US4121083A
Expired / Lapsed
US
⏱️ 0.0 years remaining
Method and apparatus for plasma flame-spraying coating material onto a substrate
Assignee: Metco Inc
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Filing: 1977-04-27
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Granted: 1978-10-17
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Expires: 1997-04-27
Abstract
Abstract Method and apparatus for plasma flame-spraying coating material onto a substrate by means of passing a plasma-forming gas through a nozzle electrode, passing an arc-forming current between said nozzle electrode and a rear electrode to form a plasma effluent, introducing coating material into the plasma effluent, passing the plasma effluent axially through a wall shroud extending from the exit of said nozzle electrode and forming a flame shroud for the plasma effluent at least within the wall shroud.
Inventors
- 👤 Richard T. Smyth
Bibliographic Details
Application Number
—
Jurisdiction
US
Data Source
google_patents
Last Synchronized
2026-10-27 22:49
CPC Classifications
H; H05; H05H; H05H1/00; H05H1/24; H05H1/26; H05H1/32; H05H1/42; B; B05; B05B; B05B7/00; B05B7/16; B05B7/22; B05B7/222; B05B7/226; C; C23; C23C; C23C4/00; C23C4/12; C23C4/134; H05H1/28; H05H1/34; H05H1/341; H05H1/3478; H05H1/3457
Claims Analysis
Total Claims: 44
Claim 1
Independent Claim
87 words
A plasma spray gun assembly for coating substrates comprising, in combination; a nozzle electrode having a nozzle passage therethrough; a rear electrode; means for passing plasma-forming gas through the nozzle electrode; means for passing an arc-forming current between said electrodes to form a plasma effluent; means for introducing spray coating material into the plasma effluent; a wall shroud for said plasma effluent extending from the exit of the nozzle electrode; and means for forming a flame shroud for said plasma effluent at least within the wall shroud.
Claim 2
Dependent Claim
87 words
A plasma spray gun assembly for coating substrates comprising, in combination; a nozzle electrode having a nozzle passage therethrough; a rear electrode; means for passing plasma-forming gas through the nozzle electrode; means for passing an arc-forming current between said electrodes to form a plasma effluent; means for introducing spray coating material into the plasma effluent; a wall shroud for said plasma effluent extending from the exit of the nozzle electrode; and means for forming a flame shroud for said plasma effluent at least within the wall shroud.
Claim 3
Dependent Claim
21 words
A plasma spray gun assembly according to claim 1 wherein said spray coating material is in the form of a powder.
Claim 4
Dependent Claim
53 words
A plasma spray gun assembly according to claim 1 wherein said means for forming a flame shroud for said plasma effluent at least within the wall shroud comprises means for directing said flame shroud at an angle of between about 160° to about 180° with respect to the axis of the plasma effluent.
Claim 5
Dependent Claim
49 words
A plasma spray gun assembly according to claim 1 wherein said means for forming a flame shroud for said plasma effluent at least within the wall shroud comprises means for directing said flame shroud at an angle of about 180° with respect to the axis of the plasma effluent.
Claim 6
Dependent Claim
38 words
A plasma spray gun assembly according to claim 4 wherein said means for forming a flame shroud for said plasma effluent at least within the wall shroud comprises burner means disposed adjacent the outlet of the wall shroud.
Claim 7
Dependent Claim
38 words
A plasma spray gun assembly according to claim 5 wherein said burner means includes an annular plenum chamber having jet orifice means directed at an angle of about 180° with respect to the axis of the plasma effluent.
Claim 8
Dependent Claim
26 words
A plasma spray gun assembly according to claim 6 wherein said burner means further includes combustion gas inlet means that pass longitudinally through said wall shroud.
Claim 9
Dependent Claim
18 words
A plasma spray gun assembly according to claim 1 further comprising means for water cooling said wall shroud.
Claim 10
Dependent Claim
17 words
A plasma spray gun assembly according to claim 1 wherein said wall shroud is of cylindrical configuration.
Claim 11
Dependent Claim
30 words
A plasma spray gun assembly according to claim 2 wherein said means for introducing powdered coating material into the plasma effluent is disposed adjacent the exit of the electrode nozzle.
Claim 12
Dependent Claim
35 words
A plasma spray gun assembly according to claim 1 wherein said means for forming a flame shroud for said plasma effluent within the wall shroud includes means for burning a high molecular weight combustion mixture.
Claim 13
Dependent Claim
18 words
A plasma spray gun assembly according to claim 11 wherein the high molecular weight combustion mixture includes propane.
Claim 14
Dependent Claim
33 words
A plasma spray gun assembly according to claim 1 further comprising means for forming an annular curtain effect around the plasma effluent as it leaves the wall shroud and passes towards the substrate.
Claim 15
Dependent Claim
34 words
A plasma spray gun assembly according to claim 13 wherein said means for forming an annular curtain effect includes an annular manifold and orifice means mounted adjacent the outer end of said wall shroud.
Claim 16
Dependent Claim
51 words
A plasma spray gun assembly according to claim 1 wherein said means for forming a flame shroud for said plasma effluent at least within the wall shroud comprises means for directing said flame shroud at an angle having a component extending parallel to the direction of flow of said plasma effluent.
Claim 17
Dependent Claim
54 words
A plasma spray gun assembly according to claim 1 wherein said means for forming a flame shroud for said plasma effluent at least within the wall shroud comprises means for directing said flame shroud at an angle having a component extending in a direction opposite to the direction of flow of said plasma effluent.
Claim 18
Dependent Claim
35 words
A plasma spray gun assembly according to claim 6 further comprising second jet orifice means directed at an angle of from about 0° to about 180° with respect to the axis of the plasma effluent.
Claim 19
Dependent Claim
33 words
A plasma spray gun assembly according to claim 6 further comprising second jet orifice means directed at an angle having a component extending parallel to the direction of flow of said plasma effluent.
Claim 20
Dependent Claim
36 words
A plasma spray gun assembly according to claim 6 further comprising second jet orifice means directed at an angle having a component extending in a direction opposite to the direction of flow of said plasma effluent.
Claim 21
Dependent Claim
25 words
A plasma spray gun assembly according to claim 1 wherein said wall shroud has a radially-inwardly directed lip portion disposed towards the exit end thereof.
Claim 22
Dependent Claim
79 words
A process for plasma flame-spraying coating material onto a substrate, which comprises the steps of: passing a plasma-forming gas through a nozzle electrode; passing an arc-forming current between said nozzle electrode and a rear electrode to form a plasma effluent; introducing coating material into the plasma effluent; passing the plasma effluent longitudinally through a wall shroud extending from the exit of said nozzle electrode; and forming a flame shroud for said plasma effluent at least within the wall shroud.
Claim 23
Dependent Claim
79 words
A process for plasma flame-spraying coating material onto a substrate, which comprises the steps of: passing a plasma-forming gas through a nozzle electrode; passing an arc-forming current between said nozzle electrode and a rear electrode to form a plasma effluent; introducing coating material into the plasma effluent; passing the plasma effluent longitudinally through a wall shroud extending from the exit of said nozzle electrode; and forming a flame shroud for said plasma effluent at least within the wall shroud.
Claim 24
Dependent Claim
23 words
A process for plasma flame-spraying coating material onto a substrate according to claim 21 wherein said coating material is in a powder form.
Claim 25
Dependent Claim
39 words
A process for plasma flame-spraying coating material onto a substrate according to claim 21 wherein said flame shroud is directed at an angle of between about 160° to about 180° with respect to the axis of the plasma effluent.
Claim 26
Dependent Claim
35 words
A process for plasma flame-spraying coating material onto a substrate according to claim 23 wherein said flame shroud is directed at an angle of about 180° with respect to the axis of the plasma flame.
Claim 27
Dependent Claim
26 words
A process for plasma flame-spraying coating material onto a substrate according to claim 21 further comprising the step of passing cooling water through said wall shroud.
Claim 28
Dependent Claim
26 words
A process for plasma flame-spraying coating material onto a substrate according to claim 21 further comprising the step of preheating combustion gas for the flame shroud.
Claim 29
Dependent Claim
31 words
A process for plasma flame-spraying coating material onto a substrate according to claim 21 wherein said coating material is introduced into the plasma effluent adjacent the exit of the electrode nozzle.
Claim 30
Dependent Claim
29 words
A process for plasma flame-spraying coating material onto a substrate according to claim 21 wherein a mixture for forming said flame shroud is a high molecular weight combustion mixture.
Claim 31
Dependent Claim
25 words
A process for plasma flame-spraying coating material onto a substrate according to claim 21 wherein a combustion mixture for forming said flame shroud includes propane.
Claim 32
Dependent Claim
25 words
A process for plasma flame-spraying coating material onto a substrate according to claim 21 wherein a combustion mixture for forming said flame shroud includes acetylene.
Claim 33
Dependent Claim
26 words
A process for plasma flame-spraying coating material onto a substrate according to claim 21 wherein a combustion mixture for forming said flame shroud includes MAPP gas.
Claim 34
Dependent Claim
26 words
A process for plasma flame-spraying coating material onto a substrate according to claim 21 wherein a combustion mixture for forming said flame shroud includes APACHI gas.
Claim 35
Dependent Claim
25 words
A process for plasma flame-spraying coating material onto a substrate according to claim 21 wherein a combustion mixture for forming said flame shroud includes hydrogen.
Claim 36
Dependent Claim
23 words
A process for plasma flame-spraying coating material onto a substrate according to claim 21 wherein said coating material is a fusible powdered metal.
Claim 37
Dependent Claim
22 words
A process for plasma flame-spraying coating material onto a substrate according to claim 21 wherein said coating material is a ceramic material.
Claim 38
Dependent Claim
21 words
A process for plasma flame-spraying coating material onto a substrate according to claim 21 wherein said coating material is a carbide.
Claim 39
Dependent Claim
38 words
A process for plasma flame-spraying coating material onto a substrate according to claim 21 further comprising the step of forming a fluid annular curtain around the plasma effluent as it leaves the wall shroud passing towards said substrate.
Claim 40
Dependent Claim
37 words
A process for plasma flame-spraying coating material onto a substrate according to claim 21 wherein said flame shroud is directed at an angle having a component extending parallel to the direction of flow of said plasma effluent.
Claim 41
Dependent Claim
40 words
A process for plasma flame-spraying coating material onto a substrate according to claim 21 wherein said flame shroud is directed at an angle having a component extending in a direction opposite to the direction of flow of said plasma effluent.
Claim 42
Dependent Claim
75 words
A process for plasma flame-spraying coating material onto a substrate according to claim 21 wherein a portion of the mixture for forming said flame shroud is introduced at an angle of about 180° with respect to the axis of the plasma effluent and a second portion of the mixture for forming said flame shroud is introduced at an angle of from about 0° to about 180° with respect to the axis of the plasma effluent.
Claim 43
Dependent Claim
73 words
A procsss for plasma flame-spraying coating material onto a substrate according to claim 21 wherein a portion of the mixture for forming said flame shroud is introduced at an angle of about 180° with respect to the axis of the plasma effluent and a second portion of the mixture for forming said flame shroud is introduced at an angle having a component extending parallel to the direction of flow of said plasma effluent.
Claim 44
Dependent Claim
76 words
A process for plasma flame-spraying coating material onto a substrate according to claim 21 wherein a portion of the mixture for forming said flame shroud is introduced at an angle of about 180° with respect to the axis of the plasma effluent and a second portion of the mixture for forming said flame shroud is introduced at an angle having a component extending in a direction opposite to the direction of flow of said plasma effluent.
References Cited (Backward Citations)
USPTO Annuity & Maintenance Windows
| Annuity Stage | Window Opens | Payment Deadline | Surcharge Period Until | Estimated Fee | Status |
|---|---|---|---|---|---|
| 3.5 Years (Year 4) | 1981-10-16 | 1982-04-17 | 1982-10-17 | $2000.00 | Window Closed / Lapsed |
| 7.5 Years (Year 8) | 1985-10-16 | 1986-04-17 | 1986-10-17 | $3760.00 | Window Closed / Lapsed |
| 11.5 Years (Year 12) | 1989-10-16 | 1990-04-17 | 1990-10-17 | $7700.00 | Window Closed / Lapsed |