Coating reinforcing underlayment and method of manufacturing same

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 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;
• (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;
• and
• (d) applying a topcoating to the bonding material and dry particles.

A method of preparing a surface of a substrate for the application of a non-stick, wear-resistance coating to the surface, said method comprising the steps of:

• (a) placing the substrate on a grounded support;
• (b) applying a wet electro-conductive non-stick bonding material to the surface of the substrate;
• (c) electrostatically attracting a single layer of substantially uniform dry particles to the wet electro-conductive bonding material;
• (d) at least partially curing the wet electro-conductive 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;
• and
• (e) applying a topcoating to the bonding material and dry particles.

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) evenly 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;
• (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;
• and
• (d) applying a topcoating to the bonding material and dry particles.

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) evenly coating the bonding material with a single 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.

A method of forming a wear-resistance coating on a surface of a substrate, said method comprising:

• (a) applying an electrically or electrostatically grounded wet bonding material to the surface of the substrate;
• (b) evenly coating the bonding material with a single 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) shrinking the wet bonding material by 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.