# US 10,311,996 B2 · Electrically insulating material for thermal sprayed coatings matching the coefficient of thermal expansion of the underlying body > Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt - Number: US 10,311,996 B2 - Document ID: US10311996B2 - Status: Granted - Kind: B2 - Application number: 14/376,264 - Filed: 2014-01-24 - Published: 2015-02-12 - Granted: 2019-06-04 - Earliest claimed: 2013-02-20 - Assignees: Oerlikon Metco (US) Inc. - Applicants: Oerlikon Metco (US) Inc. - Inventors: Atin Sharma; Johannes D. Rauch - Web page: https://patentgrep.com/patent/US10311996B2 ## CPC - H01B 3/448: {from other vinyl compounds} - C04B 35/053: Fine ceramics - C04B 35/443: Magnesium aluminate spinel - C04B 35/62655: {Drying, e.g. freeze-drying, spray-drying, microwave or supercritical drying} - C04B 35/6281: {Alkaline earth metal oxides} - C04B 35/62813: {Alumina or aluminates} - C04B 35/6303: {Inorganic additives} - C04B 35/63416: {Polyvinylalcohols [PVA]; Polyvinylacetates} - C23C 4/10: Oxides, borides, carbides, nitrides or silicides; Mixtures thereof - C23C 4/11: Oxides - H01B 3/10: metallic oxides (ceramics H01B3/12) - H01B 3/447: {from acrylic compounds} - C04B 2235/3206: Magnesium oxides or oxide-forming salts thereof - C04B 2235/3217: Aluminum oxide or oxide forming salts thereof, e.g. bauxite, alpha-alumina - C04B 2235/5436: micrometer sized, i.e. from 1 to 100 micron - C04B 2235/5472: Bimodal, multi-modal or multi-fraction - C04B 2235/72: Products characterised by the absence or the low content of specific components, e.g. alkali metal free alumina ceramics - Y02E 60/50: Fuel cells - H01B: CABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES (selection for magnetic properties H01F1/00; waveguides H01P {; printed circuits H05K}) - C04B: LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE {(roofing granules E04D7/005)}; CERAMICS (devitrified glass-ceramics C03C10/00); REFRACTORIES; TREATMENT OF NATURAL STONE - C23C: COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL (making metal-coated products by extrusion B21C23/22; covering with metal by connecting pre-existing layers to articles, see the relevant places, e.g. B21D39/00, B23K; metallising of glass C03C; metallising mortars, concrete, artificial stone, ceramics or natural stone C04B41/00; enamelling of, or applying a vitreous layer to, metals C23D; treating metal surfaces or coating of metals by electrolysis or electrophoresis C25D; single-crystal film growth C30B; by metallising textiles D06M11/83; decorating textiles by locally metallising D06Q1/04) - Y02E: REDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION ## Abstract Compositions and method for preparing thermally sprayed coatings are disclosed. The inventive compositions include at least one component that is electrically-insulating and/or non-subliming at thermal spray temperatures; and at least one component that has a high coefficient of thermal expansion. The invention also provides a compositions and methods for preparing a coating comprising a spinel, from materials that do not comprise a spinel; and also provides non-spinel materials used to prepare coatings comprising spinel. The invention includes coatings made from the materials and methods; and articles comprising the coatings. ## Claims ### Claim 1 A material comprising a particle comprising a core portion comprising a first mixture, and an encasing portion comprising a second mixture, the first mixture comprising at least 50 mol % of a high-CTE material (component B1) and comprising less than 50 mol % of a non-sublimating electrical insulator (component A1); the second mixture comprising at least 50 mol % of a non-sublimating electrical insulator (component A2) and comprising less than 50 mol % of a high-CTE material (component B2); and wherein at least one of component A1 and component B1 has an average particle size up to about 100 microns; at least one of component A2 and component B2 has an average particle size up to about 20 microns; and component B1 having a coefficient of thermal expansion (CTE) at least about 10 μm/m/K; wherein the encasing portion at least partially encases the core portion, and wherein the material comprises essentially no spinel. ### Claim 2 (depends on 1) The material of claim 1, wherein component A1 and component A2 are independently chosen from one or both of a) one or more oxide of trivalent or tetravalent metals, or b) one or more salts with binding properties. ### Claim 3 (depends on 1) The material of claim 1, wherein component A1 and component A2 are independently chosen from one or more of oxide of Al, In, Ga, Y, Sc, Mg, Si, Ti, Ge, Zr, Hf, Sn, Nb, Mn, or a rare earth metal. ### Claim 4 (depends on 1) The material of claim 1, wherein component A1 and component A2 comprise Al2O3. ### Claim 5 (depends on 1) The material of claim 1, wherein component B2 has a coefficient of thermal expansion at least about 10 μm/m/K. ### Claim 6 (depends on 1) The material of claim 1, wherein component B1 and component B2 are independently chosen from one or more of a simple oxide, a double oxide, a triple oxide, an alkali metal halide, an alkaline metal halide, or a metal. ### Claim 7 (depends on 1) The material of claim 1, wherein component B1 and component B2 comprise MgO. ### Claim 8 (depends on 1) The material of claim 1, comprising a plurality of cores. ### Claim 9 (depends on 8) The material of claim 8, wherein the cores comprise particles that are at least one of monolithic or an agglomerate of smaller particles. ### Claim 10 (depends on 1) The material of claim 1, comprising a plurality of agglomerated encased cores. ### Claim 11 (depends on 1) The material of claim 1, wherein the core further comprises an outer layer that is non-electrically conducting and non-sublimating. ### Claim 12 (depends on 11) The material of claim 11, wherein the outer layer comprises one or both of a) one or more oxides of trivalent or tetravalent metals, or b) one or more salt with binding properties. ### Claim 13 (depends on 1) The material of claim 1, further comprising a binder. ### Claim 14 (depends on 1) The material of claim 1, further comprising a dispersant. ### Claim 15 (depends on 1) A thermal spray coating prepared by thermally spraying the material of claim 1 onto a substrate. ### Claim 16 (depends on 15) The thermal spray coating of claim 15, the thermal spray coating comprising one or more spinel. ### Claim 17 (depends on 15) The thermal spray coating of claim 15, wherein the substrate comprises at least one of iron, steel, aluminum, copper, Fe—Cr alloy, Cr-rich steel, cobalt, Co-alloy, nickel, Ni-alloy, bronze, or titanium. ### Claim 18 A particle comprising a core portion comprising a first mixture, and an encasing portion comprising a second mixture, the first mixture comprising at least 50 mol % of a high-CTE material having CTE greater than or about 10 μm/m/K (component B1) and comprising less than 50 mol % of a non-sublimating electrical insulator (component A1); the second mixture comprising at least 50 mol % of in a non-sublimating electrical insulator (component A2) and comprising less than 50 mol % of a high-CTE material (component B2); and wherein at least one of component A1 and component B1 has an average particle size up to about 100 microns; at least one of component A2 and component B2 has an average particle size up to about 20 microns; and wherein the encasing portion at least partially encases the core portion, and wherein the particle comprises essentially no spinel. ### Claim 19 (depends on 1) A method of manufacturing a thermal spray coating comprising: obtaining a material according to claim 1; obtaining a substrate; and forming a coating on the substrate by applying the material to the substrate by a thermal spray process. ### Claim 20 (depends on 19) The method of claim 19, wherein the material does not comprise spinel, and the thermal spray coating comprises a spinel. ### Claim 21 (depends on 19) The method of claim 19, wherein the material comprises Al2O3, and the thermal spray coating does not comprise A12O3. ### Claim 22 (depends on 19) The method of claim 19, wherein the substrate comprises at least one of iron, steel, aluminum, copper, Fe—Cr alloy, Cr-rich steel, cobalt, Co-alloy, nickel, Ni-alloy, bronze, or titanium.