Appeal 2007-0950
Application 11/099,264
The plain language of independent claim 1 specifies a method for
applying a plasma sprayed coating comprising at least the step, among other
things, of injecting a suspension of carrier liquid and any solid particles
containing any thermal barrier coating constituents, into any plasma jet of
any plasma spray device, capable of forming a gradient film at any point at
which the plasma jet is being formed or has been formed. Indeed, we find
the Specification discloses the liquid suspension is introduced into the
plasma jet “typically at or near the plasma flame” (Specification ¶ 6).
Independent claim 14 contains the same language and further specifies
separately injecting the liquid suspension and solid thermal barrier coating
constituent particles other than in a liquid/solid mixture into the plasma jet.
Independent claim 20 specifies a device capable for applying a thermal
barrier coating system comprising at least, among other things, a liquid
injector and a powder injector for injecting suspension and a powder,
respectively, into a plasma jet exiting any plasma gun capable of applying a
thermal barrier coating system. Claim 12, dependent on claim 1, requires
the same separate liquid and powder injections as claim 14. Claim 17,
dependent on claim 14, specifies the barrier coating constituents in the liquid
suspension have a particle size of about 10 microns and the particulate
thermal barrier coating constituents have a particle size larger than about 74
microns.
We agree with the Examiner’s findings of fact from Strutt, Peterson,
and Gambino, to which we add the following. We find Strutt would have
disclosed to one of ordinary skill in this art a method for reprocessing
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