# US 10,245,615 B2 · Surface treatment

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- Number: US 10,245,615 B2
- Document ID: US10245615B2
- Status: Granted
- Kind: B2
- Application number: 13/810,110
- Filed: 2011-07-15
- Published: 2013-09-12
- Granted: 2019-04-02
- Earliest claimed: 2010-07-15
- Assignees: Commonwealth Scientific and Industrial Research Organisation; James Cook University
- Applicants: Andrew James Poole; Rocky De Nys; Peter King; Stefan Gulizia; Mahnaz Jahedi
- Inventors: Andrew James Poole; Rocky De Nys; Peter King; Stefan Gulizia; Mahnaz Jahedi
- Web page: https://patentgrep.com/patent/US10245615B2

## CPC

- C08J 7/046: Forming abrasion-resistant coatings; Forming surface-hardening coatings
- B05D 1/12: Applying particulate materials (B05D1/06, B05D1/10 take precedence)
- B32B 15/08: of synthetic resin
- B32B 15/20: comprising aluminium or copper {(B32B15/016 and B32B15/017 take precedence)}
- B32B 27/04: as impregnant, bonding, or embedding substance {(not used)}
- C08J 7/06: with compositions not containing macromolecular substances
- C09D 5/1618: {inorganic}
- C09D 7/69: {Particle size larger than 1000 nm}
- C23C 4/08: containing only metal elements (C23C4/073 takes precedence)
- C23C 24/04: Impact or kinetic deposition of particles
- C08K 3/015: Biocides (macromolecular substances as carriers for biocide material A01N25/10)
- C08K 5/0058: {Biocides; (macromolecular substances as carriers for biocide material A01N25/10)}
- C08K 2003/085: {Copper}
- C08K 2003/0893: {Zinc}
- Y10T 428/24413: Metal or metal compound
- Y10T 428/249954: With chemically effective material or specified gas other than air, N, or carbon dioxide in void-containing component
- Y10T 428/249976: Voids specified as closed
- C08J: WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H (working, e.g. shaping, of plastics B29)
- B05D: PROCESSES FOR APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL (conveying articles or workpieces through baths of liquid B65G, e.g. B65G49/02)
- B32B: LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- C09D: COATING COMPOSITIONS, e.g. PAINTS, VARNISHES OR LACQUERS; FILLING PASTES; CHEMICAL PAINT OR INK REMOVERS; INKS; CORRECTING FLUIDS; WOODSTAINS; PASTES OR SOLIDS FOR COLOURING OR PRINTING; USE OF MATERIALS THEREFOR (cosmetics A61K; processes for applying liquids or other fluent materials to surfaces, in general, B05D; staining wood B27K5/02; glazes or vitreous enamels C03C; natural resins, French polish, drying-oils, driers, turpentine, per se, C09F; polishing compositions other than French polish, ski waxes C09G; adhesives or use of materials as adhesives C09J; materials for sealing or packing joints or covers C09K3/10; materials for stopping leaks C09K3/12; processes for the electrolytic or electrophoretic production of coatings C25D)
- C23C: COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL (making metal-coated products by extrusion B21C23/22; covering with metal by connecting pre-existing layers to articles, see the relevant places, e.g. B21D39/00, B23K; metallising of glass C03C; metallising mortars, concrete, artificial stone, ceramics or natural stone C04B41/00; enamelling of, or applying a vitreous layer to, metals C23D; treating metal surfaces or coating of metals by electrolysis or electrophoresis C25D; single-crystal film growth C30B; by metallising textiles D06M11/83; decorating textiles by locally metallising D06Q1/04)
- C08K: Use of inorganic or non-macromolecular organic substances as compounding ingredients (paints, inks, varnishes, dyes, polishes, adhesives C09)
- Y10T: TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION

## Abstract

A method of protecting a polymer surface against fouling, which method comprises embedding in the polymer surface particles having antifouling properties, wherein the particles are embedded in the polymer surface by a spray mechanism in which the particles are accelerated and sprayed onto the polymer surface with a suitable velocity such that the particles become embedded in the polymer surface, wherein the particles are embedded in the polymer surface without an adhesive or binder and wherein the particles do not form a continuous layer on the polymer surface.

## Claims

### Claim 1

A polymer composite having antifouling properties, wherein the polymer composite comprises:
at least a top surface layer formed of a polymeric material having an elastic modulus of no more than 3000 MPa, the polymeric material defining a top surface plane of the polymer composite, and
particles having antifouling properties embedded in the top surface layer formed of the polymeric material, wherein
the embedded particles are present as individual entities and/or clusters of individual particles and do not form a continuous layer on the top surface layer of the polymer composite, and wherein
at least some of the particles are embedded completely below the top surface plane of the polymer composite, wherein
any individual entity of particle embedded completely below the top surface plane of the polymer composite or any cluster of individual particles embedded completely below the top surface plane of the polymer composite is in a respective pocket establishing an open-ended channel in the polymeric material to the top surface plane of the polymer composite, wherein the respective pocket is a crater or a cavity, and wherein
at least one pocket has a respective open-ended channel having a first cross-section width less than that of a diameter of a particle located within the at least one pocket, the first cross-section width measured in a direction parallel to the top surface plane of the polymer composite, wherein the at least one pocket is in direct open fluid communication with the top surface plane of the polymeric composite via the respective open-ended channel.

### Claim 2 (depends on 1)

The polymer composite according to claim 1, wherein the polymer composite has an elastic modulus of no more than 2000 MPa.

### Claim 3

A polymer composite having a functionalised surface property, the polymer composite comprising:
at least a top surface layer comprising a polymeric material having an elastic modulus of no more than 3000 MPa, the polymeric material defining a top surface plane of the polymer composite; and
particles having a functional property embedded in the polymeric material of the top surface layer, wherein the embedded particles are present as individual entities and/or clusters of individual particles and do not form a continuous layer on the top surface layer of the polymer composite, and wherein
at least some of the particles are embedded completely below the top surface plane of the polymer composite such that portions of the polymeric material at least partly surround the particles embedded completely below the top surface plane of the polymer composite, wherein
any individual entity of particle embedded completely below the top surface plane of the polymer composite or any cluster of individual particles embedded completely below the top surface plane of the polymer composite is in a respective pocket establishing an open-ended channel to the top surface plane of the polymer composite, the open-ended channel providing direct open fluid communication between the top surface plane of the polymer composite and the respective pocket, wherein the respective pocket is a crater or a cavity, and wherein
at least one pocket has a respective open-ended channel having a first cross-section width less than that of a diameter of a particle located within the at least one pocket, the first cross-section width measured in a direction parallel to the top surface plane of the polymer composite.

### Claim 4 (depends on 3)

The polymer composite according to claim 3, wherein the polymer composite has an elastic modulus of no more than 2000 MPa.

### Claim 5 (depends on 3)

The polymer composite according to claim 3, wherein the embedded particles provide antifouling properties by a chemical release mechanism.

### Claim 6 (depends on 3)

The polymer composite according to claim 3, wherein the polymer is a thermoplastic or cured thermoset polymer.

### Claim 7 (depends on 3)

The polymer composite according to claim 3, wherein the embedded particles have an average particle size of up to 200 μm.

### Claim 8 (depends on 3)

The polymer composite according to claim 3, wherein the embedded particles provide anti-biofouling properties to the polymer surface.

### Claim 9 (depends on 3)

The polymer composite according to claim 3, wherein the embedded particles are anti-biofouling particles selected from the group consisting of copper, zinc and/or compounds and alloys composed therefrom.

### Claim 10 (depends on 3)

The polymer composite according to claim 3, which further comprises a substrate located beneath the top surface layer formed of the polymeric material.

### Claim 11 (depends on 3)

The polymer composite according to claim 3, wherein the embedded particles have a particle density which is at least 5 g/m2 and no more than 300 g/m2.

### Claim 12 (depends on 5)

The polymer composite according to claim 5, wherein the polymeric material is a thermoplastic or cured thermoset polymer.

### Claim 13 (depends on 6)

The polymer composite according to claim 6, wherein the embedded particles have an average particle size of up to 100 μm.

### Claim 14 (depends on 12)

The polymer composite according to claim 12, wherein the embedded particles are anti-biofouling particles selected from the group consisting of copper, zinc and/or compounds and alloys composed therefrom.

### Claim 15 (depends on 13)

The polymer composite according to claim 13, wherein the particles are anti-biofouling particles selected from the group consisting of copper, zinc and/or compounds and alloys composed therefrom.

### Claim 16

A polymer composite having a functionalized surface property, the polymer composite comprising:
a substrate having at least a top surface layer formed of a polymeric material having an elastic modulus of no more than 1500 MPa, the polymeric material defining a top surface plane of the polymer composite, and
particles having a functional property embedded in the top surface layer of the polymeric material by a spray mechanism in which the particles are accelerated and sprayed onto the top surface layer with a suitable velocity such that at least some of the particles are embedded completely below the top surface plane of the polymer composite, wherein
the embedded particles are present as separate entities and do not form a continuous layer on the top surface layer of the substrate, and wherein
any individual entity of the particles embedded completely below the top surface plane of the polymer composite is in a respective pocket in the polymeric material, the respective pocket formed by impact of the particle on the top surface layer of polymeric material, wherein the respective pocket is a crater or a cavity, and wherein
the respective pocket includes an open-ended channel providing direct open fluid communication between a particle embedded in the respective pocket and the top surface plane of the polymeric material, wherein the open-ended channel has a first cross-section width less than that of a diameter of a particle located within the respective pocket, the first cross-section width measured in a direction parallel to the top surface plane of the polymer composite, and wherein
any of the particles embedded completely below the top surface plane of the polymer composite in one of the respective pockets is unconnected directly through the polymeric material forming the top surface layer of the polymer composite by the open-ended channels to adjacent particles embedded completely below the top surface plane of the polymer composite in other respective pockets to thereby not be in fluid communication with the adjacent particles directly through the polymeric material.

### Claim 17 (depends on 16)

The polymer composite as in claim 16, wherein the open-ended channels have a dimension which is less than a diameter of the embedded particles.

### Claim 18 (depends on 16)

The polymer composite as in claim 16, wherein the functional property of the particles is an anti-biofouling property.