US20160152840A1 - Hydrophobic coating for coated article - Google Patents
Hydrophobic coating for coated article Download PDFInfo
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- US20160152840A1 US20160152840A1 US15/016,380 US201615016380A US2016152840A1 US 20160152840 A1 US20160152840 A1 US 20160152840A1 US 201615016380 A US201615016380 A US 201615016380A US 2016152840 A1 US2016152840 A1 US 2016152840A1
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- 238000000576 coating method Methods 0.000 title claims description 46
- 239000011248 coating agent Substances 0.000 title claims description 41
- 230000002209 hydrophobic effect Effects 0.000 title claims description 22
- 239000002245 particle Substances 0.000 claims abstract description 153
- 230000003075 superhydrophobic effect Effects 0.000 claims abstract description 47
- VYPSYNLAJGMNEJ-UHFFFAOYSA-N Silicium dioxide Chemical compound O=[Si]=O VYPSYNLAJGMNEJ-UHFFFAOYSA-N 0.000 claims abstract description 31
- 229920001296 polysiloxane Polymers 0.000 claims abstract description 24
- 239000011159 matrix material Substances 0.000 claims abstract description 13
- 229910052575 non-oxide ceramic Inorganic materials 0.000 claims abstract description 12
- 239000011225 non-oxide ceramic Substances 0.000 claims abstract description 12
- -1 polysiloxane Polymers 0.000 claims abstract description 12
- 239000002923 metal particle Substances 0.000 claims abstract description 11
- OKTJSMMVPCPJKN-UHFFFAOYSA-N Carbon Chemical compound [C] OKTJSMMVPCPJKN-UHFFFAOYSA-N 0.000 claims abstract description 9
- 229910052799 carbon Inorganic materials 0.000 claims abstract description 9
- 229920000642 polymer Polymers 0.000 claims abstract description 9
- 229910000000 metal hydroxide Inorganic materials 0.000 claims abstract description 6
- 150000004692 metal hydroxides Chemical class 0.000 claims abstract description 6
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 claims description 41
- 239000000758 substrate Substances 0.000 claims description 17
- 239000000203 mixture Substances 0.000 claims description 6
- 230000003746 surface roughness Effects 0.000 claims description 5
- 239000004005 microsphere Substances 0.000 claims description 4
- 238000007654 immersion Methods 0.000 claims description 3
- 239000007788 liquid Substances 0.000 claims description 3
- 230000002035 prolonged effect Effects 0.000 claims description 3
- 229920005573 silicon-containing polymer Polymers 0.000 description 12
- 239000003795 chemical substances by application Substances 0.000 description 7
- 230000015572 biosynthetic process Effects 0.000 description 5
- 230000008901 benefit Effects 0.000 description 4
- 239000010410 layer Substances 0.000 description 4
- 238000000034 method Methods 0.000 description 4
- ZWEHNKRNPOVVGH-UHFFFAOYSA-N 2-Butanone Chemical compound CCC(C)=O ZWEHNKRNPOVVGH-UHFFFAOYSA-N 0.000 description 3
- 238000009825 accumulation Methods 0.000 description 3
- 239000002131 composite material Substances 0.000 description 3
- XEEYBQQBJWHFJM-UHFFFAOYSA-N Iron Chemical compound [Fe] XEEYBQQBJWHFJM-UHFFFAOYSA-N 0.000 description 2
- PXHVJJICTQNCMI-UHFFFAOYSA-N Nickel Chemical compound [Ni] PXHVJJICTQNCMI-UHFFFAOYSA-N 0.000 description 2
- 239000000919 ceramic Substances 0.000 description 2
- 238000000151 deposition Methods 0.000 description 2
- 239000004205 dimethyl polysiloxane Substances 0.000 description 2
- 238000003618 dip coating Methods 0.000 description 2
- FFUAGWLWBBFQJT-UHFFFAOYSA-N hexamethyldisilazane Chemical compound C[Si](C)(C)N[Si](C)(C)C FFUAGWLWBBFQJT-UHFFFAOYSA-N 0.000 description 2
- 239000000463 material Substances 0.000 description 2
- 229910052751 metal Inorganic materials 0.000 description 2
- 239000002184 metal Substances 0.000 description 2
- 229910001092 metal group alloy Inorganic materials 0.000 description 2
- 150000002739 metals Chemical class 0.000 description 2
- 229920000435 poly(dimethylsiloxane) Polymers 0.000 description 2
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- 239000005909 Kieselgur Substances 0.000 description 1
- 239000006057 Non-nutritive feed additive Substances 0.000 description 1
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- RTAQQCXQSZGOHL-UHFFFAOYSA-N Titanium Chemical compound [Ti] RTAQQCXQSZGOHL-UHFFFAOYSA-N 0.000 description 1
- 239000000654 additive Substances 0.000 description 1
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- XAGFODPZIPBFFR-UHFFFAOYSA-N aluminium Chemical compound [Al] XAGFODPZIPBFFR-UHFFFAOYSA-N 0.000 description 1
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- 239000010941 cobalt Substances 0.000 description 1
- 229910017052 cobalt Inorganic materials 0.000 description 1
- GUTLYIVDDKVIGB-UHFFFAOYSA-N cobalt atom Chemical compound [Co] GUTLYIVDDKVIGB-UHFFFAOYSA-N 0.000 description 1
- 230000007423 decrease Effects 0.000 description 1
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- 229910021641 deionized water Inorganic materials 0.000 description 1
- 230000008021 deposition Effects 0.000 description 1
- LIKFHECYJZWXFJ-UHFFFAOYSA-N dimethyldichlorosilane Chemical compound C[Si](C)(Cl)Cl LIKFHECYJZWXFJ-UHFFFAOYSA-N 0.000 description 1
- 239000000975 dye Substances 0.000 description 1
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- 229910052742 iron Inorganic materials 0.000 description 1
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- 238000012986 modification Methods 0.000 description 1
- 230000004048 modification Effects 0.000 description 1
- 229910052759 nickel Inorganic materials 0.000 description 1
- 230000006911 nucleation Effects 0.000 description 1
- 238000010899 nucleation Methods 0.000 description 1
- FPLYNRPOIZEADP-UHFFFAOYSA-N octylsilane Chemical compound CCCCCCCC[SiH3] FPLYNRPOIZEADP-UHFFFAOYSA-N 0.000 description 1
- 239000000049 pigment Substances 0.000 description 1
- 229920001343 polytetrafluoroethylene Polymers 0.000 description 1
- 239000004810 polytetrafluoroethylene Substances 0.000 description 1
- 238000010248 power generation Methods 0.000 description 1
- 230000000979 retarding effect Effects 0.000 description 1
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- 239000000377 silicon dioxide Substances 0.000 description 1
- 239000002356 single layer Substances 0.000 description 1
- 238000005507 spraying Methods 0.000 description 1
- 239000003381 stabilizer Substances 0.000 description 1
- 239000000725 suspension Substances 0.000 description 1
- 239000010936 titanium Substances 0.000 description 1
- 229910052719 titanium Inorganic materials 0.000 description 1
Images
Classifications
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- C08L83/04—Polysiloxanes
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- C—CHEMISTRY; METALLURGY
- C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
- 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
- C09D5/00—Coating compositions, e.g. paints, varnishes or lacquers, characterised by their physical nature or the effects produced; Filling pastes
- C09D5/16—Antifouling paints; Underwater paints
- C09D5/1656—Antifouling paints; Underwater paints characterised by the film-forming substance
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-
- C—CHEMISTRY; METALLURGY
- C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
- 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
- C09D183/00—Coating compositions based on macromolecular compounds obtained by reactions forming in the main chain of the macromolecule a linkage containing silicon, with or without sulfur, nitrogen, oxygen, or carbon only; Coating compositions based on derivatives of such polymers
- C09D183/04—Polysiloxanes
-
- C—CHEMISTRY; METALLURGY
- C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
- 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
- C09D5/00—Coating compositions, e.g. paints, varnishes or lacquers, characterised by their physical nature or the effects produced; Filling pastes
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-
- C—CHEMISTRY; METALLURGY
- C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
- 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
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- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
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- Y10T428/259—Silicic material
Definitions
- This disclosure relates to anti-icing or icephobic coatings for reducing ice and water formation or accumulation on a surface.
- the component may include an anti-icing or icephobic coating to reduce ice accumulation by reducing adhesion between the ice and the coating. In operation of the component, sheer loads from drag, wind, or other forces exceed the adhesive strength and shed the accumulated ice.
- An article according to an example of the present disclosure includes a superhydrophobic body that has a matrix of at least one of silicone or polysiloxane, and non-silica (SiO2) particles dispersed through the matrix.
- the non-silica (SiO2) particles include at least one of oxide particles, non-oxide ceramic particles, metal particles, polymer particles, carbon particles, metal hydroxide particles, or oxide-hydroxide particles.
- the non-silica (SiO2) particles include at least one of the metal particles or the carbon particles.
- the non-silica (SiO2) particles include at least one of the metal hydroxide particles or the oxide-hydroxide particles.
- the non-silica (SiO2) particles include the oxide particles.
- the non-silica (SiO2) particles include at least one of the metal particles or the non-oxide ceramic particles.
- the non-silica (SiO2) particles include the non-oxide ceramic particles.
- the non-silica (SiO2) particles include the polymer particles, and the polymer particles are polytetrafluorothylene particles.
- the non-silica (SiO2) particles include at least two different kinds of particles with respect to composition.
- one of the at least two different kinds of particles is microsphere particles.
- one of the at least two different kinds of particles is hydrophobic particles and another of the at least two different kinds of particles is water durability particles.
- the water durability particles increase water durability of the superhydrophobic coating with respect to ability to retain superhydrophobic surface properties over prolonged immersion in liquid water.
- the non-silica (SiO2) particles include at least two different kinds of particles with respect to size.
- the superhydrophobic body has a mass ratio of the two different kinds of particles that is between 0.3 and 2.
- the non-silica (SiO2) particles have a surface roughness on the nanometer scale.
- the superhydrophobic body consists essentially of the silicone or polysiloxane.
- An article according to an example of the present disclosure includes a substrate and a superhydrophobic coating on the substrate.
- the superhydrophobic coating includes a matrix of at least one of silicone or polysiloxane and particles dispersed through the matrix.
- the particles include at least one of non-oxide ceramic particles, metal particles, or carbon particles.
- the particles include the metal particles.
- the particles include the non-oxide ceramic particles.
- the particles include the carbon particles.
- FIG. 1 illustrates an example coated article.
- FIG. 2 illustrates another example coated article having at least two different kinds of hydrophobic particles.
- FIG. 3 illustrates a graph of water (deionized) contact angle versus time immersed in water.
- FIG. 4 illustrates another example coated article having a primer layer between a superhydrophobic coating and a substrate.
- FIG. 1 illustrates selected portions of an example coated article 20 having anti-icing or icephobic properties.
- the coated article 20 may be any type of component that would benefit from anti-icing.
- the coated article 20 may be an aircraft component, aerospace component, heat exchanger component, wind turbine component or any other component where there is a desire to reduce or eliminate ice formation.
- the coated article 20 generally includes a substrate 22 and a superhydrophobic coating 24 on the substrate 22 .
- the term “superhydrophobic” and variations thereof refers to an advancing water contact angle that is greater than 140° and a receding water contact angle that is within 20% of the advancing water contact angle.
- the superhydrophobic coating 24 is located on the surface of the substrate 22 exposed to the surrounding environment to protect the substrate 22 from ice formation.
- the substrate 22 may comprise any material to which the superhydrophobic coating 24 may adhere, including metal alloys (e.g. alloys based on the metals aluminum, titanium, nickel, cobalt, iron, etc.), polymers, polymer blends, ceramics, glasses, and/or composites and combinations thereof.
- the superhydrophobic coatings of the present disclosure are designed to shed water and thereby avoid ice formation.
- the superhydrophobic coating 24 may be considered to be an anti-icing or icephobic coating and may reduce or inhibit ice accumulation on the substrate by retarding or preventing the nucleation or formation of ice.
- the superhydrophobic coating 24 is designed to be compatible with or stable to intermittent or extended exposures at elevated temperatures (up to ⁇ 550° F.), such as might be encountered in certain aerospace components.
- the superhydrophobic coating 24 is further designed to be simple to apply.
- the superhydrophobic coating 24 is applied to the substrate 22 as a single layer in one deposition step (e.g. a single spray coating, flow coating, dip coating, etc. application), although certain attributes may also be attained through a multi-step or multi-layer application process.
- one deposition step e.g. a single spray coating, flow coating, dip coating, etc. application
- the superhydrophobic coating 24 is a composite of a silicone polymer 26 a (e.g., matrix) and hydrophobic particles 26 b (e.g., filler particles).
- the silicone polymer 26 a may contain additives or processing aids, such as anti-foaming agents, pigments, dyes, stabilizers, and the like known to those practiced in the art.
- the silicone polymer may be a silicone, fluorosilicone, polysiloxane, room temperature vulcanized silicone, or other type of silicone composition or combination thereof.
- the particles 26 b are inherently hydrophobic or surface-functionalized with a hydrophobic agent that renders the particle surfaces hydrophobic and contribute to the superhydrophobic properties of the coating 24 .
- the particles 26 b may be nanosized particles.
- the particles 26 b are monodisperse nanosized silica, such as fumed amorphous silica (SiO2).
- the particles 26 b may include combinations of different sized particles.
- Other suitable nanosized particles may include crystalline and amorphous oxides, non-oxide ceramics, metals and metal alloys, polymers and polymer blends, carbons, and metal hydroxides and oxide-hydroxides (such as natural and synthetic clays, mica, and diatomaceous earth). If the particles 26 b are not inherently hydrophobic their surfaces may be rendered hydrophobic by surface functionalizing with an appropriate hydrophobic agent.
- the hydrophobic agent may be any type of agent that suitably bonds to the surfaces of the particles 26 b and renders the particles hydrophobic.
- the hydrophobic agent may be a functionalized silane coupling agent, polydimethylsiloxane, hexamethyldisilazane, octylsilane, dimethyldichlorosilane, or a combination thereof.
- the composition of the superhydrophobic coating 24 may be characterized by a mass ratio of the silicone polymer 26 a to the hydrophobic particles 26 b.
- the mass ratio is between 0.5 and 3, and in some examples 0.5-1.5.
- the superhydrophobic coating 24 may include only the silicone polymer 26 a and the particles 26 b.
- the use of nanosized hydrophobic particles 26 b in combination with the silicone polymer 26 a may render the coating 24 superhydrophobic. That is, the superhydrophobic coating 24 exhibits an advancing water contact angle that is greater than 140° and a receding water contact angle that is within 20% of the advancing water contact angle (i.e., a contact angle hysteresis that is less than 20%).
- a user may determine the advancing and receding water contact angles with known equipment and testing techniques, such as the Wilhelmy plate method or using a contact angle goniometer.
- FIG. 2 illustrates another example coated article 120 .
- the coated article 120 includes a superhydrophobic coating 124 on the substrate 22 .
- the superhydrophobic coating 124 includes a silicone polymer 126 a and particles 126 b, as described with regard to FIG. 1 .
- the superhydrophobic coating 124 includes particles 128 . That is, the superhydrophobic coating 124 includes at least two different kinds of hydrophobic particles, the particles 126 b and the particles 128 .
- the particles 126 b and the particles 128 may differ in composition, size, morphology, or other characteristic.
- the particles 126 b may be nanosized hydrophobic particles, as described above, and the particles 128 may be microsized particles.
- the microsized particles 128 may be polymeric, such as silicone or polytetrafluoroethylene particles, and have a surface roughness on the nanometer scale (0.1-500 nanometers).
- the particles 128 cooperate with the particles 126 b and the silicone polymer 126 a to contribute to the superhydrophobic properties of the coating 124 .
- the particles 128 reduce the need to use high amounts of the particles 126 b.
- the superhydrophobic coating 124 can include generally less of the particles 126 b in comparison to a coating that does not include the particles 128 and maintain approximately the same or better hydrophobicity performance.
- the superhydrophobic coating 124 includes a mass ratio of the silicone polymer 126 a to the particles 126 b that is 0.5-10 and a mass ratio of the microsized particles 128 to nanosized particles 126 b that is 0-10, such as 0.1-10.
- the mass ratio of silicone polymer 126 a to particles 126 b is 4-6 and the mass ratio of particles 128 to particles 126 b is 0.3-2.
- Using surface functionalized nanosized silica particles as the particles 126 b and microsized silicone particles as the particles 128 renders the coating 124 to be superhydrophobic.
- the microsized particles may have a size of 1-100 micrometers, and in some examples 5-25 micrometers.
- the nanosized silica particles may have a size of 1-200 nanometers, and in some examples 1-50 nanometers.
- the microsized particles 128 may be regarded as a “roughening agent” to the silicone polymer 126 a to enhance the surface roughness of the superhydrophobic coating 124 and enhance hydrophobicity.
- the microsized particles 128 may be a ceramic, metallic, polymeric, or composite material having hydrophobic properties and a surface roughness on the nanometer scale (0.1-500 nanometers). Particles 128 may be inherently hydrophobic or surface-functionalized with a hydrophobic agent. Further, microsized particles that are not hydrophobic may also be suitable in certain coating formulations, if the microsized particles are sufficiently coated or wetted by the silicone matrix of the coating.
- Utilizing at least two different kinds of particles in the superhydrophobic coating 124 also enhances the water durability of the superhydrophobic coating 124 .
- water durability is defined as the ability of the superhydrophobic coating 124 to retain superhydrophobic surface properties (i.e. advancing contact angle >140° with less than 20% contact angle hysteresis) over prolonged immersion in liquid water.
- FIG. 3 illustrates a graph of water contact angle versus time immersed in water.
- Sample 1 and sample 2 were prepared by depositing coatings of different compositions on substrates using a known dip coating technique and a suspension of silicone polymer (NUSIL R-2180) and nanosized silica particles (ALFA-AESAR), as described above, in methyl ethyl ketone.
- Sample 1 additionally included microsized silicone particles (TOSPEARL 1110A polydimethylsiloxane microspheres) as described above.
- the microsized silicone microspheres had an average size of approximately 11 micrometers and a relatively smooth surface morphology having a roughness on the nanometer scale.
- Samples 1 and 2 were aged by immersing the coated substrates in deionized water at ambient temperature.
- the graph line 230 represents a plot of the advancing water contact angle of sample 1 as a function of time immersed, and the graph line 232 represents a plot of the receding water contact angle of sample number 1.
- Graph line 234 represents a plot of the advancing water contact angle of sample number 2 as a function of time immersed, and graph line 236 represents a plot of the receding water contact angle of sample number 2.
- the receding contact angle 236 of sample 2 declined substantially as a function of time immersed in the water.
- the receding contact angle 232 of sample 1 did not exhibit such a decline and suggests that the particles 128 , such as the microsized silicone particles in sample 1, enhance water durability of superhydrophobic coatings.
- FIG. 4 illustrates another example coated article 220 that is similar to the coated article 20 of FIG. 1 but includes a primer layer 240 between the superhydrophobic coating 24 and the substrate 22 .
- the primer layer 240 may be a metal-organic material that is adapted to bond to the superhydrophobic coating 24 and the material of the substrate 22 .
Abstract
Description
- The present is a continuation to U.S. Provisional patent application Ser. No. 12/874,677, filed Sep. 2, 2010.
- This disclosure relates to anti-icing or icephobic coatings for reducing ice and water formation or accumulation on a surface.
- Surfaces of aircraft, power generation (e.g. wind turbines and land-based gas turbines), and architectural components may collect moisture that can freeze and debit the performance of the component. The component may include an anti-icing or icephobic coating to reduce ice accumulation by reducing adhesion between the ice and the coating. In operation of the component, sheer loads from drag, wind, or other forces exceed the adhesive strength and shed the accumulated ice.
- An article according to an example of the present disclosure includes a superhydrophobic body that has a matrix of at least one of silicone or polysiloxane, and non-silica (SiO2) particles dispersed through the matrix. The non-silica (SiO2) particles include at least one of oxide particles, non-oxide ceramic particles, metal particles, polymer particles, carbon particles, metal hydroxide particles, or oxide-hydroxide particles.
- In a further embodiment of any of the foregoing embodiments, the non-silica (SiO2) particles include at least one of the metal particles or the carbon particles.
- In a further embodiment of any of the foregoing embodiments, the non-silica (SiO2) particles include at least one of the metal hydroxide particles or the oxide-hydroxide particles.
- In a further embodiment of any of the foregoing embodiments, the non-silica (SiO2) particles include the oxide particles.
- In a further embodiment of any of the foregoing embodiments, the non-silica (SiO2) particles include at least one of the metal particles or the non-oxide ceramic particles.
- In a further embodiment of any of the foregoing embodiments, the non-silica (SiO2) particles include the non-oxide ceramic particles.
- In a further embodiment of any of the foregoing embodiments, the non-silica (SiO2) particles include the polymer particles, and the polymer particles are polytetrafluorothylene particles.
- In a further embodiment of any of the foregoing embodiments, the non-silica (SiO2) particles include at least two different kinds of particles with respect to composition.
- In a further embodiment of any of the foregoing embodiments, one of the at least two different kinds of particles is microsphere particles.
- In a further embodiment of any of the foregoing embodiments, one of the at least two different kinds of particles is hydrophobic particles and another of the at least two different kinds of particles is water durability particles. The water durability particles increase water durability of the superhydrophobic coating with respect to ability to retain superhydrophobic surface properties over prolonged immersion in liquid water.
- In a further embodiment of any of the foregoing embodiments, the non-silica (SiO2) particles include at least two different kinds of particles with respect to size.
- In a further embodiment of any of the foregoing embodiments, the superhydrophobic body has a mass ratio of the two different kinds of particles that is between 0.3 and 2.
- In a further embodiment of any of the foregoing embodiments, the non-silica (SiO2) particles have a surface roughness on the nanometer scale.
- In a further embodiment of any of the foregoing embodiments, the superhydrophobic body consists essentially of the silicone or polysiloxane.
- An article according to an example of the present disclosure includes a substrate and a superhydrophobic coating on the substrate. The superhydrophobic coating includes a matrix of at least one of silicone or polysiloxane and particles dispersed through the matrix. The particles include at least one of non-oxide ceramic particles, metal particles, or carbon particles.
- In a further embodiment of any of the foregoing embodiments, the particles include the metal particles.
- In a further embodiment of any of the foregoing embodiments, the particles include the non-oxide ceramic particles.
- In a further embodiment of any of the foregoing embodiments, the particles include the carbon particles.
- The various features and advantages of the disclosed examples will become apparent to those skilled in the art from the following detailed description. The drawings that accompany the detailed description can be briefly described as follows.
-
FIG. 1 illustrates an example coated article. -
FIG. 2 illustrates another example coated article having at least two different kinds of hydrophobic particles. -
FIG. 3 illustrates a graph of water (deionized) contact angle versus time immersed in water. -
FIG. 4 illustrates another example coated article having a primer layer between a superhydrophobic coating and a substrate. -
FIG. 1 illustrates selected portions of an example coatedarticle 20 having anti-icing or icephobic properties. It is to be understood that the coatedarticle 20 may be any type of component that would benefit from anti-icing. For instance, the coatedarticle 20 may be an aircraft component, aerospace component, heat exchanger component, wind turbine component or any other component where there is a desire to reduce or eliminate ice formation. - The coated
article 20 generally includes asubstrate 22 and asuperhydrophobic coating 24 on thesubstrate 22. The term “superhydrophobic” and variations thereof refers to an advancing water contact angle that is greater than 140° and a receding water contact angle that is within 20% of the advancing water contact angle. In the illustrated embodiment, thesuperhydrophobic coating 24 is located on the surface of thesubstrate 22 exposed to the surrounding environment to protect thesubstrate 22 from ice formation. Thesubstrate 22 may comprise any material to which thesuperhydrophobic coating 24 may adhere, including metal alloys (e.g. alloys based on the metals aluminum, titanium, nickel, cobalt, iron, etc.), polymers, polymer blends, ceramics, glasses, and/or composites and combinations thereof. In comparison to icephobic coatings that address anti-icing via reducing ice adhesion strength, the superhydrophobic coatings of the present disclosure are designed to shed water and thereby avoid ice formation. Thesuperhydrophobic coating 24 may be considered to be an anti-icing or icephobic coating and may reduce or inhibit ice accumulation on the substrate by retarding or preventing the nucleation or formation of ice. Thesuperhydrophobic coating 24 is designed to be compatible with or stable to intermittent or extended exposures at elevated temperatures (up to ˜550° F.), such as might be encountered in certain aerospace components. Thesuperhydrophobic coating 24 is further designed to be simple to apply. In the simplest embodiment thesuperhydrophobic coating 24 is applied to thesubstrate 22 as a single layer in one deposition step (e.g. a single spray coating, flow coating, dip coating, etc. application), although certain attributes may also be attained through a multi-step or multi-layer application process. - The
superhydrophobic coating 24 is a composite of asilicone polymer 26 a (e.g., matrix) andhydrophobic particles 26 b (e.g., filler particles). Thesilicone polymer 26 a may contain additives or processing aids, such as anti-foaming agents, pigments, dyes, stabilizers, and the like known to those practiced in the art. The silicone polymer may be a silicone, fluorosilicone, polysiloxane, room temperature vulcanized silicone, or other type of silicone composition or combination thereof. Theparticles 26 b are inherently hydrophobic or surface-functionalized with a hydrophobic agent that renders the particle surfaces hydrophobic and contribute to the superhydrophobic properties of thecoating 24. - The
particles 26 b may be nanosized particles. In one example, theparticles 26 b are monodisperse nanosized silica, such as fumed amorphous silica (SiO2). Alternatively, theparticles 26 b may include combinations of different sized particles. Other suitable nanosized particles may include crystalline and amorphous oxides, non-oxide ceramics, metals and metal alloys, polymers and polymer blends, carbons, and metal hydroxides and oxide-hydroxides (such as natural and synthetic clays, mica, and diatomaceous earth). If theparticles 26 b are not inherently hydrophobic their surfaces may be rendered hydrophobic by surface functionalizing with an appropriate hydrophobic agent. The hydrophobic agent may be any type of agent that suitably bonds to the surfaces of theparticles 26 b and renders the particles hydrophobic. For example, the hydrophobic agent may be a functionalized silane coupling agent, polydimethylsiloxane, hexamethyldisilazane, octylsilane, dimethyldichlorosilane, or a combination thereof. - The composition of the
superhydrophobic coating 24 may be characterized by a mass ratio of thesilicone polymer 26 a to thehydrophobic particles 26 b. In one example, the mass ratio is between 0.5 and 3, and in some examples 0.5-1.5. In a further example, thesuperhydrophobic coating 24 may include only thesilicone polymer 26 a and theparticles 26 b. The use of nanosizedhydrophobic particles 26 b in combination with thesilicone polymer 26 a may render thecoating 24 superhydrophobic. That is, thesuperhydrophobic coating 24 exhibits an advancing water contact angle that is greater than 140° and a receding water contact angle that is within 20% of the advancing water contact angle (i.e., a contact angle hysteresis that is less than 20%). A user may determine the advancing and receding water contact angles with known equipment and testing techniques, such as the Wilhelmy plate method or using a contact angle goniometer. -
FIG. 2 illustrates another example coatedarticle 120. In this disclosure, like reference numerals designate like elements where appropriate, and reference numerals with the addition of one-hundred or multiples thereof designate modified elements that are understood to incorporate the same features and benefits of the corresponding original elements. In this case, thecoated article 120 includes asuperhydrophobic coating 124 on thesubstrate 22. Thesuperhydrophobic coating 124 includes asilicone polymer 126 a andparticles 126 b, as described with regard toFIG. 1 . Additionally, thesuperhydrophobic coating 124 includesparticles 128. That is, thesuperhydrophobic coating 124 includes at least two different kinds of hydrophobic particles, theparticles 126 b and theparticles 128. Theparticles 126 b and theparticles 128 may differ in composition, size, morphology, or other characteristic. - In the illustrated example, the
particles 126 b may be nanosized hydrophobic particles, as described above, and theparticles 128 may be microsized particles. Themicrosized particles 128 may be polymeric, such as silicone or polytetrafluoroethylene particles, and have a surface roughness on the nanometer scale (0.1-500 nanometers). Theparticles 128 cooperate with theparticles 126 b and thesilicone polymer 126 a to contribute to the superhydrophobic properties of thecoating 124. In this regard, theparticles 128 reduce the need to use high amounts of theparticles 126 b. Thus, thesuperhydrophobic coating 124 can include generally less of theparticles 126 b in comparison to a coating that does not include theparticles 128 and maintain approximately the same or better hydrophobicity performance. - In one example, the
superhydrophobic coating 124 includes a mass ratio of thesilicone polymer 126 a to theparticles 126 b that is 0.5-10 and a mass ratio of themicrosized particles 128 tonanosized particles 126 b that is 0-10, such as 0.1-10. In a more particular example, the mass ratio ofsilicone polymer 126 a toparticles 126 b is 4-6 and the mass ratio ofparticles 128 toparticles 126 b is 0.3-2. Using surface functionalized nanosized silica particles as theparticles 126 b and microsized silicone particles as theparticles 128 renders thecoating 124 to be superhydrophobic. - The microsized particles may have a size of 1-100 micrometers, and in some examples 5-25 micrometers. The nanosized silica particles may have a size of 1-200 nanometers, and in some examples 1-50 nanometers. The
microsized particles 128 may be regarded as a “roughening agent” to thesilicone polymer 126 a to enhance the surface roughness of thesuperhydrophobic coating 124 and enhance hydrophobicity. - Alternatively, the
microsized particles 128 may be a ceramic, metallic, polymeric, or composite material having hydrophobic properties and a surface roughness on the nanometer scale (0.1-500 nanometers).Particles 128 may be inherently hydrophobic or surface-functionalized with a hydrophobic agent. Further, microsized particles that are not hydrophobic may also be suitable in certain coating formulations, if the microsized particles are sufficiently coated or wetted by the silicone matrix of the coating. - Utilizing at least two different kinds of particles in the
superhydrophobic coating 124 also enhances the water durability of thesuperhydrophobic coating 124. Herein, water durability is defined as the ability of thesuperhydrophobic coating 124 to retain superhydrophobic surface properties (i.e. advancing contact angle >140° with less than 20% contact angle hysteresis) over prolonged immersion in liquid water. -
FIG. 3 illustrates a graph of water contact angle versus time immersed in water. Sample 1 and sample 2 were prepared by depositing coatings of different compositions on substrates using a known dip coating technique and a suspension of silicone polymer (NUSIL R-2180) and nanosized silica particles (ALFA-AESAR), as described above, in methyl ethyl ketone. Sample 1 additionally included microsized silicone particles (TOSPEARL 1110A polydimethylsiloxane microspheres) as described above. The microsized silicone microspheres had an average size of approximately 11 micrometers and a relatively smooth surface morphology having a roughness on the nanometer scale. Samples 1 and 2 were aged by immersing the coated substrates in deionized water at ambient temperature. - The
graph line 230 represents a plot of the advancing water contact angle of sample 1 as a function of time immersed, and thegraph line 232 represents a plot of the receding water contact angle of sample number 1.Graph line 234 represents a plot of the advancing water contact angle of sample number 2 as a function of time immersed, andgraph line 236 represents a plot of the receding water contact angle of sample number 2. The recedingcontact angle 236 of sample 2 declined substantially as a function of time immersed in the water. The recedingcontact angle 232 of sample 1 did not exhibit such a decline and suggests that theparticles 128, such as the microsized silicone particles in sample 1, enhance water durability of superhydrophobic coatings. -
FIG. 4 illustrates another example coatedarticle 220 that is similar to thecoated article 20 ofFIG. 1 but includes aprimer layer 240 between thesuperhydrophobic coating 24 and thesubstrate 22. For instance, theprimer layer 240 may be a metal-organic material that is adapted to bond to thesuperhydrophobic coating 24 and the material of thesubstrate 22. - Although a combination of features is shown in the illustrated examples, not all of them need to be combined to realize the benefits of various embodiments of this disclosure. In other words, a system designed according to an embodiment of this disclosure will not necessarily include all of the features shown in any one of the Figures or all of the portions schematically shown in the Figures. Moreover, selected features of one example embodiment may be combined with selected features of other example embodiments.
- The preceding description is exemplary rather than limiting in nature. Variations and modifications to the disclosed examples may become apparent to those skilled in the art that do not necessarily depart from the essence of this disclosure. The scope of legal protection given to this disclosure can only be determined by studying the following claims.
Claims (18)
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US9260629B2 (en) | 2016-02-16 |
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