface of the substrate.
Claim 31
Dependent Claim
15 words
Method, according to claim 18, wherein: more than one surface of the substrate is coated.
Claim 32
Dependent Claim
14 words
Method, according to claim 18, wherein: the coating is diffusion bonded to the substrate.
Claim 33
Dependent Claim
12 words
Method, according to claim 18, wherein: the substrate is a planar substrate.
Claim 34
Dependent Claim
13 words
Method, according to claim 18, wherein: the substrate is a substantially cylindrical substrate.
Claim 35
Dependent Claim
64 words
Method, according to claim 18, wherein: the substrate is an object selected from the group consisting of a valve seat, a draw tool, a can punch, a container seaming tool, a bearing, a helical travelling wave tube, a resistive heating element, an article of cookware, a replacement joint, a gun barrel, a cylinder liner, a razor, a knife, a scalpel, and a drill bit.
Claim 36
Dependent Claim
17 words
Method, according to claim 18, wherein: the coating is formed as a chip-breaker on a cutting tool.
References Cited (Backward Citations)
No citation records indexed.
USPTO Annuity & Maintenance Windows
| Annuity Stage | Window Opens | Payment Deadline | Surcharge Period Until | Estimated Fee | Status |
|---|---|---|---|---|---|
| 3.5 Years (Year 4) | 2000-07-14 | 2001-01-13 | 2001-07-15 | $2000.00 | Window Closed / Lapsed |
| 7.5 Years (Year 8) | 2004-07-14 | 2005-01-13 | 2005-07-15 | $3760.00 | Window Closed / Lapsed |
| 11.5 Years (Year 12) | 2008-07-14 | 2009-01-13 | 2009-07-15 | $7700.00 | Window Closed / Lapsed |