WO2012034018A1

WO2012034018A1 - Powder thermal spray device and system

Info

Publication number: WO2012034018A1
Application number: PCT/US2011/050998
Authority: WO
Inventors: William P. Garamond
Original assignee: Integrated Green Technogies Llc
Priority date: 2010-09-09
Filing date: 2011-09-09
Publication date: 2012-03-15

Abstract

A powder thermal spray device for coating parts with a curable and/or meltable powder including a powder spray gun configured to spray the powder toward the part to be coated and at least one heater configured to direct generated heat toward the part to be coated for curing and/or melting the powder. A manifold can couple the at least one heater to the powder spray gun, which can be an electrostatic powder spray gun.

Description

POWDER THERMAL SPRAY DEVICE AND SYSTEM

Cross-Reference to Related Applications

[0001] This application claims priority to and the benefit of U.S. Provisional Application No. 61/381,111, filed on September 9, 2010, which application is incorporated in its entirety in this document by reference.

Field of the Invention

[0002] The field of this invention relates generally to a powder spray gun device and system, and more particularly to an electrostatic powder thermal spray device and system.

Background of the Invention

[0003] Conventional powder coatings are relatively hard coatings that come in an almost limitless variety of colors and finishes. Depending on the specification, the coatings can be abrasion-resistant. In use, the powder coating can be relatively permanent if the powder coated item is installed without damage and maintained regularly, such as by washing at regular intervals. A correctly applied powder coating, although not metallurgically bonded to the metal, will typically not crack, chip or peel as quickly as conventional paint films.

[0004] Powder coating is typically used to apply a decorative and/or protective finish to a wide range of materials and products that are used by both industries and consumers. The powder used for the process typically is a mixture of finely ground particles of pigment, resin, and additives which is sprayed onto a surface to be coated. In operation, the electrostatically charged powder particles adhere to the electrically grounded surfaces of the items to be coated. Conventionally, the coated items are placed in a curing oven and heated to a desired temperature for a desired period of time, which causes the adhered particles to fuse into a smooth coating. The result is a uniform, durable, high-quality, and attractive finish.

[0005] In powder coating, the powder is conventionally applied by either lowering the part into a fluidized bed of powder, which may or may not be electrostatically charged, or spraying the part with electrostatically charged powder. In either case, the coated part must be placed in an oven, usually in a factory setting, where the powder particles melt, coalesce and bond to the metallic or other substrate surface and form a continuous film. [0006] Thus, conventionally, an item or part to be powder coated is limited to a size smaller than the size of the curing oven. In the past, if the part is too large to fit into a curing oven, powder coating has not been an option for providing a protective coating on the part.

Problematically, many parts that would desirably be powder coated cannot physically be relocated from their environment or are otherwise not easily moved into a curing oven, such as, for example, a boat hull or bridge structural steel. However, because the boat or bridge is not movable into an oven, there has not been a way for them to be powder coated in the past.

[0007] Therefore, there is a need in the industry to be able to apply powder coatings outside of a factory and/or without the use of a conventional curing oven. The present invention fulfills these needs and provides further related advantages as describe herein.

SUMMARY

[0008] Disclosed herein is a powder thermal spray device for coating parts with a curable or meltable powder. In one aspect, the powder thermal spray device comprises a powder spray gun that is configured to spray the powder toward the part to be coated. Optionally, it is contemplated that the powder spray gun can be a conventional electrostatic powder spray gun. In another aspect, the powder thermal spray device can further comprises at least one heater for generating heat. In operation, heat from the at least one heater can be directed toward the part to be coated for melting the powder.

[0009] In one aspect, the at least one heater can comprises a heat generating element that is configured to convert energy from a fuel into heat and a heat shield that is configured to direct or otherwise orient the heat in a desired direction. In one aspect, and without limitation, the fuel can be natural gas, propane, electricity and the like. In another aspect, and without limitation, the heat generating element can be a burner, a resistive element, an IR radiation element, a UV radiation element, and the like. In still another aspect, the heat shield has an open end and defines a shield cavity. In one aspect, at least a portion of the heat shield can be operatively positioned circumferentially around the heat generating element so that heat is urged out of the open end of the heat shield and directed toward a desired portion of the part to be heated. [0010] In one aspect, the powder thermal spray device can further comprises a manifold that is coupled, either integrally or selectively attached, to a portion of the powder spray gun. In one aspect, a proximal end portion of the manifold can configured to be fixedly or selectively attached to the powder spray gun. In one aspect, a distal end portion of the manifold can be configured to be coupled to the at least one heater. Thus, the manifold can couple the at least one heater to the spray gun, and the manifold can position the at least one heater in a desired position and at a desired angle relative to the spray gun.

[0011] In another aspect, the powder thermal spray device further comprises means for controlling the at least one heater. The means for controlling the at least one heater can comprise a processor and, optionally, a temperature sensing device electrically coupled to the processor. In one aspect, the processor can be programmed to activate an output device when the temperature sensing device senses a predetermined temperature. In another aspect, the processor can be programmed to automatically adjust the temperature of the at least one heater in response to the temperature sensed by the temperature sensing device. In still another aspect, the at least one heater can be adjusted and controlled with at least one manually operated valve.

[0012] In one aspect, it is contemplated that the powder thermal spray device can be manufactured as an integrated unit comprising the spray gun, and the at least one heater. Alternatively, the thermal spray gun device can be manufactured and/or sold as an add-on kit for a conventional spray gun.

DETAILED DESCRIPTION OF THE FIGURES

[0013] These and other features of the preferred embodiments of the invention will become more apparent in the detailed description in which reference is made to the appended drawings wherein:

[0014] FIG. 1 is a perspective view of a powder thermal spray gun device according to one aspect, showing a plurality of heaters coupled to a spray gun with a manifold.

[0015] FIG. 2 is a second perspective view of the powder thermal spray device of FIG. 1.

[0016] FIG. 3 is a third perspective view of the powder thermal spray device of FIG. 1. [0017] FIG. 4 is top elevational view of the powder thermal spray device of FIG. 1.

[0018] FIG. 5 is a bottom elevational view of the manifold and heaters of the powder thermal spray device of FIG. 1.

[0019] FIG. 6 is a perspective view of the powder thermal spray device of FIG. 1 positioned on a movable hand truck.

DETAILED DESCRIPTION OF THE INVENTION

[0020] The present invention can be understood more readily by reference to the following detailed description, examples, drawing, and claims, and their previous and following description. However, before the present devices, systems, and/or methods are disclosed and described, it is to be understood that this invention is not limited to the specific devices, systems, and/or methods disclosed unless otherwise specified, as such can, of course, vary. It is also to be understood that the terminology used herein is for the purpose of describing particular aspects only and is not intended to be limiting.

[0021] The following description of the invention is provided as an enabling teaching of the invention in its best, currently known embodiment. To this end, those skilled in the relevant art will recognize and appreciate that many changes can be made to the various aspects of the invention described herein, while still obtaining the beneficial results of the present invention. It will also be apparent that some of the desired benefits of the present invention can be obtained by selecting some of the features of the present invention without utilizing other features. Accordingly, those who work in the art will recognize that many modifications and adaptations to the present invention are possible and can even be desirable in certain circumstances and are a part of the present invention. Thus, the following description is provided as illustrative of the principles of the present invention and not in limitation thereof.

[0022] As used throughout, the singular forms "a," "an" and "the" include plural referents unless the context clearly dictates otherwise. Thus, for example, reference to "a heater" can include two or more such heaters unless the context indicates otherwise.

[0023] Ranges can be expressed herein as from "about" one particular value, and/or to "about" another particular value. When such a range is expressed, another aspect includes from the one particular value and/or to the other particular value. Similarly, when values are expressed as approximations, by use of the antecedent "about," it will be understood that the particular value forms another aspect. It will be further understood that the endpoints of each of the ranges are significant both in relation to the other endpoint, and independently of the other endpoint.

[0024] As used herein, the terms "optional" or "optionally" mean that the subsequently described event or circumstance may or may not occur, and that the description includes instances where said event or circumstance occurs and instances where it does not. As used herein, the terms "cure" or "curing" mean to melt or fuse particles into a smooth and/or textured continuous coating.

[0025] A powder thermal spray device and system is provided, according to various aspects. In one aspect, as illustrated in Figures 1-5, the powder thermal spray device 10 comprises a spray gun 12 and at least one heater 14 operatively coupled to the spray gun. In another aspect, the powder thermal spray device further comprises means for controlling the at least one heater.

[0026] With reference to Figures 1-3, the spray gun 12 can be a conventional powder spray gun configured to spray powder towards a part to be coated. In one aspect, the spray gun can be a conventional electrostatic powder spray gun. Details of such a conventional electrostatic powder spray gun are well know to one skilled in the art and are not described in this disclosure.

Exemplary conventional electrostatic powder spray guns include those manufactured by Nordson, Gema, Wagner, Red line, Eastwood, Mitsuba, Iontech, Parker Ionics, Sames and others.

[0027] In another aspect, the powder can be a thermal plastic resin (thermoplastic), a thermal set (thermalset) resin and the like. In still another aspect, the powder can be electrostatically charged as it leaves the gun, or alternatively, by a tribo-charging effect as the powder is sprayed.

Optionally, it is contemplated that the selected powder can be sprayed without being

electrostatically charged. Powder can be supplied to the spray gun 12 from a source of powder through a powder feed line 16 coupled to the spray gun.

[0028] The at least one heater 14 can comprise a heat generating element 18 configured to convert energy from a source of fuel into heat and /or electromagnetic radiation. In one aspect and without limitation, the at least one heater can be powered by natural gas, propane, electricity, and the like. In still another aspect and without limitation, the heat generated by the at least one source of heat can be at least one of convection, R radiation, UV radiation, microwave radiation, laser light and the like. It is contemplated that each at least one heater can produce a desired energy level that is substantially fixed or can be selectively varied. In various aspects, the desired energy level can be between about 50 to about 2 million BTUs, between about 50 to about 1 million BTUs, or any desired energy level therebetween. It is further contemplated that the at least one heater operatively coupled to the electrostatic powder spray gun can be selected based on the desired energy level. Thus, it is contemplated that the at least one heater can be interchangeably operatively coupled to the electrostatic powder spray gun to customize the heat that can be operatively supplied or otherwise generated by the device.

[0029] Optionally, in versions in which a plurality of heaters are operatively coupled to the electrostatic powder spray gun, it is contemplated that the heaters can be selected as desired from heaters powered by, without limitation, natural gas, propane, electricity, convection, IR radiation, UV radiation and the like. In this aspect, the plurality of heaters can be the same type of heaters, or, optionally, the plurality of heaters can comprise at least two different types of heaters, e.g., a propane heater and Infra Red heater.

[0030] If, for example, the at least one heater 14 is a gas heater, the heat generating element 18 can be a burner and the fuel from the source of fuel can be propane. In one aspect, the burner can be a 50 BTU burner, a 2 million BTU burner, or a burner configured to output any amount of heat between 50 and 2 million BTU. Fuel can be supplied from the source of fuel, which is typically pressurized, to the burner of each heater through a gas feed line 20. Similarly, air from a source of pressurized air can be supplied to the each heater 14 through a pressurized air feed line 22. In another example, if the at least one heater is an electric heater, the heat generating element can be a resistive element and the fuel can be electricity.

[0031] As illustrated in Figures 2 and 4, the at least one heater 14 can comprise a heat shield 28 configured to direct heat in a desired direction. In one aspect, the heat shield can have an open end 30 and can define a shield cavity. In another aspect, the heat shield can be positioned on the heater so that at least a portion of the heat generating element of the heater is therein the cavity of the heat shield. As can be appreciated, the generated heat can be directed by the heat shield toward the open end 30 of the shield. In one aspect, the heat shield 28 can be substantially circular in cross-sectional shape. In another aspect, the heat shield can be substantially oval in cross-sectional shape. In other aspects, it is contemplated that the heat shield 28 can be any geometric shape capable of directing heat in a desired direction.

[0032] In one aspect, the powder thermal spray device 10 further comprises a manifold 32. In another aspect, the manifold can be configured to position the at least one heater 14 relative to the spray gun 12. For example, a proximal end 34 of the manifold can be configured for mounting to the spray gun, and a distal end 36 of the manifold can be configured for attachment of the at least one heater 14. In one aspect, the distal end of the manifold can define a plurality of bores and/or slots 38 configured to receive a fastener attached to the heater. The bores and/or slots can be defined in a plurality of locations so that the position and/or orientation of the heater relative to the spray gun 12 can be adjusted as desired.

Referring now to Figure 4, in another aspect, if the distal end 36 of the manifold defines a plurality of slots 38, the slots can be configured so that the angle formed between a longitudinal axis LH of the heater 14 and a longitudinal axis Ls of the spray gun 12 can be selectively adjusted. For example, the heater could be positioned such that the longitudinal axis LH of the heater is substantially parallel to the longitudinal axis Lsof the spray gun so that heat is directed from the open end 30 of the heat shield 28 in a direction substantially parallel to the longitudinal axis of the spray gun. In another example, the heater 14 could be positioned such that the longitudinal axis LH of the heater is at an acute angle relative to the longitudinal axis heat of the spray gun 12, and heat can be directed from the open end of the heat shield at an acute angle relative to the longitudinal axis of the spray gun.

[0033] In another aspect, the manifold 32 can be configured to distribute gas and/or pressurized air from the respective sources of gas and pressurized air. In this aspect and as illustrated in Figure 5, a gas duct 40 can be defined therein the manifold, the gas duct in fluid communication with a gas attachment element 42 and the gas feed line 20 of each heater 14. In use, as described more fully below, the source of fuel can be coupled to the gas attachment element 42, and fuel can flow from the source of fuel through the gas duct to each gas feed line. The gas feed line 20 can be coupled to the burner 18 of each heater 14 of the at least one heater. Thus, the manifold can allow a user of the powder thermal spray device 10 to couple a single source of fuel to the device and distribute the fuel to each heater attached thereto. [0034] Similarly, an air duct 44 can be defined therein the manifold 32, the air duct in fluid communication with an air attachment element 46 and the air feed line 22 of each heater 14. In use, as described more fully below, the source of air can be coupled to the air attachment element, and air can flow from the source of pressurized air through the air duct to each air feed line. The air feed line 22 can be coupled to each heater 14 of the at least one heater. Thus, the manifold can allow a user of the device 10 to couple a single source of air to the device and distribute the pressurized air to each heater attached thereto.

[0035} With reference now to Figures 2, 3, 5, and 6, the means for controlling the at least one heater 14 can comprise at least one of: a gas valve 48 configured for controlling the flow of gas to the at least one heater, an air valve 50 configured for controlling the flow of air to the at least one heater, a processor and/or a controller 52, and a temperature sensing device 54. In one aspect, the processor can be configured to allow for the controlled flow of pressurized air, fuel gases, and/or power. In another aspect, the processor can be positioned in an enclosure attached to the device 10.

[0036] In one aspect, the temperature sensing device 54 can be a thermocouple or other similar device known in the art configured to measure the temperature of the at least one heater 14. The thermocouple can be positioned in the cavity of the heat shield 28 and can be electrically coupled to the processor so that the temperature sensed by the thermocouple is transmitted to the processor. In another aspect, the temperature sensing device can comprise a non-contact thermometer, such as, for example and without limitation, an infrared thermometer and the like, configured to measure the temperature of an object being heated by the heater. For example, the non-contact thermometer could be positioned on the manifold 32 and directed toward an object being heated. The non-contact thermometer can sense the temperature of the object being heated and can transmit the sensed temperature to the processor. In still another aspect, the temperature sensing device can comprise a thermocouple and a non-contact thermometer, so that both the temperature of the heater 14 and the object being heated are transmitted to the processor. In a further aspect, the temperature sensor device 54 can be electrically coupled to the processor and, optionally, can be selectively mountable to the powder thermal spray device 10.

[0037] In one aspect, the processor can be programmed to automatically adjust the amount of heat being output by the at least one heater 14 based on the temperature of the heater and/or the object being heated. For example, if the object being heated has been heated to a predetermined temperature, the processor could cause the gas valve 48 and/or the air valve 50 to close fully. In another example, if the object being heated has nearly been heated to a predetermined temperature, the processor could cause the gas valve to close partially. In still another example, if the heater is not generating enough heat, the processor could cause the gas valve 48 to open more.

[0038] In another aspect, the processor can be coupled to an output device such as a screen, an LED, and/or an audible alarm so that a user of the powder thermal spray device 10 is notified to manually adjust the heater. For example, upon the object being heated reaching a

predetermined temperature, the processor can cause the user to be notified by producing an audible beep, so that the user can manually adjust the gas control valve 48. In another example, a LED could emit a light to signal the user that the heater 14 and/or the object have reached a predetermined temperature. Thus, it is contemplated that the processor or temperature sensor device 54 can conventionally display the sensed temperature reading and display the temperature to the operator so that the operator can manually adjust the means for controlling the at least one heater 14-

[0039] In one aspect, the powder thermal spray device 10 can be manufactured as an integrated unit comprising the spray gun 12 and the at least one heater 14. Alternatively, the thermal spray gun device can be manufactured and/or sold as an add-on kit for converting a conventional spray gun to a powder thermal spray device as described 10 herein. For example, a user could be provided an assembly comprising at least the at least one heater 14 and the manifold 32. The at least one heater 14 and the manifold 32 could be coupled to a conventional spray gun 12 by a user to form the powder thermal spray device.

[0040] It is contemplated that at least a portion of the powder thermal spray device 10, the source of powder, the source of fuel, and/or the source of air is portable and can be mounted on a cart 56, such as for example and without limitation a hand truck for easy movement, as illustrated in Figure 6. Alternatively, the spray gun 12 and/or the at least one heater 14 can be fixedly attached to a fixture for operation.

[0041] In use, a powder pump can carry the powder from either a fluidized bed feeder or from a non fluidized container. The feeder can be a reservoir from which the powder to be sprayed is pumped through the spray gun 12. This may be, for example and without limitation, a fluidizing device, a pressurized device, gravity feed device, a simple container, or the like. An air pump or equivalent device can used to convey the powder through the powder feed line 16 to the spray gun. An electrostatic charge generating device may also be connected in the console or in the spray gun by means such as a hose.

[0042] As one will appreciate from the disclosure herein, the powder thermal spray device 10 can be used to direct the flow of powder, an electrostatic charge, and generated heat towards the object to be coated. The at least one heater 14 can be mounted or otherwise oriented on the spray gun 12 in such a way as to direct the heat towards the part to be coated. The directed heat may heat the part and/or melt the powder as it is being sprayed. Alternatively, the at least one heater can be used to preheat the part and before being turned down or off upon the part reaching a predetermined temperature. The powder can then be sprayed onto the preheated part. If desired, the at least one heater 14 can be activated and used to post heat or cure the adhered powder thereon the part.

[0043] It is contemplated that the powder thermal spray device 10 can be operated in a plurality of alternative modes. In one example, the thermal spray gun device can be used as a conventional electrostatic spray gun 12 which can charge powder as powder is being sprayed such that the powder will be attracted to a grounded part and stick to it. This part can then be placed in an oven or passed through a heating device or radiant cure device or equivalent and can then be further processed as desired to completion.

[0044] In a second example, the powder thermal spray device 10 can be used as an electrostatic spray gun 12 which can charge powder as the powder is being sprayed from the gun such that the powder will be attracted to a grounded part and stick there. The at least one heater 14 of the device can heat the part and melt the powder. Depending upon the powder being sprayed, the part may or may not require then being placed in an oven or passing through a heating device or radiant cure device or equivalent to be further processed to completion.

[0045] In a third example, the powder thermal spray device 10 can be used as a non- electrostatic spray gun 12 where no charge is imparted to powder as the powder is sprayed.

Simultaneously to spraying the powder, the at least one heater 14 can heat the part and melt the powder such that a useful powder coating is achieved on the part. Depending upon the powder being sprayed, the part may or may not require being placed in an oven or passed through a heating device or radiant cure device or equivalent to be furthered processed to completion. [0046] In a fourth example, the powder thermal spray device 10 can be used as a non- electrostatic spray gun 12 where no charge is imparted to the powder as it is sprayed. In this example, the at least one heater 14 of the thermal spray gun device can heat the part to a predetermined temperature. Upon the part reaching the predetermined temperature, the powder can be sprayed onto the heated surface of the part. Optionally, the part can continue to be heated as the powder is being sprayed, or alternatively, after the powder has been sprayed onto the part, the part can be heated again by the heater. In one aspect, the electrostatic function of the powder thermal spray device 10 can be used during at least a portion of this coating procedure.

[0047] In each of the above examples, the processes can be performed either indoors, such as in a factory-like setting, or outdoors at the location of the part. Parts coated by the powder thermal spray device 10 can be formed from any materials suitable for adherence of the powder being used, such as, for example metal material, non-metallic material, and the like. It is contemplated that the powder thermal spray device 10 described herein, unlike the previously existing art, can be used to coat parts of any nature or size, such as, for example and without limitation, a ship, bridge, light pole, to a small casting, sheet metal, a machine part and the like.

[0048] Although several embodiments of the invention have been disclosed in the foregoing specification, it is understood by those skilled in the art that many modifications and other embodiments of the invention will come to mind to which the invention pertains, having the benefit of the teaching presented in the foregoing description and associated drawings. It is thus understood that the invention is not limited to the specific embodiments disclosed hereinabove, and that many modifications and other embodiments are intended to be included within the scope of the appended claims. Moreover, although specific terms are employed herein, as well as in the claims which follow, they are used only in a generic and descriptive sense, and not for the purposes of limiting the described invention, nor the claims which follow.

Claims

CLAIMS What is claimed is:

1. A powder thermal spray device for coating a part with a powder, the powder thermal spray device comprising: a powder spray gun configured to spray the powder toward the part to be coated; and at least one heater for generating heat, wherein heat generated by the at least one heater is directed toward the part to be coated for curing the powder.

2. The powder thermal spray device of Claim 1, wherein the at least one heater comprises a heat generating element configured to convert energy from a fuel into heat and a heat shield configured to direct the heat in a desired direction.

3. The powder thermal spray device of Claim 2, wherein the heat generating element is a burner.

4. The powder thermal spray device of Claim 2, wherein the heat generating element is an electromagnetic energy emitter.

5. The powder thermal spray device of Claim 2, wherein the heat shield has an open end and defines a shield cavity, and wherein the heat shield is positioned on the at least one heater such that at least a portion of the heat generating element is therein the shield cavity.

6. The powder thermal spray device of Claim 5, wherein the heat shield is substantially circular in cross-sectional shape.

7. The powder thermal spray device of Claim 2, further comprising a manifold, wherein a proximal end of the manifold is fixedly attached to the powder spray gun, and wherein a distal end of the manifold is attachable to the at least one heater.

8. The powder thermal spray device of Claim 7, wherein the distal end of the manifold defines a plurality of bores extending through the manifold, and wherein the bores are configured to receive a fastener attached to the at least one heater.

9. The powder thermal spray device of Claim 8, wherein the at least one heater has a longitudinal axis, and wherein the spray gun has a longitudinal axis.

10. The powder thermal spray device of Claim 9, wherein an angle formed between the longitudinal axis of the at least one heater and the longitudinal axis of the spray gun is selectively adjustable.

11. The powder thermal spray device of Claim 9, wherein the longitudinal axis of the at least one heater is substantially parallel to the longitudinal axis of the spray gun.

12. The powder thermal spray device of Claim 7, wherein the manifold comprises a gas attachment element configured to couple the manifold to a source of fuel, and wherein the manifold defines a gas duct in fluid communication with the gas attachment element and the at least one heater.

13. The powder thermal spray device of Claim 12, wherein the manifold comprises an air attachment element configured to couple the manifold to a source of pressurized air, and wherein the manifold defines an air duct in fluid communication with the air attachment element and the at least one heater.

14. The powder thermal spray device of Claim 1 , further comprising a processor and a temperature sensing device electrically coupled to the processor

15. The powder thermal spray device of Claim 14, wherein the processor and the temperature sensing device are coupled to the spray gun.

16. The powder thermal spray device of Claim 14, wherein the processor is electrically coupled to an output device, and wherein the processor activates the output device when the temperature sensing device senses a predetermined temperature.

17. The powder thermal spray device of Claim 14, wherein the temperature sensing device is a thermocouple configured to sense the temperature of the at least one heater.

18. The powder thermal spray device of Claim 14, wherein the temperature sensing device is a non-contact thermometer configured to sense the temperature of the part being heated.

19. The powder thermal spray device of Claim 14, wherein the processor is configured to adjust the heat generated in response to the temperature sensed by the temperature sensing device.

20. The powder thermal spray device of Claim 1 , wherein the powder thermal spray device is positioned on a movable cart.

21. The powder thermal spray device of Claim 1 , wherein the powder spray gun comprises an electrostatic powder spray gun.

22. A kit for converting a conventional powder spray gun for coating a part with a powder to a powder thermal spray device, the kit comprising: at least one heater for generating heat, wherein heat generated by the at least one heater is directed toward the part to be coated for curing the powder; a manifold, wherein a proximal end of the manifold is attachable to the powder spray gun, and wherein a distal end of the manifold is attached to the at least one heater; and means for controlling the at least one heater.

23. A method for coating a part with a thermoplastic / Thermalset powder comprising: providing a powder thermal spray device comprising: an electrostatic powder spray gun configured to spray the powder toward the part to be coated; at least one heater for generating heat, wherein heat generated by the at least one heater is directed toward the part to be coated for curing the powder; and means for controlling the at least one heater; heating the part with the at least one heater to a predetermined temperature; and spraying the powder onto the part.