Patent ID: 7216814

Claim:
A thermal spray coating system comprising: a) a spray gun applicator providing means for projecting coating material through a reduced temperature zone of a flame region and onto a substrate, the spray gun applicator including a gun body having an axial conduit for passage therethrough of coating material said gun body including a fuel gas supply conduit, an oxygen supply conduit, and a compressed air conduit, an assembly mounted to a distal end portion of the gun body including a nozzle having a plurality of first channels for distally ejecting streams of oxygen-fuel gas mixtures into the flame region to provide high temperature combustion gasses and having a plurality of second channels for distally ejecting streams of compressed air into the flame region to provide the reduced temperature zone, said nozzle further comprising an axial passageway for the passage therethrough of the coating material, a proximal stem portion and a distal flange portion, said flange portion including the plurality of first and second channels in alternating arrangement, the first channels extending longitudinally through the flange portion and the second channels respectively having a radially oriented portions with inlet openings disposed around a circumferential periphery of the flange portion and longitudinally oriented portions; the assembly further including an air distributor cap having a plurality of ports for discharging compressed air distally in a direction angled inward towards the axis of the gun body and toward the flame region to provide a compression wave to rapidly melt the coating material; and b) means for supplying coating material to the spray gun applicator.