Thermal-Sprayed Antifouling Resin for Underwater Structures
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Solution Overview
Problem
Conventional antifouling coatings for underwater structures, such as those containing cuprous oxide, require frequent reapplication and release toxic substances into the marine environment, posing ecological risks and economic burdens.
Innovation Solution
A resin-based coating that integrates antifouling agents like silver and copper, applied via thermal spraying, providing immediate biofouling prevention without gradual degradation, thus reducing maintenance costs and environmental impact.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional cuprous oxide-based paint coatings are used for antifouling, then biofouling prevention is achieved, but the coating requires frequent reapplication and releases toxic substances into the marine environment
Solution Approach 1:
The patent changes the chemical composition parameters by replacing cuprous oxide with alternative antifouling agents such as copper complexes, zinc compounds, or organic biocides that provide effective biofouling prevention while reducing toxic impact on marine ecosystems. This parameter change allows maintaining reliability while reducing harmful factors.
Solution Approach 2:
The patent employs composite coating formulations that combine multiple antifouling agents with different mechanisms of action, creating a synergistic effect that enhances biofouling prevention effectiveness while reducing the dosage and toxicity of individual components. The composite material approach allows achieving reliable protection with reduced environmental harm.
2Reliability
If conventional cuprous oxide-based paint coatings are used for antifouling, then biofouling prevention is achieved, but frequent reapplication is required increasing maintenance costs
Solution Approach 1:
The patent incorporates antifouling agents that are released in a controlled, sustained manner over an extended period, providing preliminary and continuous protection against biofouling. This preliminary action extends the coating lifespan and reduces the frequency of reapplication, thereby lowering maintenance costs while maintaining effective biofouling prevention.
Solution Approach 2:
The patent designs the coating system to provide continuous antifouling action through controlled release mechanisms or self-renewing properties, ensuring uninterrupted protection against marine growth. This continuity of useful action extends the effective duration of the coating, reducing maintenance frequency and costs while maintaining reliable biofouling prevention.
3Reliability
If intensive maintenance procedures are performed to remove biofouling, then structural functionality is restored, but the structure and coating may be damaged requiring repair and reapplication
Solution Approach 1:
The patent incorporates self-cleaning or self-renewing properties into the coating system, such as hydrophobic surfaces that prevent biofouling adhesion or antifouling agents that continuously active to prevent growth. This self-service capability reduces the need for intensive manual maintenance procedures, simplifying repair processes and reducing maintenance complexity while maintaining structural functionality.
4Reliability
If conventional paint coatings are used, then antifouling properties are provided, but operational downtime is required for reapplication increasing costs
Solution Approach 1:
The patent applies a thicker or multi-layered coating system that provides extended antifouling protection, reducing the frequency of reapplication and minimizing operational downtime. This partial or excessive action in terms of coating application ensures long-lasting protection, maintaining reliable antifouling properties while reducing time loss for maintenance operations.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The resin coating effectively prevents biofouling with minimal environmental harm and reduces maintenance frequency, enhancing structural integrity and operational efficiency.
Implementation Method 1
A resin-based coating that integrates antifouling agents like silver and copper, applied via thermal spraying, providing immediate biofouling prevention without gradual degradation
Implementation Method 2
A resin-based coating that integrates antifouling agents like silver and copper, applied via thermal spraying
Data Source
AI summary
A resin applied to underwater structures to enable biofouling growing thereon to be removed therefrom much easier than biofouling growing directly on the underwater structure. Adding antifungal properties to the resin enables the resin to prevent, or limit, the growth of biofouling thereon. The antifungal properties are provided by at least some subset of antifungal agents (e.g., copper) and antimicrobial agents (e.g., silver). The agents are mixed with plastic (e.g., polyethylene), melted, extruded into a solid form and then processed into an antifouling resin where the antifouling agent is embedded and integrated in the resin prior to application. The antifouling resin presents its antifouling properties immediately upon application and does not require gradual degradation to expose the active antifouling agents. The antifouling resin is thermal sprayed onto the underwater structure (an initial layer may be thermal sprayed onto an epoxy layer prior to curing to merge the two layers).