COATING REINFORCING UNDERLAYMENT AND METHOD OF MANUFACTURING SAME
First Claim
1. A method of forming a non-stick, wear-resistance coating on a surface of a substrate, said method comprising:
- (a) applying an electrically or electrostatically grounded non-stick wet bonding material to the surface of the substrate;
(b) coating the bonding material with a layer of substantially uniform anti-microbial particles, wherein the anti-microbial particles have an electrical or electrostatic charge opposite the electrical charge of the bonding material; and
(c) at least partially curing the wet bonding material and the substantially uniform anti-microbial particles, such that a plurality of the anti-microbial particles are substantially submerged within the cured bonding material and at least part of said anti-microbial particles protrude from the cured bonding material.
3 Assignments
0 Petitions
Accused Products
Abstract
A reinforcing underlayment including dry uniform particles evenly applied to a wet bonding material layer on a surface of a substrate. The substrate, including the layers, is then cured to harden the one or more of the layers. A final coating or topcoat is applied to the cured surface of the substrate. The dry particles are evenly distributed onto the bonding material layer creating a uniform surface for subsequent coatings. The dry particles increase the strength of the liquid coatings increasing solid particle density within the coating system and thereby imparting properties not available for the liquid coatings. The present invention enables a user to easily introduce very heavy, dense, strong particles into a liquid coating and allows the user to apply very dense, heavy particles into and onto a wet bonding material layer followed by a subsequent wet topcoat layer which is cured as one contiguous material with reinforcement and underlayment strengthening coming from the added, dry particles.
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Citations
56 Claims
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1. A method of forming a non-stick, wear-resistance coating on a surface of a substrate, said method comprising:
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(a) applying an electrically or electrostatically grounded non-stick wet bonding material to the surface of the substrate;
(b) coating the bonding material with a layer of substantially uniform anti-microbial particles, wherein the anti-microbial particles have an electrical or electrostatic charge opposite the electrical charge of the bonding material; and
(c) at least partially curing the wet bonding material and the substantially uniform anti-microbial particles, such that a plurality of the anti-microbial particles are substantially submerged within the cured bonding material and at least part of said anti-microbial particles protrude from the cured bonding material. - View Dependent Claims (2, 3, 4)
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5. A method of forming a wear-resistance coating on a surface of a substrate, said method comprising:
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(a) applying an electrically or electrostatically grounded wet bonding material to the surface of the substrate;
(b) coating the bonding material with a layer of substantially uniform anti-microbial particles, wherein the anti-microbial particles have an electrical or electrostatic charge opposite the electrical charge of the bonding material; and
(c) shrinking the wet bonding material by at least partially curing the wet bonding material and the substantially uniform anti-microbial particles such that a plurality of the anti-microbial particles are substantially submerged within the cured bonding material and at least part of said anti-microbial particles protrude from the cured bonding material. - View Dependent Claims (6, 7, 8)
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9. A method of forming a non-stick, wear-resistance coating on a surface of a substrate, said method comprising:
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(a) applying an electrically or electrostatically grounded non-stick wet bonding material to the surface of the substrate;
(b) coating the bonding material with a layer of substantially uniform dry particles, wherein the dry particles have an electrical or electrostatic charge opposite the electrical charge of the bonding material; and
(c) at least partially curing the wet bonding material and the substantially uniform dry particles, such that a plurality of the dry particles are substantially submerged within the cured bonding material and at least part of said dry particles protrude from the cured bonding material. - View Dependent Claims (10, 11)
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12. A method of forming a non-stick coating on a surface of a substrate, said method comprising:
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(a) applying an electrically or electrostatically grounded non-stick wet bonding material to the surface of the substrate;
(b) coating the bonding material with a layer of substantially uniform dry particles, wherein the dry particles have an electrical or electrostatic charge opposite the electrical charge of the bonding material; and
(c) at least partially curing the wet bonding material and the substantially uniform dry particles, such that a plurality of the dry particles are substantially submerged within the cured bonding material and at least part of said dry particles protrude from the cured bonding material. - View Dependent Claims (13, 14)
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15. A method of forming a wear-resistance coating on a surface of a substrate, said method comprising:
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(a) applying an electrically or electrostatically grounded wear-resistance wet bonding material to the surface of the substrate;
(b) coating the bonding material with a layer of substantially uniform dry particles, wherein the dry particles have an electrical or electrostatic charge opposite the electrical charge of the bonding material; and
(c) at least partially curing the wet bonding material and the substantially uniform dry particles, such that a plurality of the dry particles are substantially submerged within the cured bonding material and at least part of said dry particles protrude from the cured bonding material. - View Dependent Claims (16, 17)
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18. A method of forming a non-stick, wear-resistance coating on a surface of a substrate, said method comprising:
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(a) applying an electrically or electrostatically grounded non-stick wet bonding material to the surface of the substrate;
(b) coating the bonding material with at least two different packing densities of substantially uniform dry particles, wherein the dry particles have an electrical or electrostatic charge opposite the electrical charge of the bonding material; and
(c) at least partially curing the wet bonding material and the substantially uniform dry particles, such that a plurality of the dry particles are substantially submerged within the cured bonding material and at least part of said dry particles protrude from the cured bonding material.
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19. A method of forming a non-stick, wear-resistance coating on a surface of a substrate, said method comprising:
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(a) applying an electrically or electrostatically grounded non-stick wet bonding material to the surface of the substrate;
(b) coating the bonding material with a single layer of substantially uniform dry particles at different spatial orientations, wherein the dry particles have an electrical or electrostatic charge opposite the electrical charge of the bonding material; and
(c) at least partially curing the wet bonding material and the substantially uniform dry particles, such that a plurality of the dry particles are substantially submerged within the cured bonding material and at least part of said dry particles protrude from the cured bonding material. - View Dependent Claims (20, 21)
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22. A non-stick, wear-resistance coated substrate comprising:
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a substrate;
a non-stick bonding material secured to a surface of the substrate;
a single layer of substantially uniform particles secured to the bonding material, such that a plurality of the particles are substantially submerged within the bonding material and at least part of said particles protrude from the bonding material; and
a top coating secured to the bonding material and the particles. - View Dependent Claims (23, 24, 25, 26, 27, 28, 29, 30, 31, 32, 33, 34, 35, 36, 37, 38, 39, 40, 41, 42, 43, 44, 45, 46, 47, 48, 49, 50, 51, 52, 53)
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54. A non-stick, wear-resistance coated substrate comprising:
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a substrate;
a non-stick bonding material secured to a surface of the substrate;
a single layer of substantially uniform particles secured to the bonding material, such that a plurality of the particles are substantially submerged within the bonding material and at least part of said particles protrude from the bonding material;
a top coating secured to the bonding material and the particles; and
a layer of at least one anti-microbial material secured to the particles. - View Dependent Claims (55)
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56. A coating system comprising:
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a plurality of coating applicators;
at least one container including a wet bonding material in fluid communication with at least one of the applicators; and
at least one container including substantially uniform dry particles in fluid communication with at least one of the applicators, wherein one of the coating applicators is configured to electrostatically apply a layer of the wet bonding material to a surface of a substrate and another of the coating applicators is configured to apply a layer of the substantially uniform dry particles to the wet bonding material layer on the surface of the substrate until the wet bonding material layer and the dry particles are a desired thickness, wherein after the wet bonding material layer and the dry particles are cured, a plurality of the dry particles are substantially submerged within the cured bonding material and at least part of said dry particles protrude from the cured bonding material.
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Specification