Durable polymer-aerogel based superhydrophobic coatings, a composite material

1. A method for preparing a polymer-aerogel composite coating comprising:

providing a superhydrophobic coating solution, the superhydrophobic coating solution comprising a surface derivatized polysilicate aerogel dispersed in a first solvent, the polysilicate aerogel comprising a three dimensional network of silica particles having surface functional groups derivatized with a silylating agent;

blending a polymer solution and the superhydrophobic coating solution to form a polymer-aerogel solution, wherein the polymer solution comprises one or more polymers dispersed in a second solvent;

dissolving the polymer in the polymer-aerogel blend solution at a first temperature; and

forming, a polymer-aerogel composite coating by applying the polymer-aerogel blend solution to a substrate surface while keeping the polymer-aerogel blend solution at the first temperature, such that the polymer wets the aerogel in the polymer-aerogel composite coating,

wherein the surface derivatized polysilicate aerogel is an ultra high water content acid catalyzed polysilicate aerogel formed using a third solvent, at least one alkoxy silane precursor, water, and an acid, such that a molar ratio of water to alkoxy silane precursor is in the range of about 10 or more, wherein the polysilicate aerogel comprises a three dimensional network of silica particles having surface functional groups and a plurality of pores, and wherein a fluid is disposed in the plurality of pores, the fluid comprising the third solvent; and

prior to blending the polymer solution and the superhydrophobic coating solution, replacing the fluid disposed in the plurality of pores of the polysilicate aerogel with a fourth solvent, wherein the fourth solvent is immiscible with the third solvent.

2. The method for preparing a polymer-aerogel composite coating, according to claim 1 , further comprising:

derivatizing the surface functional groups using a silylating agent to form a surface derivatized polysilicate aerogel; and

forming a superhydrophobic coating solution of the surface derivatized polysilicate aerogel in the first solvent.

3. The method for preparing a polymer-aerogel composite coating, according to claim 2 , wherein the alkoxy silane precursor comprises one or more silane compounds selected from the group consisting of methyltrimethoxy silane, vinyltrimethoxy silane, dimethyldiethoxy silane, methacryloxypropyltrimethoxy silane, mercaptopropyltrimethoxy silane, chloropropyltrimethoxy silane, bromopropyltrimethoxy silane, iodopropyltrimethoxy silane, and chloromethyltrimethoxy silane, tetraethoxysilane, tetramethoxysilane, and 1,2-bis(triethoxysilyl)ethane.

4. The method for preparing a polymer-aerogel composite coating, according to claim 2 , wherein the silylating agent comprises at least one compound selected from the group consisting of trimethylchlorosilane, trichloromethylsilane, trichlorooctylsilane, hexamethyldisilazane and a silane comprising at least one hydrophobic ligand.

5. The method for preparing a polymer-aerogel composite coating, according to claim 2 , wherein the third solvent is the same as the first solvent.

6. The method for preparing a polymer-aerogel composite coating, according to claim 2 , wherein the step of replacing the third solvent present in the plurality of pores of the polysilicate aerogel with the fourth solvent comprises:

(a) breaking up the ultra high water content acid catalyzed polysilicate aerogel to form a broken gel;

(b) adding the fourth solvent to the broken gel at a temperature in the range of about 40° C. to about 60° C. for at least about 30 minutes;

(c) removing a portion of the fourth solvent and the third solvent from the broken gel; and

(d) repeating steps b and c at least three times.

7. The method for preparing a polymer-aerogel composite coating, according to claim 2 , wherein the step of derivatizing the surface functional groups using a silylating agent to form a surface derivatized polysilicate aerogel comprises:

gradually adding to the polysilicate aerogel a silylating agent, the silylating agent comprising at least one compound selected from the group consisting of trimethylchlorosilane, trichloromethylsilane, trichlorooctylsilane, hexamethyldisilazane and a silane comprising at least one hydrophobic ligand;

storing the polysilicate aerogel in silylating agent at a temperature in the range of about 40° C. to about 60° C. for about 6 hours to about 10 hours to form a surface derivatized polysilicate aerogel; and

removing a portion of the silylating agent.

8. The method for preparing a polymer-aerogel composite coating, according to claim 2 , wherein the step of forming a coating solution of the surface derivatized polysilicate aerogel in a first solvent comprises:

washing the surface derivatized polysilicate aerogel with the fourth solvent;

washing the surface derivatized polysilicate aerogel with the first solvent at least twice; and

adding the first solvent to the surface derivatized polysilicate aerogel to form a coating solution.

9. The method for preparing a polymer-aerogel composite coating, according to claim 1 , wherein the first solvent is the same as the second solvent.

10. The method for preparing a polymer-aerogel composite coating, according to claim 1 , wherein the polymer comprises at least one compound selected from the group consisting of poly(methyl methacrylate), polystyrene, poly(butyl methacrylate), poly(tert-butyl methacrylate), poly(methyl acrylate), poly(butyl acrylate), poly(tert-butyl acrylate), poly(perfluorooctyl methacrylate) and a vinyl polymer.

11. The method for preparing a polymer-aerogel composite coating, according to claim 1 , wherein the step of forming a polymer-aerogel composite coating comprises applying the polymer-aerogel blend solution using at least one of dip coating, brush coating, roller coating, spray coating, spin coating, casting, and flow coating.

12. The method for preparing a polymer-aerogel composite coating, according to claim 1 , wherein the step of forming a polymer-aerogel composite coating further comprises heating the substrate to a second temperature greater than the first temperature.

13. The method for preparing a polymer-aerogel composite coating, according to claim 1 , wherein the substrate surface comprises at least one material selected from the group consisting of a metal, silicon, a glass, a ceramic, a plastic and a fabric.