U.S. patent application number 16/486902 was filed with the patent office on 2021-02-11 for methods for forming omniphobic thermoset compositions and related articles.
The applicant listed for this patent is BOARD OF TRUSTEES OF MICHIGAN STATE UNIVERSITY. Invention is credited to Fahad Khan, Muhammad Rabnawaz.
Application Number | 20210040348 16/486902 |
Document ID | / |
Family ID | 1000005208227 |
Filed Date | 2021-02-11 |
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United States Patent
Application |
20210040348 |
Kind Code |
A1 |
Rabnawaz; Muhammad ; et
al. |
February 11, 2021 |
METHODS FOR FORMING OMNIPHOBIC THERMOSET COMPOSITIONS AND RELATED
ARTICLES
Abstract
The disclosure relates to methods for forming an omniphobic
thermoset composition, such as an omniphobic polyurethane or epoxy
composition. First and second thermosetting components are applied
to a substrate and partially cured. A functionalized
hydrophobic/oleophobic/omniphobic polymer which is reactive with at
least the first thermosetting component is then applied to the
coated substrate, which is then further cured to form a thermoset
omniphobic coating on the substrate. The thermoset omniphobic
composition has favorable omniphobic properties, for example as
characterized by water and/or oil contact and/or sliding angles.
The thermoset omniphobic composition can be used as a coating on
any of a variety of substrates to provide omniphobic properties to
a surface of the substrate. Such omniphobic coatings can be scratch
resistant, ink/paint resistant, and optically clear. The thermoset
omniphobic composition can be applied by different coating methods
including cast, spin, roll, spray and dip coating methods.
Inventors: |
Rabnawaz; Muhammad; (East
Lansing, MI) ; Khan; Fahad; (East Lansing,
MI) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
BOARD OF TRUSTEES OF MICHIGAN STATE UNIVERSITY |
East Lansing |
MI |
US |
|
|
Family ID: |
1000005208227 |
Appl. No.: |
16/486902 |
Filed: |
April 9, 2019 |
PCT Filed: |
April 9, 2019 |
PCT NO: |
PCT/US19/26432 |
371 Date: |
August 19, 2019 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
62657339 |
Apr 13, 2018 |
|
|
|
Current U.S.
Class: |
1/1 |
Current CPC
Class: |
C08G 18/5024 20130101;
C08G 18/10 20130101; C08G 18/4045 20130101; C08G 18/4829 20130101;
C08G 77/26 20130101; C08G 18/778 20130101; C08G 18/581 20130101;
C08G 18/7831 20130101; C09D 175/04 20130101 |
International
Class: |
C09D 175/04 20060101
C09D175/04 |
Claims
1. A method for forming an omniphobic coated article, the method
comprising: applying to a substrate (i) at least one first
thermosetting component reactive with a second thermosetting
component and a functionalized omniphobic polymer and (ii) at least
one second thermosetting component reactive with the first
thermosetting component; reacting the at least one first
thermosetting component with the at least one second thermosetting
component to form a partially crosslinked reaction product
comprising (i) at least some covalent bonds between the first
thermosetting component and the second thermosetting component, and
(ii) at least some unreacted functional groups reactive with the
functionalized omniphobic polymer; applying to the partially
crosslinked reaction product at least one functionalized omniphobic
polymer having a glass transition temperature (T.sub.g) of
50.degree. C. or less, the functionalized omniphobic polymer
comprising a functional group reactive with the first thermosetting
component; and reacting the unreacted functional groups in the
partially crosslinked reaction product with the functionalized
omniphobic polymer to form a thermoset omniphobic coating on the
substrate.
2. The method of claim 1, wherein the substrate is selected from
the group of metal, plastics, a different thermoset material,
glass, wood, fabric (or textile), and ceramics.
3. The method of claim 1, wherein applying the first thermosetting
component and the second thermosetting component comprises:
applying to the substrate a mixture comprising (i) the first
thermosetting component, (ii) the second thermosetting component,
and (iii) optionally a solvent.
4. The method of claim 3, comprising performing one or more of
spraying, casting, rolling, and dipping to apply the mixture to the
substrate.
5. The method of claim 3, wherein the mixture comprises the
solvent.
6. The method of claim 5, further comprising: after applying the
first thermosetting component and the second thermosetting
component to the substrate, drying the substrate to remove the
solvent, thereby forming a coating (partially crosslinked) of the
first thermosetting component and the second thermosetting
component on the substrate.
7. The method of claim 1, further comprising: applying to the
substrate one or more additives selected from the group consisting
of nanoclay, graphene oxide, graphene, silicon dioxide (silica),
aluminum oxide, cellulose nanocrystals, carbon nanotubes, titanium
dioxide (titania), diatomaceous earth, biocides, pigments, dyes,
thermoplastics, and combinations thereof.
8. The method of claim 1, comprising reacting the at least one
first thermosetting component with the at least one second
thermosetting component to form a partially crosslinked reaction
product (i) at temperature from 20.degree. C. to 150.degree. C. and
(ii) for a time from 1 min to 300 min.
9. The method of claim 1, wherein applying the functionalized
omniphobic polymer comprises: applying to the partially crosslinked
reaction product a mixture comprising (i) the functionalized
omniphobic polymer, and (ii) a solvent.
10. The method of claim 9, further comprising: after applying the
functionalized omniphobic polymer to the partially crosslinked
reaction product, drying the substrate to remove the solvent.
11. The method of claim 1, comprising reacting the unreacted
functional groups in the partially crosslinked reaction product
with the functionalized omniphobic polymer to form a thermoset
omniphobic coating on the substrate (i) at a temperature from
20.degree. C. to 180.degree. C. and (ii) for a time from 1 hr to 24
hr.
12. The method of claim 1, wherein the thermoset omniphobic coating
comprises: a thermoset polymer comprising a crosslinked backbone,
the crosslinked backbone comprising: (i) first backbone segments
having a structure corresponding to a reaction product from the at
least one first thermosetting component with at least one of the
second thermosetting component and the functionalized omniphobic
polymer; (ii) second backbone segments having a structure
corresponding to a reaction product from the functionalized
omniphobic polymer with the first thermosetting component; (iii)
third backbone segments having a structure corresponding to a
reaction product reaction product from the second thermosetting
component with the first thermosetting component; (iv) first
linking groups linking the first backbone segments and the third
backbone segments, the first linking groups having a structure
corresponding to a reaction product of the first thermosetting
component and the second thermosetting component; and (v) second
linking groups linking the first backbone segments and the second
backbone segments, the second linking groups having a structure
corresponding to a reaction product of the first thermosetting
component and the functionalized omniphobic polymer.
13. The method of claim 12, wherein: the first backbone segments
are present in an amount ranging from 10 wt. % to 90 wt. % relative
to the thermoset polymer; the second backbone segments are present
in an amount ranging from 0.01 wt. % to 20 wt. % relative to the
thermoset polymer; and the third backbone segments are present in
an amount ranging from 10 wt. % to 90 wt. % relative to the
thermoset polymer.
14. The method of claim 1, wherein the functional group of the
functionalized omniphobic polymer is selected from the group
consisting of epoxide groups, amino groups, isocyanate groups,
hydroxyl groups, carboxylic groups, and combinations thereof
15. The method of claim 1, wherein the functionalized omniphobic
polymer is selected from the group consisting of functionalized
polysiloxanes, functionalized polyperfluoroethers, functionalized
polybutadienes, functionalized polyisobutenes, functionalized
branched polyolefins, functionalized poly(meth)acrylates, and
combinations thereof.
16. The method of claim 1, wherein the functionalized omniphobic
polymer comprises a mono-functional functionalized omniphobic
polymer.
17. The method of claim 1, wherein the functionalized omniphobic
polymer comprises a di-functional functionalized omniphobic
polymer.
18. The method of claim 1, wherein the functionalized omniphobic
polymer comprises a poly-functional functionalized omniphobic
polymer.
19. The method of claim 1, wherein the functionalized omniphobic
polymer is a liquid at a temperature in a range from -130.degree.
C. to 40.degree. C.
20. The method of claim 1, wherein the functionalized omniphobic
polymer has a molecular weight ranging from 300 to 50,000
g/mol.
21. The method of claim 1, wherein the first thermosetting
component and the second thermosetting component together
correspond to a thermoset polyurethane.
22. The method of claim 1, wherein: the first thermosetting
component comprises a polyisocyanate or a polyol; and the second
thermosetting component comprises the other of the polyisocyanate
and the polyol.
23. The method of claim 22, wherein the polyisocyanate is selected
from the group consisting of 1,5-naphthylene diisocyanate,
4,4'-diphenylmethane diisocyanate (MDI), hydrogenated MDI, xylene
diisocyanate (XDI), tetramethylxylol diisocyanate (TMXDI),
4,4'-diphenyl-dimethylmethane diisocyanate, di- and
tetraalkyl-diphenylmethane diisocyanate, 4,4'-dibenzyl
diiso-cyanate, 1,3-phenylene diisocyanate, 1,4-phenylene
diisocyanate, one or more isomers of tolylene diisocyanate (TDI),
1-methyl-2,4-diiso-cyanatocyclohexane,
1,6-diisocyanato-2,2,4-trimethyl-hexane,
1,6-diisocyanato-2,4,4-trimethylhexane,
1-iso-cyanatomethyl-3-isocyanato-1,5,5-trimethylcyclohexane,
chlorinated and brominated diisocyanates, phosphorus-containing
diisocyanates, 4,4'-diisocyanatophenyl-perfluoroethane,
tetramethoxybutane 1,4-diisocyanate, butane 1,4-diisocyanate,
hexane 1,6-diisocyanate (HDI), HDI dimer (HDID), HDI trimer (HDIT),
HDI biuret, 1,5-pentamethylene diisocyanate (PDI), PDID (dimer of
PDI), PDIT (trimer of PDI), PDI biuret, dicyclohexylmethane
diisocyanate, cyclohexane 1,4-diisocyanate, ethylene diisocyanate,
phthalic acid bisisocyanatoethyl ester, 1-chloromethylphenyl
2,4-diisocyanate, 1-bromomethylphenyl 2,6-diisocyanate,
3,3-bischloromethyl ether 4,4'-diphenyldiisocyanate,
trimethylhexamethylene diisocyanate, 1,4-diisocyanato-butane,
1,2-diisocyanatododecane, and combinations thereof.
24. The method of claim 22, wherein the polyol is selected from the
group consisting of polyether polyols, hydroxylated (meth)acrylate
oligomers, glycerol, ethylene glycol, diethylene glycol,
triethylene glycol, tetraethylene glycol, propylene glycol,
dipropylene glycol, tripropylene glycol, 1,3-propanediol,
1,3-butanediol, 1,4-butanediol, neopentyl glycol, 1,6-hexanediol,
1,4-cyclohexanedimethanol, glycerol, trimethylolpropane,
1,2,6-hexanetriol, pentaerythritol, (meth)acrylic polyols,
isosorbide, and combinations thereof.
25. The method of claim 1, wherein: the first thermosetting
component comprises a polyisocyanate; the second thermosetting
component comprises a polyol; and the functional group of the
functionalized omniphobic polymer comprises an amino group.
26. The method of claim 1, the first thermosetting component and
the second thermosetting component together correspond to a
thermoset.
27. The method of claim 1, wherein: the first thermosetting
component comprises a polyepoxide or an amine; and the second
thermosetting component comprises the other of the polyepoxide and
the amine.
28. The method of claim 27, wherein the polyepoxide is selected
from the group consisting of polyepoxide-substituted aromatic
hydrocarbons, aliphatic hydrocarbons, cycloaliphatic hydrocarbons,
ethers thereof, esters thereof, imines thereof, and combinations
thereof.
29. The method of claim 27, wherein the amine is selected from the
group consisting of polyamine-substituted aromatic hydrocarbons,
aliphatic hydrocarbons, cycloaliphatic hydrocarbons, ethers
thereof, esters thereof, imines thereof, and combinations
thereof.
30. The method of claim 1, wherein: the first thermosetting
component comprises an amine; the second thermosetting component
comprises a polyepoxide; and the functional group of the
functionalized omniphobic polymer comprises an isocyanate
group.
31. The method of claim 1, the first thermosetting component and
the second thermosetting component together correspond to an
acrylic thermoset.
32. The method of claim 1, wherein the thermoset omniphobic coating
has a water contact angle in a range from 90.degree. to
120.degree..
33. The method of claim 1, wherein the thermoset omniphobic coating
has an oil contact angle in a range from 1.degree. to
65.degree..
34. The method of claim 1, wherein the thermoset omniphobic coating
has a water sliding angle in a range from 1.degree. to 30.degree.
for a 75 .mu.l droplet.
35. The method of claim 1, wherein the thermoset omniphobic coating
has an oil sliding angle in a range from 1.degree. to 20.degree.
for a 25 .mu.l droplet.
36. The method of claim 1, wherein the thermoset omniphobic coating
has a thickness ranging from 0.01 .mu.m to 500 .mu.m.
37. The method of claim 1, wherein the thermoset omniphobic coating
is scratch-resistant, ink-resistant, and optically clear.
Description
CROSS REFERENCE TO RELATED APPLICATION
[0001] Priority is claimed to U.S. Provisional Application No.
62/657,339 (filed Apr. 13, 2018), which is incorporated herein by
reference in its entirety.
STATEMENT OF GOVERNMENT INTEREST
[0002] None.
BACKGROUND OF THE DISCLOSURE
Field of the Disclosure
[0003] The disclosure relates to methods for forming an omniphobic
thermoset composition (such as an omniphobic polyurethane or epoxy
composition). First and second thermosetting components are applied
to a substrate and partially cured. A functionalized omniphobic
polymer which is reactive with at least the first thermosetting
component is then applied to the coated substrate, which is then
further cured to form a thermoset omniphobic coating on the
substrate.
Brief Description of Related Technology
[0004] When water accumulates on a surface, the surface energy of
the material is directly related to how the water will interact.
Some surfaces may allow the water to spread out into a pool with a
large surface area, whereas others may make water bead up into
droplets. The contact angle between the water droplet and the
surface is used to characterize the surface into three categories:
hydrophilic (<90.degree.), hydrophobic (90.degree.-150.degree.),
and superhydrophobic (>150.degree.). FIG. 1 is a visual
representation of a contact angle measurement.
[0005] Hydrophobicity can be achieved in two ways: controlling the
chemical interactions between water and the material surface or
altering the surface of the material. Generally, non-polar
molecular groups are responsible water beading on a surface as
opposed to spreading, due to the lower surface energies exhibited
by non-polar groups. A lower surface energy of the material will
directly relate to a high contact angle. In contrast, high-energy
materials will cause water to spread out in a thin pool, as the
polar groups present in surfaces with high energies attract the
polar water molecules.
[0006] Physically altering the surface (e.g., increasing the
roughness thereof) of the material may also increase the
hydrophobicity of a material. By creating pillars or other similar
features on a textured surface, water interacts with an increased
surface area on the material, thus amplifying the chemical
interactions between water and the surface. An image depicting how
texturing the surface leads to increased contact angle can be seen
below in FIG. 2. The use of a rough surface with nano-wells such as
in FIG. 2 prevents water droplets from entering etched grooves.
However, under a high enough pressure, the water will still
disperse into the wells and such coatings are expensive and
difficult to manufacture.
[0007] Another method (not shown) utilizes a sponge coating that is
doped with a hydrophobic material to prevent water dispersion. The
sponge method works well at repelling water, but is not a durable
material and will eventually degrade. Both of the previous methods
generally either lack the feature of optical transparency or
require costly additional steps and/or components to provide
optical transparency. Optical transparency is key for the coating
to allow for coated materials to still be visible.
[0008] A material that repels oils is known as oleophobic or
lipophobic depending on if the repelling action is a physical or
chemical property, respectively, and operates analogously to
hydrophobic materials. These materials are often used on touch
screen displays so that bodily oils and sweat gland secretions do
not build up on the surface of a screen. A material that exhibits
both hydrophobic and oleophobic properties is known as omniphobic.
Such materials with very high contact angles are often regarded as
"self-cleaning" materials, as contaminants will typically bead up
and roll off the surface. As such, these materials have possible
applications in screen display, window, sealant, and building
material coatings.
[0009] Flu et al. U.S. Publication No. 2016/0200937 discloses
polyurethane-based and epoxy-based compositions that be used as
coatings and adhesives with abrasion-resistant, ink-resistant,
anti-graffiti, anti-fingerprint properties. The disclosed process
for making the compositions requires graft and block copolymer
components along with a two-step/two-pot manufacturing process,
increasing the time to manufacture and cost of the product.
SUMMARY
[0010] In one aspect, the disclosure relates to a method for
forming an omniphobic coated article, the method comprising:
applying to a substrate (i) at least one first thermosetting
component (e.g., monomer, comonomer, prepolymer, oligomer, polymer
with 2+ polymerizable functional groups) reactive with a second
thermosetting component and a functionalized omniphobic polymer and
(ii) at least one second thermosetting component (e.g., monomer,
comonomer, prepolymer, oligomer, polymer with 2+ polymerizable
functional groups) reactive with the first thermosetting component;
reacting the at least one first thermosetting component with the at
least one second thermosetting component to form a partially
crosslinked reaction product (e.g., not fully crosslinked)
comprising (I) at least some covalent bonds between the first
thermosetting component and the second thermosetting component, and
(ii) at least some unreacted functional groups reactive with the
functionalized omniphobic polymer (e.g., unreacted functional
groups from first thermosetting component; such as unreacted
isocyanate, amine, hydroxy, and/or epoxide groups); applying to the
partially crosslinked reaction product (e.g., a top surface thereof
opposite the interface between the partially crosslinked reaction
product and the substrate) at least one functionalized omniphobic
polymer having a glass transition temperature (T.sub.g) of
50.degree. C. or less, the functionalized omniphobic polymer
comprising a functional group (e.g., epoxide group, amino group,
isocyanate group, hydroxyl group, carboxylic group) reactive with
the first thermosetting component (e.g., "polymerization reaction
product" when incorporated into the thermoset network or just a
"reaction product" when a monofunctional functionalized omniphobic
polymer is incorporated as a pendant or terminal chain in the
thermoset network); and reacting the unreacted functional groups in
the partially crosslinked reaction product with the functionalized
omniphobic polymer to form a thermoset omniphobic coating on the
substrate. This final reaction or (full) curing step incorporates
the functionalized hydrophobic/oleophobic polymer into the
thermoset by reaction with the unreacted functional groups from the
first thermosetting component. This step can include further
crosslinking between the first and second thermosetting components,
given the partial crosslinking nature of the first reacting step.
The functionalized omniphobic polymer can be more generally
characterized as a functionalized hydrophobic/oleophobic/omniphobic
polymer, given that it has hydrophobic and oleophobic
characteristics.
[0011] Various refinements of the disclosed thermoset omniphobic
composition are possible.
[0012] In a refinement, the substrate is selected from the group of
metal, plastics, a different thermoset material, glass, wood, 3D
printed objects, fabric (or textile), and ceramics. The substrate
is not particularly limited, and generally can be formed from any
material desired for protection with an omniphobic coating, in
particular given the good, broad adhesive capabilities of the
thermoset omniphobic composition. For example, the substrate can be
a metal, plastic, a different thermoset material (e.g., a primer
material; material other than the other than thermoset omniphobic
composition), glass, wood, fabric (or textile), or ceramic
material. Examples of specific metals include steel, aluminum,
copper, etc. Examples of specific plastics include polyvinyl
alcohol (PVOH), ethylene vinyl alcohol (EVOH), polyethylene
terephthalate (PET), polypropylene (PP), polyethylene (PE), starch,
chitosan, etc. Suitable wood materials can be any type of wood
commonly used in home, office, and outdoor settings. Suitable glass
materials can be those used for building windows, automobile
windows, etc. In some embodiments, the substrate is a top layer of
a coating or series of coatings on a different underlying
substrate. For example, the coated article can include a substrate
material as generally disclosed herein, one or more intermediate
coatings on the substrate (e.g., an epoxy coating, an acrylic
coating, another primer coating, etc.), and the thermoset
omniphobic composition on the one or more intermediate coatings as
the final, external coating on the coated article.
[0013] In a refinement, applying the first thermosetting component
and the second thermosetting component comprises: applying to the
substrate a mixture comprising (i) the first thermosetting
component, (ii) the second thermosetting component, and (iii)
optionally a solvent. In a further refinement, the method comprises
performing one or more of spraying, casting, rolling, and dipping
to apply the mixture to the substrate. In a further refinement, the
mixture comprises the solvent. The solvent can be an aprotic
organic solvent such as acetone, tetrahydrofuran, 2-butanone,
esters (e.g., methyl, ethyl, n-propyl, butyl esters of acetic acid
such as n-butyl acetate, etc.), dimethylformamide, dimethyl
carbonate, etc. In some embodiments, a reaction catalyst such as
salts of tin (e.g., tin(II) 2-ethylhexanoate) or iron, and tertiary
amines (e.g., triethylamine) can be included in the mixture, for
example to catalyze the reaction between a polyisocyanate and a
polyol as the first and second thermosetting components to form a
thermoset polyurethane. Tertiary amines can be used as catalysts
for epoxy curing, which are added into the formulation or generated
in situ during amine reaction with epoxy.
[0014] In a yet further refinement, the method further comprises
after applying the first thermosetting component and the second
thermosetting component to the substrate, drying the substrate to
remove the solvent, thereby forming a coating (partially
crosslinked) of the first thermosetting component and the second
thermosetting component on the substrate. Drying is generally
performed at ambient conditions and before heating to accelerate
the reaction to form the partially crosslinked reaction product.
However, some reaction/partial crosslinking between the first and
second thermosetting components can occur during drying, but the
majority of reaction occurs after solvent removal. In certain
cases, partial crosslinking can be performed under ambient
conditions without heating the samples prior to application of the
functionalized omniphobic polymer.
[0015] In a refinement, the method further comprises (e.g., prior
to partial crosslinking/partial curing): applying to the substrate
one or more additives selected from the group consisting of
nanoclay, graphene oxide, graphene, silicon dioxide (silica),
aluminum oxide, cellulose nanocrystals, carbon nanotubes, titanium
dioxide (titania), diatomaceous earth, biocides, pigments, dyes,
thermoplastics, and combinations thereof. The additives can be
included in the mixture with the first thermosetting component, the
second thermosetting component, and the (optional) solvent, and
then applied together on the substrate.
[0016] In a refinement, the method comprises reacting the at least
one first thermosetting component with the at least one second
thermosetting component to form a partially crosslinked reaction
product (i) at temperature from 20.degree. C. to 150.degree. C.
(e.g., 20.degree. C., 40.degree. C., or 60.degree. C. to 80.degree.
C., 100.degree. C., or 150.degree. C.) and (ii) for a time from 1
min to 300 min (e.g., 1, 2, 5, or 10 min to 20, 40, 60, 120, or 300
min). The reaction can be performed with or without heating the
reaction mixture. Room-temperature (e.g., 20.degree. C. to
30.degree. C.) reactions are possible with longer reaction times
and/or the addition of a catalyst
[0017] In a refinement, applying the functionalized omniphobic
polymer comprises: applying to the partially crosslinked reaction
product a mixture comprising (i) the functionalized omniphobic
polymer, and (ii) a solvent. The same solvents (or a different
solvent) can be used as for the mixture with the first and second
thermosetting component. The mixture can be applied by spraying,
casting, rolling, and dipping as well.
[0018] In a further refinement, the method further comprises: after
applying the functionalized omniphobic polymer to the partially
crosslinked reaction product, drying the substrate to remove the
solvent. Drying is generally performed at ambient conditions and
before heating to accelerate the reaction to form the fully
cured/crosslinked thermoset omniphobic coating. However, some
reaction/further crosslinking between the first and second
thermosetting components as well as the functionalized omniphobic
polymer can occur during drying, but the majority of reaction
occurs after solvent removal. Drying also provides some time for
the functionalized omniphobic polymer as applied to the external
surface of the partially crosslinked reaction product to penetrate
into the interior of the partially crosslinked reaction product
coating. Depending on the thickness of the partially crosslinked
reaction product coating and the drying time before full curing
(e.g., either due to application of heat or at low/ambient
temperatures such as with a catalyst), the functionalized
omniphobic polymer can be incorporated into either an exterior/top
region of the final thermoset omniphobic coating, or it can be
distributed substantially throughout the thermoset omniphobic
coating (e.g., for sufficient drying time and/or sufficiently thin
partially crosslinked reaction product coatings such that the
functionalized omniphobic polymer penetrates essentially completely
through the coating to the substrate prior to curing). The
functionalized omniphobic polymer as applied to the top layer of
the partially crosslinked coating will generally diffuse through
the samples. The functionalized omniphobic polymer is very reactive
with the unreacted (first) thermosetting component functional
groups, and as a result, the relative degree of incorporation of
the % of the functionalized omniphobic polymer can exhibit a normal
concentration gradient that gradually decreases from the outer
surface of the final coating towards the bottom of the final
coating adjacent to the substrate.
[0019] In a refinement, the method comprises reacting the unreacted
functional groups in the partially crosslinked reaction product
with the functionalized omniphobic polymer to form a thermoset
omniphobic coating on the substrate (i) at a temperature from
20.degree. C. to 180.degree. C. and (ii) for a time from 1 hr to 24
hr. Curing can be performed by heating (e.g., in an oven, with
exposure to a heat lamp, etc.) at a temperature from 70.degree. C.
or 100.degree. C. to 140.degree. C. or 180.degree. C. and/or for a
time from 1 hr, 2 hr, or 4 hr to 6 hr, 12 hr, or 24 hr. Lower
heating temperature or ambient temperature curing also possible,
such as room temperature curing (e.g., 20.degree. C. to 30.degree.
C.) for 8 hr-240 hr, or lower heating (e.g., 30.degree. C. or
40.degree. C. to 60.degree. C. for 4 hr-96 hr or 60.degree. C. to
80.degree. C. for 1 hr-72 hr).
[0020] In a refinement, the thermoset omniphobic coating comprises:
a thermoset polymer comprising a crosslinked backbone, the
crosslinked backbone comprising: (i) first backbone segments having
a structure corresponding to a (polymerization) reaction product
(e.g., polymerization reaction product when incorporated into the
thermoset network) from the at least one first thermosetting
component with at least one of the second thermosetting component
and the functionalized hydrophobic/oleophobic/omniphobic polymer;
(ii) second backbone segments having a structure corresponding to a
(polymerization) reaction product from the functionalized
omniphobic polymer with the first thermosetting component; (iii)
third backbone segments having a structure corresponding to a
(polymerization) reaction product (e.g., polymerization reaction
product when incorporated into the thermoset network) reaction
product from the second thermosetting component with the first
thermosetting component; (iv) first linking groups linking the
first backbone segments and the third backbone segments, the first
linking groups having a structure corresponding to a reaction
product of the first thermosetting component and the second
thermosetting component; and (v) second linking groups linking the
first backbone segments and the second backbone segments, the
second linking groups having a structure corresponding to a
reaction product of the first thermosetting component and the
functionalized omniphobic polymer.
[0021] In a further refinement, the first backbone segments are
present in an amount ranging from 10 wt. % to 90 wt. % relative to
the thermoset polymer; the second backbone segments are present in
an amount ranging from 0.01 wt. % to 20 wt. % (e.g., 0.2-8 wt. % or
1-5 wt. % more preferably) relative to the thermoset polymer; and
the third backbone segments are present in an amount ranging from
10 wt. % to 90 wt. % relative to the thermoset polymer. More
generally, the first, second, and third backbone segments can be
incorporated into the thermoset omniphobic coating in a variety of
relative weight amounts.
[0022] In an embodiment, the first backbone segments are present in
an amount ranging from 10 wt. % to 90 wt. % relative to the
thermoset omniphobic coating (e.g., at least 10, 15, or 20 wt. %
and/or up to 30, 40, 50, 60, 70, 80, or 90 wt. %; such as 30 wt. %
to 70 wt. %). In an embodiment, the second backbone segments are
present in an amount ranging from 0.01 wt. % to 20 wt. % relative
to the thermoset omniphobic coating (e.g., at least 0.01, 0.1, 0.2,
0.5, 1, 2, 3, or 5 wt. % and/or up to 3, 5, 8, 10, 15 or 20 wt. %;
such as 0.2 wt. % to 8 wt. % or 1 wt. % to 5 wt. %). In an
embodiment, the third backbone segments are present in an amount
ranging from 10 wt. % to 90 wt. % relative to the thermoset
omniphobic coating (e.g., at least 10, 20, 30, 40, or 50 wt. %
and/or up to 70, 80, or 90 wt. %, such as 30 wt. % to 70 wt. %).
The foregoing ranges can apply as well to the relative weight
amounts of the first thermosetting component, the functionalized
omniphobic polymer, and the second thermosetting component relative
to the total weight amount of the three components before
crosslinking reactions and/or relative to all monomeric,
oligomeric, and polymeric reaction components added thereto. These
components can be derived from renewable as well as non-renewable
resources.
[0023] In a refinement, the functional group of the functionalized
omniphobic polymer is selected from the group consisting of epoxide
groups, amino groups, isocyanate groups, hydroxyl groups,
carboxylic groups, and combinations thereof (e.g., for
multifunctional functionalized omniphobic polymers). Several
specific functionalized omniphobic polymer functional groups and
their complementary groups in the first thermosetting component are
illustrated as follows. Isocyanate groups in the functionalized
omniphobic polymer can react with amino groups of the first
thermosetting component to make a urea linkage, such as in an epoxy
thermosets. Amino groups in the functionalized omniphobic polymer
can react with isocyanate groups in the first thermosetting
component to make a urea link, such as in a polyurethane thermoset.
Amino groups in the functionalized omniphobic polymer can react
with epoxide groups in the first thermosetting component to make
beta-hydroxy tertiary amine links, such as in an epoxy thermoset.
Amino groups in the functionalized omniphobic polymer can react
with carboxylic groups in the first thermosetting component to make
an amide link, such as in an acrylic thermoset. Amino groups in the
functionalized omniphobic polymer can react with isocyanate groups
of the first thermosetting component to make a urea linkage, such
as in an epoxy thermosets cured with anhydrides having added
isocyanate groups to the anhydride monomer units. Epoxide groups in
the functionalized omniphobic polymer can react with amino groups
in the first thermosetting component to make beta-hydroxy tertiary
amine links, such as in an epoxy thermoset. Hydroxyl groups in the
functionalized omniphobic polymer can react with isocyanate groups
in the first thermosetting component to make a urethane link, such
as in a polyurethane thermoset. Hydroxyl groups in the
functionalized omniphobic polymer can react with carboxylic groups
in the first thermosetting component to make an ester link, such as
in an acrylic thermoset. Carboxylic groups in the functionalized
omniphobic polymer can react with hydroxyl groups in the first
thermosetting component to make an ester link, such as in a
polyurethane thermoset. Carboxylic groups in the functionalized
omniphobic polymer can react with amino groups in the first
thermosetting component to make an amide link, such as in an epoxy
thermoset.
[0024] In a refinement, the functionalized omniphobic polymer is
selected from the group consisting of functionalized polysiloxanes,
functionalized polyperfluoroethers, functionalized polybutadienes,
functionalized polysilazanes, functionalized polyisobutenes,
functionalized branched polyolefins, functionalized
poly(meth)acrylates, and combinations thereof.
[0025] In a refinement, the functionalized omniphobic polymer
comprises a mono-functional functionalized omniphobic polymer
(e.g., having only a single functional group reactive with the
first thermosetting component, such as at a terminal location of
the hydrophobic polymer; such as a mono-functional
polysiloxane).
[0026] In a refinement, the functionalized omniphobic polymer
comprises a di-functional functionalized omniphobic polymer (e.g.,
having only two functional groups reactive with the first
thermosetting component, such as at terminal locations of the
hydrophobic polymer; such as a di-functional polysiloxane).
[0027] In a refinement, the functionalized omniphobic polymer
comprises a poly-functional functionalized omniphobic polymer
(e.g., having three, four, or more functional groups reactive with
the first thermosetting component, such as at terminal locations of
the hydrophobic polymer and/or as pendant groups along the backbone
of the hydrophobic polymer; such as a poly-functional
polysiloxane).
[0028] In a refinement, the functionalized omniphobic polymer is a
liquid at a temperature in a range from -130.degree. C. to
40.degree. C. In various embodiments, the functionalized omniphobic
polymer is a liquid at a temperature in a range from 10.degree. C.
to 40.degree. C. (e.g., from 20.degree. C. to 30.degree. C., or
about room temperature, such as where the functionalized omniphobic
polymer has a melting temperature (T.sub.m) below 10.degree. C. or
20.degree. C.). The amine groups can be terminal and/or pendant
from the hydrophobic polymer.
[0029] In a refinement, the functionalized omniphobic polymer has a
molecular weight ranging from 300 to 50,000 g/mol. The
functionalized omniphobic polymer can have any suitable molecular
weight in view of desired glass transition temperature, for example
having a molecular weight ranging from 300 to 50,000 g/mol. In
various embodiment, the molecular weight can be at least 300, 800,
1000, 1500, or 2000 and/or up to 1000, 2000, 3000, 5000, or 50,000
g/mol. The molecular weight can be expressed as a number-average or
weight-average value in the units of gram/mole (g/mol). Some
embodiments can include a blend of two or more functionalized
omniphobic polymers with different average molecular weights, such
as one with 300-1500 g/mol and another with 1500-50,000 g/mol with
a higher average molecular weight than the first. Blends of
functionalized omniphobic polymers (e.g., differing in molecular
weight and/or in degree of functionality) can improve the
combination of water- and oil-repellency properties of the final
composition. For example, a mono-functionalized polysiloxane can
provide better water and oil repellency than a di-functionalized
polysiloxane. Low MW functionalized polysiloxanes (e.g., PDMS, such
as having a MW range of about 800-1200 g/mol or an average MW of
about 1000 g/mol) can provide an improved water repellency, while
Higher MW functionalized polysiloxanes (e.g., PDMS, such as about
2000 g/mol or above for an average or range of MW) can provide an
improved oil repellency.
[0030] In a refinement, the first thermosetting component and the
second thermosetting component together correspond to a thermoset
polyurethane. For example, the first and second thermosetting
components can include at least one polyisocyanate and at least one
polyol, where at least one component is reactive with the
functional group of the functionalized omniphobic polymer.
[0031] In a refinement, the first thermosetting component comprises
a polyisocyanate or a polyol; and the second thermosetting
component comprises the other of the polyisocyanate and the polyol.
The polyisocyanate can be di-, tri-, or higher functional such as a
diisocyanate, triisocyanate, blend of multiple polyisocyanates with
same or different functionality; polyol can be di-, tri-, or higher
functional such as a diol, triol, blend of multiple polyols with
same or different functionality; at least one polyisocyanate or
polyol has a functionality greater than two for crosslinking.
[0032] The "first" and "second" labels for the thermosetting
components are interchangeable with respect to their ability to
react with each other and form a crosslinked, thermoset network
portion of the final thermoset polymer, which in the case of a
polyisocyanate/polyol combination corresponds to a urethane linking
group as the first linking group L1. The distinction is that the
first thermosetting component is also capable of reacting with the
functional group of the functionalized omniphobic polymer, while
the second thermosetting component could (but need not) also be
capable of reacting with the functional group of the functionalized
omniphobic polymer.
[0033] For example, the polyisocyanate can be first thermosetting
component when the functionalized omniphobic polymer has an
isocyanate-reactive functional group (e.g., such as an amino group
to form a urea group as the second linking group L2, or such as a
hydroxyl group for form a urethane group as second linking group
L2), in which case the polyol can be the second thermosetting
component and need not react (or be unable to react) with the
functionalized omniphobic polymer. Similarly, the polyol can be
first thermosetting component when the functionalized omniphobic
polymer has a hydroxyl-reactive functional group (e.g., such as a
carboxylic group to form an ester group as the second linking group
L2), in which case the polyisocyanate can be the second
thermosetting component and need not react (or be unable to react)
with the functionalized omniphobic polymer.
[0034] In a further refinement, the polyisocyanate is selected from
the group consisting of 1,5-naphthylene diisocyanate,
4,4'-diphenylmethane diisocyanate (MDI), hydrogenated MDI, xylene
diisocyanate (XDI), tetramethylxylol diisocyanate (TMXDI),
4,4'-diphenyl-dimethylmethane diisocyanate, di- and
tetraalkyl-diphenylmethane diisocyanate, 4,4'-dibenzyl
diiso-cyanate, 1,3-phenylene diisocyanate, 1,4-phenylene
diisocyanate, one or more isomers of tolylene diisocyanate (TDI),
1-methyl-2,4-diiso-cyanatocyclohexane,
1,6-diisocyanato-2,2,4-trimethyl-hexane,
1,6-diisocyanato-2,4,4-trimethylhexane,
1-iso-cyanatomethyl-3-isocyanato-1,5,5-trimethylcyclohexane,
chlorinated and brominated diisocyanates, phosphorus-containing
diisocyanates, 4,4'-diisocyanatophenyl-perfluoroethane,
tetramethoxybutane 1,4-diisocyanate, butane 1,4-diisocyanate,
hexane 1,6-diisocyanate (HDI), HDI dimer (HDID), HDI trimer (HDIT),
HDI biuret, 1,5-pentamethylene diisocyanate (PDI), PDID (dimer of
PDI), PDIT (trimer of PDI), PDI biuret, dicyclohexylmethane
diisocyanate, cyclohexane 1,4-diisocyanate, ethylene diisocyanate,
phthalic acid bisisocyanatoethyl ester, 1-chloromethylphenyl
2,4-diisocyanate, 1-bromomethylphenyl 2,6-diisocyanate,
3,3-bischloromethyl ether 4,4'-diphenyldiisocyanate,
trimethylhexamethylene diisocyanate, 1,4-diisocyanato-butane,
1,2-diisocyanatododecane, and combinations thereof.
[0035] In a further refinement, the polyol is selected from the
group consisting of polyether polyols, hydroxylated (meth)acrylate
oligomers, glycerol, ethylene glycol, diethylene glycol,
triethylene glycol, tetraethylene glycol, propylene glycol,
dipropylene glycol, tripropylene glycol, 1,3-propanediol,
1,3-butanediol, 1,4-butanediol, neopentyl glycol, 1,6-hexanediol,
1,4-cyclohexanedimethanol, glycerol, trimethylolpropane,
1,2,6-hexanetriol, pentaerythritol, (meth)acrylic polyols,
isosorbide, and combinations thereof.
[0036] In a refinement, the first thermosetting component comprises
a polyisocyanate; the second thermosetting component comprises a
polyol; and the functional group of the functionalized omniphobic
polymer comprises an amino group.
[0037] In a refinement, the first thermosetting component and the
second thermosetting component together correspond to a thermoset
epoxy. For example, the first and second thermosetting components
can include at least one polyepoxide and at least one amine
(monoamine or polyamine) or anhydride (e.g., forming a beta-hydroxy
ester reaction product link, such as at high reaction
temperatures), where at least one component is reactive with the
functional group of the functionalized omniphobic polymer.
[0038] In a refinement, the first thermosetting component comprises
a polyepoxide or an amine; and the second thermosetting component
comprises the other of the polyepoxide and the amine. The
polyepoxide can be di-, tri-, or higher functional such as a
diepoxide, triepoxide, blend of multiple polyisocyanates with same
or different functionality; amine can be mono-, di-, tri-, or
higher functional such as a monoamine, diamine, tri amine, blend of
multiple polyols with same or different functionality; at least one
polyepoxide has a functionality greater than two or at least one
amine has a functionality greater than one for crosslinking (i.e.,
since a single --NH.sub.2 primary amino group can react with two
epoxide groups, either some species with 3+ epoxide groups or 2+
amino groups (which can form 44-bonds with epoxides) are used for
crosslinking). Typically a diepoxide and a diamine are used.
[0039] The "first" and "second" labels for the thermosetting
components are interchangeable with respect to their ability to
react with each other and form a crosslinked, thermoset network
portion of the final thermoset polymer, which in the case of a
polyepoxide/amine combination corresponds to a beta-hydroxy
(tertiary) amine linking group as the first linking group L1. A
"beta-hydroxy amine" includes a structure in which a hydroxyl group
is attached to a beta carbon, the beta-carbon is attached to an
alpha-carbon, and the alpha carbon in the one directly attached to
the nitrogen atom of the reacted amine. The beta-hydroxy amine can
be represented by a --CH(OH)--CH.sub.2--NR.sub.1R.sub.2 group in
the cured epoxy thermoset, where R.sub.4 and R.sub.2 can be another
beta-hydroxy group or the remainder of the amine thermosetting
component. The distinction is that the first thermosetting
component is also capable of reacting with the functional group of
the functionalized omniphobic polymer, while the second
thermosetting component could (but need not) also be capable of
reacting with the functional group of the functionalized omniphobic
polymer.
[0040] For example, the polyepoxide can be first thermosetting
component when the functionalized omniphobic polymer has an
epoxide-reactive functional group (e.g., such as an amino group to
form a beta-hydroxy amine group as the second linking group L2), in
which case the amine can be the second thermosetting component and
need not react (or be unable to react) with the functionalized
omniphobic polymer. Similarly, the amine can be first thermosetting
component when the functionalized omniphobic polymer has an
amine-reactive functional group (e.g., such as an isocyanate to
form a urea as the second linking group, such as an epoxide group
to form a beta-hydroxy amine group as the second linking group,
such as a carboxylic acid group to form an amide group as the
second linking group L2), in which case the polyepoxide can be the
second thermosetting component and need not react (or be unable to
react) with the functionalized omniphobic polymer.
[0041] In a further refinement, the polyepoxide is selected from
the group consisting of polyepoxide-substituted aromatic
hydrocarbons, aliphatic hydrocarbons, cycloaliphatic hydrocarbons,
ethers thereof, esters thereof, imines thereof, and combinations
thereof. The polyepoxide can include hydrocarbons with two or more
epoxide groups and one or more aromatic, aliphatic, cycloaliphatic,
ether, ester, and/or imine groups in the hydrocarbon to which the
epoxide groups are attached. Suitable polyepoxides can be derived
from petroleum and plant materials. Suitable polyepoxides include
two or more glycidyl ether groups (i.e., epoxide-containing
groups). Some examples of polyepoxides include, but are not limited
to, bisphenol A epoxy (e.g., diglycidyl ether of bisphenol A having
1 or 2-25 bisphenol A repeat units), bisphenol F epoxy (e.g.,
diglycidyl ether of bisphenol F having 1 or 2-25 bisphenol F repeat
units), epoxy phenol novolac, epoxy cresol novolac, cycloaliphatic
epoxies, halogenated epoxies, epoxy-vinyl esters,
tetraglycidylmethylenedianiline (TGMDA), 3,4-epoxycyclohexylmethyl
3,4-epoxycyclohexanecarboxylate (ECC),
bis[3,4-epoxycyclohexylmethyl] adipate (BECHMA), poly(glycidyl
methacrylate), epoxies of rosin acid, epoxies of diphenolic acid,
epoxies of tannin acid, epoxies derived from glucose, isosorbide
epoxies, eugenol epoxides, furan epoxides, cathechin epoxides,
vanillin-based epoxies, quercetin epoxides, epoxies derived from
gallic acid, epoxides from phenols, epoxides from cardanols,
epoxides from plant oils, terpene oxides (e.g., limonene dioxide),
and combinations thereof.
[0042] In a further refinement, the amine is selected from the
group consisting of polyamine-substituted aromatic hydrocarbons,
aliphatic hydrocarbons, cycloaliphatic hydrocarbons, ethers
thereof, esters thereof, imines thereof, and combinations thereof.
The amine can include hydrocarbons with two or more amino groups
and one or more aromatic, aliphatic, cycloaliphatic, ether, ester,
and/or imine groups in the hydrocarbon to which the amino groups
are attached. Suitable amines can be derived either petrochemicals
or plant materials. Some examples include, but are not limited to,
isophorone diamine, diaminopropyl isosorbide, furfuryldiamine,
polylysine, menthane diamine, tris(dimethylaminomethyl)phenol,
melamine, bis(3-aminopropyl)amine,
N,N'-bis(3-aminopropyl)-1,3-propanediamine,
3,3'-diamino-N-methyldipropylamine, tris(3-aminopropyl)amine,
1,2-bis(3-aminopropylamino)ethane, diethylenetriamine,
polyetheramines (e.g., JEFFAMINE polyetheramines available from
Huntsman Chemical). The amines can be primary, secondary or a
combination of both.
[0043] In a refinement, the first thermosetting component comprises
an amine; the second thermosetting component comprises a
polyepoxide; and the functional group of the functionalized
omniphobic polymer comprises an isocyanate group.
[0044] In a refinement, the first thermosetting component and the
second thermosetting component together correspond to an acrylic
thermoset. An acrylic thermoset can include acrylic or methacrylic
oligomer or polymer chains having grafted (e.g., randomly,
statistically, gradiently or blockwise) reactive groups, such as
carboxylic, carboaxmide, hydroxyl, acrylic double bond, and/or
epoxide groups. These groups can reacts with themselves or with
co-reactants. Examples carboxyl-diepoxides, hydroxyl-epoxy and urea
or melamine condensation products, alkoxymethyl
carboxamide-self-reactive, epoxy, alkyd, functional vinyl, allylic
double bond-peroxide catalyzed, and allylic double bond-peroxide
catalyzed grafted reactive groups.
[0045] In a refinement, the thermoset omniphobic coating has a
water contact angle in a range from 90.degree. to 120.degree.. In a
refinement, the thermoset omniphobic coating has an oil contact
angle in a range from 1.degree. to 65.degree.. In a refinement, the
thermoset omniphobic coating has a water sliding angle in a range
from 1.degree. to 30.degree. for a 75 .mu.l droplet. In a
refinement, the thermoset omniphobic coating has an oil sliding
angle in a range from 1.degree. to 20.degree. for a 25 .mu.l
droplet.
[0046] More generally, the omniphobic properties of the thermoset
omniphobic coating (e.g., for the cured composition) can be
characterized in terms of one or more contact angles and/or sliding
angles for water and/or oil droplets (e.g., vegetable oil and/or
hexadecane) on the thermoset coating (e.g., as a coating on a
substrate). The following ranges are representative of coatings
according to the disclosure which display favorable omniphobic
properties. In an embodiment, the coating has a water contact angle
in a range from 90.degree. to 120.degree. (e.g., at least
90.degree., 95.degree., 100.degree., or 105.degree. and/or up to
110.degree., 115.degree., or 120.degree.; such as for the cured
composition as a coating). In some cases, the water contact angle
can be up to about 125.degree. for non-smooth or rough surfaces. In
an embodiment, the coating has an oil contact angle in a range from
0.degree. or 1.degree. to 65.degree. (e.g., at least 1.degree.,
10.degree., 20.degree., or 30.degree. and/or up to 40.degree.,
50.degree., 60.degree., or 65.degree.; such as for the cured
composition as a coating). In an embodiment, the composition has a
water sliding angle in a range from 0.degree. or 1.degree. to
30.degree. for a 75 .mu.l droplet (e.g., at least 1.degree.,
2.degree., 4.degree., 6.degree., or 8.degree. and/or up to
10.degree., 15.degree., 20.degree., or 30.degree.; such as for the
cured composition as a coating). In an embodiment, the coating has
an oil sliding angle in a range from 0.degree. or 1.degree. to
20.degree. for a 25 .mu.l droplet (e.g., at least 1.degree.,
2.degree., 4.degree., 6.degree., or 8.degree. and/or up to
10.degree., 12.degree., 15.degree., or 20.degree.; such as for the
cured composition as a coating). The contact angles for the
omniphobic coatings can be higher when nanofillers (e.g., clay,
silica, etc.) are included in the composition as compared to
corresponding compositions without any nanofillers.
[0047] In a refinement, the thermoset omniphobic coating has a
thickness ranging from 0.01 .mu.m to 500 .mu.m. More generally, the
thermoset omniphobic coating can have any desired thickness on the
substrate. In common applications, the coating has a thickness
ranging from 0.010 .mu.m to 500 .mu.m, for example at least 0.01,
10, 20, 50, or 100 .mu.m and/or up to 200, 500 .mu.m. Typical cast
coatings can have thicknesses of 10 .mu.m to 100 .mu.m. Typical
spin coatings can have thicknesses of 0.05 .mu.m or 0.10 .mu.m to
0.20 .mu.m or 0.50 .mu.m. Multiple coating layers can be applied to
substrate to form even thicker layers of the composition 100 (e.g.,
above 500 .mu.m or otherwise) if desired.
[0048] In a refinement, the thermoset omniphobic coating is
scratch-resistant, ink-resistant, and optically clear.
[0049] In another aspect, the disclosure relates to an omniphobic
coated article formed by or resulting from the disclosed method in
any of its variously disclosed embodiments.
[0050] While the disclosed methods and compositions are susceptible
of embodiments in various forms, specific embodiments of the
disclosure are illustrated (and will hereafter be described) with
the understanding that the disclosure is intended to be
illustrative, and is not intended to limit the claims to the
specific embodiments described and illustrated herein.
BRIEF DESCRIPTION OF THE DRAWINGS
[0051] For a more complete understanding of the disclosure,
reference should be made to the following detailed description and
accompanying drawings wherein:
[0052] FIG. 1 is a diagram illustrating measurement of a contact
angle for a liquid droplet on a surface.
[0053] FIG. 2 is a diagram illustrating how contact angles for a
given liquid droplet on a surface can vary as a function of surface
topology (e.g., flat or smooth surface vs. textured surfaces).
[0054] FIG. 3 illustrates a method for forming a thermoset
omniphobic composition coating according to the disclosure.
[0055] FIG. 4 illustrates a thermoset omniphobic composition
according to the disclosure.
[0056] FIG. 5 illustrates a coated article according to the
disclosure in which the thermoset omniphobic composition has a
homogeneous structure.
DETAILED DESCRIPTION
[0057] The disclosure relates to methods for forming an omniphobic
thermoset composition (such as an omniphobic polyurethane or epoxy
composition). First and second thermosetting components are applied
to a substrate and partially cured. A functionalized
hydrophobic/oleophobic polymer which is reactive with at least the
first thermosetting component is then applied to the coated
substrate, which is then further cured to form a thermoset
omniphobic coating on the substrate. This second curing step
incorporates the functionalized hydrophobic/oleophobic polymer into
the thermoset by reaction with the unreacted functional groups from
the first thermosetting component. This second curing step can
include further crosslinking between the first and second
thermosetting components, given the partial crosslinking nature of
the first reacting step. The thermoset omniphobic composition has
favorable omniphobic properties, for example as characterized by
water and/or oil contact and/or sliding angles. The thermoset
omniphobic composition can be used as a coating on any of a variety
of substrates to provide omniphobic properties to a surface of the
substrate. Such omniphobic coatings can be scratch resistant,
ink/paint resistant, and optically clear. The thermoset omniphobic
composition can be applied by different coating methods including
cast, spin, roll, spray and dip coating methods.
[0058] The disclosed composition includes a polymer which can be
used as a coating with the ability to bind to metal, glass, wood,
fabrics, and ceramics with relative ease, in particular due to the
strong adhesive properties of its urethane group or epoxy group
constituents in various embodiments. The polymer coating has an
omniphobic quality, repelling water, oils, inks, and spray paints,
thus allowing for a coating that not only has typical hydrophobic
and oleophobic properties, but also protects a surface from pen
inks and various paints. The final polymer product is optically
clear (even for relatively thick coatings such as up to about 500
.mu.m), making it an ideal choice for coating computer and phone
screens, windows, and cameras (e.g., lenses or protective/shielding
windows therefor) for cars or other vehicles, whether human- or
autopilot-driven. The polymer can be manufactured without fluorine
as a component and/or as a one-pot reaction process, thus reducing
the overall cost when compared to products currently manufactured.
Coatings formed from the polymer composition are durable due to the
final crosslinked thermoset matrix. The composition can be used in
water-repellent, oil-repellent, anti-fingerprint, anti-smudge,
and/or anti-graffiti coatings or paints.
[0059] FIG. 3 illustrates a method for forming a thermoset
omniphobic composition coating according to the disclosure, for
example an optically clear, durable and self-cleaning epoxy,
polyurethane, or other thermoset material (e.g., acrylics or
alkyds) omniphobic coating. As an illustration for a thermoset
epoxy omniphobic coating, an initial epoxy coating is created and
drop cast onto the desired substrate (e.g., glass, metal, etc.), as
shown in FIG. 3 (top row, left image). After partially crosslinking
for a pre-determined amount of time, isocyanate-functionalized
polydimethyl siloxane (PDMS-NCO) is applied in a suitable solvent
via a cotton ball or cotton roller and then air dried to set and
cured at an elevated temperature. FIG. 3 (top row, middle and right
images) illustrates the application of the PDMS-NCO to the
partially cured epoxy coating and its absorption or permeation into
the interior of the partially cured/crosslinked epoxy coating
matrix prior to full curing (bottom row, right image). The result
is a thermoset epoxy polymer coating that contains a matrix of PDMS
units that are covalently bonded to the thermoset polymer via urea
links resulting from isocyanate groups (in PDMS-NCO) reactions with
amino groups (in the epoxy amine hardener), which coating is
optically clear and highly resistant to water, oil, and graffiti.
The same process can be applied to a thermoset polyurethane, in
which case an amino-functionalized PDMS (PDMS-NH.sub.2) can be
substituted for the PDMS-NCO used for modification of a partially
crosslinked epoxy coating. Specifically, the result in this case is
a thermoset polyurethane polymer coating that contains a matrix of
PDMS units that are covalently bonded to the thermoset polymer via
urea links resulting from amino groups (in PDMS-NH.sub.2) reactions
with isocyanate groups (in the polyurethane polyisocyanate
monomer). The --NCO and --NH.sub.2 functional groups in the
functionalized PDMS serve as a reactant to help disperse the PDMS
throughout the partially cured/crosslinked matrix, avoiding
aggregates that can turn the coating opaque and hinder the optical
and repellent performance of the coating. This approach does not
require graft or block copolymers, and this approach works with
various thermosets (e.g., epoxy, urethane, etc.), and it is thus a
significant advancement in the ease of implementation and
automation of a historically challenging problem.
[0060] The disclosure illustrates a simple, scalable strategy that
transforms a non-oleophilic and mildly water-repellent coating into
a water- and oil-repellent, anti-graffiti and anti-smudge coating.
The general approach is to modify a non-oil repellent (and mildly
hydrophobic) coating into an oil- and water-repellent coating while
retaining excellent mechanical and optical properties. The examples
illustrate successful epoxy and polyurethane coatings formed using
this approach, and both showed extremely good properties.
Additionally, this approach can be applied to other coatings such
as acrylics, alkyds, for example. Also, this approach can be easily
applied to self-cleaning thermoset composites such as epoxy
composites, for example including epoxy/clay, epoxy/graphene,
epoxy/cellulose nanocrystal, epoxy/carbon-nanotube, epoxy/titania
(TiO.sub.2), and epoxy/silica (SiO.sub.2) composites. Such
composites can also be prepared with a thermoset polyurethane or
other coating matrix according to the disclosure.
[0061] The disclosure illustrates methods to prepare optically
clear, durable and self-cleaning epoxy and polyurethane coatings
(that are extendable to other types of coatings too). The disclosed
methods address the challenges of graft copolymer approaches and
the use of volatile solvents related to the optically clear and
durable, water and oil-repellent, and anti-graffiti coatings. This
approach is applicable to a variety of coatings both in the
presence and absence of particles/fillers in the matrix, which is
not the case with the other approaches. Two characteristics of the
disclosed methods include: 1) formation of a partially crosslinked
matrix that allows the self-cleaning polymers such as polysiloxane
(or other functionalized omniphobic polymers) to permeate into the
matrix to ensure its uniform distribution in the matrix; and 2)
presence of complementary reactive groups in the partially
crosslinked matrix (e.g., unreacted amino or isocyanate groups for
epoxy and polyurethane monomers, respectively) as well as the
self-cleaning polymer (e.g., isocyanate or amino groups for
PDMS-NCO or PDMS-NH.sub.2). Preferably, these complementary groups
react substantially faster than the reactions between the
corresponding groups in the thermoset monomers, thus promoting
permeation and reaction of the functionalized omniphobic polymer
with the thermoset matrix before the full curing of thermoset
coating occurs. For example, the PDMS-NCO/amine hardener reaction
is faster than the epoxy resin/amine hardener reaction for a
thermoset epoxy. Similarly, the PDMS-NH.sub.2/polyisocyanate
reaction is faster than the polyisocyanate/polyol reaction for a
thermoset polyurethane.
Omniphobic Composition
[0062] FIG. 4 illustrates a thermoset omniphobic composition, for
example for use as a coating according to the disclosure. FIG. 4
qualitatively illustrates various backbone segments (B) and linking
groups (L) in a crosslinked thermoset polymer 100. The thermoset
polymer 100 includes a crosslinked backbone B, which in turn
includes (i) first backbone segments B1, (ii) second backbone
segments B2, (iii) third backbone segments B3, (iv) first linking
groups L1 (e.g., urethane (or carbamate), beta-hydroxy amino)
linking first backbone segments and third backbone segments, and
(v) second linking groups L2 (e.g., urea) linking first backbone
segments and second backbone segments.
[0063] As described in more detail below, in embodiments
corresponding to a thermoset polyurethane composition, the first
backbone segments B1 can result from a polyisocyanate (e.g.,
monomer, oligomer, or polymer), the second backbone segments B2 can
result from a polysiloxane or other omniphobic polymer (e.g.,
amino-functional omniphobic polymer), and the third backbone
segments B3 can result from a polyol (e.g., monomer, oligomer, or
polymer). The first linking groups L1 can include urethane (or
carbamate) groups and be represented by the general structure
--NR.sub.1--C(.dbd.O)O--, where R.sub.1 can be H or a
C.sub.1-C.sub.12 linear, branched, or cyclic substituted or
unsubstituted hydrocarbon group, such as an aliphatic (e.g., alkyl,
alkenyl) group or an aromatic group, or a combination of different
R.sub.1 groups (such as when multiple different reactive components
are used). The second linking groups L2 can include urea groups and
can be represented by the general structure
--NR.sub.2--C(.dbd.O)--NR.sub.3--, where R.sub.2 and R.sub.3
independently can be H or a C.sub.1-C.sub.12 linear, branched, or
cyclic substituted or unsubstituted hydrocarbon group, such as an
aliphatic (e.g., alkyl, alkenyl) group or an aromatic group, or a
combination of different R.sub.2 and/or R.sub.3 groups (such as
when multiple different reactive components are used).
[0064] As similarly described in more detail below, in embodiments
corresponding to a thermoset epoxy composition, the first backbone
segments B1 can result from an amine (e.g., mono- or poly-amine;
monomer, oligomer, or polymer), the second backbone segments B2 can
result from a polysiloxane or other omniphobic polymer (e.g.,
isocyanate-functional omniphobic polymer), and the third backbone
segments B3 can result from a polyepoxide (e.g., monomer, oligomer,
or polymer). The first linking groups L1 can include beta-hydroxy
(tertiary) amine groups and be represented by the general structure
--CH(OH)--CH.sub.2--NR.sub.1R.sub.2, where R.sub.1 and R.sub.2
independently can be another beta-hydroxy group or the remainder of
the amine thermosetting component. The second linking groups L2 can
include urea groups and can be represented by the general structure
--NR.sub.2--C(.dbd.O)--NR.sub.3--, where R.sub.2 and R.sub.3
independently can be H or a C.sub.1-C.sub.12 linear, branched, or
cyclic substituted or unsubstituted hydrocarbon group, such as an
aliphatic (e.g., alkyl, alkenyl) group or an aromatic group, or a
combination of different R.sub.2 and/or R.sub.3 groups (such as
when multiple different reactive components are used).
[0065] The first backbone segments B1 generally have a structure
corresponding to a (polymerization) reaction product from at least
one first thermosetting component after it has reacted with at
least one of a second thermosetting component and a functionalized
omniphobic polymer having a glass transition temperature (T.sub.g)
of 70.degree. C. or 50.degree. C. or less (described below). The
first backbone segments B1 can result from a single first
thermosetting component species or a blend of two or more different
first thermosetting component species with the same or different
degree of functionality, but each being able to react with the
second thermosetting component and the functionalized omniphobic
polymer. For example, in embodiments corresponding to a thermoset
polyurethane composition, the first backbone segments B1 can have a
structure corresponding to at least one of a urethane reaction
product and a urea reaction product from at least one
polyisocyanate (e.g., diisocyanate, triisocyanate, or higher degree
of isocyanate functionality) with a polyol (urethane) or an
amine-functional omniphobic polymer (urea). The first backbone
segments B1 can result from a single polyisocyanate (e.g., a
diisocyanate, a triisocyanate) species or a blend of two or more
different polyisocyanate species with the same or different degree
of isocyanate functionality. Similarly, in embodiments
corresponding to a thermoset epoxy composition, the first backbone
segments B1 can have a structure corresponding to at least one of a
beta-hydroxy (tertiary) amine product and a urea reaction product
from at least one amine (e.g., monoamine, diamine, triamine, or
higher degree of isocyanate functionality) with a epoxide
(beta-hydroxy amine) or an isocyanate-functional omniphobic polymer
(urea). The first backbone segments B1 can result from a single
amine (e.g., monoamine, diamine, triamine) species or a blend of
two or more different amine species with the same or different
degree of amine functionality.
[0066] The second backbone segments B2 generally have a structure
corresponding to a (polymerization) reaction product from at least
one functionalized omniphobic polymer having a glass transition
temperature (T.sub.g) of 70.degree. C. or 50.degree. C. or less
after it has reacted with the first thermosetting component. The
functionalized omniphobic polymer includes a functional group
reactive with the first thermosetting component (e.g., epoxide
group, amino group, isocyanate group, hydroxyl group, carboxylic
group). For example, in embodiments corresponding to a thermoset
polyurethane composition, the second backbone segments B2 can have
a structure corresponding to a urea reaction product from at least
one amine-functional omniphobic polymer having a glass transition
temperature (T.sub.g) of 70.degree. C. or 50.degree. C. or less
(e.g., monoamine-functional, diamine-functional, or higher degree
of amine functionality) and a polyisocyanate. Similarly, in
embodiments corresponding to a thermoset epoxy composition, the
second backbone segments B2 can have a structure corresponding to a
beta-hydroxy (tertiary) amine reaction product from at least one
isocyanate-functional omniphobic polymer having a glass transition
temperature (T.sub.g) of 70.degree. C. or 50.degree. C. or less
(e.g., mono isocyanate-functional, diisocyanate-functional, or
higher degree of isocyanate functionality) and an amine (e.g.,
monoamine, diamine, triamine). In various embodiments, the
functionalized omniphobic polymer has a glass transition
temperature in a range from -150.degree. C. to 70.degree. C. or
50.degree. C. (e.g., at least -150.degree. C., -120.degree. C.,
-100.degree. C., or -50.degree. C. and/or up to -10.degree. C.,
0.degree. C., 10.degree. C., 20.degree. C., 30.degree. C.,
40.degree. C., 50.degree. C., 60.degree. C., or 70.degree. C.). The
functionalized omniphobic polymer can be either in a liquid or a
rubbery state at common use temperatures of the final coating, for
example in a range from 10.degree. C. to 40.degree. C. or
20.degree. C. to 30.degree. C. In various embodiments, the
functionalized omniphobic polymer is a liquid at a temperature in a
range from 10.degree. C. to 40.degree. C. (e.g., from 20.degree. C.
to 30.degree. C., or about room temperature, such as where the
functionalized omniphobic polymer has a melting temperature
(T.sub.m) below 10.degree. C. or 20.degree. C.). The functional
groups (e.g., amino, isocyanate, hydroxyl, carboxylic) can be
terminal and/or pendant from the omniphobic polymer. In an
embodiment, the functional groups are terminal groups on a
omniphobic polymer (e.g., linear omniphobic polymer with one or two
terminal functional groups). The second backbone segments B2 can
result from a single functionalized omniphobic polymer species or a
blend of two or more different functionalized omniphobic polymer
species with the same or different degree of functionality. The
functionalized omniphobic polymer can generally include one or more
of functionalized polysiloxanes, functionalized
polyperfluoroethers, functionalized polybutadienes, functionalized
poly(ethylene glycol) methyl ether ("PEO"), functionalized
polyisobutylene ("RIB"), functionalized branched polyolefins,
functionalized low molecular weight polyolefins, functionalized
polyacrylates and polymethacrylates (e.g., also including
C.sub.2-C.sub.16 pendant alkyl groups), and any other omniphobic
polymer with a glass transition temperature of 70.degree. C. or
50.degree. C. or less. In an embodiment, the functionalized
omniphobic polymer, the second backbone segments B2, and/or the
corresponding omniphobic composition can be free from fluorine or
fluorinated components (e.g., not using functionalized
polyperfluoroethers or other fluorine-containing components during
synthesis).
[0067] The third backbone segments B3 generally have a structure
corresponding to a (polymerization) reaction product from at least
one second thermosetting component after it has reacted with the
first thermosetting component. The third backbone segments B3 can
result from a single second thermosetting component species or a
blend of two or more different second thermosetting component
species with the same or different degree of functionality, but
each being able to react with the first thermosetting component.
For example, in embodiments corresponding to a thermoset
polyurethane composition, the third backbone segments B3 can have a
structure corresponding to a urethane reaction product from at
least one polyol (e.g., diol, triol, or higher degree of hydroxyl
functionality) and a polyisocyanate. The third backbone segments B3
can result from a single polyol species or a blend of two or more
different polyol species with the same or different degree of
hydroxyl functionality. Similarly, in embodiments corresponding to
a thermoset epoxy composition, the third backbone segments B3 can
have a structure corresponding to a beta-hydroxy (tertiary) amine
product from at least one amine (e.g., monoamine, diamine,
triamine, or higher degree of isocyanate functionality) with a
epoxide (beta-hydroxy amine). The third backbone segments B3 can
result from a single epoxide species or a blend of two or more
different amine epoxide with the same or different degree of
epoxide functionality.
[0068] The first linking groups L1 have a structure corresponding
to a reaction product of a first functional group of the first
thermosetting component and a second functional group of the second
thermosetting component. The second linking groups L2 have a
structure corresponding to a reaction product of the first
functional group of the first thermosetting component and a third
functional group of the functionalized omniphobic polymer. The
first, second, and third functional groups generally can be
selected from isocyanate, hydroxy, amino, epoxide, and carboxylic
groups. In certain embodiments, the first functional group, the
second functional group, and the third functional group are
different from each other, (e.g., isocyanate, hydroxy, and amino,
respectively, for thermoset polyurethane with an amino-functional
omniphobic polymer; amino, epoxide, and isocyanate respectively for
a thermoset epoxy with an isocyanate-functional omniphobic
polymer). For example, in embodiments corresponding to a thermoset
polyurethane composition, The first linking groups L1 can have a
structure corresponding to a urethane reaction product of a
polyisocyanate as the first thermosetting component (i.e., with an
isocyanate group as the first functional group) and a polyol as the
second thermosetting component (i.e., with a hydroxyl group as the
second functional group), and the second linking groups L2 can have
a structure corresponding to a urea reaction product of the
polyisocyanate as the first thermosetting component and an
amine-functional omniphobic polymer as the functionalized
omniphobic polymer (i.e., with an amino group as the third
functional group). Similarly, in embodiments corresponding to a
thermoset epoxy composition, The first linking groups L1 can have a
structure corresponding to a beta-hydroxy amine reaction product of
an amine as the first thermosetting component (i.e., with an amino
group as the first functional group) and a polyepoxide as the
second thermosetting component (i.e., with an epoxide group as the
second functional group), and the second linking groups L2 can have
a structure corresponding to a urea reaction product of the amine
as the first thermosetting component and an isocyanate-functional
omniphobic polymer as the functionalized omniphobic polymer (i.e.,
with an isocyanate group as the third functional group).
[0069] In some embodiments, the first and third functional groups
have a higher reaction rate with each other relative to the first
and second functional groups with each other, for example under the
same reaction (e.g., drying, heating, and/or curing) conditions. In
some embodiments, the second and third functional groups are
generally non-reactive. As an illustration and in the context of
the representative thermoset polyurethane and thermoset epoxy
compositions according the disclosure, the reaction between
isocyanate and amino groups is relatively fast, in particular in
comparison to a corresponding reaction between isocyanate and
hydroxyl groups and a corresponding reaction between amino and
epoxide groups. Thus, for a thermoset polyurethane composition, the
isocyanate and amino groups (fast reaction) can correspond to the
first and third functional groups, respectively, while the
isocyanate and hydroxyl groups (slow reaction) can correspond to
the first and second functional groups, respectively. Likewise, for
a thermoset epoxy composition, the amino and isocyanate groups
(fast reaction) can correspond to the first and third functional
groups, respectively, while the amino and epoxide groups (slow
reaction) can correspond to the first and second functional groups,
respectively.
[0070] The polyisocyanate is not particularly limited and generally
can include any aromatic, alicyclic, and/or aliphatic isocyanates
having at least two reactive isocyanate groups (--NCO). Suitable
polyisocyanates contain on average 2-4 isocyanate groups. In some
embodiments, the polyisocyanate includes a diisocyanate. In some
embodiments, the polyisocyanate includes triisocyanate. Suitable
diisocyanates can have the general structure
(O.dbd.C=N)--R--(N.dbd.C.dbd.O), where R can include aromatic,
alicyclic, and/or aliphatic groups, for example having at least 2,
4, 6, 8, 10 or 12 and/or up to 8, 12, 16, or 20 carbon atoms.
Examples of specific polyisocyanates include 1,5-naphthylene
diisocyanate, 4,4'-diphenylmethane diisocyanate (MDI), hydrogenated
MDI, xylene di isocyanate (XDI), tetramethylxylol diisocyanate
(TMXDI), 4,4'-diphenyl-dimethylmethane diisocyanate, di- and
tetraalkyl-diphenylmethane diisocyanate, 4,4'-dibenzyl
diisocyanate, 1,3-phenylene diisocyanate, 1,4-phenylene
diisocyanate, one or more isomers of tolylene diisocyanate (TDI,
such as toluene 2,4-diisocyanate),
1-methyl-2,4-diiso-cyanatocyclohexane,
1,6-diisocyanato-2,2,4-trimethyl-hexane,
1,6-diisocyanato-2,4,4-trimethylhexane,
1-iso-cyanatomethyl-3-isocyanato-1,5,5-trimethylcyclohexane,
chlorinated and brominated diisocyanates, phosphorus-containing
diisocyanates, 4,4'-diisocyanatophenyl-perfluoroethane,
tetramethoxybutane 1,4-diisocyanate, butane 1,4-diisocyanate,
hexane 1,6-diisocyanate (or hexamethylene diisocyanate; HDI), HDI
dimer (HDID), HDI trimer (HDIT), HDI biuret, 1,5-pentamethylene
diisocyanate (PDI), PDID (dimer of PDI), PDIT (trimer of PDI), PDI
biuret, dicyclohexylmethane diisocyanate, cyclohexane
1,4-diisocyanate, ethylene diisocyanate, phthalic acid
bisisocyanatoethyl ester, 1-chloromethylphenyl 2,4-diisocyanate,
1-bromomethylphenyl 2,6-diisocyanate, 3,3-bischloromethyl ether
4,4'-diphenyldiisocyanate, trimethylhexamethylene diisocyanate,
1,4-diisocyanato-butane, 1,2-diisocyanatododecane, and combinations
thereof. The polyisocyanate can be biobased or made of synthetic
feedstock. Examples of suitable biobased polyisocyanates include
pentamethylene diisocyanate trimer, and polyisocyanates formed from
base compounds to which isocyanate groups are attached (e.g., via
suitable derivatization techniques), including
isocyanate-terminated poly(lactic acid) having two or more
isocyanate groups, isocyanate-terminated poly(hydroxyalkanaotes)
having two or more isocyanate groups, isocyanate-terminated
biobased polyesters having two or more isocyanate groups.
[0071] The functionalized omniphobic polymer is not particularly
limited and generally can include any omniphobic polymer with glass
transition temperature of 70.degree. C. or 50.degree. C. or less,
such as in a range from -150.degree. C. to 70.degree. C. or
50.degree. C. The functional group of the functionalized omniphobic
polymer can include one or more epoxide groups, amino groups,
isocyanate groups, hydroxyl groups, and carboxylic groups (e.g.,
including only one type of functional group). Amine groups in the
amino-functional omniphobic polymers can include one or both of a
primary amine and a secondary amine (e.g., R.sup.1NH.sub.2 and
R.sup.1R.sup.2NH, respectively, where R.sup.1 and R.sup.2 can be
the same or different groups other than hydrogen, for example
hydrocarbon groups). Examples of general classes of functionalized
omniphobic polymers include functionalized polysiloxanes,
functionalized polyperfluoroethers, functionalized polybutadienes,
functionalized polyolefins (e.g., polyethylene, polypropylene,
polybutylene), and combinations or mixtures thereof. The
functionalized polyperfluoroether (e.g., functionalized
polyperfluoropolyethers) can include mono-, di-, or higher
functionalized polyperfluoroethers, or a blend of thereof, such as
a blend of mono- and di-functional polyperfluorothers. The
functionalized polybutadiene can include mono-, di-, or higher
functional polybutadienes, or a blend of thereof, such as a blend
mono- and di-functional polybutadienes. Many suitable
functionalized omniphobic polymers are commercially available
(e.g., amine-, isocyanate-, or other functional
polydimethylsiloxane (PDMS) with a variety of available degrees of
functionality and molecular weights). Omniphobic polymers that are
not commercially available in their functionalized form can be
functionalized using conventional chemical synthesis techniques,
for example including but not limited to hydroamination, thiol-ene
Michael reaction of amine-carrying thiols, Mitsunobu reaction, and
reductive amination.
[0072] The functionalized polysiloxane is not particularly limited
and generally can include any polysiloxane having mono-, di-, or
higher degrees functionality. In some embodiments, the
functionalized polysiloxane includes a mono-functional
polysiloxane. In some embodiments, the functionalized polysiloxane
includes a di-functional polysiloxane. The polysiloxane can be a
polydialklylsiloxane having --Si(R.sub.1R.sub.2)--O-- repeat units,
where R.sub.1 and R.sub.2 independently can be C.sub.1-C.sub.12
linear or branched alkyl groups, C.sub.4-C.sub.12 cycloalkyl
groups, unsubstituted aromatic groups, or substituted aromatic
groups, in particular where R.sub.1 and R.sub.2 are methyl groups
for a polydimethylsiloxane (PDMS). The functional groups are
suitably terminal groups. For example, in an amine-functional
polydialklylsiloxane, the structure and terminal groups can be
represented by
NH.sub.2--R.sub.3--[Si(R.sub.1R.sub.2)--O].sub.x--R.sub.3--NH.sub.2
for a diamine or
NH.sub.2--R.sub.3--[Si(R.sub.1R.sub.2)--O].sub.x--R.sub.3 for a
monoamine, where R.sub.3 independently can be H (when a terminal
group) or C.sub.1-C.sub.12 linear or branched alkyl (when a
terminal group or a linker for a terminal amine). The functional
groups additionally can be pendant groups, for example in a
amine-functional polydialklylsiloxane represented by
R.sub.3--[Si(R.sub.1R.sub.2)--O].sub.x--[Si(R.sub.1'R.sub.2')--O].sub.y---
R.sub.3, where R.sub.1' and R.sub.2' independently can be the same
as R.sub.1 and R.sub.2, but at least one or both of R.sub.1' and
R.sub.2' independently is a C.sub.1-C.sub.12 linear or branched
alkyl linker group with a terminal amine group (e.g., --NH.sub.2).
Illustrative isocyanate-functional polydialklylsiloxanes can be
represented by the foregoing structures with isocyanate groups
(--NCO) replacing the amino groups (--NH.sub.2). Some examples of
functionalized polyslioxanes include functionalized
polydimethylsiloxane, functionalized polymethylphenylsiloxane, and
functionalized polydiphenylsiloxane.
[0073] Some examples of polyperfluoropolyethers with functional
group(s) include functionalized poly(n-hexafluoropropylene oxide)
(e.g., --(CF.sub.2CF.sub.2CF.sub.2O)n-)NH.sub.2 or
--(CF.sub.2CF.sub.2CF.sub.2O)n-)NCO for amino or isocyanate groups)
and functionalized poly(hexafluoroisopropylene oxide) (e.g.,
--(CF(CF.sub.3)CF.sub.2O)nNH.sub.2 or PFPO-NH.sub.2;
--(CF(CF.sub.3)CF.sub.2O)nNCO or PFPO-NCO). Some examples of
functionalized atactic polyolefins include functionalized
poly(1-butene), branched polyethylene, poly(cis-isoprene),
poly(trans-isoprene), and poly (1-octene). Some examples of
functionalized polyacrylates include poly(3-functionalized propyl
acrylate). Similarly, mono-functional polymers include
mono-functional polyisobutylene (e.g., PIB-NH.sub.2; PIB-NCO),
mono-functional polypolyethylene glycol (e.g., PEG-NH.sub.2,
PEG-NCO), mono-functional poly(1-butene) (e.g., PB-NH.sub.2,
PB-NCO, cis and trans) can also be used as the low-glass transition
temperature (T.sub.g less than 70.degree. C. or 50.degree. C.)
polymers, either alone or in combination with other functionalized
omniphobic polymers.
[0074] The functionalized omniphobic polymers can have any suitable
molecular weight in view of desired glass transition temperature,
for example having a molecular weight ranging from 300 to 50,000
g/mol. In various embodiments, the molecular weight can be at least
300, 800, 1000, 1500, or 2000 and/or up to 1000, 2000, 3000, 5000,
or 50,000 g/mol. The molecular weight can be expressed as a
number-average or weight-average value in the units of gram/mole
(g/mol). Alternatively or additionally, the functionalized
omniphobic polymer can have a number of repeat units ranging from 4
to 600 (e.g., at least 4, 10, 12, 15, 20, or 25 and/or up to 12,
15, 20, 30, 40, 60, 200, or 600; such as a (number) average number
of repeat units). Some embodiments can include a blend of two or
more amine-functionalized omniphobic polymers with different
average molecular weights, such as one with 300-1500 g/mol and
another with 1500-50,000 g/mol with a higher average molecular
weight than the first. Blends of functionalized omniphobic polymers
(e.g., differing in molecular weight and/or in degree of
functionality) can improve the combination of water- and
oil-repellency properties of the final composition. For example, a
mono-functional polysiloxane can provide better water and oil
repellency than a di-functional polysiloxane. Low MW functionalized
polysiloxanes (e.g., PDMS, such as having a MW range of about
800-1200 g/mol or an average MW of about 1000 g/mol) can provide an
improved water repellency, while Higher MW functionalized
polysiloxanes (e.g., PDMS, such as about 2000 g/mol or above for an
average or range of MW) can provide an improved oil repellency.
[0075] The polyol is not particularly limited and generally can
include any aromatic, alicyclic, and/or aliphatic polyols with at
least two reactive hydroxyl/alcohol groups (--OH). Suitable polyol
monomers contain on average 2-4 hydroxyl groups on aromatic,
alicyclic, and/or aliphatic groups, for example having at least 4,
6, 8, 10 or 12 and/or up to 8, 12, 16, or 20 carbon atoms. In some
embodiments, the polyol is a diol. In some embodiments, the polyol
is a triol. Examples of specific polyols include one or more of
polyether polyols (e.g., polypropylene oxide-based triols such as
commercially available MULTRANOL 4011 with a MW of about 300),
triethanolamine, hydroxylated (meth)acrylate oligomers (e.g.,
2-hydroxylethyl methacrylate or 2-hydroxyethyl acrylate), glycerol,
ethylene glycol, diethylene glycol, triethylene glycol,
tetraethylene glycol, propylene glycol, dipropylene glycol,
tripropylene glycol, 1,3-propanediol, 1,3-butanediol,
1,4-butanediol, neopentyl glycol, 1,6-hexanediol,
1,4-cyclohexanedimethanol, glycerol, trimethylolpropane,
1,2,6-hexanetriol, pentaerythritol, (meth)acrylic polyols (e.g.,
having random, block, and/or alternating hydroxyl functionalities
along with other (meth)acrylic moieties), and isosorbide. The
polyol can be biobased or made of synthetic feedstock. Examples of
suitable biobased polyols include isosorbide, poly(lactic acid)
having two or more hydroxyl groups, poly(hydroxyalkanaotes) having
two or more hydroxyl groups, and biobased poly(esters) having two
or more hydroxyl groups (e.g., as terminal groups).
[0076] The polyepoxide is not particularly limited and generally
can include polyepoxide-substituted aromatic hydrocarbons,
aliphatic hydrocarbons, cycloaliphatic hydrocarbons, ethers
thereof, esters thereof, imines thereof, and combinations thereof.
The polyepoxide can include hydrocarbons with two or more epoxide
groups and one or more aromatic, aliphatic, cycloaliphatic, ether,
ester, and/or imine groups in the hydrocarbon to which the epoxide
groups are attached. Suitable polyepoxides can be derived from
petroleum and plant materials. Suitable polyepoxides include two or
more glycidyl ether groups (i.e., epoxide-containing groups). Some
examples of polyepoxides include, but are not limited to, bisphenol
A epoxy (e.g., diglycidyl ether of bisphenol A having 1 or 2-25
bisphenol A repeat units), bisphenol F epoxy (e.g., diglycidyl
ether of bisphenol F having 1 or 2-25 bisphenol F repeat units),
epoxy phenol novolac, epoxy cresol novolac, cycloaliphatic epoxies,
halogenated epoxies, epoxy-vinyl esters,
tetraglycidylmethylenedianiline (TGMDA), 3,4-epoxycyclohexylmethyl
3,4-epoxycyclohexanecarboxylate (ECC),
bis[3,4-epoxycyclohexylmethyl] adipate (BECHMA), poly(glycidyl
methacrylate), epoxies of rosin acid, epoxies of diphenolic acid,
epoxies of tannin acid, epoxies derived from glucose, isosorbide
epoxies, eugenol epoxides, furan epoxides, cathechin epoxides,
vanillin-based epoxies, quercetin epoxides, epoxies derived from
gallic acid, epoxides from phenols, epoxides from cardanols,
epoxides from plant oils, terpene oxides (e.g., limonene dioxide),
and combinations thereof.
[0077] The amine is not particularly limited and generally can
include polyamine-substituted aromatic hydrocarbons, aliphatic
hydrocarbons, cycloaliphatic hydrocarbons, ethers thereof, esters
thereof, imines thereof, and combinations thereof. The amine can
include hydrocarbons with two or more amino groups and one or more
aromatic, aliphatic, cycloaliphatic, ether, ester, and/or imine
groups in the hydrocarbon to which the amino groups are attached.
Suitable amines can be derived either petrochemicals or plant
materials. Some examples include, but are not limited to,
isophorone diamine, diaminopropyl isosorbide, furfuryldiamine,
polylysine, menthane diamine, tris(dimethylaminomethyl)phenol,
melamine, bis(3-aminopropyl)amine,
N,N'-bis(3-aminopropyl)-1,3-propanediamine,
3,3'-diamino-N-methyldipropylamine, tris(3-aminopropyl)amine,
1,2-bis(3-aminopropylamino)ethane, diethylenetriamine,
polyetheramines (e.g., JEFFAMINE polyetheramines available from
Huntsman Chemical). The amines can be primary, secondary, or a
combination of both.
[0078] In some embodiments including a thermoset polyurethane
polymer, at least one of the polyisocyanate and the polyol is a
tri- or higher functional isocyanate or alcohol/hydroxy compound,
respectively, to promote crosslinking of the backbone segments in
the final thermoset polyurethane polymer. Alternatively or
additionally, in some embodiments, the functionalized omniphobic
polymer is a tri- or higher amine-functional compound (e.g.,
tri-functional amine PDMS) so that the omniphobic polymer can serve
as a crosslinker, either alone or in combination with
polyisocyanate and/or polyol crosslinkers.
[0079] In some embodiments including a thermoset epoxy polymer, at
least one polyepoxide has a functionality greater than two or at
least one amine has a functionality greater than one promote
crosslinking of the backbone segments in the final epoxy
polyurethane polymer. Specifically, since a single primary amino
group can react with two epoxide groups, either some species with
three or more epoxide groups or two or more amino groups (which can
form four or more bonds with epoxides) are used for crosslinking.
Typically a diepoxide and a diamine are used. Alternatively or
additionally, in some embodiments, the functionalized omniphobic
polymer is a tri- or higher isocyanate-functional compound (e.g.,
tri-functional isocyanate PDMS) so that the omniphobic polymer can
serve as a crosslinker, either alone or in combination with
polyepoxide and/or amine crosslinkers.
[0080] The first, second, and third backbone segments can be
incorporated into the thermoset polymer in a variety of relative
weight amounts. In an embodiment, the first backbone segments are
present in an amount ranging from 10 wt. % to 90 wt. % relative to
the thermoset polymer (e.g., at least 10, 15, or 20 wt. % and/or up
to 30, 40, 50, 60, 70, 80, or 90 wt. %; such as 30 wt. % to 70 wt.
%), which amounts can equivalently correspond to the first
thermosetting component(s), for example as added to a reaction
mixture and relative to all monomeric, oligomeric, and polymeric
reaction components added thereto. In an embodiment, the second
backbone segments are present in an amount ranging from 0.01 wt. %
to 20 wt. % relative to the thermoset polymer (e.g., at least 0.01,
0.1, 0.2, 0.5, 1, 2, 3, or 5 wt. % and/or up to 3, 5, 8, 10, 15 or
20 wt. %; such as 0.2 wt. % to 8 wt. % or 1 wt. % to 5 wt. %),
which amounts can equivalently correspond to the functionalized
omniphobic polymer(s), for example as added to a partially
crosslinked reaction product already on a substrate and relative to
all monomeric, oligomeric, and polymeric reaction components added
thereto. In an embodiment, the third backbone segments are present
in an amount ranging from 10 wt. % to 90 wt. % relative to the
thermoset polymer (e.g., at least 10, 20, 30, 40, or 50 wt. %
and/or up to 70, 80, or 90 wt. %, such as 30 wt. % to 70 wt. %),
which amounts can equivalently correspond to the second
thermosetting component(s), for example as added to a reaction
mixture and relative to all monomeric, oligomeric, and polymeric
reaction components added thereto.
[0081] Similarly, the first, second, and third backbone segments
can be incorporated into the thermoset polymer in a variety of
relative molar amounts based on the corresponding reactive
functional groups of their corresponding monomeric, oligomeric, and
polymeric reaction components. Suitably, approximately a 1:1 molar
ratio of combined second and third functional groups (e.g., hydroxy
and amino groups, respectively; epoxide and isocyanate groups,
respectively) relative to first functional groups (e.g., isocyanate
groups; amino groups) is used when combining reactive components to
make the omniphobic composition. In most cases, first functional
groups are added in a slight molar excess. Final molar ratios of
(i) first functional groups to (ii) second and third functional
groups combined are typically between 1:1 to 1.6:1, for example at
least 1:1, 1.1:1, or 1.2:1 and/or up to 1.4:1, 1.5:1, or 1.6:1.
[0082] In an embodiment, the thermoset polymer crosslinked backbone
can include further types of backbone segments. For example, the
backbone can include fourth backbone segments which have a
structure corresponding to a reaction product of a mono-functional
monomer component having only one first functional group reactive
with the second thermosetting component or the functionalized
omniphobic polymer. Such mono-functional monomers can be applied to
the substrate in combination with the first and second
thermosetting components when forming the partially crosslinked
reaction product. The mono-functional monomer component can be, for
example, a monoisocyanate or a monoepoxide, which can be used as a
means to control crosslinking degree as well as to incorporate
hydrophobic or other functional groups at an external or boundary
portion of the thermoset polymer. Examples of monoisocyanates
include R--(N.dbd.C.dbd.O) and examples of monoepoxides include
R--(C.sub.2H.sub.4O) (i.e., oxirane or epoxide group), where R can
include aromatic, alicyclic, and/or aliphatic groups, for example
having at least 2, 4, 6, 8, 10 or 12 and/or up to 8, 12, 16, or 20
carbon atoms. The fourth backbone segments can be present in an
amount ranging from 0.01 wt. % to 4 wt. % relative to the thermoset
polymer (e.g., at least 0.01, 0.1, 0.2, or 0.5 wt. % and/or up to
1, 2, or 4 wt. %), which amounts can equivalently correspond to the
mono-functional monomer component, for example as added to a
reaction mixture and relative to all monomeric, oligomeric, and
polymeric reaction components added thereto.
[0083] In an embodiment, the thermoset omniphobic composition can
include any suitable organic or inorganic filler or additive, which
can be included to improve one or more of mechanical properties,
optical properties, electrical properties, and omniphobic
properties of the final composition. Examples of suitable fillers
or additives include nanoclay, graphene oxide, graphene, silicon
dioxide (silica), aluminum oxide, diatomaceous earth, cellulose
nanocrystals, carbon nanotubes, titanium dioxide (titania), and
combinations or mixtures thereof. In addition, the fillers can
include biocides, pigments, dyes, a thermoplastic material, or a
combination thereof. The fillers can be added in the range from
0.01 wt. % to 10 wt. %, for example in range from 1 wt. % to 5 wt.
%. The presence of organic or inorganic fillers in the omniphobic
composition can affect the clarity of the resulting composition, in
which case the amount and size of the fillers can be selected in
view of the desired clarity properties of the composition as well
as the mechanical, electrical, omniphobic or other functional
properties of the final composition.
[0084] The omniphobic properties of the thermoset composition
(e.g., for the cured composition) can be characterized in terms of
one or more contact angles and/or sliding angles for water and/or
oil droplets (e.g., vegetable oil and/or hexadecane) on the
thermoset composition (e.g., as a coating on a substrate). The
following ranges are representative of compositions according to
the disclosure which display favorable omniphobic properties. In an
embodiment, the composition has a water contact angle in a range
from 90.degree. to 120.degree. (e.g., at least 90.degree.,
95.degree., 100.degree., or 105.degree. and/or up to 110.degree.,
115.degree., or 120.degree.; such as for the cured composition as a
coating). In some cases, the water contact angle can be up to about
125.degree. for non-smooth or rough surfaces. In an embodiment, the
composition has an oil contact angle in a range from 0.degree. or
1.degree. to 65.degree. (e.g., at least 1.degree., 10.degree.,
20.degree., or 30.degree. and/or up to 40.degree., 50.degree.,
60.degree., or 65.degree.; such as for the cured composition as a
coating). In an embodiment, the composition has a water sliding
angle in a range from 0.degree. or 1.degree. to 30.degree. for a 75
.mu.l droplet (e.g., at least 1.degree., 2.degree., 4.degree.,
6.degree., or 8.degree. and/or up to 10.degree., 15.degree.,
20.degree., or 30.degree.; such as for the cured composition as a
coating). In an embodiment, the composition has an oil sliding
angle in a range from 0.degree. or 1.degree. to 20.degree. for a 25
.mu.l droplet (e.g., at least 1.degree., 2.degree., 4.degree.,
6.degree., or 8.degree. and/or up to 10.degree., 12.degree.,
15.degree., or 20.degree.; such as for the cured composition as a
coating). The contact angles for the omniphobic coatings can be
higher when nanofillers (e.g., clay, silica, etc.) are included in
the composition as compared to corresponding compositions without
any nanofillers.
[0085] The thermoset omniphobic composition generally has a
homogeneous structure, for example a homogenous thermoset solid
with the first, second, and third backbone segments being generally
evenly distributed throughout the composition. This is illustrated
in FIG. 5 with the thermoset omniphobic composition 100 shown as a
homogeneous coating on a substrate 200 with the backbone segments
B1, B2, B3 distributed throughout. This is in contrast to a common
"self-stratified" structure with a siloxane (or other hydrophobic
or omniphobic polymer group) rich surface and bulk thermoset region
with little or no siloxane (or other hydrophobic or omniphobic
polymer group). The homogeneous structure can result from the
formation of a partially crosslinked matrix between the first and
second thermosetting components that allows the functionalized
omniphobic polymer such as polysiloxane to be absorbed and permeate
into the partially crosslinked matrix to promote its uniform
distribution in the final matrix. The presence of complementary
reactive groups in the partially crosslinked matrix (e.g.,
unreacted amino or isocyanate groups for epoxy and polyurethane
monomers, respectively, in the first thermosetting component) as
well as the functionalized omniphobic polymer (e.g., isocyanate or
amino groups for PDMS-NCO or PDMS-NH.sub.2) allows the
functionalized omniphobic polymer to react and form covalent bonds
with the matrix components as the partially crosslinked matrix
becomes a fully cured thermoset omniphobic composition with all
three backbone segments.
Coated Article
[0086] FIG. 5 illustrates an aspect of the disclosure in which a
coated article 300 (e.g., desirably having omniphobic properties on
at least one surface thereof) includes a substrate 200 and the
thermoset omniphobic composition 100 coated on a surface 202 of the
substrate 200. The composition 100 can be in the form of a coating
or film on an external, environment-facing surface 202 of the
substrate 200 (e.g., where the surface 202 would otherwise be
exposed to the external environment in the absence of the
composition 100). In this case, the thermoset omniphobic
composition 100 provides omniphobic protection to the underlying
substrate 200.
[0087] The substrate 200 is not particularly limited, and generally
can be formed from any material desired for protection with an
omniphobic coating, in particular given the good, broad adhesive
capabilities of the thermoset omniphobic composition 100. For
example, the substrate can be a metal, plastic, a different
thermoset material (e.g., a primer material; material other than
the other than thermoset omniphobic composition), glass, wood,
fabric (or textile), or ceramic material. Examples of specific
metals include steel, aluminum, copper, etc. Examples of specific
plastics include polyvinyl alcohol (PVOH), ethylene vinyl alcohol
(EVOH), polyethylene terephthalate (PET), polypropylene (PP),
polyethylene (PE), starch, chitosan, etc. Suitable wood materials
can be any type of wood commonly used in home, office, and outdoor
settings. Suitable glass materials can be those used for building
windows, automobile windows, etc. In some embodiments, the
substrate 200 is a top layer of a coating or series of coatings on
a different underlying substrate. For example, the coated article
can include a substrate 200 material as generally disclosed herein,
one or more intermediate coatings on the substrate 200 (e.g., an
epoxy coating, an acrylic coating, another primer coating, etc.),
and the thermoset omniphobic composition 100 on the one or more
intermediate coatings as the final, external coating on the coated
article 300.
[0088] The thermoset omniphobic composition 100 can have any
desired thickness on the substrate 200. In common applications, the
composition 100 has a thickness ranging from 0.010 .mu.m to 500
.mu.m, for example at least 0.01, 10, 20, 50, or 100 .mu.m and/or
up to 200, 500 .mu.m. Typical cast coatings can have thicknesses of
10 .mu.m to 100 .mu.m. Typical spin coatings can have thicknesses
of 0.05 .mu.m or 0.10 .mu.m to 0.20 .mu.m or 0.50 .mu.m. Multiple
coating layers can be applied to substrate 200 to form even thicker
layers of the composition 100 (e.g., above 500 .mu.m or otherwise)
if desired.
Method of Making the Composition and Coated Article
[0089] The thermoset omniphobic composition according to the
disclosure generally can be formed as illustrated in FIG. 3. At
least one first thermosetting component as described above and at
least one second thermosetting component reactive therewith and as
described above are applied to a substrate 200, in particular a top
or exposed surface 202 thereof, for example in the form of a
mixture 110 as illustrated. The mixture 110 can further include a
casting or other solvent for the thermosetting components,
catalysts, organic and/or inorganic fillers, etc. The mixture 110
can include a suitable reaction or casting solvent or medium, for
example an aprotic organic solvent such as acetone,
tetrahydrofuran, 2-butanone, other ketones (e.g., methyl n-propyl
ketone, methyl isobutyl ketone, methyl ethyl ketone, ethyl n-amyl
ketone), esters (e.g., C.sub.1-C.sub.4 alkyl esters of
C.sub.1-C.sub.4 carboxylic acids, such as methyl, ethyl, n-propyl,
butyl esters of acetic acid such as n-butyl acetate, etc., n-butyl
propionate, ethyl 3-ethoxy propionate), dimethylformamide, dimethyl
carbonate, etc. In some cases, a mixture of two or more solvents
can be used for the initial application and subsequent partial
crosslinking reaction. In some embodiments, a reaction catalyst can
be added to the mixture 110 to catalyze the reaction between the
thermosetting components (e.g., polyisocyanate and polyol for a
polyurethane). Various commercial and laboratory-synthesized
catalysts can be used, for example including, but not limited to,
complexes and/or salts of tin (e.g., tin(II) 2-ethylhexanoate) or
iron, and tertiary amines (e.g., triethylamine),
1,8-Diazabicyclo[5.4.0]undec-7-ene (DBU) and
1,4-Diazabicyclo[2.2.2]octane (DABCO). The mixture 110 can be
applied to the substrate 200 using any suitable method, such as by
casting, spraying, rolling and/or dipping.
[0090] The first and second thermosetting components are then
reacted with each other to form a partially crosslinked reaction
product 120 on the substrate 200. The partially crosslinked
reaction product 120 includes at least some covalent bonds between
the first thermosetting component and the second thermosetting
component, and at least some unreacted functional groups reactive
with the functionalized omniphobic polymer. The partially
crosslinked structure of the reaction product 120 permits
subsequent application, absorption, and permeation of the
functionalized omniphobic polymer into and throughout the product
120 as a preliminary coating on the substrate 200. Reaction to form
the partially crosslinked reaction product 120 generally can be
performed at any suitable reaction temperature(s) and time(s),
which can be selected such that there is sufficient time to
partially (but not completely) crosslink/cure the components of the
reaction mixture 110, thus leaving some unreacted functional groups
for eventual full curing/crosslinking in the final thermoset
composition. In an embodiment, reaction to form the partially
crosslinked reaction product is performed (i) at temperature from
20.degree. C., 30.degree. C., 40.degree. C., or 60.degree. C. to
80.degree. C., 100.degree. C., 120.degree. C., or 150.degree. C.
and (ii) for a time from 1 min or 5 min to 120 min or 300 min.
Thus, reaction can be performed with or without heating the
reaction mixture. Room-temperature (e.g., 20.degree. C. to
30.degree. C.) reactions are possible with longer reaction times
and/or the addition of a catalyst. Initial reaction between the
first thermosetting component and the second thermosetting
component can be relatively slow and can involves heating and/or
the use of a catalyst. In contrast, the subsequent reaction between
the first thermosetting component and the functionalized omniphobic
polymer can be very fast and need not be heated for suitable
reaction times in various embodiments.
[0091] In some embodiments, after applying the first and second
thermosetting components the substrate 200, the substrate 200 can
be dried to remove solvent present in the corresponding mixture
110, thereby forming a coating of the first thermosetting component
and the second thermosetting component on the substrate 200 (e.g.,
which can include some partial crosslinking between the
thermosetting components as a result of the drying). Drying is
generally performed at ambient conditions and before heating to
accelerate the reaction to form the partially crosslinked reaction
product. However, some reaction/partial crosslinking between the
first and second thermosetting components can occur during drying,
but the majority of reaction occurs after solvent removal. In
certain cases, partial crosslinking can be performed under ambient
conditions without heating the samples prior to application of the
functionalized omniphobic polymer.
[0092] At least one functionalized omniphobic polymer is then
applied to the partially crosslinked reaction product 120 (e.g., a
top or exposed surface thereof), for example in the form of a
mixture 130 as illustrated. The mixture 130 can further include a
casting or other solvent for the functionalized omniphobic polymer.
The solvent of the mixture 130 can be the same or different as that
for the mixture 110. The mixture 130 can be applied to the
partially crosslinked reaction product 120 using any suitable
method, such as by casting, spraying, rolling and/or dipping. The
unreacted functional groups in the partially crosslinked reaction
product 120 are reacted with the functionalized omniphobic polymer
in the mixture 130 to form the thermoset omniphobic coating 100 on
the substrate 200 as illustrated. Such reaction or curing can be
performed by heating (e.g., in an oven, with exposure to a heat
lamp, etc.) at a temperature from 80.degree. C. or 100.degree. C.
to 140.degree. C. or 180.degree. C. and/or for a time from 1 hr to
24 hr. Lower heating temperature or ambient temperature curing is
also possible, such as room temperature curing (e.g., 20.degree. C.
to 30.degree. C.) for 4 hr-240 hr or 5-10 days (e.g., at least 4,
8, 12, 16, or 24 hr and/or up to 12, 16, 24, 48, 72, 96, 120, or
240 hr), lower heating (e.g., 30.degree. C. or 40.degree. C. to
60.degree. C. for 4 hr-96 hr or 2-4 days or 60.degree. C. to
80.degree. C. for 1 hr-72 hr or 1-3 days).
[0093] In some embodiments, after applying the functionalized
omniphobic polymer to the partially crosslinked reaction product
120, the substrate 200 can be dried to remove the solvent from the
mixture 130. Drying is generally performed at ambient conditions
and before heating to accelerate the reaction to form the fully
cured/crosslinked thermoset omniphobic coating. However, some
reaction/further crosslinking between the first and second
thermosetting components as well as the functionalized omniphobic
polymer can occur during drying, but the majority of reaction
generally occurs after solvent removal. Drying also provides some
time for the functionalized omniphobic polymer as applied to the
external surface of the partially crosslinked reaction 120 product
to penetrate into the interior of the partially crosslinked
reaction product 120 coating. Depending on the thickness of the
partially crosslinked reaction product 120 coating and the drying
time before full curing (e.g., either due to application of heat or
at low/ambient temperatures such as with a catalyst), the
functionalized omniphobic polymer can be incorporated into either
an exterior/top region of the final thermoset omniphobic coating
100, or it can be distributed substantially throughout the
thermoset omniphobic coating 100. For example, with sufficient
drying time and/or sufficiently thin partially crosslinked reaction
product 120 coatings, the functionalized omniphobic polymer can
penetrate essentially completely through the coating to the
substrate 200 prior to curing. The functionalized omniphobic
polymer in the mixture 130 as applied to the top layer of the
partially crosslinked coating 120 will generally diffuse through
the coating (e.g., as illustrated in the top right panel of FIG.
3). The functionalized omniphobic polymer can be very reactive with
the unreacted (first) thermosetting component functional groups,
and as a result, the relative degree of incorporation of the
functionalized omniphobic polymer (e.g., as a local weight fraction
or percent) can exhibit a normal concentration gradient that
gradually decreases from the outer surface of the final coating 100
towards the bottom of the final coating adjacent to the substrate
200 and original exposed surface 202.
Examples
[0094] The following examples illustrate the disclosed compositions
and methods, but are not intended to limit the scope of any claims
thereto. In the following examples, thermoset omniphobic
compositions generally according to the disclosure are prepared and
applied as a film or coating on a test substrate such as glass. The
applied films or coatings can then be evaluated according to a
variety of tests as described below in order to characterize their
relative degree of omniphobicity.
[0095] Contact Angle: Contact angles (see FIG. 1) are determined by
applying a liquid droplet on a test coating surface that is
stationary and horizontal with respect to gravity. Any specified
liquids can be used, but omniphobic coatings are generally
characterized by determining contact angles for water droplets and
separately for oil droplets (e.g., a cooking or other common
vegetable oil, hexadecane or other oily liquid hydrocarbon). The
applied droplets have a volume of about 5 .mu.l (e.g., about 3
.mu.l to 10 .mu.l), although the measured contact angle is not
particularly sensitive to actual droplet volume in these ranges.
Once applied to the test coating, the droplet can be visually
interrogated through any suitable means to determine the contact
angle (e.g., using conventional digital image photography and
digital image analysis). Suitably, (cured) omniphobic composition
coatings according to the disclosure have a water contact angle in
a range from 90.degree. to 120.degree. (e.g., at least 90.degree.,
95.degree., 100.degree., or 105.degree. and/or up to 110.degree.,
115.degree., or 120.degree.). Suitably, (cured) omniphobic
composition coatings according to the disclosure have an oil
contact angle in a range from 10.degree. to 65.degree.(e.g., at
least 10.degree., 20.degree., or 30.degree. and/or up to
40.degree., 50.degree., 60.degree., or 65.degree.).
[0096] Sliding Angle: Sliding angles are determined by applying a
liquid droplet on a test coating surface that is initially
horizontal with respect to gravity. The test coating surface is
then gradually ramped at a controlled/known angle relative to the
horizontal plane. Droplets which do not initially spread will
remain stationary on the test surface until the test surface is
ramped to a sufficiently high angle to cause the droplets to slide
down the ramped test surface. The test surface angle at which
sliding begins is the sliding angle of the test coating. Any
specified liquids can be used, but omniphobic coatings are
generally characterized by determining contact angles for water
droplets and separately for oil droplets (e.g., a cooking or other
common vegetable oil, hexadecane or other oily liquid hydrocarbon).
The applied droplets have a specified volume, which is generally
about 75 .mu.l (e.g., about 50 .mu.l to 150 .mu.l) for water and
about 20 .mu.l (e.g., about 5 .mu.l to 40 .mu.l) for oil. Once
applied to the test coating, the droplet can be visually
interrogated through any suitable means to determine the sliding
angle (e.g., using conventional digital image photography and
digital image analysis). Suitably, (cured) omniphobic composition
coatings according to the disclosure have a water sliding angle in
a range from 0.degree. or 1.degree. to 30.degree. (e.g., at least
1.degree., 2.degree., 4.degree., 6.degree., or 8.degree. and/or up
to 10.degree., 15.degree., 20.degree., or 30.degree.). Suitably,
(cured) omniphobic composition coatings according to the disclosure
have an oil contact angle in a range from 0.degree. or 1.degree. to
20.degree.(e.g., at least 1.degree., 2.degree., 4.degree.,
6.degree., or 8.degree. and/or up to 10.degree., 12.degree.,
15.degree., or 20.degree.).
[0097] Scratch Resistance: Scratch resistance is evaluated on a
scale of 1 (worst) to 5 (best) by attempting to scratch a test
coating surface using materials of various hardness, such as a
human fingernail, the corner/edge of a glass slide, a metal (e.g.,
stainless steel) knife, etc. The test surface is rated as "1" for a
given scratching material if there is substantial damage or
delamination of the test coating surface after being scratched. The
test surface is rated as "5" for a given scratching material if
there is no observable damage or marking on the test coating
surface after being scratched. These qualitative numbers were
obtained based on the criteria including: 1) the depth of the
scratch, 2) is scratch damaging the surface, and 3) whether the
scratch be felt if touched by hand.
[0098] Permanent Ink Resistance: Permanent ink resistance is
evaluated on a scale of 1 (worst) to 5 (best) by applying an ink
marking on a test coating surface using a permanent ink marker
(e.g., SHARPIE permanent ink marker or equivalent) and then
attempting to wipe off the marking using a tissue (e.g., KIMWIPE
laboratory cleaning tissue or equivalent). The test surface is
rated as "1" if all of the ink marking remains on the test coating
surface after being wiped. The test surface is rated as "5" if all
of the ink marking is removed from the test coating surface after
being wiped. These numbers give an estimation of the
ink-resistance, which are qualitatively assigned by taking two
aspects in consideration: 1) the amount of ink left behind after a
single wipe of the sample, and 2) the ink left behind after
multiple wipes of the sample.
[0099] Optical Properties/Transmittance or Clarity: The optical
transmittance (or clarity) of a sample film was tested using a
Perkin Elmer Lambda 25 UV-Vis spectrometer, and the result was
rated on a scale from 1 (worst) to 5 (excellent), with a reference
glass having 100% transmittance as a reference:
TABLE-US-00001 Rating Optical Transmittance 5 .sup. >95% 4
90-94%. 3 81-89% 2 70-80% 1 .sup. <70%
[0100] The following examples provides experimental details for the
formation of epoxy and polyurethane substrate coatings for (a)
partially cured epoxy and polyurethane coatings that are modified
with a functionalized PDMS applied to the top coating surface prior
to full curing, (b) epoxy and polyurethane coatings that are
modified with a functionalized PDMS mixed in situ with the
thermosetting monomers prior to application and curing of the
coating, and (c) comparative epoxy and polyurethane coatings that
are not modified with a functionalized PDMS. In terms of coating
clarity, anti-ink resistance, scratch resistance, water repellency,
and oil repellency, the coated substrates are generally ranked (a),
(b), (c) in terms of favorable performance. The examples further
illustrate the including of various fillers and reaction solvents
for the disclosed methods and resulting articles/compositions.
Example 1--Epoxy Coating Systems with and without Top-Layer PDMS
Functionalization
[0101] Example 1 illustrates thermoset epoxy omniphobic coatings
according to the disclosure and including an epoxide thermosetting
component, an amine thermosetting component, and an
isocyanate-functional PDMS omniphobic polymer (Samples 1.1-1.4).
Example 1 further illustrates comparative thermoset epoxy coatings
including an epoxide thermosetting component and an amine
thermosetting component, but no isocyanate-functional PDMS
omniphobic polymer (Samples 1.5-1.8).
[0102] Sample 1.1: Bisphenol A (BRA) diglycidyl ether (180 mg) was
dissolved in 1 mL acetone and then to this solution JEFFAMINE-230
polyetheramines (60 mg) was added and sonicated at 60.degree. C.
for 1 hr. The resulting solution was then casted on glass slides
and left for solvent evaporation. After complete evaporation it was
partially cured for 5 min at 120.degree. C. and then allowed to
cool down. Then an isocyanate-functional PDMS (PDMS-NCO; 2K
molecular weight; 25 mg/4 mL solution in acetone) was added with a
syringe to top of the partially cured coating. It was then left for
solvent evaporation and then cured at 120.degree. C. for 12 h in
oven for curing.
[0103] Sample 1.2: BPA diglycidyl ether (180 mg) was dissolved in 1
mL acetone and then to this solution JEFFAMINE.about.230 (60 mg)
was added and sonicated at 60.degree. C. for 20 min. Then to this
solution 4 mg nanoclay (dispersed in 0.2 mL acetone) was added and
again sonicate at 60.degree. C. for 1 hr. The resulting solution
was then casted on glass slides and left for solvent evaporation.
After complete evaporation it was partially cured for 5 min at
120.degree. C. and then allowed to cool down. Then on its top layer
PDMS-NCO (2K) (25 mg/4 mL acetone) was added with a syringe. It was
then left for solvent evaporation and then cured at 120.degree. C.
for 12 h in oven.
[0104] Sample 1.3: BPA diglycidyl ether (180 mg) was dissolved in 1
mL acetone and then to this solution JEFFAMINE-230 (60 mg) was
added and sonicated at 60.degree. C. for 20 min. Then to this
solution 4 mg cellulose nanocrystal (dispersed in 0.2 mL acetone)
was added and again sonicate at 60.degree. C. for 1 hr. The
resulting solution was then casted on glass slides and left for
solvent evaporation. After complete evaporation it was partially
cured for 5 min at 120.degree. C. and then allowed to cool down.
Then on its top layer PDMS-NCO (2K) (25 mg/4 mL acetone) was added
with help of syringe. It was then left for solvent evaporation and
then cured at 120.degree. C. for 12 hrs in oven.
[0105] Sample 1.4: BPA diglycidyl ether (180 mg) was dissolved in 1
mL acetone and then to this solution JEFFAMINE.about.230 (60 mg)
was added and sonicated at 60.degree. C. for 20 min. Then to this
solution 4 mg Graphene oxide (dissolved in 0.3 mL acetone) was
added and again sonicate at 60.degree. C. for 1 hr. The resulting
solution was then casted on glass slides and left for solvent
evaporation. After complete evaporation it was partially cured for
5 min at 120.degree. C. and then allowed to cool down. Then on its
top layer PDMS-NCO (2K) (25 mg/4 mL acetone) was added with help of
syringe. It was then left for solvent evaporation and then cured at
120.degree. C. for 12 hrs in oven.
[0106] Sample 1.5: BPA diglycidyl ether (180 mg) was dissolved in 1
mL acetone and then to this solution JEFFAMINE.about.230 (60 mg)
was added and sonicated at 60.degree. C. for 1 hr. The resulting
solution was then casted on glass slides and left for solvent
evaporation. After complete evaporation it was then cured at
120.degree. C. for 12 h in oven. (Reference for Sample 1-1)
[0107] Sample 1.6: BPA diglycidyl ether (180 mg) was dissolved in 1
mL acetone and then to this solution JEFFAMINE.about.230 (60 mg)
was added and sonicated at 60.degree. C. for 20 min. Then to this
solution 4 mg nanoclay (dispersed in 0.2 mL acetone) was added and
again sonicate at 60.degree. C. for 1 hr. The resulting solution
was then casted on glass slides and left for solvent evaporation.
After complete evaporation it was cured at 120.degree. C. for 12 h
in oven. (Reference for Sample 1.2)
[0108] Sample 1.7: BRA diglycidyl ether (180 mg) was dissolved in 1
mL acetone and then to this solution JEFFAMINE-230 (60 mg) was
added and sonicated at 60.degree. C. for 20 min. Then to this
solution 4 mg cellulose nanocrystal (dispersed in 0.2 mL acetone)
was added and again sonicate at 60.degree. C. for 1 hr. The
resulting solution was then casted on glass slides and left for
solvent evaporation. After complete evaporation it was then cured
at 120.degree. C. for 12 hrs in oven. (Reference for Sample
1.3)
[0109] Sample 1.8: BRA diglycidyl ether (180 mg) was dissolved in 1
mL acetone and then to this solution JEFFAMINE.about.230 (60 mg)
was added and sonicated at 60.degree. C. for 20 min. Then to this
solution 4 mg Graphene oxide (dispersed in 0.3 mL acetone) was
added and again sonicate at 60.degree. C. for 1 hr. The resulting
solution was then casted on glass slides and left for solvent
evaporation. After complete evaporation it was then cured at
120.degree. C. for 12 hrs in oven. (Reference for Sample 1.4)
[0110] Results: The samples were evaluated for clarity, ink
resistance, scratch resistance, contact angles, and sliding angles
as generally described above. For Samples 1.1-1.3 and 1.5-1.7, the
clarity was more than 85% (ranked as 5 on the scale of 1-5, where 5
is best). Samples 1.4 and 1.8 had transmittance values of 81% (rank
3) and 95% (rank 5), respectively. On a scale of 1-5, where 5 is
best, the anti-ink properties for Samples 1.1-1.4 was 5, while for
Samples 1.5-1.8, the anti-ink performance was 1. On a scale of 1-5,
where 5 is best, the scratch resistance properties for Samples
1.1-1.8 were 5. For Samples 1.1-1.4, water droplets (size 75 .mu.L)
had a sliding angle in the range 14-17.+-.3.degree.. For Samples
1.1-1.4, water contact angle (size 5 .mu.L) was in the range
104-107.+-.1.degree.. For Samples 1.1-1.4, hexadecane droplets
(size 5 .mu.L) had a sliding angle in the range 6-9.+-.1.degree..
For Samples 1.1-1.4, hexadecane droplet (size 5 .mu.L) contact
angle was in the range 30-54.+-.2.degree.. For Samples 1.5-1.8,
water droplets (size 75 .mu.L) had a sliding angle in the range
28-31.+-.1.degree.. For Sample 1.5-1.8, hexadecane droplets (size 5
.mu.L) exhibited tailing (wetting).
Example 2--Epoxy Coating Systems with In-Situ Mixing of PDMS
Functionalization
[0111] Example 3 illustrates thermoset epoxy omniphobic coatings
including an epoxide thermosetting component, an amine
thermosetting component, and an isocyanate-functional PDMS
omniphobic polymer, but without first forming a partially
crosslinked coating that is subsequently functionalized with the
PDMS omniphobic polymer (Samples 2.1-2.3).
[0112] Sample 2.1: BPA diglycidyl ether (180 mg) was dissolved in 1
mL acetone and then to this solution JEFFAMINE.about.230 (60 mg)
followed by addition of 5 mg PDMS NCO (2K) (dissolved in 0.25 mL
acetone) was added and sonicated at 60.degree. C. for 1 hr. The
resulting solution was then cast on glass slides and left for
solvent evaporation. After complete evaporation it was then cured
at 120.degree. C. for 12 hrs in oven.
[0113] Sample 2.2: BPA diglycidyl ether (180 mg) was dissolved in 1
mL acetone and then to this solution JEFFAMINE-230 (60 mg) followed
by 4 mg nanoclay (dispersed in 0.2 mL acetone) addition and then to
this solution 5 mg PDMS NCO (2K) (dissolved in 0.25 mL acetone) was
added and sonicate at 60.degree. C. for 1 hr. The resulting
solution was then casted on glass slides and left for solvent
evaporation and then cured at 120.degree. C. for 12 hrs in
oven.
[0114] Sample 2.3: BPA diglycidyl ether (180 mg) was dissolved in 1
mL acetone and then to this solution JEFFAMINE.about.230 (60 mg)
followed by 4 mg CNC (dispersed in 0.2 mL acetone) addition. Then
to this solution 5 mg PDMS NCO2 (2K) (dissolved in 0.25 mL acetone)
was added and sonicate at 60.degree. C. for 1 hr. The resulting
solution was then casted on glass slides and left for solvent
evaporation and then cured at 120.degree. C. for 12 hrs in
oven.
[0115] Results: The samples were evaluated for clarity, ink
resistance, scratch resistance, contact angles, and sliding angles
as generally described above. For Samples 2.1-2.3, the clarity was
ranked as 3 on the scale of 1-5, where 5 is best. On a scale of
1-5, where 5 is best, the scratch resistance properties for Samples
2.1-2.3 was 5. On a scale of 1-5, where 5 is best, the anti-ink
properties for Samples 2.1-2.3 were 3. For Samples 2.1 and 2.3,
water droplets (size 75 .mu.L) had sliding angles in the range
17-20.+-.3.degree. while Sample 2.2 had water sliding angles at
15.+-.3.degree.. For Samples 2.1-2.3, hexadecane droplets (size 5
.mu.L) wet the surface (exhibiting tailing upon sliding).
Example 3--Polyurethane Coating Systems with and without Top-Layer
PDMS Functionalization
[0116] Example 3 illustrates thermoset polyurethane omniphobic
coatings according to the disclosure and including a polyisocyanate
thermosetting component, a polyol thermosetting component, and an
amino-functional PDMS omniphobic polymer (Samples 3.1-3.6). Example
3 further illustrates comparative thermoset omniphobic coatings
including a polyisocyanate thermosetting component and a polyol
thermosetting component, but without an amino-functional PDMS
omniphobic polymer (Samples 3.7-3.9).
[0117] Sample 3.1: 0.7 mL of polyol (MULTRANOL 4011) was dissolved
in 1 mL acetone and then to this solution 1.1 mL hexamethylene
diisocyanate trimer (HDIT; DESMODUR N 100A) was added and sonicated
at room temperature for 1 hr. The resulting solution was then cast
on glass slides and left for solvent evaporation. After complete
evaporation it was partially cured for 5 min at 120.degree. C. and
then allowed to cool down. Then on its top layer an
amino-functional PDMS (PDMS-NH2; molecular weight 2K; 25 mg/4 mL
solution in acetone) was added with help of syringe. It was then
left for solvent evaporation and then cured at 120.degree. C. for 6
hrs in oven.
[0118] Sample 3.2: 0.7 mL polyol (MULTRANOL 4011) was dissolved in
1 mL acetone and then to this solution 4 mg nanoclay (dispersed in
0.2 mL acetone) was added and sonicated for 20 min at room
temperature. Then to this solution 1.1 mL HDIT (DESMODUR N 100A)
was added and vortex .about.1 min and then sonicated at room
temperature for 1 hr. The resulting solution was then casted on
glass slides and left for solvent evaporation. After complete
evaporation it was partially cured for 5 min at 120.degree. C. and
then allowed to cool down. Then on its top layer PDMS-NH2 (2K) (25
mg/4 mL acetone) was added with help of syringe. It was then left
for solvent evaporation and then cured at 120.degree. C. for 6 hrs
in oven.
[0119] Sample 3.3: 0.7 mL polyol (MULTRANOL 4011) was dissolved in
1 mL acetone and then to this solution 4 mg cellulose nanocrystal
(dispersed in 0.2 mL acetone) was added and sonicated for 20 min at
room temperature. Then to this solution 1.1 mL HDIT (DESMODUR N
100A) was added and vortex .about.1 min and then sonicated at room
temperature for 1 hr. The resulting solution was then casted on
glass slides and left for solvent evaporation. After complete
evaporation it was partially cured for 5 min at 120.degree. C. and
then allowed to cool down. Then on its top layer PDMS-NH2 (2K) (25
mg/4 mL acetone) was added with help of syringe. It was then left
for solvent evaporation and then cured at 120.degree. C. for 6 hrs
in oven.
[0120] Sample 3.4: 0.7 mL polyol (MULTRANOL 4011) was dissolved in
1 mL acetone and then to this solution 1.1 mL HDIT (DESMODUR N
100A) was added and sonicated at room temperature for 1 hr. The
resulting solution was then cast on glass slides and left for
solvent evaporation. After complete evaporation it was partially
cured for 5 min at 120.degree. C. and then allowed to cool down.
Then on its top layer PDMS-NH2 (2K) (50 mg/4 mL acetone) was added
with help of cotton. It was then left for solvent evaporation and
then cured at 120.degree. C. for 6 hrs in oven.
[0121] Sample 3.5: 0.7 mL polyol (MULTRANOL 4011) was dissolved in
1 mL acetone and then to this solution 4 mg nanoclay (dispersed in
0.2 mL acetone) was added and sonicated for 20 min at room
temperature. Then to this solution 1.1 mL HDIT (DESMODUR N 100A)
was added and vortex .about.1 min and then sonicated at room
temperature for 1 hr. The resulting solution was then casted on
glass slides and left for solvent evaporation. After complete
evaporation it was partially cured for 5 min at 120.degree. C. and
then allowed to cool down. Then on its top layer PDMS-NH2 (2K) (50
mg/4 mL acetone) was added with help of cotton. It was then left
for solvent evaporation and then cured at 120.degree. C. for 6 hrs
in oven.
[0122] Sample 3.6: 0.7 mL polyol (MULTRANOL 4011) was dissolved in
1 mL acetone and then to this solution 4 mg cellulose nanocrystal
(dispersed in 0.2 mL acetone) was added and sonicated for 20 min at
room temperature. Then to this solution 1.1 mL HDIT (DESMODUR N
100A) was added and vortex .about.1 min and then sonicated at room
temperature for 1 hr. The resulting solution was then casted on
glass slides and left for solvent evaporation. After complete
evaporation it was partially cured for 5 min at 120.degree. C. and
then allowed to cool down. Then on its top layer PDMS-NH2 (2K) (50
mg/4 mL acetone) was added with help of cotton. It was then left
for solvent evaporation and then cured at 120.degree. C. for 6 hrs
in oven.
[0123] Sample 3.7: 0.7 mL polyol (MULTRANOL 4011) was dissolved in
1 mL acetone and then to this solution 1.1 mL HDIT (DESMODUR N
100A) was added and sonicated at room temperature for 1 hr. The
resulting solution was then cast on glass slides and left for
solvent evaporation. After complete evaporation then it was cured
at 120.degree. C. for 6 hrs in oven. (Reference for Samples 3.1 and
3.4)
[0124] Sample 3.8: 0.7 mL polyol (MULTRANOL 4011) was dissolved in
1 mL acetone and then to this solution 4 mg nanoclay (dispersed in
0.2 mL acetone) was added and sonicated for 20 min at room
temperature. Then to this solution 1.1 mL HDIT (DESMODUR N 100A)
was added and vortex .about.1 min and then sonicated at room
temperature for 1 hr. The resulting solution was then casted on
glass slides and left for solvent evaporation. After complete
evaporation it was then cured at 120.degree. C. for 6 hrs in oven.
(Reference for Samples 3.2 and 3.5)
[0125] Sample 3.9: 0.7 mL polyol (MULTRANOL 4011) was dissolved in
1 mL acetone and then to this solution 4 mg cellulose nanocrystal
(dispersed in 0.2 mL acetone) was added and sonicated for 20 min at
room temperature. Then to this solution 1.1 mL HDIT (DESMODUR N
100A) was added and vortex .about.1 min and then sonicated at room
temperature for 1 hr. The resulting solution was then casted on
glass slides and left for solvent evaporation. After complete
evaporation it was then cured at 120.degree. C. for 6 hrs in oven.
(Reference for Samples 3.3 and 3.6)
[0126] Results: The samples were evaluated for clarity, ink
resistance, scratch resistance, contact angles, and sliding angles
as generally described above. For Samples 3.1-3.9, the clarity was
more than 85% (ranked as 5 on the scale of 1-5, where 5 is best).
For Samples 3.1-3.6, the anti-ink is ranked as 5 on the scale of
1-5, where 5 is best). On a scale of 1-5, where 5 is best, the
scratch resistance properties for Samples 3.1-3.9 were 5. For
Samples 3.1-3.3, on the scale of 1-5, where 5 is best; water and
hexadecane repellency were 5, with quantitative data as follows.
For Samples 3.1-3.3, water droplets (size 50 um) had sliding angles
in the range 17-21.+-.1.degree.. For Samples 3.1-3.3, water contact
angle (size 10 um) was in the range 97-102.+-.3.degree.. For
Samples 3.1-3.3, hexadecane droplets (size 10 um) had sliding
angles in the range 9-11.+-.2.degree.. For Samples 3.1-3.3,
hexadecane droplet (size 10 um) contact angle was in the range
38-40.+-.1.degree.. For Samples 3.4-3.6 (cotton application), on
the scale of 1-5, where 5 is best, water and hexadecane repellency
were 5. For Samples 3.7-3.9 (no PDMS), on the scale of 1-5, where 4
is best, water repellency was 3-4 and hexadecane repellency was 1
(exhibited surface wetting).
Example 4--Polyurethane Coating Systems with In-Situ Mixing of PDMS
Functionalization
[0127] Example 4 illustrates thermoset epoxy omniphobic coatings
including a polyisocyanate thermosetting component, a polyol
thermosetting component, and an amino-functional PDMS omniphobic
polymer, but without first forming a partially crosslinked coating
that is subsequently functionalized with the PDMS omniphobic
polymer (Samples 4.1-4.3).
[0128] Sample 4.1: 0.7 mL polyol (MULTRANOL 4011) was dissolved in
1 mL acetone and then this solution 1.1 mL HDIT (DESMODUR N 100A)
was added followed by addition of 5 mg PDMS-NH2 (2K) (dissolved in
0.2 mL acetone) and sonicated at room temperature for 1 hr. The
resulting solution was then casted on glass slides and left for
solvent evaporation and then cured at 120.degree. C. for 6 hrs in
oven.
[0129] Sample 4.2: 0.7 mL polyol (MULTRANOL 4011) was dissolved in
1 mL acetone and then this solution 1.1 mL HDIT (DESMODUR N 100A)
was added followed by addition of 4 mg of nanoclay (dissolved in
0.2 mL acetone). Then to this solution 5 mg PDMS-NH2 (2K)
(dissolved in 0.2 mL acetone) and sonicated at room temperature for
1 hr. The resulting solution was then casted on glass slides and
left for solvent evaporation and then cured at 120.degree. C. for 6
hrs in oven.
[0130] Sample 4.3: 0.7 mL polyol (MULTRANOL 4011) was dissolved in
1 mL acetone and then this solution 1.1 mL HDIT (DESMODUR N 100A)
was added followed by addition of 4 mg of CNC (dissolved in 0.2 mL
acetone). Then to this solution 5 mg PDMS-NH2 (2K) (dissolved in
0.2 mL acetone) and sonicated at room temperature for 1 hr. The
resulting solution was then casted on glass slides and left for
solvent evaporation and then cured at 120.degree. C. for 6 hrs in
oven.
[0131] Results: The samples were evaluated for clarity, ink
resistance, scratch resistance, contact angles, and sliding angles
as generally described above. For Samples 4.1-4.3, the clarity was
ranked as 3 on the scale of 1-5, where 5 is best. For Samples
4.1-4.3, the anti-ink was ranked as 4 on the scale of 1-5, where 5
is best). On a scale of 1-5, where 5 is best, the scratch
resistance properties were 4.5. On the scale of 1-5, where 5 is
best; water repellency was 4, and hexadecane repellency was 1
(wetted by the hexadecane). For Samples 4.1-4.3, water droplets
(size 75 .mu.L) had sliding angles in the range 28-31.+-.3.degree..
For Samples 4.1-4.3, hexadecane wet these surfaces.
Example 5--Solvent Selection
[0132] Example 5 illustrates the effect of various solvents used in
epoxy coating systems (Samples 5.1-5.9) and polyurethane coating
systems (Samples 5.10-5.15).
[0133] Sample 5.1 was prepared as above for Samples 1.1-1.3, but
with changing the solvent acetone to 2-Butanone.
[0134] Sample 5.2 was prepared as above for Samples 1.1-1.3, but
with changing the solvent acetone to acetonitrile.
[0135] Sample 5.3 was prepared as above for Samples 1.1-1.3, but
with changing the solvent acetone to methanol.
[0136] Sample 5.4 was prepared as above for Samples 1.1-1.3, but
with changing the solvent acetone to ethanol.
[0137] Sample 5.5 was prepared as above for Samples 1.1-1.3, but
with changing the solvent acetone to dimethyl carbonate.
[0138] Sample 5.6 was prepared as above for Samples 1.1-1.3, but
with changing the solvent acetone to THF.
[0139] Sample 5.7 was prepared as above for Samples 1.1-1.3, but
with changing the top layer solvent acetone to THF.
[0140] Sample 5.8 was prepared as above for Samples 1.1-1.3, but
with changing the top layer solvent acetone to 2-Butanone.
[0141] Sample 5.9 was prepared as above for Samples 1.1-1.3, but
with changing the top layer solvent acetone to acetonitrile.
[0142] Results: The samples were evaluated for clarity, ink
resistance, scratch resistance, contact angles, and sliding angles
as generally described above. For Samples 5.1-5.9 (except 5.6-5.7),
the clarity was ranked as 3 on the scale of 1-5, where 5 is best.
For Samples 5.6-5.7, the clarity was ranked as 5. For Samples
5.1-5.9, the anti-ink resistance was ranked as 5 on the scale of
1-5, where 5 is best). On a scale of 1-5, where 5 is best, the
scratch resistance properties were 5 for samples 5.1-5.9. On the
scale of 1-5, where 5 is best; Samples 5.6-5.7, ranked as 5 for
water and hexadecane repellency. For Samples 5.1-5.5 and 5.8-5.9,
they are ranked as 2 for water and hexadecane repellency.
[0143] Sample 5.10 was prepared as above for Samples 3.1-3.3, but
with changing the solvent acetone to 2-Butanone.
[0144] Sample 5.11 was prepared as above for Samples 3.1-3.3, but
with changing the solvent acetone to acetonitrile.
[0145] Sample 5.12 was prepared as above for Samples 3.1-3.3, but
with changing the solvent acetone to THF.
[0146] Sample 5.13 was prepared as above for Samples 3.1-3.3, but
with changing the top layer solvent acetone to THF.
[0147] Sample 5.14 was prepared as above for Samples 3.1-3.3, but
with changing the top layer solvent acetone to 2-Butanone.
[0148] Sample 5.15 was prepared as above for Samples 3.1-3.3, but
with changing the top layer solvent acetone to acetonitrile.
[0149] Results: The samples were evaluated for clarity, ink
resistance, scratch resistance, contact angles, and sliding angles
as generally described above. For Samples 5.10-5.15 (except 5.12
and 5.13), the clarity was ranked as 3 on the scale of 1-5, where 5
is best. For Samples 5.12 and 5.13, the clarity was ranked as 5.
For samples 5.10-5.15 the anti-ink resistance was ranked as 5 on
the scale of 1-5, where 5 is best). On a scale of 1-5, where 5 is
best, the scratch resistance properties were 5 for samples
5.10-5.15. On the scale of 1-5, where 5 is best; Samples 5.12-5.13
ranked as 5 for water and hexadecane repellency. For Samples
5.10-5.11 and 5.14-5.15, they are ranked as 3 for water and 1 for
hexadecane repellency.
Example 6--PDMS Molecular Weight
[0150] Example 6 illustrates the effect of different PDMS molecular
weights used in epoxy coating systems (Samples 6.1-6.3) and
polyurethane coating systems (Samples 6.4-6.6).
[0151] Samples 6.1-6.3 were prepared as above for Samples 1.1-1.3
(epoxy system), but with changing the PDMS-NH2 (2K molecular
weight) to PDMS-NH2 (1K molecular weight).
[0152] Samples 6.4-6.6 were prepared as above for Samples 3.1-3.3
(polyurethane system), but with changing the PDMS-NH2 (2K molecular
weight) to PDMS-NH2 (1K molecular weight).
[0153] Results: The samples were evaluated for clarity, ink
resistance, scratch resistance, contact angles, and sliding angles
as generally described above. For Samples 6.1-6.3, the clarity was
ranked as 5 on the scale of 1-5, where 5 is best. For Samples
6.1-6.3, the anti-ink resistance was ranked as 5 on the scale of
1-5, where 5 is best). On a scale of 1-5, where 5 is best, the
scratch resistance properties were 5 for Samples 6.1-6.3. On a
scale of 1-5, where 5 is best, Samples 6.1-6.3 ranked as 5 for
water repellency (sliding angles: 19-23.degree. (50 .mu.L), contact
angles: 96-101.degree. 5 .mu.L). Samples 6.1-6.3 ranked as 5 for
hexadecane repellency (sliding angles: 10-11.degree. 10 .mu.L,
contact angles: 39-52.degree. 5 .mu.L). For Samples 6.4-6.6, the
clarity ranked as 5 on the scale of 1-5, where 5 is best. For
Samples 6.4-6.6, the anti-ink resistance ranked as 5 on the scale
of 1-5, where 5 is best). On a scale of 1-5, where 5 is best, the
scratch resistance properties were 4 for Samples 6.4-6.6. On a
scale of 1-5, where 5 is best, Samples 6.4-6.6 ranked as 5 for
water repellency. Samples 6.4-6.6 ranked as 5 for hexadecane
repellency.
Example 7--Polyurethane Coating Systems with Top-Layer PDMS
Functionalization Applied to Large Substrates
[0154] Example 7 illustrates thermoset polyurethane omniphobic
coatings according to the disclosure and including a polyisocyanate
thermosetting component (UH80 available from Sherwin-Williams), a
polyol thermosetting component (CC939 available from
Sherwin-Williams), and an amino-functional PDMS omniphobic polymer
in a scaled-up process in which the coatings are applied to
large-area substrates of about 15 cm.times.15 cm (about 6
inch.times.6 inch) and about 15 cm.times.30 cm (about 6
inch.times.12 inch) (Samples 7.1-7.3). An initial base coat or
layer of polyurethane is applied with the polyisocyanate
thermosetting component and the polyol thermosetting component
using a spraying, casting, or drawdown bar method, and then the top
layer of the base coat is contacted and functionalized with an
amino-functional PDMS omniphobic polymer via dipping (Sample 7.1),
spray coating (Sample 7.2), or brush coating (Sample 7.3).
[0155] Sample 7.1: In general, a base layer of polyurethane was
applied to a large-area substrate with a drawdown bar, and then the
coated substrate was dipped in diamino-PDMS solution (i.e., having
two amino functional groups per PDMS chain). First, urethane
coating solutions were prepared by mixing polyol (CC939; 1 mol) and
polyisocyanates (UH80; 1.1 mol). Then the base urethane coating was
applied to the substrates from the coating solutions using a
drawdown bar method. The films were allowed to air-dry until the
films were vitrified (typically for 1 hr at about 20-25.degree. C.
or room temperature). Then, these films on the coated substrates
were dipped into a diamino-PDMS solution (NH.sub.2--PDMS-NH.sub.2;
MW 2500 g/mol) solution (1 wt. % in hexane) for different time
periods ranging from 5 seconds up to 3 minutes dip time. Then,
panels were immediately rinsed with pentane to remove an unreacted
PDMS chains from the surface. The end films were not only water-
and oil-repellent but also very clear and showed good ink-resistant
properties.
[0156] Sample 7.2: In general, a base layer of polyurethane was
applied to a large-area substrate with a drawdown bar, and then the
coated substrate was spray coated with an amino-PDMS solution
(i.e., having one amino functional group per PDMS chain). First,
urethane coating solutions were prepared by mixing polyol (CC939; 1
mol) and polyisocyanates (UH80; 1.1 mol). Then the base urethane
coating was applied to the substrates from the coating solutions
using a drawdown bar method. The films were allowed to air-dry
until the films were vitrified. Then, these films were spray coated
with an amino-PDMS solution (PDMS-NH.sub.2; MW 2000 g/mol) solution
(1-5 wt. % in hexane) until the surfaces of the films were
completely covered/wet by the amino-PDMS solution. Then, the panels
were immediately rinsed with pentane to remove unreacted PDMS
chains from the surface. The films were allowed to air-dry for
several hours at about 20-25.degree. C. (room temperature) or in
some cases heated at 70.degree. C. to speed the curing process. The
end films were not only water- and oil-repellent, but also showed
good ink-resistant properties.
[0157] Sample 7.3: In general, a base layer of polyurethane was
applied to a large-area substrate with a drawdown bar, and then the
coated substrate was brush coated with an amino-PDMS solution
(i.e., having one amino functional group per PDMS chain). First,
urethane coating solutions were prepared by mixing polyol (CC939; 1
mol) and polyisocyanates (UH80; 1.1 mol). Then the base urethane
coating was applied to the substrates from the coating solutions
using spraying, casting, and drawdown bar methods. The films were
allowed to air-dry until the films were vitrified. Then, these
films were brush coated with an amino-PDMS solution (PDMS-NH.sub.2;
MW 2000 g/mol) solution (1-5 wt. % in hexane) until the surfaces of
the films were completely covered/wet by the amino-PDMS solution.
Then, the panels were immediately rinsed with pentane to remove
unreacted PDMS chains from the surface. The films were allowed to
air-dry for several hours at about 20-25.degree. C. (room
temperature) or in some cases heated at 70.degree. C. to speed the
curing process. The end films were not only water- and
oil-repellent, but also showed good clarity and ink-resistant
properties.
[0158] Because other modifications and changes varied to fit
particular operating requirements and environments will be apparent
to those skilled in the art, the disclosure is not considered
limited to the example chosen for purposes of illustration, and
covers all changes and modifications which do not constitute
departures from the true spirit and scope of this disclosure.
[0159] Accordingly, the foregoing description is given for
clearness of understanding only, and no unnecessary limitations
should be understood therefrom, as modifications within the scope
of the disclosure may be apparent to those having ordinary skill in
the art.
[0160] All patents, patent applications, government publications,
government regulations, and literature references cited in this
specification are hereby incorporated herein by reference in their
entirety. In case of conflict, the present description, including
definitions, will control.
[0161] Throughout the specification, where the compositions,
processes, kits, or apparatus are described as including
components, steps, or materials, it is contemplated that the
compositions, processes, or apparatus can also comprise, consist
essentially of, or consist of, any combination of the recited
components or materials, unless described otherwise. Component
concentrations can be expressed in terms of weight concentrations,
unless specifically indicated otherwise. Combinations of components
are contemplated to include homogeneous and/or heterogeneous
mixtures, as would be understood by a person of ordinary skill in
the art in view of the foregoing disclosure.
* * * * *