Patent ID: 8273406

Claim:
A method for coating a solid substrate with a curable resin, said method consisting essentially of the steps of: (a) placing a quantity of said substrate consisting of particulate solids into a container; (b) placing a quantity of a first resin selected from liquid epoxy resins into said container, wherein said quantity of said first resin is an amount in the range of from about 0.4 to about 2.0 pounds of said first resin per 100 pounds of said particulate solids; (c) mixing said particulate solids with said first resin in said container to form a first interim product which is damp and which has no visible clumps or agglomerates; (d) placing a quantity of a liquid hardener for said first resin in said container with said damp first interim product while continuing said mixing, wherein said quantity of said hardener is an amount in the range of from about 0.15 to about 0.35 pounds of said hardener per pound of said first resin to thereby form a second interim product which is damp; (e) placing a quantity of a second resin in said container with said damp second interim product while continuing said mixing, wherein said second resin is a novolac resin, and, further, wherein said quantity of said second resin is an amount in the range of from about 1.04 to about 4.3 pounds of said second resin per 100 pounds of said particulate solids; (f) placing a quantity of a curing agent for said novolac resin in said container with said damp second interim product and said novolac, wherein the quantity of said curing agent for said novolac resin is an amount in the range of from about 0.05 to about 0.22 pounds of said curing agent per 100 pounds of said particulate solids; (g) continuing said mixing to thereby produce a dry flowable product which is comprised of said particulate solids having an undercoating in contact with said particulate solids, and an over coating in contact with said undercoating, said undercoating consisting essentially of said first resin and a hardener therefor and, said over coating consisting essentially of said second resin and a curing agent therefor; wherein said first resin is curing and said second resin is curable and; (h) terminating said mixing; wherein the temperature of said particulate solids, said first resin, said liquid hardener for said first resin, said second resin and said curing agent for said second resin is equal to or less than ambient temperature.