Appeal 2007-0950
Application 11/099,264
as-synthesized nanoparticles powder in an aggregated form suitable for
conventional spray deposition of nanostructured coatings, the resulting
spray-dried powders having an optimal range of 10-50 microns (Strutt, e.g.,
col. 3, ll. 48-64, and col. 4, l. 47 to col. 5, l. 51, and col. 7, ll. 20-33). Strutt
further discloses “a method for direct nanoparticle injection of
as-synthesized powders into the combustion flame or plasma of a
conventional thermal spray deposition device, wherein the . . . powders are
first dispersed in a liquid medium by means of ultrasound,” which “[d]irect
injection . . . method allows reproducible deposition of . . . coatings without
an intermediate [spray drying] step” (id., e.g., col. 3, l. 65, to col. 4, 1. 6; see
also col. 3, ll. 48-54, and col. 9, ll. 28-40). In this method, the
nanostructured powder feeds having a particle size of 3 to 30 nanometers are
directly introduced to a thermal spray after ultrasound dispersion to form a
colloidal suspension or slurry (id., col. 7, ll. 34-47).
In the latter method, a suspension or slurry of nanoparticles can be
directly introduced into the fuel feed of the plasma gun, which method
permits, among other things, two nanoparticle feed systems operating
continuously (Strutt, col. 7, l. 34, to col. 8, l. 5). The direct injection of
colloidal suspension of nanostructured powders into the combustion zone of
a thermal spray gun produced coating similar to those generated using
powder agglomerates as feed materials (id., col. 7, l. 34, to col. 8, l. 5). The
direct injection method can also be used to incorporate ceramic
nanostructured particles into the nanocomposite coating, and a method in
which “a slurry mixture of ceramic nanoparticles and hollow microspheres is
introduced into a combustion flame or plasma . . . to selectively melt the
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