US Patent 7959983 Thermal spray formation of polymer compositions

A system and method for applying a material, such as a polymer composition, to a substrate, the method comprising mixing the material with a heated carrier gas stream, spraying the material through a nozzle, and radiant and convective heating of the material during transport. Preferred embodiments of the system and method can be used to spray polyetherimides, polyimides, polyamides, thermoset resins (e.g., and epoxies, polyesters and silicones), liquid crystal polymers, compositions comprising a blowing agent, compositions comprising a binder, compositions comprising a metallized material, compositions that produce an open cell foam, and compositions that produce a closed cell foam.