Appeal 2006-2523
Application 10/206,496
substrate particles . . . suspended in an alcohol-based solution containing
metal oxo-hydroxides” wherein “[t]he temperature of the solution is
increased and water is added to the solution to catalyze the polymerization of
the metal oxo-hydroxides” to coat “the surface of the metal substrate
particles with metal oxide” (Specification [0002]). Appellants exemplify the
process “[w]hen solutions are used to coat the substrate” as including in “the
initial solution” such ingredients as “ethanol . . . as the primary solvent,
phosphates . . . and metal oxo-hydroxides” or “[o]ther precursors [which]
include metal salts and alkoxides” (Specification [0003]).
Appellants then state that
[t]o further elaborate on the preceding example, there are two
common types of sol-gel solutions that can be used to form
coated substrates, a gelatinous solution with a low [ethanol]
content, and a liquid solution with a higher [ethanol] content.
The nature of the solution, whether liquid or gelatinous is
determined by the [ethanol] content of the solution. A gelatinous
solution is created when the alcohol content is about 30% to
about 40% alcohol by volume. If the alcohol content of the
solution is greater than about 40% alcohol by volume, the
solution will be a homogeneous liquid. . . . .
The LPP solutions are most useful in coating small metal
substrates that are suspended in the solution, while the gelatinous
form of such solutions are useful for applying a continuous, low
density coating on larger substrates. The present invention is
based on a liquid phase polymerization solution that avoids
gelation by controlling the appropriated polymerization reaction.
Specification, [0004]-[0005] (emphasis supplied).
disclosure of the prior art processes in the Background of the Invention and
the patents have not been made of record.
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