Methods of making highly durable superhydrophobic, oleophobic and anti-icing coatings
First Claim
Patent Images
1. A method of preparing a hydrophobic coating on a substrate comprising:
- a) applying to said substrate a coating composition, comprising i) a binder, ii) first particles having a size of about 30 microns to about 225 microns, and iii) a solvent, to provide a base coating; and
b) applying to said base coating a composition comprising second particles, wherein, prior to the application of the second particles to the base coating,i) the second particles have been modified with hexamethyldisilazane,ii) the second particles comprise covalently bound polydimethylsiloxane, oriii) the second particles comprise one or more covalently bound moieties independently selected from the group consisting of alkyl, haloalkyl, and perfluoroalkyl moieties, which one or more moieties are covalently bound to said second particles by reaction of particles with a silanizing agent of formula (I), said silanizing agent of formula (I) having the structure;
R4-nSi—
Xn
(I)where n is an integer from 1 to 3;
each R is independently selected from(i) C1 to 20 alkyl optionally substituted with one or more fluorine atoms;
or(ii) —
Z—
((CF2)q(CF3))r, wherein Z is a C1-12 divalent alkane radical or a C2-12 divalent alkene or alkyne radical, q is an integer from 1 to 12, and r is an integer from 1-4;
each X is independently selected from the group consisting of —
H, —
Cl, —
I, —
Br, —
OH, —
OR2, NHR3, and —
N(R3)2;
each R2 is an independently selected C1 to 4 alkyl or haloalkyl group; and
each R3 is an independently selected H, C1 to 4 alkyl or haloalkyl group;
wherein the hydrophobic coating has a contact angle with water that is greater than about 120°
at a temperature of 18°
C. to 23°
C.;
wherein the hydrophobic coating has a surface in contact with the substrate and an exposed surface comprising the binder that is not in contact with the substrate, the exposed surface having an arithmetical mean roughness from about 0.2 microns to about 20 microns, or a ten point mean roughness from about 1 micron to about 100 microns;
wherein, in the resulting hydrophobic coating, the first particles are primarily distributed within and coated with the binder and the second particles are primarily distributed on the exposed surface; and
wherein the hydrophobic coating has a greater number of second particles on the exposed surface than on the surface in contact with the substrate.
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Abstract
Disclosed are methods of preparing durable hydrophobic, oleophobic, and anti-icing coatings on a substrate comprising the application of a binder containing particles to the substrate and the application of hydrophobic and oleophobic particles to the binder. In the resulting coating, the particles applied with the binder are primarily distributed within and coated by the binder and the hydrophobic/oleophobic particles are distributed on or at the exposed surface where they can interact with liquids.
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Citations
18 Claims
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1. A method of preparing a hydrophobic coating on a substrate comprising:
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a) applying to said substrate a coating composition, comprising i) a binder, ii) first particles having a size of about 30 microns to about 225 microns, and iii) a solvent, to provide a base coating; and b) applying to said base coating a composition comprising second particles, wherein, prior to the application of the second particles to the base coating, i) the second particles have been modified with hexamethyldisilazane, ii) the second particles comprise covalently bound polydimethylsiloxane, or iii) the second particles comprise one or more covalently bound moieties independently selected from the group consisting of alkyl, haloalkyl, and perfluoroalkyl moieties, which one or more moieties are covalently bound to said second particles by reaction of particles with a silanizing agent of formula (I), said silanizing agent of formula (I) having the structure;
R4-nSi—
Xn
(I)where n is an integer from 1 to 3; each R is independently selected from (i) C1 to 20 alkyl optionally substituted with one or more fluorine atoms;
or(ii) —
Z—
((CF2)q(CF3))r, wherein Z is a C1-12 divalent alkane radical or a C2-12 divalent alkene or alkyne radical, q is an integer from 1 to 12, and r is an integer from 1-4;each X is independently selected from the group consisting of —
H, —
Cl, —
I, —
Br, —
OH, —
OR2, NHR3, and —
N(R3)2;each R2 is an independently selected C1 to 4 alkyl or haloalkyl group; and each R3 is an independently selected H, C1 to 4 alkyl or haloalkyl group; wherein the hydrophobic coating has a contact angle with water that is greater than about 120°
at a temperature of 18°
C. to 23°
C.;wherein the hydrophobic coating has a surface in contact with the substrate and an exposed surface comprising the binder that is not in contact with the substrate, the exposed surface having an arithmetical mean roughness from about 0.2 microns to about 20 microns, or a ten point mean roughness from about 1 micron to about 100 microns; wherein, in the resulting hydrophobic coating, the first particles are primarily distributed within and coated with the binder and the second particles are primarily distributed on the exposed surface; and wherein the hydrophobic coating has a greater number of second particles on the exposed surface than on the surface in contact with the substrate. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18)
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Specification