Vessels Comprising a Composite Envelope

Abstract

The invention relates to a hull of a vessel having characteristic surface properties, allowing an increase in surface runoff while benefiting from an inherent anti-fouling property and an original aesthetic appearance. Furthermore, the invention allows the incorporation of said outer composite envelope into the structure of the hull, thereby preventing delamination problems and inherently providing a vessel hull with the above-mentioned properties.

Claims

1. A vessel hull comprising in an external envelope intended to be in contact with an outer liquid element, a metal powder characterized in that: said powder: contains more than 30% by mass of grains for which the diameter is greater than 45 μm and is partly in contact with said outer liquid element; the envelope has a thickness of less than 1 mm, and in that the powder comprises a copper powder with at least 60% by mass of copper based on the mass of powder.

2. The vessel hull according to claim 1 characterized in that the metal powder is a powder comprising at least one metal selected from among magnesium, tin, technetium, rhenium, titanium, iron, chromium, cobalt, gold, zinc, platinum, cadmium, aluminium, nickel, silver, beryllium, calcium, strontium, copper, preferentially aluminium and/or copper.

3. The vessel hull according to claim 1 or 2, characterized in that the external envelope comprises a concentration gradient of powder grains, for example oriented from the inside to the outside of the vessel and preferentially increasing.

4. The vessel hull according to any one of claims 1 to 3, characterized in that the copper is phosphorus-containing or oxidized, preferentially with an oxidation level of the copper greater than 95% by mass of oxidized copper with respect to the total mass of copper in the powder.

5. The vessel hull according to any one of claims 1 to 4, characterized in that the metal powder comprises at least one non-metal inorganic compound such as nitrogen, oxygen, phosphorus, arsenic, sulfur, fluorine, chlorine, bromine, carbon, silicon.

6. The vessel hull according to any one of claims 1 to 5, characterized in that said metal powder is comprised in an organic or inorganic binder, or a mixture of both, thereby forming a composite.

7. The vessel hull according to claim 6, characterized in that the organic binder is an organic polymer preferentially selected from among polyester, polyurethane, epoxy polymer, vinyl ester or in that the inorganic binder is an inorganic polymer preferentially selected from among silica, polydimethylsiloxanes, polythiazyls, polysilanes, polygermanes, more preferentially a silica polymer.

8. The vessel hull according to claim 6 or 7, characterized in that the composite comprises a mass proportion of powder/binder comprised from 1/2 to 2/1 respectively, preferentially from 1.25/1 to 1.6/1 respectively.

9. The vessel hull according to any one of claims 6 to 8, characterized in that the composite comprises fiber materials, such as glass fiber, carbon fiber, Kevlar®, or a mixture thereof.

10. A hull, a foil, a directional element such as a rudder or a fin, a propulsion element such as a propeller or a jet pipe comprising an external envelope as defined according to any one of claims 1 to 9.

11. A vessel comprising an external envelope as defined according to any one of claims 1 to 9.

12. The vessel according to claim 11, characterized in that it is selected from among a boat, a sub-marine, a wind surfing board, a kite surf, a water ski, a wake board, a surf, a paddle board, a jet ski, a canoe or a kayak.

13. A method for manufacturing a vessel hull comprising the following steps: a. providing a binder/metal powder mixture, b. depositing a layer of the mixture on a mold of a vessel hull; c. optionally adding fiber materials in said binder; d. hardening the binder/metal powder mixture for example by treatment with light, with heat or by adding a hardening agent optionally added to the mixture; e. optionally adding at least one additional structure layer and/or reinforcement layer on the first hardened layer in step c.; f. removing the vessel hull from the mold; characterized in that the metal powder contains more than 30% by mass of grains for which the diameter is greater than 45 μm.

14. The manufacturing method according to claim 13, characterized in that the metal powder comprises at least one metal selected from among magnesium, tin, technetium, rhenium, titanium, iron, chromium, cobalt, gold, zinc, platinum, cadmium, aluminium, nickel, silver, beryllium, calcium, strontium, copper, preferentially aluminium and/or copper.

15. The manufacturing method according to one of claim 13 or 14, characterized in that the powder contains at least 60% by mass of copper.

16. The manufacturing method according to claim 14 or 15, characterized in that the copper is oxidized or phosphorus-containing.

17. The manufacturing method according to claim 16, characterized in that the oxidation level of the copper is greater than 95% by mass of oxidized copper based on the total mass of copper.

18. The manufacturing method according to any one of claims 13 to 17, characterized in that the metal powder comprises at least one non-metal inorganic compound such as nitrogen, oxygen, arsenic, sulfur, fluorine, chlorine, bromine, carbon, silicon.

19. The manufacturing method according to any one of claims 13 to 18, characterized in that the binder is an organic polymer, preferentially selected from among polyester, polyurethane, an epoxy polymer, a vinyl ester or in that the binder is an inorganic polymer preferentially selected from among silica, polydimethylsiloxanes, polythiazyls, polysilanes, polygermanes, more preferentially a silica polymer.

20. The manufacturing method according to any one of claims 13 to 19, characterized in that the mass proportion of metal powder/binder is comprised from 1/2 to 2/1 respectively, preferentially from 1.25/1 to 1.6/1 respectively.

21. The manufacturing method according to any one of claims 13 to 20, characterized in that the composite comprises fiber materials, such as glass fiber, carbon fiber, Kevlar®, or a mixture thereof.

22. A vessel hull which may be obtained by the method of any one of claims 13 to 21.

Description

FIGURES

[0163] FIG. 1: Photograph of a boat hull made according to the present invention.

[0164] The hull (in contact with the water) is in a composite according to the present invention, the upper portion of the hull (white in the photograph) is in a more common composite.

EXAMPLES

[0165] In order to illustrate the present invention, the following examples were made. By no means is the object of the present invention limited to these single examples.

[0166] 1. A CuP.sub.8-Based Powder

[0167] The powder of CuP.sub.8, for which the grain size is not controlled is known for being used in brazing.

[0168] Conventionally, the latter has the following characteristics: [0169] Rated composition (mass %): Cu: 92 [0170] P: 8 [0171] Melting point: 710-750° C. [0172] Density: 8 g/cm.sup.3 [0173] Procedure for making the copper-phosphorus powder according to the invention. According to the present invention, the copper-phosphorus alloy containing a phosphorus percentage between 2 and 16%, preferably 8%, is introduced into the melting bath. This alloy is then atomized with water under conditions such that the grain size result has to be found between 8 and 150 μm (D50), the oxygen level is comprised between 0.3 and 5% by weight. [0174] The following powder was thereby obtained:

TABLE-US-00001 TABLE 1 Grain size, retained accumulated % (ISO4497) Percentage Retained accumulated Particle sizes per slice percentages ≧125 μm 0.0 0.0 ≧106 μm 0.9 0.9 ≧90 μm 4.5 5.4 ≧75 μm 6.6 12.0 ≧63 μm 8.4 20.4 ≧45 μm 20.8 41.2 <45 μm 58.8 58.8 Total 100% 100% (41.2 + 58.8) [0175] Obtained density: 2.67 g/cm.sup.3 (ISO3923/2) [0176] Obtained P %: 8.0% by mass

[0177] 2. Oxidized Copper Powder

[0178] The same procedure as for the copper-phosphate was applied for the copper. The following powder was thereby obtained:

TABLE-US-00002 TABLE 2 Grain size, retained accumulated % (ISO4497) Percentages Retained accumulated Particle sizes per slice percentages ≧125 μm 0.0 0.0 ≧106 μm 1.0 1.0 ≧75 μm 8.1 9.1 ≧63 μm 7.9 17.0 ≧45 μm 19.2 36.2 <45 μm 63.8 63.8 Total 100% 100% (36.2 + 63.8) [0179] Obtained density: 2.88 g/cm.sup.3 [0180] O.sub.T %: 0.35% by mass (ISO4491-4) [0181] Next, the obtained powder was passed into a strip oven at a temperature greater than 500° C. (about 800° C. in this case) for oxidizing it, under a controlled atmosphere. [0182] A powder with the same grain size as earlier was obtained with: [0183] Obtained density: 1.60 g/cm.sup.3 [0184] O.sub.T %: 0.08% by mass [0185] Cu %>99.7% by mass

[0186] 3. Example of Obtained Composite/Coatings

[0187] The composites are simply obtained by mixing the compounds with each other.

[0188] Before proceeding with the manufacturing of the vessel hulls (expensive), tests were conducted by means of the coatings of the composites according to the present invention. The laying of the coatings of table 3 is accomplished in the following standard way.

[0189] First it is preceded with sanding or sand blasting of the surface to be treated (grain of 120).

[0190] The times for hardening the polyester primer (about 6 h at 20° C. per layer) were observed. It may then be preceded with active drying of the part with compressed air or by ovening at 25° C. in a cabin for 20 minutes. It is possible to degrease the surface to be treated.

[0191] It is quite possible to apply the composite with a roller or a gun (with in this case the requirement of observing a constant angle for projecting the composite on the surface at 90° for a maximum covering).

[0192] The storage of the coated product may be accomplished in a room treated in a controlled atmosphere at 20° C. ideally for 12 hours for efficient hardening (For a boat, this is more difficulty to obtain, this is why accelerated hardeners give the possibility of achieving the catalysis as far as a minimum of 5° C.). Once this hardening period is completed, sanding or sand blasting with a grain of 120 is carried out for getting rid from the surface of starch excesses and of oxide excesses and obtaining a smooth surface of metal.

TABLE-US-00003 TABLE 3 Composite 1 Composite 2 Composite 3 Composite 4 Metal powder CuP.sub.8 Oxidized copper Oxidized copper CuP.sub.8 (powder of example 1) (powder of example 2) (powder of example 2) (powder of example 1) Binder Hybrid polyester 84% Hybrid polyester 84% Vinyl ester, ready for Vinyl ester, ready (mass Acetone 8% Acetone 8% use commercially for use available proportions) Paraffin Styrene 2% Paraffin Styrene 2% available commercially Coloring agent 4% Coloring agent 4% Hardener (mass METHYL ETHYL METHYL ETHYL proportions) PEROXIDE, 2% PEROXIDE, 2% Mass Powder = 1.275 Powder = 1.275 Powder = 1 Powder = 1 proportions of Binder = 1 Binder = 1 Binder = 1.5 Binder = 1.5 Powder/Binder (estimated value) (estimated value) Achievable Yes Yes Yes Yes suspension Setting time 60 minutes 60 minutes 60 minutes 60 minutes

[0193] 4. Examples of Biocidal Activities and Improvement of the Movement of Fluids

[0194] Results of the laboratory tests have shown that the coatings using the same type of composite as the present invention have remarkable biocidal properties (see examples of FR1357099, FR1400766, and PCT/EP2014 065 498).

[0195] Further, preliminary tests have shown that coatings using the same type of composite as the present invention have high biocidal properties (including anti-microbial properties) when they are exposed to various fluids such as water.

[0196] Further, laboratory tests have shown an increase in the rate of flow of fluid over the whole surface covered with coatings using the same composite as the present invention. Indeed, an ordinary plastic substrate was in one case, coated with the coating according to the invention (compound No. 2 in table 3—oxidized copper at 99.9%) and only in the other case with the composite binder of No. 2. A drop of liquid is deposited on each substrate at the same level and both coated substrates were tilted with the same angle relatively to the horizontal (as far as more or less 65°), which gave the possibility of directly comparing the rates of the descending liquid drops. This direct comparison gave the possibility of establishing that the coating using the same composite of the present invention gave the possibility of increasing the rate from 10 to 30% relatively to the binder alone. This inherent property of the coatings using the same composite of the present invention (which seems to be related to the presence of copper powder) gives the possibility of contemplating a long lasting way and without any cost of saving the energy expenditures as to the propulsion of vessels, or by increasing the speed thereof.

[0197] 5. Boat Hull

[0198] A boat hull (cf. FIG. 1) was thereby produced. The composite used was that of formula No. 4 according to the table 3 above. The composite in the liquid state obtained was handled like any resin conventionally used for the manufacturing of such hulls of boats (and according to the general method described above). All the technical effects reckoned with of the thereby produced hull were obtained.