# US 2023/0265294 A1 · Marine coating formulations > Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt - Number: US 2023/0265294 A1 - Document ID: US20230265294A1 - Status: Published application - Kind: A1 - Application number: 18/041,092 - Filed: 2021-08-11 - Published: 2023-08-24 - Earliest claimed: 2020-08-12 - Assignees: Calix, Inc. - Applicants: Calix Ltd. - Inventors: Mark Geoffrey Sceats; Robert Van Merkestein; Adam Vincent; Philip Hodgson; Andrew Okely - Web page: https://patentgrep.com/patent/US20230265294A1 ## CPC - C09D 5/1656: {characterised by the film-forming substance (C09D5/1637 takes precedence)} - C09D 5/084: {Inorganic compounds} - C09D 5/1618: {inorganic} - C09D 5/1681: {Antifouling coatings characterised by surface structure, e.g. for roughness effect giving superhydrophobic coatings or Lotus effect} - C09D 5/1687: {Use of special additives} - C09D 7/61: inorganic - C09D 7/69: {Particle size larger than 1000 nm} - B08B 17/02: Preventing deposition of fouling or of dust - C08K 3/22: of metals - C08K 7/24: inorganic - 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) - B08B: CLEANING IN GENERAL; PREVENTION OF FOULING IN GENERAL - C08K: Use of inorganic or non-macromolecular organic substances as compounding ingredients (paints, inks, varnishes, dyes, polishes, adhesives C09) ## Abstract A formulation for a coating for applications on maritime infrastructure or vessels to inhibit fouling and corrosion that comprises: (a) a nano-active material; and (b) a polymer binder; and (c) additives which include pigments, booster antifoulants, booster anticorrosion materials, solvents, polymerisation activators, viscosity modifiers and fillers, where the nano-active material, the binder and additives provide the coating with the desired most desirable properties of antifoul, anticorrosion, adhesion, and strength, required for the coating application. ## Claims ### Claim 1 A formulation comprising: (a) a nano-active material comprising a powder material with an average particle size in the range of 1-300 microns, with a volumetric pore surface area greater than 100 m2/cm3; and (b) a polymer binder; and (c) additives comprising pigments, booster antifoulants, booster anticorrosion materials, solvents, polymerisation activators, viscosity modifiers and fillers; wherein the booster anticorrosion materials comprise lanthanide material; wherein the mixture of the nano-active material, the binder and the additives provides an antifouling and anticorrosion coating to maritime infrastructure or vessels, when applied. ### Claim 2 (depends on 1) The formulation of claim 1, wherein the nano-active material is at least 10 wt %, and 30-75% of the set coating weight depending on the coating application. ### Claim 3 (depends on 1) The formulation of claim 1, wherein the nano-active material is a powder material with an average particle size typically in the range of 1-300 microns, which is sufficiently porous with a volumetric pore surface area greater than 100 m2/cm3. ### Claim 4 (depends on 3) The formulation of claim 3, wherein the nano-active material is a powder material with an average particle size typically in the range of 4-10 microns. ### Claim 5 (depends on 3) The formulation of claim 3, wherein the nano-active materials include nano-active powders with a chemical composition of AgO, ZnO, CuO, Cu2O, MgO, SiO2, Al2O3, Mn3O4 and combinations thereof. ### Claim 6 (depends on 5) The formulation of claim 5, wherein the chemical purity of these materials is 80% or more. ### Claim 7 (depends on 6) The formulation of claim 6, wherein the chemical purity of these materials is greater than 95%. ### Claim 8 (depends on 1) The formulation of claim 1, wherein the polymer binder is drawn from a wide range of polymer materials, including acrylic, saturated or unsaturated polyester, alkyd, polyurethane or polyether, polyvinyl, cellulosic, silicon-based polymers, co-polymers thereof, and contain reactive groups such as epoxy, carboxylic acid, hydroxyl, isocyanate, amide, carbamate, amine and carboxylate groups, among others, including mixtures thereof, wherein combinations of film-forming polymers are used, and wherein the materials include thermosetting polymers, polymers that require initiators, accelerants, or polymers that set through volatilisation of solvents, wherein the selection of the binder and additives are determined to provide a coating which is adhesive to the substrate, hard, ablative, hydrophobic or superhydrophobic as required for the application when combined the with nano-active material. ### Claim 9 (depends on 8) The formulation of claim 8, wherein the applications include an inner coating or primer for coating on appropriately prepared steels of various compositions, aluminium, aluminium alloys, zinc-aluminium alloys, clad aluminium, and aluminium plated steel, wherein the substrates comprise more than one metal or metal alloy, in that the substrate is a combination of two or more metal substrates assembled together, such as hot dipped galvanized steel assembled with aluminium substrates; wherein the adhesion of the coating is an important consideration for the selection of the binder and additives, and the corrosion inhibition is an important consideration for selection of the nano-active material, while maintaining the fouling inhibition. ### Claim 10 (depends on 9) The formulation of claim 9, wherein in the application, the corrosion properties are enhanced by the addition of booster anticorrosion material such as lanthanide materials, where the materials, including the binding of the booster anticorrosion material to the nano-active material and the binder, are determined to release the anticorrosion materials at a rate to inhibit and repair any corrosion of the substrate. ### Claim 11 (depends on 1) The formulation of claim 1, wherein the applications include an outer coating where the fouling inhibition is an important consideration, a selection of the nano-active material with biofoulant properties, and the booster antifoulants which are selected to inhibit the growth of primary, secondary and tertiary foulants. ### Claim 12 (depends on 1) The formulation of claim 1, wherein the booster antifoulant is a biocide, and its impact is directed towards the inhibition of primary and secondary foulants through release of the antifoulant into the water at a release rate determined by the dissolution of the antifoulants and the other constituents of the coating, or the ablation of the coating, and the nano-active materials are directed towards inhibition of the tertiary foulants within the coating. ### Claim 13 (depends on 12) The formulation of claim 12, wherein the booster antifoulant is bound within the nano-active material. ### Claim 14 (depends on 12) The formulation of claim 12, wherein the booster antifoulant is a second nano-active material. ### Claim 15 (depends on 1) The formulation of claim 1 for a hydrophobic or superhydrophobic coating for coating a vessel in which the nano-active material, or other additives, spontaneously produces indentations, or the indentations are printed during or after application, where such indentations reduce the hydrodynamic drag of the vessel and the antifouling nano-active material and the booster material inhibit fouling when the vessel is stationary. ### Claim 16 (depends on 15) The formulation of claim 15, in which the indentations regenerates as the coating is worn down by friction.