US 11,919,026 B1
System, apparatus, and method for deflected thermal spraying
David J. Cook, Naperville, IL (US); and Keith A. Kowalsky, Oyster Bay, NY (US)
Assigned to Flame-Spray Industries, Inc., Port Washington, NY (US)
Filed by Flame-Spray Industries, Port Washington, NY (US)
Filed on May 31, 2018, as Appl. No. 15/993,662.
Int. Cl. B05B 7/22 (2006.01); C23C 4/12 (2016.01); C23C 4/134 (2016.01)
CPC B05B 7/226 (2013.01) [B05B 7/224 (2013.01); C23C 4/12 (2013.01); C23C 4/134 (2016.01)] 20 Claims
OG exemplary drawing
 
1. A plasma spray system (100) for projecting a horizontally deflected particle stream (91) onto a surface (80) using a plurality of gases (510) that include a plasma gas (512) and a secondary gas (518), said plasma spray system (100) comprising:
a cathode (212);
a wire (310) that includes a free end (370),
a horizontal plane perpendicular to said wire (310) in which said cathode (212) rotates around said free end (370) of said wire (310), wherein said horizontally deflected particle stream (91) is deflected either (a) in the direction of the rotation of the cathode (212) or (b) opposite to the direction of the rotation of the cathode (212);
a nozzle (220) that includes a nozzle face with an opening (224); and
a non-symmetrical passageway configuration (549) that causes said secondary gas (518) flowing through said non-symmetrical passageway configuration (549) to deflect said horizontally deflected particle stream (91),
wherein said plasma gas (512) is directed to said cathode (212) to create a plasma arc (60) between said free end (370) of said wire (310) and said cathode (212);
wherein said deflected particle stream (90) is created by said plasma arc (60) melting said free end (370) of said wire (310).