# US 2020/0400093 A1 · Systems and methods for a cylinder bore coating fill material > Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt - Number: US 2020/0400093 A1 - Document ID: US20200400093A1 - Status: Published application - Kind: A1 - Application number: 16/446,369 - Filed: 2019-06-19 - Published: 2020-12-24 - Earliest claimed: 2019-06-19 - Assignees: Ford Global Technologies, LLC - Applicants: Ford Global Technologies, LLC - Inventors: Larry Dean Elie; Hamed Ghaednia; Clifford E. Maki; Timothy George Beyer; Arup Kumar Gangopadhyay; James Maurice Boileau - Web page: https://patentgrep.com/patent/US20200400093A1 ## CPC - C23C 4/06: Metallic material - F02F 1/004: {Cylinder liners (F02F1/08, F02F1/16 take precedence)} - B05D 1/36: Successively applying liquids or other fluent materials, e.g. without intermediate treatment - C23C 4/01: Selective coating, e.g. pattern coating, without pre-treatment of the material to be coated - C23C 4/067: containing free particles of non-metal elements, e.g. carbon, silicon, boron, phosphorus or arsenic - C23C 4/131: Wire arc spraying - C23C 4/18: After-treatment - F02F 1/20: characterised by constructional features providing for lubrication - F02F 2200/00: Manufacturing - 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) - F02F: CYLINDERS, PISTONS OR CASINGS, FOR COMBUSTION ENGINES; ARRANGEMENTS OF SEALINGS IN COMBUSTION ENGINES - B05D: PROCESSES FOR APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL (conveying articles or workpieces through baths of liquid B65G, e.g. B65G49/02) ## Abstract Methods and systems are provided for filling surface pores of a cylinder inner surface coating with one or more fill materials to provide desired material and performance properties. In one example, a cylinder for an engine includes an inner surface including a coating having a plurality of surface pores, at least a portion of the plurality of surface pores filled with one or more fill materials, the one or more fill materials configured to decrease friction, increase tribofilm formation, adjust heat transfer, decrease material deposit, and/or decrease run-in duration. ## Claims ### Claim 1 A cylinder for an engine, comprising: an inner surface comprised of an upper region, a lower region, and a middle region disposed intermediate the upper region and the lower region, the inner surface including a coating having a plurality of surface pores, at least a portion of the plurality of surface pores filled with one or more fill materials, the one or more fill materials configured to decrease friction, increase tribofilm formation, adjust heat transfer, decrease combustion material deposit, and/or decrease run-in duration. ### Claim 2 (depends on 1) The cylinder of claim 1, wherein the one or more fill materials include graphite, molybdenum disulfide, silver nanoparticles, copper-based powders or pastes, copper, tungsten disulfide, copper oxide nanoparticles, and/or graphene. ### Claim 3 (depends on 1) The cylinder of claim 1, wherein the one or more fill materials include copper-, aluminum-, and/or silver-based particles. ### Claim 4 (depends on 1) The cylinder of claim 1, wherein the one or more fill materials include platinum, palladium, and/or rhodium. ### Claim 5 (canceled) ### Claim 6 (depends on 1) The cylinder of claim 1, wherein only surface pores present in the upper region and/or lower region are filled with the one or more fill materials. ### Claim 7 (depends on 1) The cylinder of claim 1, wherein all surface pores present in the middle region are free from the one or more fill materials. ### Claim 8 (depends on 1) The cylinder of claim 1, wherein the middle region includes a first sub-region, a second sub-region, and a third sub-region, the second sub-region disposed intermediate the first sub-region and the third sub-region, and wherein surface pores present in the upper region, the lower region, and the second sub-region are filled with the one or more fill materials and surface pores present in the first sub-region and the third sub-region are free from the one or more fill materials. ### Claim 9 (depends on 1) The cylinder of claim 1, wherein only surface pores present in the middle region are filled with the one or more fill materials. ### Claim 10 (depends on 1) The cylinder of claim 1, wherein the middle region has a different average surface porosity than an average surface porosity of the upper region and/or lower region. ### Claim 11 (depends on 1) The cylinder of claim 1, wherein the coating is free of the fill material other than in the at least a portion of the plurality of surface pores. ### Claim 12 (depends on 1) The cylinder of claim 1, wherein each surface pore of the at least a portion of the plurality of surface pores that is filled with the one or more fill materials is fully filled with the one or more fill materials. ### Claim 13 A method, comprising: forming a coating on an inner surface of a cylinder bore, the coating including a plurality of surface pores; applying a mask to the coating; applying a fill material to at least one unmasked region of the coating; removing the mask after applying the fill material; finishing the inner surface to reveal the coating in the at least one unmasked region, the finishing including maintaining the fill material in surface pores of the plurality of surface pores within the at least one unmasked region. ### Claim 14 (depends on 13) The method of claim 13, wherein the mask is applied before applying the fill material and the mask is removed before finishing the inner surface. ### Claim 15 (depends on 14) The method of claim 14, wherein applying the mask includes applying the mask to a middle region of the coating and wherein applying the fill material comprises applying the fill material to both an upper region of the coating and a lower region of the coating, the middle region positioned intermediate the lower region and the upper region. ### Claim 16 (depends on 13) The method of claim 13, wherein applying the fill material includes spraying the fill material on the at least one unmasked region of the coating. ### Claim 17 (depends on 13) The method of claim 13, wherein applying the fill material comprises applying one or more of graphite, molybdenum disulfide, silver nanoparticles, copper-based powders or pastes, copper oxide nanoparticles, graphene, and aluminum-based particles. ### Claim 18 A cylinder for an engine, comprising: a cylinder bore; and a piston configured to reciprocate within the cylinder bore, the cylinder bore including: an inner surface including an upper region configured to circumferentially surround the piston when the piston is at top dead center, a lower region configured to circumferentially surround the piston when the piston is at bottom dead center, and a middle region positioned between the upper region and the lower region; a coating on the inner surface, the coating having a plurality of surface pores; and fill material filling only surface pores of the plurality of surface pores in the upper region and/or lower region and not filling surface pores of the middle region. ### Claim 19 (depends on 18) The cylinder of claim 18, wherein the fill material includes one or more of graphite, molybdenum disulfide, silver nanoparticles, copper oxide nanoparticles, graphene, and aluminum-based particles. ### Claim 20 (depends on 18) The cylinder of claim 18, wherein an outer surface of the coating is free from the fill material, and wherein the coating is comprised of a different material than the fill material.