Methods and formulations for superhydrophic, self-cleaning, and icephobic polymer coatings and objects having coatings thereon

Abstract

An object has a superhydrophic, self-cleaning, and icephohic coating includes a substrate and a layer disposed on the substrate, the layer resulting from coating with a formulation having an effective amount of microstructuring microparticles, liquid silane having one or more groups configured to graft to a microstructuring microparticle and at least another group that results in hydrophobicity. The microstructuring microparticles are dispersed in the liquid silane. Another effective amount of synthetic adhesive, selected from thermosetting adhesives, moisture curing adhesives or polymers that form a strong interaction with a surface, is in solution with a solvent. Upon curing, the layer has a contact angle greater than 90″ and a sliding angle of less than 10° and less than 5% of an area of the layer is removed in a Tape test.

What is claimed is: 
     
         1 . An object having a superhydrophic, self-cleaning, and icephobic coating comprising:
 a substrate; and   a layer disposed on the substrate; the layer resulting from coating with a formulation comprising:
 an effective amount of microstructuring microparticles; 
 liquid silane having One or more groups configured to graft to a microstructuring microparticle and at least another group that results in hydrophobicity; the microstructuring microparticles being dispersed in the liquid silane; and 
 another effective amount of synthetic adhesive selected from thermosetting adhesives, moisture curing adhesives or polymers that form a strong interaction with a surface; the synthetic adhesive being in solution with a solvent; 
 wherein, upon curing, the layer has a contact angle greater than 150° and a sliding angle of less than 10° and less than 5% of an area of the layer is removed in a Tape test. 
   
     
     
         2 . The object of  claim 1  wherein said microstructuring microparticles comprise silica microparticies. 
     
     
         3 . The object of  claim 2  wherein said one or more groups comprise one or more tri-ethoxy groups. 
     
     
         4 . The object of  claim 1  wherein said one or more groups comprise one or more tri-ethoxy groups. 
     
     
         5 . The object of  claim 4  wherein the liquid silane comprises a fluoroalkyl silane. 
     
     
         6 . The object of  claim 5  wherein the liquid silane comprises tridecafluorooctyl-triethoxy silane. 
     
     
         7 . The object of  claim 5  wherein the synthetic adhesive is cyanoacrylate. 
     
     
         8 . The object of  claim 7  wherein the cyanoacrylate is ethyl 2-cyanoacrylate. 
     
     
         9 . The object of  claim 7  wherein the solvent is acetone. 
     
     
         10 . The object of  claim 2  wherein the silica microparticles are hydrophobic fumed silica nanoparticles. 
     
     
         11 . The object of  claim 2  wherein said effective amount is between 3% weight and about 5% weight when being dispersed in the liquid silane. 
     
     
         12 . The object of  claim 2  wherein the effective amount is between 3% weight and about 5% weight when being dispersed in the liquid silane; and wherein said another effective amount is between about 10% to about 50% weight when in solution with the solvent; and wherein said solvent is acetone. 
     
     
         13 . The object of  claim 2  wherein the effective amount is between greater than 2% weight and about 5% weight when being dispersed in the liquid silane; and wherein said another effective amount is between about 10% to about 50% weight when in solution with the solvent; and wherein said solvent is acetone. 
     
     
         14 . The object of  claim 1  wherein curing comprises heating for a predetermined time at a predetermined temperature. 
     
     
         15 . The object of  claim 14  wherein the predetermined time is between 30 min and 75 min and wherein the predetermined temperature is between 80′ C. and 110° C. 
     
     
         16 . The object of  claim 15  wherein the predetermined temperature is between 90° C. and 110° C. 
     
     
         17 . An icephobic coating formulation comprising:
 an effective amount of microstructuring microparticles;   liquid silane having one or more groups configured to graft to a microstructuring microparticle and at least another group that results in hydrophobicity; the microstructuring microparticles being dispersed in the liquid silane; and   another effective amount of synthetic adhesive selected from thermosetting adhesives, moisture curing adhesives or polymers that form a strong interaction with a surface; the synthetic adhesive being in solution with a solvent;   wherein, upon mixing the effective amount of microstructuring microparticles suspended in the liquid silane with said another effective amount of synthetic adhesive dissolved in the solvent and coating on a substrate and curing, a layer that has a contact angle greater than 90° and a sliding angle of less than 10°, less than 5% of an area of the layer is removed in a Tape test is obtained.   
     
     
         18 . The icephobic coating formulation of  claim 17  wherein said microstructuring microparticles comprise silica microparticles. 
     
     
         19 . The icephobic coating formulation of  claim 18  wherein said one or more groups comprise one or more tri-ethoxy groups. 
     
     
         20 . The icephobic coating formulation of  claim 17  wherein said one or more groups comprise one or more tri-ethoxy groups. 
     
     
         21 . The icephobic coating formulation of  claim 20  wherein the liquid silane comprises a fluoroalkyl silane. 
     
     
         22 . The icephobic coating formulation of  claim 21  wherein the liquid silane comprises tridecafluorooctyl-triethoxy silane. 
     
     
         23 . The icephobic coating formulation of  claim 21  wherein the synthetic adhesive is cyanoacrylate. 
     
     
         24 . The icephobic coating formulation of  claim 23  wherein the cyanoacrylate is ethyl 2-cyanoacrylate. 
     
     
         25 . The icephobic coating formulation of  claim 23  wherein the solvent is acetone. 
     
     
         26 . The icephobic coating formulation of  claim 18  wherein the silica microparticles are hydrophobic fumed silica nanoparticles. 
     
     
         27 . The icephobic coating formulation of  claim 18  wherein said effective amount is between 0.5% weight and about 5% weight when being dispersed in the liquid silane. 
     
     
         28 . The icephobic coating formulation of  claim 18  wherein the effective amount is between 2% weight and about 4% weight when being dispersed in the liquid silane; and wherein said another effective amount is about 50% weight when in solution with the solvent and said solvent is acetone. 
     
     
         29 . The icephobic coating formulation of  claim 18  wherein the effective amount is between eater than 2% weight and about 4% weight when being dispersed in the liquid silane; and wherein said another effective amount is about 50% weight when in solution with the solvent and said solvent is acetone. 
     
     
         30 . The icephobic coating formulation of  claim 17  wherein curing comprises heating for a predetermined time at a predetermined temperature. 
     
     
         31 . The icephobic coating formulation of  claim 14  wherein the predetermined time is between 30 min and 75 min and wherein the predetermined temperature is between 80° C. and 110° C. 
     
     
         32 . The icephobic coating formulation of  claim 15  wherein the predetermined temperature is between 90° C. and 110° C. 
     
     
         33 . A method for obtaining an icephobic durable coating, the method comprising:
 forming a first solution by suspending an effective amount of microstructuring microparticles in liquid silane; the liquid silane having one or more groups configured to graft to a microstructuring microparticle and at least another group that results in hydrophobicity;   stirring the first solution for a first predetermined time, the first predetermined time selected such that the microstructuring microparticles react with the liquid silane; forming a second solution by dissolving another effective amount of synthetic adhesive in a solvent; the synthetic adhesive being selected from thermosetting adhesives, moisture curing adhesives, radiation cured adhesives or polymers that form a strong interaction with a surface;   mixing the first solution with the second solution in predetermined proportions; resulting in a third solution;   coating a substrate with the third solution; and   allowing evaporation of excess solvent in the third solution coated on the substrate; and curing the third solution coated on the substrate by heating for a second predetermined time at a predetermined temperature.   
     
     
         34 . The method of  claim 33  wherein said microstructuring microparticles comprise silica microparticles. 
     
     
         35 . The method of  claim 34  wherein said one or more groups comprise one or more tri-ethoxy groups. 
     
     
         36 . The method of  claim 33  wherein said one or more groups comprise one or more tri-ethoxy groups. 
     
     
         37 . The method of  claim 36  wherein the liquid silane comprises a fluoroalkyl silane. 
     
     
         38 . The method t of  claim 37  wherein the liquid silane comprises tridecafluorooctyl-triethoxy silane. 
     
     
         39 . The method of  claim 37  wherein the synthetic adhesive is cyanoacrylate. 
     
     
         40 . The method of  claim 39  wherein the cyanoacrylate is ethyl 2-cyanoacrylate. 
     
     
         41 . The method of  claim 39  wherein the solvent is acetone. 
     
     
         42 . The method of  claim 34  wherein the silica microparticles are hydrophobic fumed silica nanoparticles. 
     
     
         43 . The method of  claim 34  wherein said effective amount is between 0.5% weight and about 5% weight when being dispersed in the liquid silane. 
     
     
         44 . The method of  claim 34  wherein the effective amount is between 2% weight and about 4% weight when being dispersed in the liquid silane; and wherein said another effective amount is about 50% weight when in solution with the solvent and said solvent is acetone. 
     
     
         45 . The method of  claim 34  wherein the effective amount is between greater than 2% weight and about 4% weight when being dispersed in the liquid silane; and wherein said another effective amount is about 50% weight when in solution with the solvent and said solvent is acetone. 
     
     
         46 . The method of  claim 33  wherein curing comprises heating for a predetermined time at a predetermined temperature. 
     
     
         47 . The method of  claim 46  wherein the predetermined time is between 30 min and 75 min and wherein the predetermined temperature is between 80° C. and 110° C. 
     
     
         48 . The method of  claim 47  wherein the predetermined temperature is between 90° C. and 110° C. 
     
     
         49 . The method of  claim 33  wherein the predetermined proportions comprises substantially equal parts of the first solution and the second solution. 
     
     
         50 . A method for assembling an icephobic coating formulation, the method comprising:
 forming a first solution by suspending an effective amount of inicrostructuring microparticles in liquid silane; the liquid silane having one or more groups configured to graft to a microstructuring microparticle and at least another group that results in hydrophobicity;   stirring the first solution for a first predetermined time, the first predetermined time selected such that the microstructuring microparticles react with the liquid silane;   forming a second solution by dissolving another effective amount of synthetic adhesive in a solvent; the synthetic adhesive being selected from thermosetting adhesives, moisture curing adhesives or polymers that form a strong interaction with a surface; and   mixing the first solution with the second solution in predetermined proportions.   
     
     
         51 . The method of  claim 50  wherein the icephobic coating formulation is assembled in an inert atmosphere. 
     
     
         52 . The method of  claim 50  wherein the mixing the first solution with the second solution in predetermined proportions occurs a predetermined time interval after the forming the first solution and the forming the second solution. 
     
     
         53 . The method of  claim 52  wherein the forming the first solution and the forming the second solution occur in an inert atmosphere. 
     
     
         54 . A coating product comprising:
 a sealable container; the sealable container comprising an icephobic coating formulation assembled by the method of  claim 50 ; wherein the sealable container is sealed in the inert atmosphere.   
     
     
         55 . A coating product comprising:
 two sealable containers; one sealable container comprising the first solution assembled by the method of  claim 53 ; and another sealable container comprising the second solution assembled by the method of  claim 53 ; wherein the two sealable containers are sealed in the inert atmosphere.   
     
     
         56 . The object of  claim 5  wherein the synthetic adhesive is epoxy. 
     
     
         57 . The object of  claim 56  wherein the epoxy is Part A (60-100% Bisphenol A diglycidyl Ether resin) Part B (60-100% Trimethylhexane-1,6-diamine) at 20:5 ratio. 
     
     
         58 . The object of  claim 57  wherein the solvent is acetone. 
     
     
         59 . The object of  claim 5  wherein the synthetic adhesive is urethane acrylate. 
     
     
         60 . The object of  claim 59  wherein the urethane acrylate is between 50 to 65% Mercapto-ester. 
     
     
         61 . The object of  claim 59  wherein the solvent is acetone