Method for making a submersible surface with antifouling protection
A method for manufacturing a submerged surface, such as the hull of a marine vessel or a submerged grate or conduit, uses particles that are electrically conductive and disposes those particles on the exposed surface. The particles are held in, place by an electrically conductive composite material, such as a conductive gel coat, and a charge distribution layer is used to spread the current through all parts of the conductive outer surface.
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1. Field of the Invention
The present invention is generally related to the prevention of fouling by marine microorganisms on submersed surfaces and, more particularly, to a method for making an electrically conductive surface which efficiently and effectively conducts current in contact with water to affect a characteristic of the water at the boundary layer in contact with the submerged surface.
2. Description of the Related Art
Those skilled in the art of marine vessels and marine propulsion devices are aware of the disadvantages associated with the growth of marine organisms on submerged surfaces, such as boat hulls. These disadvantages are also inherent with regard to other submerged surfaces, such as water intake grates. One method for inhibiting the growth of microorganisms on submerged surfaces is to provide a biocidal agent that is used on the surface. Other methods use electricity to induce the creation of chlorine bubbles in salt water applications or change the pH of the water immediately proximate the submerged surface in fresh water applications. The creation of chlorine or increased acidity near the submerged surface typically uses an electric current to induce the chemical reaction which results in this beneficial effect. However, difficulty has been experienced in providing the necessary structure which is both electrically conductive and sufficiently robust to withstand many repeated cycles of current flow which is able to produce the desired results.
British patent 2,222,832, which issued to Andoe and was published on Mar. 21, 1990, describes a method of protecting the hulls of marine vessels from fouling. The method comprises measuring the surface configuration and shape of the hull (e.g. by running a computer mouse over the hull), cutting strips of predominately copper foil material corresponding to the configuration of the hull which includes at least one structure thereon made of a metal of dissimilar composition to the foil material, applying the strips in overlapping relation but spaced from at least the structure, and smoothing and rolling a roller device over the strips to adhere the strips to the hull. A cathodic protection system is also applied. An adhesive with anti-fouling properties is used.
U.S. Pat. No. 4,428,989, which issued to Marshall on Jan. 31, 1984, describes an anti-fouling and anti-sliming gel coat. A polymeric composition contains copper flakes in sufficient quantities to render the entire thickness of the polymeric composition electrically conductive. The copper flake is treated to remove oxides and reacted with conventional epoxy resins modified with an epoxidized polyol. The formulation not only exhibits outstanding anti-fouling properties but also exhibits anti-sliming properties. The composition is useful as a gel coat and when utilized on ships, boats, and other watercraft, a vessel results which requires no additional anti-fouling or anti-sliming treatment for several years. The composition can also be used to great advantage as a liner for pipes and conduits used to transport salt or freshwater where fouling of the pipes is a problem.
U.S. Pat. No. 5,192,603, which issued to Slater et al. on Mar. 9, 1993, describes a protection system for substrates against aquatic fouling. It comprises coating the substrate with an elastomeric undercoat and with a topcoat of a room temperature vulcanisable silicone rubber. The elastomeric undercoat is generally harder than the room temperature vulcanisable silicone rubber foul resistant top coat. The abrasion and tear resistance of the silicone rubber foul resistant layer is markedly increased by the use of the elastomeric undercoat.
U.S. Pat. No. 5,354,603, which issued to Errede et al. on Oct. 11, 1994, describes an anti-fouling/anti-corrosive composite marine structure. The structure comprises a marine substrate having adhered to at least a portion of its surface a layer of a water permeable composite article comprising a non-woven fibrous web having entrapped therein active particulate to provide the marine substrate with protection against at least one of fouling and corrosion. Underwater surfaces such as ship hulls, buoys, docks, intake pipes, etc., can be protected against marine growth and corrosion by adhering thereto the composite sheet article of the invention.
U.S. Pat. No. 6,173,669, which issued to Staerzl on Jan. 16, 2001, discloses an apparatus and method for inhibiting fouling of an underwater surface. The system comprises two conductive surfaces and a device that alternates the direction of electric current between the two surfaces. The current is caused to flow through sea water in which the two surfaces are submerged or partially submerged. A monitor measures the current flowing from one of the two conductive surfaces and compares it to the current flowing into the other conduction surface to assure that no leakage of current of substantial quantity exists.
U.S. Pat. No. 6,209,472, which issued to Staerzl on Apr. 3, 2001, discloses an apparatus and method for inhibiting fouling of an underwater surface. The system provides an electric current generator which causes an electric current to flow proximate the underwater surface. A source of power, such as a battery, provides electrical power to the electric current generator. The flow of current passes from the underwater surface through water surrounding the surface or in contact with the surface, and a point of ground potential. The point of ground potential can be a marine propulsion system attached to a boat on which the underwater surface is contained.
U.S. Pat. No. 6,514,401, which issued to Chyou et al. on Feb. 4, 2003, describes an anti-fouling system. The system is adapted to be used for an underwater structure immersed in seawater. The anti-biofouling system includes a conductive layer, comprising carbon fiber, graphite powder and binder, formed on a surface of the underwater structure for serving as an anode, a cathode, and a power supply for providing a current, thereby performing an electrolytic reaction for the anti-biofouling system such that a fouling organism is prohibited from attaching to the surface of the underwater structure.
U.S. Pat. No. 6,547,952, which issued to Staerzl on Apr. 15, 2003, discloses a system for inhibiting fouling of an underwater surface. The surface is combined with a protective surface of glass in order to provide an anode from which electrons can be transferred to seawater for the purpose of generating gaseous chlorine on the surface to be protected. Ambient temperature cure glass (ATC glass) provides a covalent bond on an electrically conductive surface, such as nickel-bearing paint.
U.S. Pat. No. 6,973,890, which issued to Staerzl on Dec. 13, 2005, discloses a self-adaptive system for an apparatus which inhibits fouling of an underwater surface. A system is provided which automatically calibrates a marine fouling prevention system. It responds to movement between fresh and saltwater bodies of water, detects damage to the hull or other submerged surface, and responds to the use of the fouling prevention system with different sizes of marine vessels.
U.S. Pat. No. 7,025,013, which issued to Staerzl et al. on Apr. 11, 2006, discloses a multilayered submersible structure with fouling inhibiting characteristics. The structure has an outer coating that is disposed in contact with water in which the structure is submerged, a current distribution layer or charge distribution layer, an electrical conductor connectable in electrical communication to a source of electrical power, and a support structure. By selectively energizing the current distribution layer, or charge distribution layer, chemical and ionic changes can be caused in the water immediately adjacent the outer coating or layer to inhibit the growth of marine organisms on the outer surface of the submersible structure.
U.S. Pat. No. 7,131,877, which issued to Staerzl on Nov. 7, 2006, discloses a method for protecting a marine propulsion system. An electrically conductive coating is provided on a housing structure of a marine propulsion system. By impressing a current on the electrically conductive coating, which can be a polymer material, the housing structure is used as an anode in a cathodic protection system. In addition, the use of the electrically conductive coating on the housing structure as an anode inhibits the growth of marine fouling on the outer surface of the housing structure by forming chlorine gas in a saltwater environment and by forming an acidic water layer near the surface in a non-saltwater environment.
The patents described above are hereby expressly incorporated by reference in the description of the present invention.
In fouling prevention systems that utilize electric current to change the characteristic of the water immediately adjacent the submerged surface, it is necessary to provide a surface which is electrically conductive and which is robust. Since most binders, such as polymer matrices, are not sufficiently electrically conductive for these purposes, higher current densities are necessary to achieve the desired results of producing chlorine in saltwater environments or changing the acidity of the water in freshwater environments. The use of higher current magnitudes reduces the expected electrically conductive life of the submerged surface. In the production of marine vessels having this capability of generating chlorine on the submerged surface, or changing the acidity of the freshwater near the submerged surface, it is necessary to manufacture the watercraft in an efficient and effective manner which also produces an electrically conductive surface that is robust and can withstand many current conducting cycles during its life.
SUMMARY OF THE INVENTIONA method for making a submersible surface which is resistive to fouling, in accordance with a preferred embodiment of the present invention, comprises the steps of providing a layer of electrically conductive composite material and disposing a coating of an electrically conductive particulate on a surface of the layer of electrically conductive composite material which is exposed to water when the submersible surface is disposed in a body of water.
In a preferred embodiment of the present invention, the method can further comprise the steps of providing a mold, disposing a layer of a temporary holding agent to an inner surface of the mold, spraying the coating of the electrically conductive particulate onto the layer of the temporary holding agent, and spraying the layer of electrically conductive composite material onto the coating of the electrically conductive particulate. In one embodiment of the present invention, the method further comprises the steps of disposing a charge distribution layer onto the layer of electrically conductive composite material. The charge distribution layer can be a carbon fiber mat in one embodiment and can comprise a layer of electrically conductive particulates sprayed onto the electrically conductive composite material in an alternative embodiment. The method can further comprise the step of disposing at least one electrical conductor in electrical communication with the charge distribution layer and attaching a support structure to the layer of electrically conductive composite material. In one embodiment of the present invention, the method further comprises disposing a layer of insulative composite material between the layer of electrically conductive composite material and the support structure.
In the embodiment described immediately above, the electrically conductive composite material can be an electrically conductive gel coat material. The temporary holding agent can be a mold release agent. At least one electrical conductor is disposed in electrical communication with the charge distribution layer and, in a particularly preferred embodiment of the present invention, the electrical conductor is a strip of carbon fiber. The support structure can comprise a layer of fiberglass material. The layer of insulated composite material can comprise an electrically non-conductive, or electrically insulative, gel coat.
Many of the steps described above are particularly applicable to the production of watercraft that comprise fiberglass hulls which are manufactured by using a mold and then successively disposing various layers into the mold until a complete watercraft hull is manufactured. The finished hull is then removed from the mold. However, it should be understood that the present invention can also be used in association with metal hull marine vessels, such as ships. In that case, the structure is produced in a generally opposite sequence, beginning with the electrically conductive metal hull and providing sequential layers until the outermost surface, which is contact with the body of water in which the marine vessel is operated, is completed.
The method of the present invention, can therefore comprise the steps of disposing an electrically insulative coating on an electrically conductive hull of a marine vessel, disposing the layer of electrically conductive composite material onto the electrically insulative coating, and spraying the coating of electrically conductive particulate on the surface of the layer of electrically conductive composite material. It can further comprise the step of pressing the coating of the electrically conductive particulate into the surface of the layer of electrically conductive composite material. This pressing step can comprise the step of using a roller to press the coating of the electrically conductive particulate into the surface of the layer of electrically conductive composite material.
The present invention will be more fully and completely understood from a reading of the description of the preferred embodiment in conjunction with the drawings, in which:
Throughout the description of the preferred embodiment of the present invention, like components will be identified by like reference numerals.
An important purpose of the present invention is to assure that the wetted surface of a submerged object is uniformly conductive across the surface. In other words, one of its intended functions is to avoid concentration of highly conductive material in one portion of the submerged surface with other portions of the submerged surface being more resistive. When this deleterious condition exists, certain portions of the submerged surface carry a significantly higher proportion of electric current than the more resistive portions and this non-uniformity of current conduction can lead to oxidation of those portions of the submerged surface which carry the higher current load. Although other benefits are achieved from the method of the present invention, the uniformity of conduction is an important result that can be achieved from the use of the present invention.
The present invention can be applied in two distinct ways. One method is intended to produce a boat which is manufactured through the use of a mold, as is the case in many fiberglass boats. An alternative application of the present invention can be used in the manufacture of boats or slips having metallic or electrically conductive hulls. Both embodiments of the present invention will be described below.
Later steps of a preferred embodiment of the present invention will be described in conjunction with the alternative embodiment utilizing the carbon fiber mat 60. However, it should be understood that the spraying technique, which provides a charge distribution layer comprising a layer-of electrically conductive particles 64, is also within the scope of the present invention.
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U.S. Pat. No. 6,173,669, described above, discusses the history of fouling prevention which extends back over 2,000 years. These techniques include the use of various materials to inhibit marine growth, including many toxic materials. In addition, various high and low frequency sound waves have been used to discourage fouling of marine vessel surfaces. This history of combating marine growth on submerged surfaces is described in numerous patents that are cited in U.S. Pat. No. 6,173,669. These patents date from 1910 and extend to very recently granted patents. The technique and technology described in published papers and patents fully recognize that electric current can be used to alter a characteristic of the water immediately surrounding a submerged surface. In saltwater applications, this characteristic change typically involves the production of gaseous chlorine. In freshwater applications, this characteristic typically involves the pH, for acidity level, of the water immediately surrounding the submerged surface. The primary purpose of the present invention is to provide an efficient manufacturing procedure that allows the exposed surface of a marine hull, or other submerged device, to be made highly conductive while also being sufficiently robust to have a long useful life. The provision of the electrically conductive particulate material, such as carbon or graphite-powder, at the exposed surface of the submerged layer achieves these purposes. In addition, as described above, the spraying of these conductive particles on the outer surface of an electrically conductive composite material not only improves the conductivity of the structure, but allows lower current densities to be used to accomplish the change in the water adjacent the submerged surface.
Although the present invention has been described in particular detail and illustrated to show several embodiments, it should be understood that alternative embodiments are also within its scope.
Claims
1. A method for making a submersible surface which is resistive to fouling, comprising the steps of:
- providing a layer of electrically conductive composite material; and
- disposing a coating of an electrically conductive particulate on a surface of said layer of electrically conductive composite material which is exposed to water when said submersible surface is disposed in a body of water; and
- pressing said coating of said electrically conductive particulate into said surface of said layer of electrically conductive composite material.
2. The method of claim 1, wherein:
- said electrically conductive composite material is an electrically conductive gel coat material.
3. The method of claim 1, further comprising:
- providing a mold;
- disposing a layer of a temporary holding agent to an inner surface of said mold;
- spraying said coating of said electrically conductive particulate onto said layer of said temporary holding agent; and
- spraying said layer of electrically conductive composite material on to said coating of said electrically conductive particulate.
4. The method of claim 3, wherein:
- said temporary holding agent is a mold release agent.
5. The method of claim 3, further comprising:
- disposing a charge distribution layer on to said layer of electrically conductive composite material.
6. The method of claim 5, wherein:
- said charge distribution layer comprises a carbon fiber mat.
7. The method of claim 5, wherein:
- said charge distribution layer comprises a layer of electrically conductive particulates sprayed on to said electrically conductive composite material.
8. The method of claim 5, further comprising:
- disposing at least one electrical conductor in electrical communication with said charge distribution layer.
9. The method of claim 8, wherein:
- said at least one electrical conductor is a strip of carbon fiber.
10. The method of claim 8, further comprising:
- attaching a support structure to said layer of electrically conductive composite material.
11. The method of claim 10, wherein:
- said support structure comprises a layer of fiberglass material.
12. The method of claim 10, further comprising:
- disposing a layer of insulative composite material between said layer of electrically conductive composite material and said support structure.
13. The method of claim 12, wherein:
- said layer of insulative composite material comprises an electrically nonconductive gel coat.
14-17. (canceled)
18. A method for making a submersible surface which is resistive to fouling, comprising the steps of:
- providing a mold;
- disposing a layer of a temporary holding agent to an inner surface of said mold;
- spraying a coating of an electrically conductive particulate onto said layer of said temporary holding agent;
- spraying a layer of electrically conductive composite material on to said coating of said electrically conductive particulate, said coating of said electrically conductive particulate being disposed on a surface of said layer of electrically conductive composite material which is exposed to water when said submersible surface is disposed in a body of water; and
- pressing said coating of said electrically conductive particulate into said surface of said layer of electrically conductive composite material.
19. The method of claim 18, further comprising:
- disposing a charge distribution layer on to said layer of electrically conductive composite material.
20. The method of claim 19, further comprising:
- disposing at least one electrical conductor in electrical communication with said charge distribution layer.
21. The method of claim 18, further comprising:
- attaching a support structure to said layer of electrically conductive composite material.
22. The method of claim 21, further comprising:
- disposing a layer of insulative composite material between said layer of electrically conductive composite material and said support structure.
23. The method of claim 18, wherein:
- said electrically conductive composite material is an electrically conductive gel coat material and said temporary holding agent is a mold release agent.
24. The method of claim 19, wherein:
- said charge distribution layer comprises a carbon fiber mat.
25. The method of claim 19, wherein:
- said charge distribution layer comprises a layer of electrically conductive particulates sprayed on to said electrically conductive composite material.
26. The method of claim 20, wherein:
- said at least one electrical conductor is a strip of carbon fiber.
27. The method of claim 21, wherein:
- said support structure comprises a layer of fiberglass material.
28. The method of claim 22, wherein:
- said layer of insulative composite material comprises an electrically nonconductive gel coat.
29. (canceled)
30. A method for making a submersible surface which is resistive to fouling, comprising the steps of:
- providing a layer of electrically conductive composite material;
- disposing a coating of an electrically conductive particulate on a surface of said layer of electrically conductive composite material which is exposed to water when said submersible surface is disposed in a body of water;
- disposing a charge distribution layer in contact with said layer of electrically conductive composite material;
- disposing at least one electrical conductor in electrical communication with said charge distribution layer; and
- pressing said coating of said electrically conductive particulate into said surface of said layer of electrically conductive composite material.
31. The method of claim 30, wherein:
- said electrically conductive composite material is an electrically conductive gel coat material.
32. The method of claim 30, wherein:
- said charge distribution layer comprises a carbon fiber mat.
33. The method of claim 30, wherein:
- said charge distribution layer comprises a layer of electrically conductive particulates sprayed on to said electrically conductive composite material.
34. The method of claim 30, wherein:
- said at least one electrical conductor is a strip of carbon fiber.
35. The method of claim 30, further comprising:
- providing a mold;
- disposing a layer of a temporary holding agent to an inner surface of said mold;
- spraying said coating of said electrically conductive particulate onto said layer of said temporary holding agent; and
- spraying said layer of electrically conductive composite material on to said coating of said electrically conductive particulate.
36. The method of claim 35, further comprising:
- attaching a support structure to said layer of electrically conductive composite material, said support structure comprising a layer of fiberglass material.
37. The method of claim 35, wherein:
- said temporary holding agent is a mold release agent.
38. The method of claim 36, further comprising:
- disposing a layer of insulative composite material between said layer of electrically conductive composite material and said support structure, said layer of insulative composite material comprising an electrically nonconductive gel coat.
39-42. (canceled)
43. The method of claim 1, wherein:
- said pressing step comprises the step of using a roller to press said coating of said electrically conductive particulate into said surface of said layer of said electrically conductive composite material.
44. The method of claim 18, wherein:
- said pressing step comprises the step of using a roller to press said coating of said electrically conductive particulate into said surface of said layer of said electrically conductive composite material.
45. The method of claim 30, wherein:
- said pressing step comprises the step of using a roller to press said coating of said electrically conductive particulate into said surface of said layer of said electrically conductive composite material.
Type: Application
Filed: May 7, 2007
Publication Date: Apr 8, 2010
Applicant:
Inventor: Richard E. Staerzl (Fond du Lac, WI)
Application Number: 11/800,596
International Classification: B63B 59/04 (20060101);