Spray Coating Patents (Class 219/121.47)
  • Patent number: 11013099
    Abstract: A method for coating a surface with a coating jet containing coating particles includes forming the coating jet from at least two partial jets. The method also includes forming one of the exit channels as a spray channel for a first gas stream containing the coating particles. The method also includes forming the other of the exit channels as a control channel. In case of a deviation of the ascertained spray angle (?) from the predetermined target spray angle, the method also includes increasing the volume flow of a first partial jet of the at least two partial jets, and decreasing the volume flow of a second partial jet of the at least two partial jets.
    Type: Grant
    Filed: November 16, 2017
    Date of Patent: May 18, 2021
    Assignee: Bayerische Motoren Werke Aktiengesellschaft
    Inventors: Jochen Zierhut, Wolfram Wagener, Ronald Goelz
  • Patent number: 11006512
    Abstract: A hollow electrode assembly through which gas from a gas supply can pass and be effused across the casing of the electrode for supplying a gas for a plasma discharge. The gas passing the electrode goes from a higher gas pressure environment inside the electrode to a lower gas pressure environment on the outside of the electrode. The casing of the electrode through which the gas effuses can be a metal or metal allow which provides for a controlled flow of the gas through the wall. The flow rate of the gas can be controlled by one or more of the porosity of the metal or metal alloy used, the type of gas used, the pressure differential between the inside and outside of the electrode, and the temperature of the system. The electrode assembly can be used in and high temperature plasma generators.
    Type: Grant
    Filed: August 20, 2018
    Date of Patent: May 11, 2021
    Assignee: Aureon Energy Ltd.
    Inventor: Montgomery William Childs
  • Patent number: 10975463
    Abstract: A method for coating a workpiece by using a spraying device is provided. The coating of the workpiece is performed according to at least one coating parameter and at least the following steps are performed during the coating: sensing a locational heat distribution in a working area of a surface of the workpiece; and adjusting the at least one coating parameter in accordance with the sensed heat distribution. A device for coating a workpiece is also provided.
    Type: Grant
    Filed: September 30, 2015
    Date of Patent: April 13, 2021
    Assignee: SIEMENS AKTIENGESELLSCHAFT
    Inventors: Arturo Flores Renteria, Sascha Martin Kyeck, Catrina Michel, Alexandr Sadovoy, Tolga Yagci
  • Patent number: 10945330
    Abstract: A plasma spraying device includes a torch head which has a plasma channel that extends between a cathode and an anode. The plasma channel is bounded by a plurality of neutrodes which are electrically insulated from each other. A gap extends between the frontmost neutrode and the anode, which gap is divided into at least two sections. There is a radial distance and an axial distance between the two sections. An insulating disk is arranged in each of the two sections.
    Type: Grant
    Filed: August 21, 2017
    Date of Patent: March 9, 2021
    Assignee: OERLIKON METCO AG
    Inventor: Silvano Keller
  • Patent number: 10844505
    Abstract: An intermediate rotogravure product has a cylindrical case onto which a circumferential copper layer extends, the circumferential copper layer having a characteristic surface roughness Rz and porosity. A copper engraving layer is on the circumferential copper layer. A method for engraving into adds a copper engraving layer, followed by engraving a predetermined pattern. A rotogravure cylinder product and method add a copper engraving layer on the circumferential copper layer that can be engraved in accordance with a predefined pattern and protected with a protection layer.
    Type: Grant
    Filed: January 17, 2018
    Date of Patent: November 24, 2020
    Assignee: PARAMOUNT INTERNATIONAL SERVICES, LTD.
    Inventor: Ioannis Ioannou
  • Patent number: 10604830
    Abstract: A thermal metal spraying apparatus for applying a metal coating to a target surface. The apparatus provides a cathode, a wire feed stock having a free end, and a wire guide that directs the free end of the wire feedstock to a position for establishing and maintaining a plasma transferred wire arc between the cathode and the free end of the wire feedstock. The wire guide maintains at least three points of contact with the wire feedstock as the wire feedstock is fed through the wire guide.
    Type: Grant
    Filed: June 6, 2017
    Date of Patent: March 31, 2020
    Assignee: Comau LLC
    Inventors: Paulo Espirito Santo Rosa, David R. Collins, Andrea Muzio
  • Patent number: 10576484
    Abstract: A spray coating apparatus includes a cathode and an anode nozzle to form a pair. A front end of the anode nozzle is provided with three or more plasma jet jetting holes, and a spray material jetting hole is disposed at the center of an area surrounded by the plasma jet jetting holes. The spray material jetted through the jetting hole is fed into the center axis of a complex plasma arc or a complex plasma jet. The spray material jetted through the spray material jetting hole is melted at high thermal efficiency, to thereby enhance yield of coating film. Reflection of the spray material by the outer periphery of plasma flame, penetration of the spray material through plasma flame, and scattering of the spray material caused by reflection or penetration, due to the differences in particle diameter, mass, etc. of the spray material is prevented.
    Type: Grant
    Filed: June 7, 2012
    Date of Patent: March 3, 2020
    Assignee: Shinwa Industry Co., Ltd.
    Inventor: Kenzo Toyota
  • Patent number: 10443196
    Abstract: A road finisher comprising a screed plate extending at right angles to the working direction of the road finisher, and a tamper bar disposed rearwardly and/or forwardly of the screed plate in the working direction, wherein at least one electrically operated heating element is present, which is configured so as to heat up a heating surface facing a road subsurface, and wherein the heating element comprises a heating layer at least partially obtained through thermal spraying onto a substrate surface, wherein the tamper bar is made from two parts with an upper tamper bar member and a lower tamper bar member assembled together. Further, a tamper bar for a road finisher and a method of manufacturing a tamper bar are provided.
    Type: Grant
    Filed: September 21, 2018
    Date of Patent: October 15, 2019
    Assignee: BOMAG GMBH
    Inventor: Gianluca Caputo
  • Patent number: 10435779
    Abstract: An apparatus for controlling deposition of material from a plasma transferred wire arc (PTWA) torch within a bore is provided. The apparatus includes a duct and a plurality of cannons. The duct includes a plurality of fluid passageways separated by cross-members. The plurality of cannons are disposed adjacent and downstream from the plurality of fluid passageways of the duct. The flow of fluid is simultaneously directed through all of the fluid passageways and the plurality of cannons and past the PTWA torch in the bore.
    Type: Grant
    Filed: March 14, 2017
    Date of Patent: October 8, 2019
    Assignee: Ford Motor Company
    Inventors: Michael J Habel, Michael Dennis Mucci, Ted A Settimo, Timothy George Beyer, Keith Alan Larson
  • Patent number: 10421142
    Abstract: This invention relates to a method and arrangement for manufacturing objects by solid freeform fabrication, especially titanium and titanium alloy objects, wherein the deposition rate is increased by supplying the metallic feed material in the form of a wire and employing two gas transferred arcs, one plasma transferred arc for heating the deposition area on the base material and one plasma transferred arc for heating and melting the feed wire.
    Type: Grant
    Filed: September 15, 2016
    Date of Patent: September 24, 2019
    Assignee: NORSK TITANIUM AS
    Inventor: Ferdinand Stempfer
  • Patent number: 10403477
    Abstract: A microwave plasma reactor for manufacturing synthetic diamond material via chemical vapor deposition, the microwave plasma reactor comprising: a microwave generator configured to generate microwaves at a frequency f; a plasma chamber comprising a base, a top plate, and a side wall extending from said base to said top plate defining a resonance cavity for supporting a microwave resonance mode, wherein the resonance cavity has a central rotational axis of symmetry extending from the base to the top plate, and wherein the top plate is mounted across said central rotational axis of symmetry; a microwave coupling configuration for feeding microwaves from the microwave generator into the plasma chamber; a gas flow system for feeding process gases into the plasma chamber and removing them therefrom; and a substrate holder disposed in the plasma chamber and comprising a supporting surface for supporting a substrate on which the synthetic diamond material is to be deposited in use; wherein the resonance cavity is con
    Type: Grant
    Filed: December 14, 2011
    Date of Patent: September 3, 2019
    Assignee: Element Six Technologies Limited
    Inventors: John Robert Brandon, Alexander Lamb Cullen, Stephen David Williams, Joseph Michael Dodson, Helen Wilman, Christopher John Howard Wort
  • Patent number: 10384180
    Abstract: Apparatuses and associated methods for forming olefins from saturated hydrocarbon feedstock are disclosed herein. In one embodiment, a carrier gas is introduced at a supersonic velocity to a feedstock injector section. A feedstock gas is introduced to the carrier gas stream using feedstock injectors that are offset in the streamwise direction one from another. The upstream feedstock injectors are positioned to inject feedstock gas to create plumes that improve penetration depth of the feedstock gas and reduce pressure losses at the downstream feedstock injectors. The feedstock gas can be regeneratively preheated by cooling the convergent-divergent nozzle. Water, steam and/or hydrogen gas can be injected into the apparatus for cooling the throat of the convergent-divergent nozzle.
    Type: Grant
    Filed: November 19, 2014
    Date of Patent: August 20, 2019
    Assignee: University of Washington
    Inventors: Carl Knowlen, Arthur T. Mattick, Carl J. Stevens, Robert Cerff, Viggo Hansen
  • Patent number: 10369629
    Abstract: The present disclosure provides three-dimensional (3D) printing methods, apparatuses, systems and/or software to form one or more three-dimensional objects, some of which may be complex. The three-dimensional objects may be formed by three-dimensional printing using one or more methodologies. In some embodiments, the three-dimensional object may comprise an overhang portion, such as a cavity ceiling, with diminished deformation and/or auxiliary support structures.
    Type: Grant
    Filed: March 1, 2018
    Date of Patent: August 6, 2019
    Assignee: Veo3D, Inc.
    Inventors: Kimon Symeonidis, Rueben Joseph Mendelsberg, Tasso Lappas, Nina Cathryn Bordeaux, Gregory Ferguson Brown, Peter Robert Stone, Benyamin Buller, Brian Charles Spink, Zachary Ryan Murphree
  • Patent number: 10276413
    Abstract: A laser processing apparatus includes a melt processing unit for processing a melt formed by laser processing, the melt processing unit being disposed downstream of a condenser in a laser beam irradiating direction. The melt processing unit includes a gas injecting section having an opening allowing the passage of a laser beam applied from the condenser, the gas injecting section injecting high-speed gas from the opening to a workpiece, and a melt sucking section having a suction port disposed so as to surround the opening of the gas injecting section, the suction port sucking the melt scattered by the high-speed gas injected from the opening. The gas injecting section is connected to high-pressure gas supply source, and the melt sucking section is connected to melt sucking unit.
    Type: Grant
    Filed: April 3, 2015
    Date of Patent: April 30, 2019
    Assignee: DISCO CORPORATION
    Inventors: Chikara Aikawa, Yuki Ogawa, Hirokazu Matsumoto
  • Patent number: 10256107
    Abstract: There is disclosed a substrate processing method for etching a substrate on which a first and a second silicon oxide layer having different film qualities are formed side by side. The substrate processing method includes: a first etching step of supplying a halogen-containing gas that is not activated to the substrate and sublimating reaction by-products generated by reaction between the halogen-containing gas and the first and the second silicon oxide layer; and a second etching step of etching the substrate by radicals generated by activating the halogen-containing gas.
    Type: Grant
    Filed: February 23, 2017
    Date of Patent: April 9, 2019
    Assignee: Tokyo Electron Limited
    Inventors: Muneyuki Imai, Satoshi Toda
  • Patent number: 10232460
    Abstract: A center pipe is used in a plasma torch for plasma cutting including a base portion and an electrode. The center pipe is inserted into the electrode and supplies cooling water into the electrode. The center pipe includes a pipe body and a contact piece. The pipe body is electrically connected to an electrical power source outside of the plasma torch via the base portion. The pipe body includes a cooling water channel therein. The pipe body is formed with an electrically conductive body. The contact piece is provided on the external circumferential surface of the pipe body and energizes the electrode through contact with the internal circumferential surface of the electrode. The contact piece has elasticity to produce a counterforce when pressed in the radial direction of the pipe body. The contact piece is formed with an electrically conductive body.
    Type: Grant
    Filed: December 4, 2015
    Date of Patent: March 19, 2019
    Assignee: KOMATSU INDUSTRIES CORPORATION
    Inventors: Yoshihiro Yamaguchi, Keita Kondo, Shigeo Morimoto, Katsuo Saio
  • Patent number: 10124354
    Abstract: The invention relates to a device for thermally coating a surface, which has at least one housing (6), a cathode (9), a primary gas distributor (11), a secondary gas distributor (12), electrically and thermally acting insulation elements (13, 14, 16), and an anode, which is designed as a consumable wire and is guided into a nozzle (19, 21) by means of a wire guide (18), wherein the nozzle (19, 21) is mounted in a centered manner and has openings (23) arranged radially in one plane on one of its sides (22).
    Type: Grant
    Filed: December 18, 2013
    Date of Patent: November 13, 2018
    Assignee: Ford Global Technologies, LLC
    Inventors: Clemens Maria Verpoort, Leander Schramm, Enrico Hauser
  • Patent number: 10060020
    Abstract: The invention relates to a device for thermally coating a surface, which has at least one housing, a cathode, which is designed as a consumable wire and at least one insulation element, wherein the housing has a non-detachable anti-adhesion layer.
    Type: Grant
    Filed: December 19, 2013
    Date of Patent: August 28, 2018
    Assignee: Ford Global Technologies, LLC
    Inventors: Clemens Maria Verpoort, Leander Schramm, Enrico Hauser
  • Patent number: 9987703
    Abstract: The plasma spraying apparatus includes a cathode, a first gas nozzle defining a first gas path between the cathode and itself, a second gas nozzle defining a second gas path between the first gas nozzle and itself, and a third gas nozzle disposed between the first and second gas nozzles to define a third gas path between the first and second gas paths. A wire is disposed at a distal end thereof in front of a nozzle opening of the second gas nozzle. A first gas sprayed through the first gas nozzle is turned into plasma flame, which melts the wire into droplets, and the droplets are sprayed onto a target by a second gas sprayed through the second gas nozzle. The third gas absorbs heat from the plasma flame to thereby turn into a high-temperature gas flow externally of the plasma flame.
    Type: Grant
    Filed: December 17, 2012
    Date of Patent: June 5, 2018
    Assignees: FUJI ENGINEERING CO., LTD., FUJIGIKEN CO., LTD., WEST NIPPON EXPRESSWAY COMPANY LIMITED
    Inventors: Masanobu Sugimoto, Kenichi Yamada, Masanobu Irie
  • Patent number: 9937512
    Abstract: The present disclosure sets forth an automated apparatus and method for applying gas plasma coatings to aircraft engine parts. The process and apparatus employ a plurality of sensors which continually monitor various process parameters associated with the coating process. If any of the measured parameters fall out of tolerance, the coating process is interrupted to allow a user to fix the source of the problem, where upon the process is reengaged. Moreover, the process and apparatus employ a pause resume circuit which uses predetermined durations for pausing and resuming the coating process.
    Type: Grant
    Filed: February 7, 2012
    Date of Patent: April 10, 2018
    Assignee: UNITED TECHNOLOGIES CORPORATION
    Inventor: John R. Pease
  • Patent number: 9815075
    Abstract: A thermal spray assembly (10) for transforming precursor material (60) into a layer of deposited material joined to a substrate body. A plasma torch (20) produces a plasma jet from a plasma nozzle (28). A feeder mechanism (30) guides the precursor material (60) into the plasma jet in use and provides a feeder orifice (70) when in an open condition. The feeder mechanism comprises a guide chamber (34) and a moveable guide mechanism (32), and the guide chamber is capable of guiding the precursor material to the feeder orifice, through which the precursor material can move from the guide chamber and enter the plasma jet at a variable mean distance from the plasma nozzle (28) in response to movement of the guide mechanism (32).
    Type: Grant
    Filed: May 22, 2015
    Date of Patent: November 14, 2017
    Assignee: Element Six GmbH
    Inventor: Andreas Krenn
  • Patent number: 9781818
    Abstract: A consumable set is provided that is usable in a plasma arc torch to direct a plasma arc to a processing surface of a workpiece. The consumable set comprises a nozzle and an alignment surface. The nozzle includes: 1) a nozzle body defining a longitudinal axis extending therethrough, and 2) a nozzle exit orifice disposed in the nozzle body for constricting the plasma arc. The nozzle exit orifice defines an exit orifice axis oriented at a non-zero bevel angle relative to the longitudinal axis. The alignment surface is generally parallel to the exit orifice axis and dimensioned to align the exit orifice such that the plasma arc impinges orthogonally on the processing surface of the workpiece. The alignment surface is configured to lay at least substantially flush against a guiding surface angled relative to the processing surface of the workpiece.
    Type: Grant
    Filed: November 14, 2016
    Date of Patent: October 3, 2017
    Assignee: Hypertherm, Inc.
    Inventors: Peter Twarog, Clifford G. Darrow, E. Michael Shipulski, Martin Higgens
  • Patent number: 9718131
    Abstract: The present disclosure relates to a process and an apparatus for producing powder particles by atomization of a feed material in the form of an elongated member such as a wire, a rod or a filled tube. The feed material is introduced in a plasma torch. A forward portion of the feed material is moved from the plasma torch into an atomization nozzle of the plasma torch. A forward end of the feed material is surface melted by exposure to one or more plasma jets formed in the atomization nozzle. The one or more plasma jets being includes an annular plasma jet, a plurality of converging plasma jets, or a combination of an annular plasma jet with a plurality of converging plasma jets. Powder particles obtained using the process and apparatus are also described.
    Type: Grant
    Filed: February 10, 2016
    Date of Patent: August 1, 2017
    Assignee: TEKNA PLASMA SYSTEMS, INC.
    Inventors: Maher I. Boulos, Jerzy W. Jurewicz, Alexandre Auger
  • Patent number: 9704694
    Abstract: A plasma spraying device may include a first electrode and a second electrode. The first electrode may define an ionizing gas channel and at least one cooling channel. A distal end of the at least one cooling gas channel opens to an exterior of the plasma spraying spray gun proximate to a distal end of the first electrode. The second electrode is at least partially disposed in the ionizing gas channel.
    Type: Grant
    Filed: July 8, 2015
    Date of Patent: July 11, 2017
    Assignee: Rolls-Royce Corporation
    Inventor: Matthew R. Gold
  • Patent number: 9664195
    Abstract: To overcome the problem associated with liquid or solid process debris from a vacuum process system falling into, and contaminating or damaging, a vacuum pumping arrangement used to evacuate the system, the inlet of the vacuum pumping arrangement is located lower than the outlet of the arrangement. This provides a net flow of gas pumped by the arrangement in a generally upwards direction thereby resisting the passage of contaminants into the arrangement.
    Type: Grant
    Filed: March 28, 2012
    Date of Patent: May 30, 2017
    Assignee: Edwards Limited
    Inventor: Austin Jonathan Daykin
  • Patent number: 9613834
    Abstract: A replaceable upper chamber section of a plasma reaction chamber in which semiconductor substrates can be processed comprises a monolithic metal cylinder having a conical inner surface which is widest at a lower end thereof, an upper flange extending horizontally outward away from the conical inner surface and a lower flange extending horizontally away from the conical inner surface. The cylinder includes an upper annular vacuum sealing surface adapted to seal against a dielectric window of the plasma chamber and a lower annular vacuum sealing surface adapted to seal against a bottom section of the plasma chamber. A thermal mass at an upper portion of the cylinder is effective to provide azimuthal temperature uniformity of the conical inner surface. A thermal choke is located at a lower portion of the cylinder and is effective to minimize transfer of heat across the lower vacuum sealing surface.
    Type: Grant
    Filed: March 26, 2010
    Date of Patent: April 4, 2017
    Assignee: LAM RESEARCH CORPORATION
    Inventors: Leonard J. Sharpless, Harmeet Singh, Michael S. Kang
  • Patent number: 9566665
    Abstract: A method of applying a laser metal formed build layer on a surface of an article is disclosed. A laser deposition head including a light source and a nozzle is positioned relative to the surface of the article by a distance that is about normal to the surface. The surface of the article is melted locally using the laser light source to form a melt pool. Powdered metal is injected into the melt pool using the nozzle. The melt pool is solidified to form the build layer having a desired microstructure on the surface of the article.
    Type: Grant
    Filed: December 6, 2013
    Date of Patent: February 14, 2017
    Assignee: Rolls-Royce Corporation
    Inventor: Quinlan Y Shuck
  • Patent number: 9564298
    Abstract: A semiconductor manufacturing apparatus may include a chamber accommodating a substrate to be processed, a first electrode providing electric field in the chamber and a second electrode opposing to the first electrode, and a first power transmitting rod connected to one of the first electrode and the second electrode. A conductive stress attenuating unit may be formed in the first power transmitting rod. Methods of manufacturing semiconductor devices using the semiconductor manufacturing apparatus are also disclosed.
    Type: Grant
    Filed: November 18, 2014
    Date of Patent: February 7, 2017
    Assignee: SAMSUNG ELECTRONICS CO., LTD.
    Inventors: Ju-hee Lee, Su-ho Lee, Won-hyuk Jang, Jae-beom Park, Ik-soo Kim, Myoung-woon Kim
  • Patent number: 9533373
    Abstract: Provided is a powder overlay nozzle that can increase the quality of an overlay layer formed on processing portion of a workpiece, and that can greatly increase workpiece productivity and maintainability. The powder overlay nozzle includes an inner nozzle member including a laser passage for passing laser beam, and an outer nozzle member externally fitted on the inner nozzle member. Between the inner nozzle member and the outer nozzle member, a discharge space for passing powder is formed. The outer nozzle member includes a supply channel for supplying the powder to the discharge space in a direction inclined with respect to an axis L of the powder overlay nozzle.
    Type: Grant
    Filed: December 24, 2014
    Date of Patent: January 3, 2017
    Assignee: TOYOTA JIDOSHA KABUSHIKI KAISHA
    Inventors: Akio Sato, Yoshinori Ishikawa
  • Patent number: 9481933
    Abstract: A cold spray nozzle assembly for applying a coating of particles to a substrate includes a nozzle defining an inner passage with a nozzle exit. The nozzle assembly also includes a particle supply member in communication with the inner passage. The particle supply member supplies the particles to flow and accelerate through the inner passage and out of the nozzle via the nozzle exit toward the substrate to be coated thereon. Furthermore, the nozzle assembly includes a laser that emits a laser beam that is transmitted through the inner passage. The laser heats at least one of the particles and the substrate to promote coating of the substrate with the particles.
    Type: Grant
    Filed: December 3, 2010
    Date of Patent: November 1, 2016
    Assignee: The Regents Of The University Of Michigan
    Inventor: Pravansu S. Mohanty
  • Patent number: 9443634
    Abstract: Provided is an atmospheric electron particle beam nozzle, with a nozzle body having a lumen disposed therethrough; an electrode that is disposed within the lumen, optionally concentrically with the nozzle body, to define an output chamber within the lumen that encompasses the electrode. Also provided is an atmospheric electron particle beam system that provides: a nozzle, that supplies a nozzle body having a lumen disposed therethrough; an electrode disposed within the lumen, optionally concentrically with the nozzle body, to define an output chamber; an RF generator that is in communication with a transformer having a number of turns and connected to a vacuum variable capacitor, and connected electrically to the electrode; and a fluid source that supplies the nozzle with a fluid. Also herein is a method of projecting an electron beam, by projecting an electron charged fluid sheath over a distance, and projecting the electron beam within the sheath.
    Type: Grant
    Filed: August 20, 2009
    Date of Patent: September 13, 2016
    Assignee: FRIPRO ENERGY, LLC
    Inventor: Thomas Edward Fairbairn
  • Patent number: 9381588
    Abstract: Multi-metal particles, apparatuses and method of making same are provided. Specifically, the multi-metal particles are of nanometer dimensions and are prepared by spatially arranged electrodes configured to generate and maintain a plasma cloud.
    Type: Grant
    Filed: March 8, 2013
    Date of Patent: July 5, 2016
    Assignee: Lotus BioEFx, LLC
    Inventors: Donald G. Faulkner, Darren R. Burgess, David John Fennimore
  • Patent number: 9382604
    Abstract: An apparatus for forming an amorphous coating film by jetting flame containing particles of a flame spray material from a flame spray gun toward a base material, causing the particles to be melted by the flame, and cooling both the particles and the flame with the means of a cooling gas before they reach the base material. The apparatus includes a tubular member provided among the path along which the flame is jetted that it surrounds the flame passing through a melting zone in which the particles are melted. The tubular member has a flow channel for the cooling gas, formed along and integrally to the tubular member.
    Type: Grant
    Filed: January 13, 2010
    Date of Patent: July 5, 2016
    Assignee: NAKAYAMA AMORPHOUS CO., LTD.
    Inventors: Ryurou Kurahashi, Masahiro Komaki, Tsunehiro Mimura
  • Patent number: 9358631
    Abstract: Internal coarse particle injection plasma transferred arc torch nozzles comprising: a heat-resistant nozzle body; at least one coarse hard-metal particle internal injection port; at least one fine hard-metal particle and matrix internal injection port; at least one gas port; and a cathode. Related systems, apparatus, compositions, and methods involving such arc torch nozzles are also disclosed.
    Type: Grant
    Filed: June 15, 2011
    Date of Patent: June 7, 2016
    Assignee: Halliburton Energy Services, Inc.
    Inventor: Jay Stuart Bird
  • Patent number: 9327302
    Abstract: A component stack is coated such that, during a first coating pass, a first angle (?) is formed between the first stack opening surface and the coating beam and, during a second coating pass, a second angle (?) is formed between the first stack opening surface and the coating beam, wherein the first angle (?) and the second angle (?) are formed in opposite directions relative to the first stack opening surface.
    Type: Grant
    Filed: September 17, 2013
    Date of Patent: May 3, 2016
    Assignee: OERLIKON METCO AG, Wohlen
    Inventors: Peter Ernst, Bernd Distler
  • Patent number: 9272360
    Abstract: Universal plasma spray extension gun systems and devices for thermal spraying of machine components are disclosed. In one embodiment, a plasma gun extension system includes: a plasma extension arm; an arm connector disposed on the plasma extension arm and configured to connect to an adjustable plasma spray gun apparatus; an arm coupler disposed on the plasma extension arm and configured to connect the plasma extension arm to a robotic arm; and a set of feed conduits disposed on the plasma extension arm between the arm coupler and the arm connector, the set of feed conduits configured to supply a flow to the adjustable plasma spray gun apparatus.
    Type: Grant
    Filed: March 12, 2013
    Date of Patent: March 1, 2016
    Assignee: General Electric Company
    Inventors: Joseph Garfield Albanese, Donald Joseph Baldwin, James Allen Fisk, Christopher Joseph Lochner
  • Patent number: 9269544
    Abstract: A plasma system is disclosed. The system includes a plasma device including an inner electrode and an outer electrode coaxially disposed around the inner electrode, wherein at least one of the inner electrode and the outer electrode is temperature controlled; an ionizable media source coupled to the plasma device and configured to supply ionizable media thereto; and a power source coupled to the inner and outer electrodes and configured to ignite the ionizable media at the plasma device to form a plasma effluent.
    Type: Grant
    Filed: January 15, 2014
    Date of Patent: February 23, 2016
    Assignee: COLORADO STATE UNIVERSITY RESEARCH FOUNDATION
    Inventors: Il-Gyo Koo, Myeong Yeol Choi, Doreene Hyatt, Amber Zagrodzki, Dean A. Hendrickson, George J. Collins
  • Patent number: 9076634
    Abstract: An upper chamber section of a plasma reaction chamber includes a ceramic window with blind bores in an upper surface for receipt of a thermal couple and a resistance temperature detector, a top chamber interface which comprises an upper surface which vacuum seals against the bottom of the window and a gas injection system comprising 8 side injectors mounted in the sidewall of the top chamber interface and a gas delivery system comprising tubing which provides symmetric gas flow to the 8 injectors from a single gas feed connection.
    Type: Grant
    Filed: September 10, 2010
    Date of Patent: July 7, 2015
    Assignee: Lam Research Corporation
    Inventors: Daniel Arthur Brown, Jeff A. Bogart, Ian J. Kenworthy
  • Patent number: 9056326
    Abstract: A device for the thermal coating of a surface, having a wire supply unit for the supply of a wire, wherein the wire acts as a first electrode, a source for plasma gas for generating a plasma gas stream, a nozzle body with a nozzle opening through which the plasma gas stream is conducted as a plasma gas jet to one wire end, and a second electrode which is arranged in the plasma gas stream before the latter enters into the nozzle opening The device is characterized in that the wire supply unit is adjustable, whereby the wire end situated in front of the nozzle opening can be moved by a certain adjustment travel. In this way, it is possible for installation tolerances in the device to be easily compensated, and high and consistent quality of the coating is attained.
    Type: Grant
    Filed: January 6, 2012
    Date of Patent: June 16, 2015
    Assignee: Ford Global Technologies, LLC
    Inventors: Leander Schramm, Alexander Schwenk, Enrico Hauser
  • Patent number: 8969754
    Abstract: Methods for depositing hardfacing material on portions of drill bits comprise providing a vertically oriented plasma transfer arc torch secured to a positioner having controllable movement in a substantially vertical plane. A rolling cutter is secured to a chuck mounted on an articulated arm of a robot. A surface of a tooth of the rolling cutter is positioned in a substantially perpendicular relationship beneath the torch. The torch is oscillated along a substantially horizontal axis. The rolling cutter is moved with the articulated arm of the robot in a plane beneath the oscillating torch. A hardfacing material is deposited on the tooth of the rolling cutter.
    Type: Grant
    Filed: May 28, 2013
    Date of Patent: March 3, 2015
    Assignee: Baker Hughes Incorporated
    Inventors: David Keith Luce, Kenneth E. Gilmore, Alan J. Massey, Timothy P. Uno, Keith L. Nehring
  • Patent number: 8968438
    Abstract: A particle collection apparatus is disclosed. The apparatus includes a baghouse housing comprising an entrance port, a collection port, a baghouse configured between the entrance port and the collection port, and a vacuum port coupled to the baghouse. The apparatus also includes a collection mechanism coupled to the collection port; and, a compression mechanism coupled to the baghouse.
    Type: Grant
    Filed: April 15, 2009
    Date of Patent: March 3, 2015
    Assignee: Innovalight, Inc.
    Inventors: Raul Cortez, Xuegeng Li, Christopher Alcantara, Karel Vanheusden
  • Patent number: 8957346
    Abstract: A thermal spraying apparatus prevents adhesion of spray fumes to unsprayed regions of a bore surface during arc spraying. The apparatus includes a spray gun movable within a cylinder bore. The spray gun has at one end thereof a first discharge opening facing a direction orthogonal to the movement direction, has a second discharge opening facing direction orthogonal to the nozzle, and has, at a predetermined region located further to the side in the movement direction of the spray gun than the nozzle, third discharge openings for discharging a fluid and facing the same direction as the nozzle. A droplet, formed as arc spray wire material melts at the tip of the spray gun, is stretched with auxiliary air. By blowing atomizing air onto the droplet, spray particles are formed and sprayed onto the bore surface. Simultaneously, fume adhesion prevention air is blown toward the cylinder bore surface.
    Type: Grant
    Filed: September 15, 2011
    Date of Patent: February 17, 2015
    Assignee: Toyota Jidosha Kabushiki Kaisha
    Inventors: Kota Kodama, Noritaka Miyamoto
  • Patent number: 8941025
    Abstract: Plume shield shroud (10) for a plasma gun (30) includes a substantially tubular member (14) comprising an axial length, a plume entry end (11), and a plume exit end (13). The shroud (10) is adapted to be mounted to a plasma gun (30). A method of protecting, confining or shielding of a gas plume of a plasma gun (30) includes mounting (20) a gas plume shroud (10) on the plasma gun (30) such that the shroud (10) is sized and configured to substantially surround at least a portion of the gas plume.
    Type: Grant
    Filed: January 25, 2011
    Date of Patent: January 27, 2015
    Assignee: Oerlikon Metco (US) Inc.
    Inventors: Richard McCullough, Mark F. Spaulding, Robert F. Savill, Jr., Ronald J. Molz
  • Patent number: 8927896
    Abstract: A battery powered handheld air plasma spray was designed, developed and successfully demonstrated. The power supply includes a battery, a dc HID ballast and a series LC matching circuit. This matching circuit is designed to maintain the performance of the HID ballast while driving arc discharges, which are rotated around the electrodes by the magnetic field of a ring magnet. The produced plasma is in a non-equilibrium state; thus, the plasma effluent is low temperature (touchable) and yet carries abundant reactive atomic oxygen, which can rapidly activate blood coagulation processes and can effectively kill numerous microbes. This invention is for blood coagulation and sterilization applications. The device may be installed in vehicles and carried and operated in open fields without AC power sources. It may be used for bleeding control in a serious mishap to treat wounds without having to move the injured.
    Type: Grant
    Filed: October 15, 2013
    Date of Patent: January 6, 2015
    Assignee: Adventix Technologies, Inc.
    Inventor: Spencer P. Kuo
  • Publication number: 20140326703
    Abstract: Plasma gun and method of applying powder to a substrate with a plasma gun. The plasma gun includes a cathode assembly (1), an anode (2), a rear neutrode (7), and an extended neutrode (8) positioned adjacent the rear neutrode (7) to define a channel bore (3) between the cathode assembly (1) and the anode (2). The extended neutrode (8) has a length greater than 38 mm. The plasma gun can also include at least one gas inlet to supply a gas to the channel bore (3) and a power supply.
    Type: Application
    Filed: February 28, 2012
    Publication date: November 6, 2014
    Applicant: SULZER METCO (US) INC.
    Inventors: Ronald J. Molz, Dave Hawley, Richard McCullough
  • Patent number: 8872056
    Abstract: A method for metalworking using an adjustable vacuum and support system for evacuating particulate matter, smoke, excess gas, and molten metal from a work area during welding and for providing adjustable support to a welding head. The vacuum system has a vacuum head and a vacuum nozzle. An adjustable mounting bracket has a first portion fixed to the vacuum head and a second portion securable to the welding head. The bracket arrangement establishes pivotal and slidable couplings between the welding head and the vacuum head. The vacuum nozzle has a support surface for being rested on a surface of a workpiece to support the vacuum head and the welding head. The support surface can be a base bevel surface at the tip of the nozzle, and an opposed suction bevel surface can have a nozzle aperture interposed therealong.
    Type: Grant
    Filed: October 22, 2013
    Date of Patent: October 28, 2014
    Inventor: Charles Klangos
  • Patent number: 8822874
    Abstract: A method and apparatus for microplasma spray coating a portion of a substrate, such as a gas turbine compressor blade, without masking any portions thereof. The apparatus includes a microplasma gun with an anode, cathode, and an arc generator for generating an electric arc between the anode and cathode. An arc gas emitter injects inert gas through the electric arc. The electric arc is operable for ionizing the gas to create a plasma gas stream. A powder injector injects powdered material into a plasma stream. A localized area of the compressor blade is coated with the powdered material without having to mask the compressor blade.
    Type: Grant
    Filed: October 31, 2012
    Date of Patent: September 2, 2014
    Assignee: United Technologies Corporation
    Inventors: Paul Zajchowski, Donn Blankenship, Gary C. Shubert
  • Patent number: 8803025
    Abstract: A plasma gun system comprising: a plasma gun comprising an outlet, wherein the plasma gun is configured to generate a plasma stream and provide the plasma stream to the outlet; and a plasma gun extension assembly configured to be coupled to the plasma gun, wherein the plasma gun extension assembly comprises an extension chamber and a port, the extension chamber having an interior diameter defined by a chamber wall and being configured to receive the plasma stream from the outlet of the plasma gun and to enable the plasma stream to expand upon entering the extension chamber, and the port being configured to introduce a powder to the expanded plasma stream at a location outside of the plasma gun.
    Type: Grant
    Filed: December 10, 2010
    Date of Patent: August 12, 2014
    Assignee: SDCmaterials, Inc.
    Inventors: Frederick P. Layman, David Leamon
  • Publication number: 20140166630
    Abstract: The plasma spraying apparatus includes a cathode, a first gas nozzle surrounding a head of the cathode therewith to form a first gas path outside of the cathode, and a second gas nozzle surrounding the first gas nozzle therewith to form a second gas path outside of the first gas nozzle. The second gas nozzle is formed with a wire path through which a wire is inserted such that a distal end of the wire is disposed in front of a nozzle opening of the second gas nozzle. The wire path has a substantially rectangular cross-section having a longer side extending in a direction in which the plasma flame extends, the wire path causing the wire to bend within elastic limit of the wire.
    Type: Application
    Filed: December 17, 2012
    Publication date: June 19, 2014
    Applicants: FUJI ENGINEERING CO., LTD., WEST NIPPON EXPRESSWAY COMPANY LIMITED, FUJIGIKEN CO., LTD.
    Inventors: Masanobu SUGIMOTO, Kenichi YAMADA, Masanobu IRIE
  • Patent number: 8742282
    Abstract: A plasma gun with two gap electrodes on opposite ends of a chamber of ablative material such as an ablative polymer. The gun ejects an ablative plasma at supersonic speed. A divergent nozzle spreads the plasma jet to fill a gap between electrodes of a main arc device, such as an arc crowbar or a high voltage power switch. The plasma triggers the main arc device by lowering the impedance of the main arc gap via the ablative plasma to provide a conductive path between the main electrodes. This provides faster triggering and requires less trigger energy than previous arc triggers. It also provides a more conductive initial main arc than previously possible. The initial properties of the main arc are controllable by the plasma properties, which are in turn controllable by design parameters of the ablative plasma gun.
    Type: Grant
    Filed: April 16, 2007
    Date of Patent: June 3, 2014
    Assignee: General Electric Company
    Inventors: Thangavelu Asokan, Gopichand Bopparaju, Adnan Kutubuddin Bohori