Claims Analysis
Total Claims: 13
Claim 1
Independent Claim
175 words
A method of plasma spraying cured thermoset coatings comprising: a. continuously introducing thermosettable resinous particles having a maximum thickness of less than about 100 microns into a region of a high velocity, plasma arc generated flame having a temperature substantially greater than the melting point of said resin, said particles being introduced externally to a device generating said plasma flame; b. maintaining the residence time of said resinous particles in said flame region for a period sufficiently long to impart sufficient thermal and kinetic energy to said particles to polymerize the resins of said particles to a substantially cross-linked or cured state upon impact with a substrate, but wherein said thermal energy alone is insufficient to polymerize said resin to said cured state; c. propelling said resinous particles towards a substrate with sufficient velocity to cause impact with sufficient force to cause said particles to flow upon said substrate to coat same with a continuous, thin coating; and d. cooling said coated substrate at a rate sufficiently slow to assist the curing of said coating.
Claim 2
Independent Claim
175 words
A method of plasma spraying cured thermoset coatings comprising: a. continuously introducing thermosettable resinous particles having a maximum thickness of less than about 100 microns into a region of a high velocity, plasma arc generated flame having a temperature substantially greater than the melting point of said resin, said particles being introduced externally to a device generating said plasma flame; b. maintaining the residence time of said resinous particles in said flame region for a period sufficiently long to impart sufficient thermal and kinetic energy to said particles to polymerize the resins of said particles to a substantially cross-linked or cured state upon impact with a substrate, but wherein said thermal energy alone is insufficient to polymerize said resin to said cured state; c. propelling said resinous particles towards a substrate with sufficient velocity to cause impact with sufficient force to cause said particles to flow upon said substrate to coat same with a continuous, thin coating; and d. cooling said coated substrate at a rate sufficiently slow to assist the curing of said coating.
Claim 3
Dependent Claim
20 words
The method of claim 1 wherein said thermal energy imparted to said particles is sufficient to liquify substantially said particles.
Claim 4
Dependent Claim
19 words
The method of claim 1 wherein said resinous particles have a melt viscosity of less than about 2000 centipoise.
Claim 5
Dependent Claim
17 words
The method of claim 1 wherein said resinous particles have a curing temperature of less than 400°F.
Claim 6
Dependent Claim
28 words
The method of claim 1 wherein the residence time of said resin particles in the vicinity of said flame is from about one-five-thousandths second to about one-five-hundredths second.
Claim 7
Dependent Claim
19 words
The method of claim 1 wherein said resin particles are propelled at a velocity of at least 500 ft./sec.
Claim 8
Dependent Claim
13 words
The method of claim 1 wherein said flame is generated from ionized argon.
Claim 9
Dependent Claim
19 words
The method of claim 1 wherein said flame is generated from an ionized gas mixture of nitrogen and argon.
Claim 10
Dependent Claim
18 words
The method of claim 6 wherein nitrogen is present as at least 20% of the ionizing gas volume.
Claim 11
Dependent Claim
32 words
The method of claim 1 wherein said substrate is located at a distance of from about three to about six inches from the introduction point of said resinous particles into said flame.
Claim 12
Dependent Claim
14 words
The method of claim 1 wherein the thermosettable resinous particles are epoxy resin particles.
Claim 13
Dependent Claim
14 words
The method of claim 1 wherein the thermosettable resinous particles are acrylic resin particles.