US 11,945,756 B2
Protective internal coatings for porous substrates
Sankar Sambasivan, Chicago, IL (US); Vikram S. Kaul, Atlanta, GA (US); and Francis R. Chapman, Chicago, IL (US)
Assigned to APPLIED THIN FILMS, INC., Skokie, IL (US)
Filed by Applied Thin Films, Inc., Skokie, IL (US)
Filed on Oct. 19, 2020, as Appl. No. 17/073,486.
Application 17/073,486 is a division of application No. 15/994,445, filed on May 31, 2018, abandoned.
Application 15/994,445 is a continuation of application No. 14/612,482, filed on Feb. 3, 2015, granted, now 9,988,316.
Application 14/612,482 is a continuation of application No. 13/608,773, filed on Sep. 10, 2012, abandoned.
Prior Publication US 2021/0221747 A1, Jul. 22, 2021
Int. Cl. C04B 38/00 (2006.01); C04B 35/195 (2006.01); C04B 35/52 (2006.01); C04B 41/00 (2006.01); C04B 41/50 (2006.01); C04B 41/85 (2006.01); C23C 18/12 (2006.01); F01D 5/28 (2006.01)
CPC C04B 38/0096 (2013.01) [C04B 35/195 (2013.01); C04B 35/522 (2013.01); C04B 38/0054 (2013.01); C04B 41/009 (2013.01); C04B 41/5092 (2013.01); C04B 41/85 (2013.01); C23C 18/1216 (2013.01); C23C 18/1229 (2013.01); C23C 18/125 (2013.01); F01D 5/288 (2013.01); C04B 2235/3206 (2013.01); C04B 2235/3208 (2013.01); F05D 2300/514 (2013.01); F05D 2300/6033 (2013.01); Y02T 50/60 (2013.01); Y10T 428/249921 (2015.04); Y10T 428/249967 (2015.04); Y10T 428/249969 (2015.04); Y10T 428/24997 (2015.04); Y10T 428/249978 (2015.04); Y10T 428/268 (2015.01)] 29 Claims
 
1. A coated material, comprising:
a porous inorganic substrate having an internal pore system comprising internal pores and interconnected interior channels in open communication with an exterior surface of the porous substrate, and having an initial open porosity with a mean pore diameter of up to 5 micrometers prior to coating; and
a cured phospho-alumina coating having a thickness of 1 nm to 500 nm that conformally coats walls of the internal pores and the interconnected interior channels, the phosphor-alumina coating having an aluminum-to-phosphorous atomic ratio of 0.5:1 to 20:1;
wherein the internal pore system is substantially maintained such that the coated material comprises internal pores and interconnected interior channels in open communication with an exterior surface of the coated material, and
wherein the coated material has an open porosity that is at least 50% of the initial open porosity of the porous substrate prior to coating.