Method of making a particle-containing plastic coating

Claim 1

The method of making particulate matter-containing plastic coatings upon articles for producing a coating selected from the group consisting of anti-slip coatings, reflective coatings and electrical insulating coatings comprising the steps of: preparing the surface of the articles by cleansing and etching, mixing dry powdered resin and dry particulate matter together with each other before application to the prepared surfaces of the articles, said dry powdered resin being a finely divided grade of resin powder selected from the group consisting of free-flowing fluidizable bed grade or electrostatic powder spraying grade, said particulate matter being selected from the group consisting of alumina grit, silicon carbide grit, silica sand grit, glass particles, quartz grit, and fiberglass particles less than one-eighth of an inch long, and mixtures thereof, said dry particulate matter having a particle size in the range from No. 50 to No. 100 grit size, the loading of the dry particulate matter in said mixture being in the range from 5 to 14 parts by weight of the particulate matter per part of the dry powdered resin, advancing said dry mixture of resin and particulate matter along a trough having a downwardly inclined wide, flat bottom surface terminating in a cascade lip, levelling the advancing dry mixture in said trough to a predetermined uniform thickness before the advancing mixture reaches said cascade lip, allowing said dry mixture of uniform thickness to cascade over said lip, moving the prepared articles beneath said cascade lip and allowing the cascading dry mixture to fall directly onto the prepared surface of each article, providing a vertical spacing between said cascade lip and the prepared surfaces of the articles to be coated which is in the range from approximately 1/8th to 1/2 of an inch, and adhering the dry mixture to the article by heating for forming a trough, durable coating having a thickness of from approximately 30 mils to 80 mils.

Claim 2

The method of making particulate matter-containing plastic coatings upon articles for producing a coating selected from the group consisting of anti-slip coatings, reflective coatings and electrical insulating coatings comprising the steps of: preparing the surface of the articles by cleansing and etching, mixing dry powdered resin and dry particulate matter together with each other before application to the prepared surfaces of the articles, said dry powdered resin being a finely divided grade of resin powder selected from the group consisting of free-flowing fluidizable bed grade or electrostatic powder spraying grade, said particulate matter being selected from the group consisting of alumina grit, silicon carbide grit, silica sand grit, glass particles, quartz grit, and fiberglass particles less than one-eighth of an inch long, and mixtures thereof, said dry particulate matter having a particle size in the range from No. 50 to No. 100 grit size, the loading of the dry particulate matter in said mixture being in the range from 5 to 14 parts by weight of the particulate matter per part of the dry powdered resin, advancing said dry mixture of resin and particulate matter along a trough having a downwardly inclined wide, flat bottom surface terminating in a cascade lip, levelling the advancing dry mixture in said trough to a predetermined uniform thickness before the advancing mixture reaches said cascade lip, allowing said dry mixture of uniform thickness to cascade over said lip, moving the prepared articles beneath said cascade lip and allowing the cascading dry mixture to fall directly onto the prepared surface of each article, providing a vertical spacing between said cascade lip and the prepared surfaces of the articles to be coated which is in the range from approximately 1/8th to 1/2 of an inch, and adhering the dry mixture to the article by heating for forming a trough, durable coating having a thickness of from approximately 30 mils to 80 mils.

Claim 12

The method of making plastic coatings upon articles which can be readily rotated such as cylinders, rods, and shafts comprising the steps of: preparing the surfaces of the articles by cleansing and etching, preheating the article, applying primary coating layer of finely divided powdered thermoplastic resin to the pre-heated article, mixing dry powdered thermoplastic resin of the same type of resin as said priming layer with dry particulate matter, said particulate matter being selected from the group consisting of alumina grit, silicon carbide grit, silica sand grit, glass particles, quartz grit, and fiberglass particles less than one-eighth of an inch long, and mixtures thereof, said dry powdered resin being a finely divided grade of powdered resin selected from the group consisting of free-flowing fluidizable bed grade or electrostatic powder spraying grade, said dry particulate matter having a particle size in the range from No. 50 to No. 100 grit size, the loading of the particulate matter in said mixture being in the range from 5 to 14 parts by weight of the dry particulate matter per part of the dry powdered resin, advancing said dry mixture of resin and particulate matter along a trough having a downwardly inclined wide, flat bottom surface terminating in a straight cascade lip, levelling the advancing dry mixture in said trough to a predetermined uniform thickness before the advancing mixture reaches said cascade lip, allowing said dry mixture of uniform thickness to cascade over said lip, rotating the prepared preheated priming-coated articles below said cascade lip at a predetermined distance beneath said lip with the axis of rotation being parallel with said lip for allowing the cascading dry mixture to fall directly onto said priming-coated layer on the rotating, preheated article, providing a vertical spacing between said cascade lip and said priming-coating layer which is in the range from approximately 1/8th to 1/2 of an inch, further adhering the dry mixture to the article by heating for forming a tough, durable coating having a thickness of from approximately 30 mils to 80 mils.

Claim 13

The method of making plastic coatings upon articles which can be readily rotated such as cylinders, rods, and shafts comprising the steps of: preparing the surfaces of the articles by cleansing and etching, preheating the article, applying primary coating layer of finely divided powdered thermoplastic resin to the pre-heated article, mixing dry powdered thermoplastic resin of the same type of resin as said priming layer with dry particulate matter, said particulate matter being selected from the group consisting of alumina grit, silicon carbide grit, silica sand grit, glass particles, quartz grit, and fiberglass particles less than one-eighth of an inch long, and mixtures thereof, said dry powdered resin being a finely divided grade of powdered resin selected from the group consisting of free-flowing fluidizable bed grade or electrostatic powder spraying grade, said dry particulate matter having a particle size in the range from No. 50 to No. 100 grit size, the loading of the particulate matter in said mixture being in the range from 5 to 14 parts by weight of the dry particulate matter per part of the dry powdered resin, advancing said dry mixture of resin and particulate matter along a trough having a downwardly inclined wide, flat bottom surface terminating in a straight cascade lip, levelling the advancing dry mixture in said trough to a predetermined uniform thickness before the advancing mixture reaches said cascade lip, allowing said dry mixture of uniform thickness to cascade over said lip, rotating the prepared preheated priming-coated articles below said cascade lip at a predetermined distance beneath said lip with the axis of rotation being parallel with said lip for allowing the cascading dry mixture to fall directly onto said priming-coated layer on the rotating, preheated article, providing a vertical spacing between said cascade lip and said priming-coating layer which is in the range from approximately 1/8th to 1/2 of an inch, further adhering the dry mixture to the article by heating for forming a tough, durable coating having a thickness of from approximately 30 mils to 80 mils.