CA2039462A1

CA2039462A1 - Room temperature curable surface coatings and methods of producing and applying same

Info

Publication number: CA2039462A1
Application number: CA002039462A
Authority: CA
Inventors: Paul N. Bosco; Terrance P. Fay
Original assignee: Paul N. Bosco; Terrance P. Fay; Ceram Tech International, Ltd.
Current assignee: Ceram Tech International Ltd
Priority date: 1990-03-28
Filing date: 1991-03-28
Publication date: 1991-09-29
Also published as: WO1991014662A1; EP0477362A4; KR920701078A; JPH04506769A; EP0477362A1; BR9105236A; AU7899491A; US5164003A; US5330794A

Abstract

ABSTRACT OF THE DISCLOSURE

A silica-based coating for, and a method for coating glass, metal, ceramic, and plastic surfaces by forming single cross-linked O-Si-O polymer chains. The coating generally comprises a binder and a filler. The binder is a mixture of silica-based polymers, colloidal silica, and metal oxide particles in an aqueous suspension. It includes four main ingredients: an alkali metal silicate; silica gel; a cross-linking agent such as methyltrimethoxysilane or tetraethoxysilane; and water. After curing, the binder forms an amorphous layer that binds the fillers to the surface. The protective coating is formed at room temperature, without the addition of energy in any form. The fillers are chosen to provide the coating with mechanical strength, abrasion resistance, and increased corrosion resistance. Fillers may also be chosen to modify the coating's dielectric constant, to improve the coating's surface lubricity, and to alter the coating's thermal coefficient of expansion. Typical fillers include clay, wollastonite, nepheline syenite, talc, flint, ceramic fibers, metallic fibers, ceramic microspheres, glass microspheres, cerium dioxide, and dichromium trioxide.

Description

ROOM TEMPERaq!UR~ C~JRABL~B 8~R:@ACE COATIN(:8 A~D NE~IOD
0~ PRQD~CING AND APP~YI~G AME

Inventors: Paul Noel Bosco, of Fort Lee, N~w ~ersey and Terrance Patrick Fay, of Vernon, New Jersey.

~I~LD OF ~E I~V~N~ION
This invention relates to silica-based coatings which bond to most ~urfaces and can be cured at room temperature to form amorphous ceramic matric~s. These protective coatings may be applied to metal, ceramic, glass, or polymer sur~aces. The coatings form an amorphous ceramic matrix upon drying at room temp0rature.

~AC~ROU~D

coatings are often used to protect surfaces against wear and corrosion. The coatings are generally composed o~
binders, fillers, and other ingredients. The binders, upon curing, hind the fillers and other i~gredients to each other and to the substrate. The fillers are added-principally as rein~orcing agents; to increase corrosion resistance; to increase abrasion resistance; to increase surface lubrici~y;`
and/or to increase the load of total solids (which increases the coating's dried-to-wet ratio and, therefors, reduces the drying shrinkage and the resultant stress cracks~.~ Other ingredients are added t~ modify physical properties of the surface, such as its color (~ g~,~the pigment in a paint).
Coatings bond to a surface by means of coupling agents. Coupling agents form bonds between the binder in ~he coating and the surface to be Goated. ~hey can also ''. '' ` ` ' '` ~, ,' i : :' ~ ~

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contribute to the cohesive strength of coatings comprising polymer chains by cross-linking the polymer chains. The use of organosilaneR as coupling agents is discussed in an article by Barry Arkles entitled ~Silane Coupling Agent chemistry,"
which was published in ~'Silicone Compounds Register and Review (S-7)," by R. Andersonl B. Arkles, and G.~. Larson (Petrach Systems, 1987), and in an article by Warde T. Collins entitled "Adhesion Promoters," which was published as Chapter 10 in "Handbook of Coatings Additives," edited by Leonard Kelbo (Marcel Dekker, 1987). The latter article is distributed by Dow Corning as Brochure No. 24-481-87.
Silica-based coatings known in the art have silica to alkaline-metal-oxide molar ratios in the binder no higher than 6.5:1. These coatinqs require the application of heat to bind to the surfaces of the material ~eing coated.
Moreover, these coatings do not ~orm true amorphous ceramic matrices at room temperature.

~VM~ARY OF T~E INVE~IO~
This invention provides novel non-toxic ceramic coatings which can bé used on glass, metal, ceramic, plastic, and other surfaces to protect these surfaces against wear and corrosion. These ceramic coatings may be designed to have a low dielectric constant. Moreover, these protective water-based coatings can be air-dried at room temperature, without the application of any additional energy in any form. The coatings are generally over 95% dry within 24 hours, and dry complPtely in six days at room temperature.
The specific composition of the coatings can be varied to closely match a property of the substrate, such as .-,: , : .
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its thermal expansion coefficient, or to match the coating toa particular application. A wide range of fillers and active ingredients may be included in the coatings to engineer the surface properties ~or a particular applica~ion. For example, specific fillers may be chosen to improve the sur~ace lubricity, abrasion resistance, or chemical resistance.
Certain fillers exhibit increased heat resistance, or can best withstand large temperature changes.
The binders used in the coatings o~ the present invention are not true solutions. They are mixtures of soluble ionic and covalent silica-based polymers, colloidal silica, and possibly metal-oxide particles in an aqueous suspension. The binder provides the ~lexibility, the bonding properties, some of the thermal and chemlcal resistance, and the integrity o~ the coating.
The following definitions should be ascribed to the terms listed below, as used in this specification and in the appended claims:
"Alkali metal silicate", as used herein, means essentially alkali metal silicate.
"Cerium dioxide", as used herein, means essentially cerium dioxide.
"Cross-linking agent", as used herein, means an agent which links one polymer chain to another.
"Dichromium trioxide", as used herein, means essentially dichromium trioxide.
"Glass", as used herein, means essentially glass.
"Lithium silicate", as used herein, means essentially lithium silicate.
"Metal" or "metallic", as used herein, means .

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essentially metal or essentially metallic.
"Methyltrimethoxysilanel', as used herein, means essentially methyltrimethoxysilane.
':Organo-functional silane", as used herein, means a silicon-containing compound in which an organic radical that does not hydrolyze attaches with a single bond to the silicon atom, and hydrolyzable radicals typically attach to the silicon atom with the other three silicon bonds. However, up to three non-hydrolyzable groups (and one hydrolyzable group) may attach to a single silicon atom. Organo-functional silanes can be represented by the chemical formula RnSiXt~n~
where R is the nonhydrolyzable organic radical, and O < n s 3.
It possesses a functionality which enables the coupling agent to bond with organic resins and polymers, metals, inorganic materials, and/or obtain specific properties (e.g., hydrophobicity). The X group is a hydrolyzable group such as an alkoxy, acyloxy, amine, or chlorine.
"Plastic" means essentially plastic.
"Potassium silicate" means essentially potassium silicate.
"Silica gel" means essentially silica gel.
"Sodium silicate" means essentially sodium silicate.
"Tetraethoxysilane" means essentially tetraethoxysilane.

It is an object of the present invention to provide improved silica-based coatings, and processes for making and applying such coatings.

More specifically, a first object of the present invention is to provide a silica-based coating which , - ~ ~. . ' .
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chemically bond~ without heating to most surfaces, including glass, metal, plastic, ceramic, and other surfaces.
A second object of the present invention is to provide a silica-based coating which can be cured at room temperature to form an amorphous ceramic matrix.
A third object of the present invention is to provide a silica-based coating which can be tailored to have specific pxoperties, such as a high emissivity, or a low dielectric constant.
A fourth object of the present invention is to provide protective ceramic coatings that are non-toxic and can be easily applied to many types of surfaces, including metal, plastic, glass, and ceramic surfaces.
A fifth object of the present invention is to provide chemically resistant amorphous alkali metal silicate coatinqs.
A sixth object of the present invention is tv provide methods for producing the above enumerated protective coatings.
These and other objects o~ the invention are achieved with the present invention, which is described in detail below and in the appended claims.

D~aIT!~D DB8CRIP~XO~ OF ~ NVE~ION
~ he coating according to the pre~ent invention is formed by combining a binder, a filler, and, in some cases, active ingredients. The volume percent of the binder is between 15 and 88%, the volume percent o~ the filler is between 12 and 80~, and the volume percent of the active ingredients is between 0 and 55~. For applications which _ _ _ _ _ _ _ ., . ... ... .... . . _ . ~ .. . . . _ . ~ _ _ .

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require especially strony honding, the preferred binder concentration range is 80%-88%. Preferred concentration ranges for the filler include 75-80%, 45-50%, and 18-24%.
Bi~er The binder is a mixture of soluble ionic and covalent silica-based polymers, colloidal silica, and metal oxide particles in an aqueous suspension. When the binder dries, it forms an amorphous layer which binds the fillers and the active ingredients together and to the substrate~ The binder functions by combining silicon dioxide with a cross-linking agent and an alkali metal oxide.
The binder has four main ingredients: an alkali metal silicate such as potassium silicate, sodium silicate or lithium silicate; silica gel; a cross-linkin~ aqent such as methyltrimethoxysilane (MTMS), tetraethoxysilane (TEOS) or any other organo-functional silane; and water. The ratios of the four components is significant. The quantities of the alkali metal silicate, the silica gel and the cross-linking agent must be such that the molar ratio of silicon dioxide to metal oxide in the binder is between 8.5:1 and 6.6:1. Ratios much above 8.5:1 result in gelation, while ratios below 6.6:1 weaken the coating's resistance to solvents. Note that the~e are the ratios in the binder itself. These ar~ not the ratios in the final product, which may include silicon dioxide or metal oxides in the other coating ingredients.
The silicon dioxide in the binder is preferably provided by the alkali metal silicate, the silica gel, and, in some preferred embodiments, the cross-linking agent.
Dichromium trioxide and cerium dioxide are often added as ~illers but may also function as cross-linking agents, in .

which case they would be part of the binder as well as part of the filler. Their presence has some beneficial ePfect on the coatings. In particular, dichromium trioxide with a particle size of 0.5 microns and smaller has been found to aid in bond-ing to the substrate and to increase thermal shock resistance.
Oth~r metal oxides and hydroxides may also function similarly.

When MTMS is used as the cross-linking agent in the binder, it reacts with water, releasing methanol and complexing the resulting silanol with other binder constituents forming essentially single cross-linked o-si-o polymer chains. This dif~ers from the usual double cross-linked oxygen bond for silicon dioxide. The bonds form differently because the fourth silicon bond is unavailable, since it has been captured by the methyl group. The normal double cross-linked bond for silicon dioxide mak~s the polymer harder but much less flexible. The enhanced ~lexibility of the coating provided by the present invention allows the coating to retain its integrity as it dries at room temperature.
The order of combining the constituents may affect the properties of the final coating, at least for low turbulence mixing of the constituents. When MTMS is added to the potassium silicate before the silica gel, and low turbulence mixing is used, the coating ~ormed is more water/alkali resistant but less flexible than the coating formed when the pokassium silicate solution and silica gel are combined before adding MTMS.~
Higher leveIs of MTMS result in a more resistant but less flexible coating which is thought to have less thermal ~`:

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stability because the methyl groups will oxidize off the polymers at some temperature and the larger amounts will generate more gases and require more accommodation within the polymer structureO
~ he nature o~ the silica gel suspension is also very important. Experiments were done using ~hree sizes for the SiO2 particles in the silica gel suspension: Remet SP30 silica gel which has a 7~8 micron average particle size; DuPont Corp Ludox AM silica gel which has a 12 micron average particle size; and DeGussa Corporation K328 silica gel which has a 30 micron average particle size. The use o~ the larger particle sizes resulted in a softer, more flexible coating becausa the silica gel did not dissolve completely, so that SiO2 particles xemained in suspension. The average distance between particles increased and the actual ratio of K2O to sio2 in the solution itself increased since more of the silica was in the bulk o~ the silica gel particles.
Increasing the ratio of silica gel to potassium silicate raises the Sio2/K2o ratio while maintaining an essentially constant solids level and, therefore, increases the brittleness of the coating.
In one preferred embodiment of the invention, potassium silicate is used as the alkali metal silicate, and NTMS is used as the cross-linking agent. More thermally stable and/or hydrophobic groupings may be substituted for the MTMS. Increased hydrophobicity and size o~ the organic group on the silane in theory will improve per~ormance since this will result in less penetration by aqueous material ~or the same concentration of pores and the same pore sizing. Phenyl silane and trifluoropropyl silane oligomer are possible - . . . .

~ 3l substitutes. ~henyl silane w~en substi~uted completely for MTNS Eormed a binder which was very water repellent and did not dissolve in boiling water. Trifluoropropyl silane oligomer should also ~orm a very hydrophobic surface.
Combinations of these compounds may also be effective as cross-linking agents.
Tetraethoxysilane (TES) is a possible substitute ~or at least part of the silica gel. Generally, reducing silica gel particle size improves the binder by making it more uniform, making it bond b~tter and making it more stable. The major impediment to using TES is its production of alcohol, and the reduction of the water content of the hinder that causes gelation as the TES level is increasedO This problem can be overcome by combining TES with silica gel or by adding ions which hinder gelation, or both~ It is also possible to substitute an oligomeric silane having fswer hydrolysis products than monomeric silanes and replace the silanes' hydrolyzable group with non-alcohol groups. Halogen and acetate terminated groups yield acids and disilazane groups yield ammonia. Some combination o~ th~se may be suitable.
The addition of transition matal oxides may be bene-ficial if they can be incorporated in sol/gel form compatible with the coating. These oxides could substitute in part for the potassium in the binder. The transition metals form multivalent covalent bonds, unlike potassium which forms monovalent ionic bonds. Thus the addition of transition metal oxides can affect the coating's hardne~s, flexibility, and chemical resistance.
Initial work has been done using various salts or oxides of cerium, chrome, titanium, tungsten, molybdenum, nickel, .

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~ ~i3 ~ 2 cobalt, zinc, boron, copper and manganese. These may best be used in colloidal dispersions ~o that the pH can ~e balanced by combining acid and base materials. Another approach to in-corporating the metal oxides would be to suspend them in surfactant/chellating agents or to start with organometallic compounds or complexes such as metallic soaps or quaternary ammonium complexes.
A preferred formulation for a binder having an SiO2 to K20 molar ration of 7.4 is:
62.4% by weight Kasil 1 from Philadelphia Quartz 1.32% by weight MTMS
36.3% by weight RemasQl SP30 No water is added during the preparation stage to the water already in the Kasil and Remasol. After the binder is made, it may be diluted with water for ease of mixing and spraying.
As nated above, dichromium dioxide may function as a binder, although it always functions as a ~iller. It may be added to the above formulation at a molar ratio of Cr203 to Sio2 in the binder of 0.267 to 1.07. The amount of Cr203 used is dictated by its role as a filler: it depends upon the particular application, and upon the other filler constituents.

Filler Fillers are added to the binder to improve the physical properties of the coatings. Because the filler constituents are usually larger than the binder constituents, their surface chemistry is less importantO The shape and size of the filler particles is important. Spherically shaped ' :

particles allow maximum solids loading ~ut there is some trade-off in porosity and coating viscosity. Platelet- and fiber-shaped particles may be added to reinforce the coating's ability to handle both internal forces (such as drying stresses~ and externally applied forces. ~owever, they can only be used at relatively low level~ since they increase the coatings' viscosity and porosity~ Hollow microspheres can be used to reduce the density and modify properties such as the dielectric constant of the coatings.
The particle size will affect the hardness and the uniformity of the coating. It must also be compatible with the desired coating thickness. In some formulations, fillers such as nepheline syenite are used because they have specific chemical interactions with other components at high tempera-ture and are useful for high temperature coatings.
The filler requirements for the coating can be further optimized by determining the best particle size distributions of the filler particles for a particular application. Furthermor~, other filler materials with better physical and chemical properties for a particular application can be found.
The preferred fillers used, along with the permissible volume ranges, include:
Dichromium Trioxide (may also have some solubility in potassium silicate and usefulness as a cross-linking agent) ...... ......................... ... 0-60 Cerium Dioxide Imay also have some solubility in potassium silicate and usefulness as a ~ross-linking agent) , ~
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.................................... 0-60 Titanium Dioxide (may also have llsefulness as a cross- linking agent) .................................... 0-60 Clay.. ~............................ O.............. 0-50 Nepheline Syenite ...................... ~......... 0-50 Wollastonite ................................ ,.... 0-50 ~alc .............................................. 0-50 Flint ............................................. 0-50 Alumina ~80 mesh).................................. 0-30 Glass Flakes (borosilicate or oda-lime glasses)...0-15 Reinforcing Agents................................. 0-50 - ceramic fibers and/or platelets - metailic fibers and/or platelets - organic fibers and/or platelets Ceramic Microspheres................................. 0-50 - Alumina/Silica microspheres (Zeeospheres 200, 600 and 800 grades from Zeelan Industries) - Glass Microspheres (S60/10000 grade ~rom 3M
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Dichromium trioxide and titanium dioxide are used to improve the bonding of the coating to the substrate.
Dichromium trioxide provides excellent resistance to chemical corrosion and abrasion. Both dichromium trioxide and titanium dioxide are relativ~ly hard, chemically inert substances. The preferred concentration range for dichromium trioxide and titanium dioxide is 0%, or 2%-~5%, although coatings have been prepared with Cr203 concentrations of about 40% and 60%.
Cerium dioxide is used to alter the electronic properties o~
the coating, as well as to cross-link the polymer chains in the binder. It provides extremely strong adhesive and cohesive bonds which are chemically inert and heat resistant.
Its preferred concentration range is o%~ or 0.5-2%. Clay, nepheline syenite, and flint are used to provide a hard coating which is thermally resistant. The preferred concentration range for clay is 0%, or 3% 15%; for nepheline syenite (preferred size: grade ~00), 0%, or 2%-10%; for flint, o%~ or 5%-30% (preferred size: -325 mesh). The mixture o~
these materials is adjusted for the particular application, e.q., to closely match the substrate's coefficient of thermal expansion. Kentucky ball clay functions as a plasticizer at high temperatures. ~lint helps raise the ratio of solids to liquids in the coating preparation. Wollastonite is a fibrous material that provides increased tensile strength. High tensile strength is critical during the curing stage, as well as in normal use. The preferred concentration range for wollastonite is 0% or 2-12%. Talc is in platelet form, which allows the coating to slip. The preferred concentration ranye for talc is 0~, or 2%-12%.

As noted above, fibers give the coating tensile .

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~ctive I~redi~nt~
Active ingredients may be added to the coatings to provide the sur~ace with a particular physical property. The active ingredients differ from the fillers because their purpose is not to improve the me¢hanical or chemical properties of the material, such as abrasion or corrosion resistance, but to a~fect, ~or example, the optical, electrical, and haat transfer properties of the surface. For example, the appearance, emissivity, or electrical conductivity of the surface may be adjustsd by adding active ingredients.

Applic tio~n The c~atings are typically applied using air spray guns or similar devices. The coatings can also be applied by dipping the substrates in the coating, or by painting the coating on the substrate. The guns can use either pressurized or suction feed systems. The sur~ace to be coate~ must be clean. If it is contaminated with an organic material such as cutting oil, that material must ~irst be removed using a low boiling-point ~olvent, or an aqueous detergent ~olution. Nost metal, glass, and ceramic sur~aces reguire surface preparation such as sand-blasting using ASTN 60-mesh alumina grit, ~o remove surface oxides before the coating is applied. ~emoving ~ ,~

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the surface oxides is necessary to allow the coating to bond properly to the surface. The coatings must usually be applied within five hours of the sur~ace preparationl otherwise the surface oxides may regrow.
Some of the coatings are poorly wetted by water, making it difficult to apply successive coatings. However, the coatings can also be engineered so that successive coatings can be readily applied.

Curing Shrinkage and ~racking problems are minimized with the use of these coatings. The coatings dry at room temperature, i.e., at any temperature between 40~ and 110F.
~he curing process can be chara~teri7ed as having three basic phases. The initial drying phase lasts 15-20 minutes.
Approximately 90% of the water content of the coating evaporates during this phase. The second phase lasts about 24 hours. From 5%-10% of the water evaporates during this phase.
At the end of the second phase, the ceramic-metal bond has not set. Thus almost all of the coating shrinkage occurs prior to the setting of the ceramic-metal bond. This minimizes the ~ormation of microcracks in the coating. ~he third phase, during which the ceramic-metal bond sPts as the remaining 1~-5% of the water evaporates, lasts up to 6 days. Aftsr these three phases there is no further significant water loss or coeting shrinkage.

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The chemicals used to practice this invention can be obtained from the following sources, although it will be appreciated that comparable chemicals can be obtained from other sources:
Ceramic Fibers -- Carborundum Corp., Niagara Falls, NY.
Cerium Dioxide -- Unocal ~olycorp, White Plains, NY.
Colloidal suspensions of silica ~el - Remet Corporation of Chadwick, N.Y. as Remet Remasol SP 30, ~rom Dupont Corporation, Wilmington, DE as Ludox; Nalco Industries, of ~aperville, Illinois, as Nalcoag 1130.
Dichromium Trioxid~ -- Ceramic Color and Chemical Co., New Brighton, PA, as ~434 Chrome Oxide Green; Cometals, IncO, New York, NY as green chrome oxide, grade 1.
Flint -- Cexamic supply Corp., Lodi, NJ.
lass Flakes ~- Owens-Corning, Toledo, OH.
Kentucky Ball Clay -- Kentucky-Tennessee Clay Co., Mayfield, KY, as OM-4 Kentucky Ball rlay.
Methyltrimethoxysilane_(MTMS) -- Union Carbide, Danbury, CT, as methyltrimethoxysilane Al630 Microspheres -- Zeelan Industries, St. Paul, ~N as Zeeospheres and Zeeolites; 3M Corp, St. Paul MN, as microspheres S60/10000.
Nepheline Syenite -- Indusmin, Inc., of Columbus, OH.
Organo-functional silanes -- IJnion Carbide, Danbury, CT; Dow Corning, Midland, MI; Huls Americ~, Bristol, PA.
Potassium silicate -- the Philadelphia Quartz -:
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~ '~ 3 Company, Valley Forge, PA, as Kasil 1 which is 8.3~ (by weight) K20 and 20.8% SiO2.
Talc -- R.T. Vanderbilt Co., Norwalk, CT as Nytal lOOHR.
Tetraethoxysilane ~TEOS) -- Huls America, Bristol, PA; PCR, Inc., of Gainesville, Fl.
Titanium Dioxide -- Grad~ R900-28, from DuPont Corporation, Wilmington, DE.
Wollastonite -- R . T . Vanderbilt Co., Norwalk, CT as Vansil W Wollastonite.

13xa~gle 1 This composition was specifically formulated for enhanced flexibility and thermal shock resis$ance on various metals.
189 grams of a 29~1% by weight solution of potassium silicate was put in water having an Sio~:K2o molar ratio of 3.93:1 (2.5 weight ratio) in a 600 mL container and slowly agitated. 109.8 grams of a 30% by weight solution of aqueous silica gel was added to the starter silicate solution while the agitation was continued. The resultant ~ixture had an SiO~:K2o molar ratio of 7.39:1 (4.6 weight ratio). 18 grams (4.23 w%) of OM-4 Kentucky Ball Clay was gradually added to the potassium silicate solution and mixing was continued for :
approximately 15 minutes. Then 8 grams (1.88 w%) of oerium dioxide, 25 grams (5.87%j of chromium trioxide, 25 grams (5.~7~) of wollastonite, ~0 grams (2~35%) of nepheline syenite, 12 grams (2.82 w%) of talc, and 25 yxams (5.87 w~) of flint were added. The agitation was increased to 300-500 RPM
and 4 grams (0.94 w%) of methyltrimethoxysilane were slowly :

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added to the existing mixture (final total sio2 to K2O molar ratio was 7.4:1). Mixing was continued for 30 minutes (hydrolysis probably reached 9o~ after 15 minute but the mix~ur~ was sti~l curing 24 hours la~er~, and ~he coating was filtered through a 120 mesh screen before being applied. A
carbon steel substrate was prepared by sand blasting with ASTM
60 mesh alumina grit. The coating was then applied to the carbon steel substrate with a Binks ~odel 2001 Air Spray gun at a pressure of about 30 psi g. This coating has also been applied to metal substrates such as aluminum, stainless steel, hastalloy, and titanium in the same manner, as well as to glass, brick, ceramic, polyester, epoxy t and polyimide substrates.
This coating composition is very resistant to thermal shock on carbon steel up to very high temperatures.
However, it is not as resistant to alkali/high temperature water exposure and experiences microcracking on curing. X-ray diffraction analysis of this coating showed that it formed an amorphous ceramic layer on the substrate.

Ex~mple 2 This coating is speci~ically formulated for high use temperatures over a wide range of metallic and caramic substrates. It is a modi~ied version of the coating described in Example l that more closely matches the thermal coefficient of stainless steel and some other metals at high temperatures.
189 yrams of a 29.1% by weight solution o~ potassium silicate in water having an Sio2:K2o molar ratio of 3.93:1 (2.5 weight ratio) was put into a 600 mL container and slowly agitated. 109.8 grams of a 30% by weight solution of aqueous , . . ~ , . :
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silica gel was slowly added to the starter silicate solution while the agitation was continued. The resultant mixture had an Sio2:K2o molar ratio of 7.39:1 (4.6 weight ratio). 18 grams (4.79 w%) of OM-4 Kentucky Ball Clay was added gradually to the potassium silicate solution and mixing was continued for a period of 15 minutes. 8 grams (2.13 w%) oP cerium dioxide, 25 grams (6.65 w%) of dichromium trioxide, 10 grams (2.66 w%) of nepheline syenite, and 12 grams ~3.19 w%) of tale was then added. The agitation was increased to 300-500 RPM and 4 grams (1.06 w~) of methyltrimethoxysilane was added to the existing mixture. The final total sio2: K2O molar ratio in the binder was 7.4:1. Mixing was continued for 30 minutes (hydrolysis probably reached 90% after 15 minutes, but was probably still curing 24 hours later), and the coating was filtered through a 120 mesh screen before application.
This coating has been successfully applied to aluminum, carbon steel, stainless steel, hastalloy, titanium, glass, brick, ceramic, polyester, epoxy, and polyimide surfaces.

Example 3 This coating is a modi~ied version of the coatings described in Examples 1 and 2~ This coating is designed to have very low porosity (with residual pores under several microns in diameter) and essentially no microcracking.
189 grams of a 29.1% by weight solution o~ potassium silicate in water having an Sio2:K2o molar ratio o~ 3O93: 1 (2.5 weight ratio) was put in a 600 mL container and 610wly agitated.

The agitation was increased to 300-500 RPM, and 4 grams of :: .
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methyltrimethoxysilane was slowly added to the starter potassium silicate solution. Mixing was continued for 15 minutes. 109.8 grams of a 30% weiqht solution of aqueous silica gel was slowly added to ~he silicate mixture while agitation was continued for an additional ~ minutes. The resultant mixture had an sio2:K20 molar xatio of 7.4:1. 100 grams (14.32 w%3 of dichromium trioxide was slowly added to the potassium silicate solution and mixing continued 15 minutes. 25 grams (3.58 w%) of ceramic fibers, 48 grams (6.87 w%) of talc, 222.4 grams (31.g5 w%) of cexamic microspheres, and 104.6 grams (15 w%) o~ water were then added. Mixing was continued for 30 minutes and the coating filtered through a 120 mesh screen before application.
While this coating is slightly less flexible than the coating of Example l, it has almost the same thermal shock resistance on steel and aluminum. It has been success~ully coated on 12" long carbon steel channels, heated to incandes-cence, sprayed with concentrated hydrochloric acid, then reheated and quenched in cold water without cracking or peeling. The coating has also been applied to aluminum, titanium, carbon steel, stainless steel, hastalloy, silver, ceramic, epoxy, glass, brick, fiberglass-reinforced phenolic resin, polyester, polyimide, and phenolic surfaces. X-ray diffraction analysis of this coating revealed that it formed an amorphous ceramic layer on the substrate. Mechanical tests of this coating showed that it had a flexion strength of about 20MPa (megapascals), a Young's Modulus o~ about 13,000 MPa, and a tensile strength of about 4Mpa. The coefficient of thermal expansion of this coating was about 5 x 106/C. This value is greater than typical values for ceramic materials, a :`

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The invention has been described in greatest detail with respect to certain preferred embodiments and specific examples. However, the invention is not limited to thos~
embodiments and examples, and is only limited in scope by the appended claims.

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Claims

THE EMBODIMENTS OF THE INVENTION IN WHICH AN EXCLUSIVE
PROPERTY OR PRIVILEGE IS CLAIMED ARE DEFINED AS FOLLOWS:

1. An amorphous ceramic coating, comprising a silica-based binder and a filler, said coating chemically bonding at room temperature to surfaces selected from the group consisting of glass, metal, ceramic and plastic, by forming single cross-linked O-Si-O polymer chains.

2. The amorphous ceramic coating as set forth in claim 1, wherein said coating chemically bonds to said surfaces by forming both single cross-linked O-Si-O polymer chains and double cross linked O-Si-O polymer chains.

3. The amorphous ceramic coating as set forth in claim 1, wherein a majority of the O-Si-O polymer chains are single cross-linked.

4. The amorphous ceramic coating as set forth in claim 1, wherein said silica-based binder comprises a cross-linking agent consisting of methyltrimethoxysilane, said cross-linking agent forming said single cross-linked O-Si-O polymer chains.

5. The amorphous ceramic coating as set forth in claim 1, wherein said silica-based binder comprises a cross-linking agent selected from the group consisting of tetraethoxysilane, and a mixture of methyltrimethoxysilane and tetraethoxysilane, said cross-linking agent forming said single cross-linked 0-Si-O polymer chains.

6. The amorphous ceramic coating as set forth in claim 1, wherein said silica-based binder comprises a cross-linking agent selected from the group consisting of alkyltrialkoxysilane, aromatictrialkoxysilane, tetraalkoxysilane, and mixtures thereof, said cross-linking agent forming said single cross-linked O-Si-O polymer chains.

7. The amorphous ceramic coating as set forth in claim 1, wherein said silica-based binder comprises a cross-linking agent consisting of an organo-functional silane, said cross-linking agent forming said single cross-linked O-si-O chains.

8. The amorphous ceramic coating as set forth in claim 1, wherein said silica-based binder comprises a cross-linking agent selected from the group consisting of cerium dioxide, dichromium trioxide, and mixtures thereof, said cross-linking agent forming said single cross-linked O-Si-O chains.

9. The amorphous ceramic coating as set forth in claim 1, wherein said silica-based binder comprises a cross-linking agent selected from the group consisting of soluble cerium salts, soluble chromium salts, and mixtures thereof, said cross-linking agent forming said single cross-linked O-Si-O
chains.

10. The amorphous ceramic coating as set forth in claim 1, wherein said silica-based binder comprises an alkali metal silicate.

11. The amorphous ceramic coating as set forth in claim 10, wherein said alkali metal silicate is selected from a group consisting of potassium silicate, sodium silicate, and lithium silicate.

12. The amorphous ceramic coating as set forth in claim 10, wherein said silica-based binder comprises silica gel.

13. An aqueous suspension, comprising a silica-based binder and a filler, said silica-based binder comprising an alkali metal silicate, silica gel, and a cross-linking agent, said aqueous suspension being suitable for forming a coating, said coating being formed upon application to a surface and curing.

14. The coating formed upon application to a surface and curing as set forth in claim 13, wherein said silica-based binder comprises alkali metal oxides, O-Si-O polymer chains, and silanol radicals.

15. The coating formed upon application to a surface and curing as set forth in claim 13, wherein said silica-based binder comprises alkali metal oxides,O-Si-O polymer chains, and a cross-linking agent selected from the group consisting of the oxides of chromium, cerium, and mixtures thereof.

16. The coating formed upon application to a surface and curing as set forth in claim 13, wherein said silica-based binder comprises alkali metal oxides, O-Si-O polymer chains, and titanium dioxide as said cross-linking agent.

17. The coating as set forth in claim 14, wherein said alkali metal silicate is potassium silicate.

18. The coating as set forth in claim 14, wherein said alkali metal silicate is selected from the group consisting of sodium silicate and lithium silicate.

19. The coating as set forth in claim 14, wherein said silica gel comprises SiO2, and wherein additional SiO2 is provided by said alkali metal silicate and said cross-linking agent, and wherein alkali metal oxides are provided by said alkali metal silicate, such that the molar ratio of the total amount of SiO2 to alkali metal oxide in the binder is between 6.6-1 and 8.5:1.

20. The coating as set forth in claim 14, wherein said silica gel comprises SiO2, and wherein additional SiO2 is provided by said alkali metal silicate and said cross-linking agent, and alkali metal oxides are provided by said alkali metal silicate, such that the molar ratio of the total amount of SiO2 to alkali metal oxide in the binder is 7.4:1.

21. The coating as set forth in claim 14, wherein said cross-linking agent consists of methyltrimethoxysilane (MTMS).

22. The coating as set forth in claim 14, wherein said cross-linking agent consists of tetraethoxysilane (TEOS).

23. The coating as set forth in claim 14, wherein said cross-linking agent is selected from the group consisting of alkyltrialkoxysilane, aromatictrialkoxysilane, and tetraalkoxysilane, and mixtures thereof.

24. The coating as set forth in claim 14, wherein said cross-linking agent is an organo-functional silane.

2. The coating as set forth in claim 14, wherein said cross-linking agent is selected from the group consisting of cerium dioxide, dichromium trioxide and cerium dioxide/dichromium trioxide mixtures.

26. The coating as set forth in claim 14, wherein said cross-linking agent is selected from the group consisting of soluble cerium salts, soluble chromium salts, and mixtures thereof.

27. The coating as set forth in claim 14, wherein said filler consists of at least two materials selected from the group consisting of dichromium trioxide at a concentration of 2-15 volume percent, titanium dioxide at a concentration of 2-15 volume percent, cerium dioxide at a concentration of 0.5-2 volume percent, clay at a concentration of 3-15 volume percent, nepheline syenite at a concentration of 2-10 volume percent, wollastonite at a concentration of 2-12 volume percent, talc at a concentration of 2-12 volume percent, flint at a concentration of 5-39 volume percent, and ceramic microspheres at a concentration of 15-25 volume percent or 50-65 volume percent.

28. The coating as set forth in claim 14, wherein said filler comprises clay at a concentration of 3-15 volume percent nepheline syenite at a concentration of 2-10 volume percent, and talc at a concentration of 2-12 volume percent.

29. The coating as set forth in claim 14, wherein said filler is selected from the group consisting of cerium dioxide, dichromium trioxide, and mixtures thereof.

30. The coating as set forth in claim 14, wherein said filler is selected from the group consisting of ceramic microspheres, ceramic plates, and ceramic fibers.

31. A method for coating a surface comprising:
providing a filler and a binder, said binder consisting essentially of an alkali metal silicate, silica gel, a cross-linking agent, and water;
combining said binder and filler;
mixing said binder and filler;
applying the resulting mixture to said surface to form a coating; and allowing the coating to dry without the application of any additional energy, such that said coating chemically bonds to said surface.

32. The method as set forth in claim 31, whereby said coating forms an amorphous ceramic matrix upon drying.

33. The method for coating a surface as set forth in claim 31, wherein said alkali metal silicate is potassium silicate.

34. The method for coating a surface as set forth in claim 31, wherein said alkali metal silicate is selected from a group consisting of sodium silicate and lithium silicate.

35. The method for coating a surface as set forth in claim 31, wherein :
said silica gel comprises Si and oxygen bonded in the ratio of one silicon atom to two oxygen atoms;
additional silicon is provided by said alkali metal silicate and said cross-linking agent; and alkali metal oxides are provided by said alkali metal silicate such that the molar ratio of the total amount of SiO2 to alkali metal oxide in the binder is between 6.6:1 and 8.5:1.

36. The method for coating a surface as set forth in claim 34, whereby said molar ratio of the total amount of SiO2 to alkali metal oxide in the binder is approximately 7.4:1.

37. The method for coating a surface as set forth in claim 31, wherein said cross-linking agent consists of methyltrimethoxysilane (MTMS).

38. The method for coating a surface as set forth in claim 31, wherein said cross-linking agent consists of tetraethoxysilane (TEOS).

39. The method for coating a surface as set forth in claim 31, wherein said cross-linking agent is selected from the group consisting of alkyltrialkoxysilane, aromatictrialkoxysilane, tetraalkoxysilane, and mixtures thereof.

40. The method for coating a surface as set forth in claim 31, wherein said cross-linking agent is an organo-functional silane.

41. The method for coating a surface as set forth in claim 31, wherein said cross-linking agent is selected from a group consisting of cerium dioxide, dichromium trioxide and mixtures thereof.

42. The method for coating a surface as set forth in claim 31, wherein said filler is comprised of two materials, said materials being selected from the group consisting of dichromium trioxide at a concentration of 2-15 volume percent, titanium dioxide at a concentration of 2 15 volume percent, cerium dioxide at a concentration of 0.5-2 volume percent, clay at a concentration of 3-15 volume percent, nepheline syenite at a concentration of 2-10 volume percent, wollastonite at a concentration of 2-12 volume percent, talc at a concentration of 2-12 volume percent, flint at a concentration of 5-30 volume percent, and ceramic microspheres at a concentration of 15-25 volume percent or 50-65 volume percent.

43. The method for coating a surface as set forth in claim 31, wherein said filler comprises clay at a concentration of 3-15 volume percent, nepheline syenite at a concentration of 2-10 volume percent, and talc at a concentration of 2-12 volume percent.

44. The method for coating a surface as set forth in claim 31, wherein said filler is selected from a group consisting of dichromium trioxide, cerium dioxide, and cerium dioxide/dichromium trioxide mixtures.

45. A method for coating a surface comprising:
providing a filler and a binder precursor, said binder precursor consisting essentially of an alkali metal silicate, silica gel, and water;
combining said binder precursor and filler;
mixing said binder precursor and filler to form a first mixture;
adding a cross-linking agent to said first mixture;
mixing said cross-linking agent and said first mixture to form a second mixture;
applying said second mixture to said surface to form a coating; and allowing the coating to dry without the application of any additional energy, such that said coating chemically bonds to said surface.

46. A method for preparing ceramic coatings comprising:
preparing a solution of at least one alkali metal silicate;
adding aqueous silica gel and agitating the mixture;
continuing the agitation while adding Kentucky Ball Clay;
continuing the agitation while adding materials selected from the group consisting of cerium oxide, dichromium dioxide, wollastonite, nepheline syenite, talc and flint;
continuing the agitation while adding a cross-linking agent;
continuing the agitation; and filtering the coating through a mesh screen.

47. A method for preparing ceramic coatings that comprising:
preparing a solution of alkali metal silicate;
adding a cross-linking agent while continuing the agitation;
adding aqueous silica gel while continuing the agitation;
adding dichromium trioxide while continuing the agitation;
adding materials selected from the group consisting of ceramic fibers, talc, ceramic microspheres, and water while continuing the agitation; and filtering the coating through a mesh screen.

48. A method for preparing ceramic coatings as set forth in claim 46, wherein the alkali metal silicate is selected from the group consisting of potassium silicate, lithium silicate and sodium silicate.

49. A method for preparing ceramic coatings as set forth in claim 47, in which the alkali metal silicate is selected from the group consisting of potassium silicate, lithium silicate, and sodium silicate.

50. A coated surface comprising a substrate and a coating;

said substrate selected from the group consisting of metal, ceramic, glass, and plastic; said coating comprising a binder and a filler, said coating being chemically bound to said substrate by single cross-linked O-Si-O polymer chains.

51. The coated surface as set forth in claim 50, wherein a majority of the O-Si-O polymer chains are single cross-linked.

52. The coated surface as set forth in claim 50, wherein said binder comprises a cross-linking agent, said cross-linking agent being selected from the group consisting of methyltrimethoxysilane, tetraethoxysilane and mixtures of methyltrimethoxysilane and tetraethoxysilane.

53. The coated surface as set forth in claim 50, wherein said binder comprises a cross-linking agent, said cross-linking agent being selected from the group consisting of alkyltrialkoxysilane, aromatictrialkoxysilane, and tetraalkoxysilane, and mixtures thereof.

54. The coated surface as set forth in claim 50, wherein said binder comprises a cross-linking agent, said cross-linking agent comprising an organo-functional silane.

55. The coated surface as set forth in claim 50, wherein said single cross-linked O-Si-O chains are formed using a cross linking agent selected from a group consisting of cerium dioxide, dichromium trioxide and cerium dioxide/dichromium trioxide mixtures.

56. A surface coated with an aqueous suspension, comprising a substrate and an aqueous suspension; said substrate selected from the group consisting of metal, ceramic, glass, and plastic; and said aqueous suspension comprising a silica-based binder and a filler, said silica-based binder comprising an alkali metal silicate, silica gel, and a cross-linking agent and said aqueous suspension being suitable for forming a durable coating upon curing.

57. The surface coated with an aqueous suspension as set forth in claim 56, said silica-based binder upon curing comprising alkali metal oxides, O-Si-O polymer chains, and silanol radicals.

58. The coated surface as set forth in claim 57, wherein said coating forms an amorphous ceramic matrix.

59. The coated surface as set forth in claim 57, wherein the alkali metal silicate is potassium silicate.

60. The coated surface as set forth in claim 57, wherein said alkali metal silicate is selected from a group consisting of sodium silicate and lithium silicate.

61. The coated surface as set forth in claim 57, wherein said silica gel comprises SiO2, and wherein additional SiO2 is provided by said alkali metal silicate and said cross-linking agent, and wherein alkali metal oxides are provided by said alkali metal silicate, such that the molar ratio of the total amount of SiO2 to alkali metal oxide in the binder is between 6.6:1 and 8.5:1.

62. The coated surface as set forth in claim 57, wherein said silica gel comprises SiO2, and wherein additional SiO2 is provided by said alkali metal silicate and said cross-linking agent, and wherein alkali metal oxides are provided by said alkali metal silicate, such that the molar ratio of the total amount of SiO2 to alkali metal oxide in the binder is 7.4:1.

63. The coated surface as set forth in claim 57, wherein said cross-linking agent is selected from the group consisting of methyltrimethoxysilane (MTMS) and tetraethoxysilane (TEOS).

64. The coated surface as set forth in claim 57, wherein said cross-linking agent is an organo-functional silane.