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EP-4737428-A1 - COATED STRUCTURE MANUFACTURING METHOD, AND COATED STRUCTURE

EP4737428A1EP 4737428 A1EP4737428 A1EP 4737428A1EP-4737428-A1

Abstract

A method for producing a coating structure of the present invention is a method for producing a coating structure having a metal-carbon composite coating on a carbon substrate, the method including an application step of applying a metal compound-containing substance onto the carbon substrate, and a heating step of heating the coated carbon substrate to form a metal-carbon composite coating on the carbon substrate. The coating structure of the present invention is a coating structure in which a metal-carbon composite coating is formed on a carbon substrate, and the metal-carbon composite coating is formed by heating the metal compound-containing substance applied onto the carbon substrate.

Inventors

  • HARA Syuhei
  • MATSUO KEN
  • NIKATA SOICHIRO

Assignees

  • Mitsui Kinzoku Company, Limited

Dates

Publication Date
20260506
Application Date
20240628

Claims (14)

  1. A method for producing a coating structure having a metal-carbon composite coating on a carbon substrate, the method comprising: an application step of applying a metal compound-containing substance onto the carbon substrate; and a heating step of heating the coated carbon substrate to form a metal-carbon composite coating on the carbon substrate.
  2. A method for producing a coating structure having a metal-carbon composite coating on a carbon substrate, the method comprising: an immersion step of immersing the carbon substrate in a metal compound-containing substance; and a heating step of heating the immersed carbon substrate to form a metal-carbon composite coating on the carbon substrate.
  3. The method for producing a coating structure according to claim 2, wherein in the immersion step, the carbon substrate is impregnated with the metal compound-containing substance under reduced pressure or vacuum.
  4. The method for producing a coating structure according to any one of claims 1 to 3, further comprising a drying step between the application step or the immersion step and the heating step.
  5. The method for producing a coating structure according to any one of claims 1 to 3, wherein the metal compound-containing substance contains a compound of at least one metal element selected from Ti, Nb, Mo, Hf, Ta, W, Zr, and Si.
  6. The method for producing a coating structure according to claim 5, wherein a content of a compound of at least one metal element selected from Ti, Nb, Mo, Hf, Ta, W, Zr, and Si in the metal compound-containing substance is more than 0 mass% and 35 mass% or less in terms of metal.
  7. The method for producing a coating structure according to claim 5, wherein the metal compound-containing substance contains a Ta compound.
  8. The method for producing a coating structure according to any one of claims 1 to 3, wherein the metal compound-containing substance has a maximum value of light transmittance in a wavelength region of 500 nm to 700 nm of 70%T or more.
  9. The method for producing a coating structure according to any one of claims 1 to 3, wherein the metal compound-containing substance has a particle size (D50) of particles in the metal compound-containing substance in dynamic light scattering of 3,000 nm or less.
  10. The method for producing a coating structure according to any one of claims 1 to 3, wherein the metal compound-containing substance has a pH of 6.5 or more and 13.5 or less.
  11. The method for producing a coating structure according to any one of claims 1 to 3, wherein in the heating step, a heating temperature is 1000°C or higher and 3500°C or lower, and a heating time is 0.5 hours or more and 2 hours or less.
  12. The method for producing a coating structure according to claim 11, wherein in the heating step, a heating temperature is 1400°C or higher and 2000°C or lower.
  13. A coating structure in which a metal-carbon composite coating is formed on a carbon substrate, wherein the metal-carbon composite coating has been formed by heating the carbon substrate coated or impregnated with the metal compound-containing substance.
  14. A metal compound-containing substance for a metal-carbon composite coating formed on a carbon substrate, wherein the metal compound-containing substance reacts with the carbon substrate to form a metal-carbon composite coating.

Description

Technical Field The present invention relates to a method for producing a coating structure, and a coating structure. Background Art In a member required to have heat resistance and reaction resistance (for example, oxidation resistance and chemical resistance), heat resistance and reaction resistance can be improved by forming a protective film such as a metal compound on the surface of a substrate of the member, and the life of the member can be extended. For example, when a tantalum carbide layer is formed as a protective film on the surface of a carbon substrate, it is common to use a CVD apparatus as disclosed in Patent Literature 1. Citation List Patent Literature Patent Literature 1: WO 2004/009515 A Summary of Invention Technical Problem However, the size and shape of the substrate capable of forming the protective film on the surface are determined in advance for each CVD apparatus, and the protective film could not be formed on the surface depending on the size and shape of the substrate. In addition, the step of forming the protective film on the surface of the substrate using the CVD apparatus took a considerable time. In view of the above problems, an object of the present invention is to provide a method for producing a coating structure, and a coating structure, regardless of the size and shape of the substrate. Solution to Problem A method for producing a coating structure of the present invention made to solve the above problems is a method for producing a coating structure having a metal-carbon composite coating on a carbon substrate, the method including an application step of applying a metal compound-containing substance onto the carbon substrate, and a heating step of heating the coated carbon substrate to form a metal-carbon composite coating on the carbon substrate. In the present description, the "metal-carbon composite coating" may be present in a state in which a metal element and a carbon element are bonded in the coating, such as a metal carbide alone or a carbon-containing material containing a metal carbide. In addition, the "metal-carbon composite coating" may be present in a state in which a metal compound other than the metal carbide is dispersed in the carbon-containing material, that is, not a state in which the metal element and the carbon element are bonded in the coating, but a state in which the metal element and the carbon element are in a mixed or dispersed state. Examples of the metal compound other than the metal carbide include metal oxides, metal nitrides, metal sulfides, and metal hydroxides. Here, the coating structure to be produced by the method for producing a coating structure of the present invention includes a coating structure having a metal-carbon composite coating on a carbon substrate, and for example, a coating structure having a metal-carbon composite coating on at least one surface (for example, the surface) of the carbon substrate, a coating structure having a metal-carbon composite coating on the entire peripheral surface of the carbon substrate, and a coating structure having a metal-carbon composite coating on a part of one surface of the carbon substrate. First, in the application step according to the method for producing a coating structure of the present invention, a metal compound-containing substance is applied onto a carbon substrate. The carbon substrate to be used in the method for producing a coating structure of the present invention may be a substrate composed only of carbon, a substrate containing carbon as a main component and having a carbon content of 50 mass% or more, or a substrate having a multilayer structure and having an outermost layer composed only of carbon or containing carbon as a main component and having a carbon content of 50 mass% or more. The carbon substrate is particularly preferably a substrate composed only of carbon. Also, the size and shape of the carbon substrate are not particularly limited as long as the carbon substrate can be heated in a stationary furnace used in a heating step to be described later. Specific examples of the carbon substrate include a crucible, a furnace material, an electrode, a fiber, a filtration device, a filter, a protective tube, a heater tube, a burner nozzle, and a refractory jig. Examples of the carbon material of the carbon substrate include fullerene, carbon nanotube, carbon nanofiber, graphene, graphene oxide, carbon nanohorn, diamond, hyperdiamond, and carbon fiber. In addition, the carbon material may be composed only of carbon or other materials containing carbon. Further, the structure of the carbon material may have a uniform tissue structure or a non-uniform tissue structure. The uniform tissue structure may be hollow or porous. Also, the non-uniform tissue structure may be, for example, a sea-island form, multilayer, hollow, or porous. Furthermore, the shape of the carbon material may be a powder shape, a plate shape, a film shape, a fiber shape, or the like, and m