Appeal 2007-1178
Application 10/376,836
a carrier substrate having a metal anchor layer disposed thereon by
electric arc spraying, wherein the anchor layer comprises nickel and
aluminum; and
catalytic material disposed on the anchor layer.
46. A catalyst member comprising:
an open carrier substrate selected from the group consisting of at least
one of monolithic honeycomb carrier substrate, woven mesh, non-mesh,
wadded fibers, and foamed metal, the open substrate having a plurality of
fluid flow paths thereon and being characterized by having a portion of the
surface area thereof obscured relative to a line of sight from a spray head,
the substrate having a metal anchor layer disposed thereon by electric arc
spraying the open substrate from the spray head; and
catalytic material disposed on the metal anchor within the gas flow
passages.
The Examiner relies upon the following references in the rejection of
the appealed claims:
Rondeau US 4,027,367 Jun. 7, 1977
Ishida US 4,455,281 Jun. 19, 1984
Donomoto US 4,798,770 Jan. 17, 1989
Gorynin US 5,204,302 Apr. 20, 1993
Draghi US 6,042,879 Mar. 28, 2000
Appellants' claimed invention is directed to a catalyst member
comprising a metal anchor layer formed on a carrier substrate by electric arc
spraying and a catalytic material disposed on the anchor layer. Claim 1 on
appeal recites that the anchor layer comprises nickel and aluminum, whereas
claim 46 on appeal defines "an open carrier substrate" selected from the
recited group of substrates, e.g., woven and non-woven mesh. Claim 46 also
recites that the open substrate has "a plurality of fluid flow paths thereon and
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