# US 10,502,130 B2 · Composite thermal barrier coating > Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt - Number: US 10,502,130 B2 - Document ID: US10502130B2 - Status: Granted - Kind: B2 - Application number: 15/433,285 - Filed: 2017-02-15 - Published: 2017-08-17 - Granted: 2019-12-10 - Earliest claimed: 2016-02-17 - Assignees: GM Global Technology Operations LLC - Applicants: GM Global Technology Operations LLC - Inventors: Russell P. Durrett; Paul M. Najt; Peter P. Andruskiewicz, IV; Jason R. Traub; Michael J. Walker - Web page: https://patentgrep.com/patent/US10502130B2 ## CPC - F02B 77/11: Thermal or acoustic insulation - B23K 1/0008: {specially adapted for particular articles or work} - C23C 4/129: Flame spraying - C23C 18/1633: {Process of electroless plating} - C23C 28/00: Coating for obtaining at least two superposed coatings either by methods not provided for in a single one of groups C23C2/00 - C23C26/00 or by combinations of methods provided for in subclasses C23C and C25C or C25D - C25D 3/12: of nickel or cobalt - C25D 7/008: {Thermal barrier coatings} - C25D 15/00: Electrolytic or electrophoretic production of coatings containing embedded materials, e.g. particles, whiskers, wires - F02F 3/10: having surface coverings (F02F3/02 takes precedence) - Y02T 50/60: Efficient propulsion technologies, e.g. for aircraft - F02B: INTERNAL-COMBUSTION PISTON ENGINES; COMBUSTION ENGINES IN GENERAL (gas-turbine plants F02C; hot-gas or combustion-product positive-displacement engine plants F02G) - B23K: SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM - 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) - C25D: PROCESSES FOR THE ELECTROLYTIC OR ELECTROPHORETIC PRODUCTION OF COATINGS; ELECTROFORMING; APPARATUS THEREFOR - F02F: CYLINDERS, PISTONS OR CASINGS, FOR COMBUSTION ENGINES; ARRANGEMENTS OF SEALINGS IN COMBUSTION ENGINES - Y02T: CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO TRANSPORTATION ## Abstract A composite thermal barrier coating (TBC) may be applied to a surface of components within an internal combustion engine. The composite TBC provides low thermal conductivity and low heat capacity insulation that is sealed against combustion gasses. The composite TBC includes three layers, bonded to one another, i.e., a first (bonding) layer, a second (insulating) layer, and a third (sealing) layer. The insulating layer is disposed between the bonding layer and the sealing layer. The bonding layer is bonded to the component and to the insulating layer. The insulating layer includes hollow microspheres that are sintered together to form insulation that provides a low effective thermal conductivity and low effective heat capacity. The sealing layer is a thin film that is configured to resist the high temperatures, present within the engine. The sealing layer is impermeable to gasses and presents a smooth surface. ## Claims ### Claim 1 A composite thermal barrier coating comprising: a first layer configured to be bonded to a substrate; a second layer bonded to the first layer; wherein the second layer comprises a plurality of hollow microspheres, bonded together to define a porous structure; and a third layer bonded to the second layer; wherein the third layer is non-permeable to combustion gases such that the third layer seals against the second layer. ### Claim 2 (depends on 1) The composite thermal barrier coating, as set forth in claim 1, wherein the first layer is configured to be bonded to a substrate comprising metal; and wherein each of the plurality of hollow microspheres include a metallic coating, such that adjacent microspheres of the plurality of hollow microspheres are bonded together at the respective coatings. ### Claim 3 (depends on 2) The composite thermal barrier coating, as set forth in claim 2, wherein the second layer includes a microstructure layer and a transition layer; wherein the transition layer is diffusion bonded to the first layer and the transition layer is bonded to the microstructure layer. ### Claim 4 (depends on 3) The composite thermal barrier coating, as set forth in claim 3, wherein the first layer comprises at least one of a copper based material, a zinc based material, and an alloy comprising copper and zinc; wherein the coating of each of the plurality of hollow microspheres comprises at least one of a nickel based material and an iron based material; and wherein the transition layer comprises at least one of a nickel based material and an iron based material, such that the transition layer is diffusion bonded to the first layer and the transition layer is sintered to the coating of the adjacent hollow microspheres of the plurality of microspheres. ### Claim 5 (depends on 2) The composite thermal barrier coating, as set forth in claim 2, wherein the coating comprises at least one of a nickel based material, a copper based material, and an alloy comprising copper and nickel. ### Claim 6 (depends on 1) The composite thermal barrier coating, as set forth in claim 1, wherein the second layer has a porosity of at least 80%. ### Claim 7 (depends on 6) The composite thermal barrier coating, as set forth in claim 6, wherein the second layer has a porosity of at least 95%. ### Claim 8 (depends on 1) The composite thermal barrier coating, as set forth in claim 1, wherein the second layer has a thickness of between 100 microns and 1 millimeter. ### Claim 9 (depends on 8) The composite thermal barrier coating, as set forth in claim 8, wherein the second layer has a thickness of between 100 and 500 microns. ### Claim 10 (depends on 9) The composite thermal barrier coating, as set forth in claim 9, wherein the second layer has a thickness of between 100 and 300 microns. ### Claim 11 (depends on 1) The composite thermal barrier coating, as set forth in claim 1, wherein a coefficient of thermal expansion characteristic of each of the first layer, the second layer, and the third layer is compatible to withstand thermal fatigue. ### Claim 12 (depends on 1) The composite thermal barrier coating, as set forth in claim 1, wherein a thickness of the third layer is not greater than 20 microns. ### Claim 13 (depends on 12) The composite thermal barrier coating, as set forth in claim 12, wherein a thickness of the third layer is not greater than 5 microns. ### Claim 14 (depends on 13) The composite thermal barrier coating, as set forth in claim 13, wherein the third layer includes a first barrier layer and a second barrier layer; wherein the first barrier layer is bonded to the second layer and the second barrier layer is bonded to the first barrier layer, such that the first barrier layer is disposed between the second barrier layer and the second layer. ### Claim 15 (depends on 1) The composite thermal barrier coating, as set forth in claim 1, wherein the second and third layers are configured to withstand pressures as high as 150 bar and configured to withstand a surface temperature as high as 1,100 degrees Celsius. ### Claim 16 (depends on 1) The composite thermal barrier coating, as set forth in claim 1, wherein each of the plurality of microspheres has a diameter of not greater than 100 μm. ### Claim 17 (depends on 16) The composite thermal barrier coating, as set forth in claim 16, wherein each of the plurality of microspheres has a diameter of between 20 and 100 μm. ### Claim 18 (depends on 17) The composite thermal barrier coating, as set forth in claim 17, wherein each of the plurality of microspheres has a diameter of between 20 and 40 μm. ### Claim 19 A component comprising: a substrate presenting a surface; and a composite thermal barrier coating including: a first layer bonded to the surface of the substrate; a second layer bonded to the first layer; wherein the second layer comprises a plurality of hollow microspheres defining a porous structure; and a third layer bonded to the second layer; wherein the third layer is non-permeable to combustion gases such that the third layer seals against the second layer. ### Claim 20 An internal combustion engine comprising: a component configured to be subjected to combustion gasses, the component including: a substrate presenting a surface; and a composite thermal barrier coating including: a first layer bonded to the surface of the substrate; a second layer bonded to the first layer; wherein the second layer comprises a plurality of hollow microspheres defining a porous structure; and a third layer bonded to the second layer; wherein the third layer is non-permeable to combustion gases such that the third layer seals against the second layer.