Method of forming a coating on a surface of a substrate

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.

The invention is claimed as follows: 
     
         1 . A coated substrate comprising:
 a substrate;   a non-stick bonding material secured to a surface of the substrate;   a layer of aramid fibers secured to the non-stick bonding material, at least a first portion of a plurality of the aramid fibers each being partially submerged within the non-stick bonding material and at least a second portion of each of said plurality of aramid fibers protruding from the non-stick bonding material; and   a top coating secured to the bonding material.   
     
     
         2 . The coated substrate of  claim 1 , wherein the substrate is selected from the group consisting of: a cooking device, a food processing device, and a food conveyor. 
     
     
         3 . The coated substrate of  claim 1 , wherein the layer of aramid fibers includes at least two different sized aramid fibers. 
     
     
         4 . The coated substrate of  claim 1 , wherein the aramid fibers are ground. 
     
     
         5 . A coated substrate comprising:
 a substrate;   a bonding material secured to a surface of the substrate;   a single layer of aramid fibers secured to a top of the bonding material; and   a top coating secured to the single layer of aramid fibers.   
     
     
         6 . The coated substrate of  claim 5 , wherein the substrate is selected from the group consisting of: a cooking device, a food processing device, and a food conveyor. 
     
     
         7 . The coated substrate of  claim 5 , wherein the single layer of aramid fibers includes at least two different sized aramid fibers. 
     
     
         8 . The coated substrate of  claim 5 , wherein the aramid fibers are ground. 
     
     
         9 . The coated substrate of  claim 5 , wherein the bonding material is a non-stick bonding material. 
     
     
         10 . A coated substrate comprising:
 a substrate;   a non-stick bonding material secured to a surface of the substrate; and   a plurality of aramid fibers in the non-stick bonding material.   
     
     
         11 . The coated substrate of  claim 10 , wherein the substrate is selected from the group consisting of: a cooking device, a food processing device, and a food conveyor. 
     
     
         12 . The coated substrate of  claim 10 , wherein the plurality of aramid fibers includes at least two different sized aramid fibers. 
     
     
         13 . The coated substrate of  claim 10 , wherein the plurality of aramid fibers are ground. 
     
     
         14 . The coated substrate of  claim 10 , which includes a top coating secured to the bonding material.