Adv Materials Inter - 2024 - Patil - Facile Approach For Designing Icephobic Coatings Using Polymers Silica Nanoparticle

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RESEARCH ARTICLE

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Facile Approach for Designing Icephobic Coatings Using


Polymers/Silica Nanoparticle Composites via Self-Formation
of Superhydrophobic Surfaces
Aravind H. Patil, Ngoc Le Trinh, Hackwon Do, Houda Gaiji, Youngho Kang, Joohan Lee,
Changhyun Chung,* and Han-Bo-Ram Lee*

negatively affect the efficiency of various


Ice accumulation and proliferation adversely affect the activities of various domestic and industrial applications,
residential, commercial, and polar research stations. Although significant including power transmission cables,
efforts are devoted to preventing ice adhesion to various surfaces by wind turbines, telecommunication
developing various anti-icing coatings, it is still necessary to enhance overall equipment, offshore platforms, solar
panels, and other infrastructure, thereby
performance and durability. Herein, a facile approach is proposed for leading to socioeconomic and safety
fabricating an icephobic coating on an aluminum 6061 (Al) substrate, by issues.[2–4] Anti-icing and de-icing tech-
coating a poly(dimethylsiloxane) (PDMS)/ poly(tetrafluoroethylene) (PTFE) niques are primarily classified into two
composite through a spin-coating method, followed by sprinkling of SiO2 categories: active and passive, which are
nanoparticles (NPs). Crosslinker/binder-free adhesion between PDMS and distinguished based on the use of an
external force.[1] Various conventional
PTFE is achieved by utilizing secondary-induced electrostatic dipole-dipole
active anti-icing methods for combat-
interactions, these interactions are supported by density functional theory ing icing issues include mechanical
(DFT) calculations as well as structural studies. Moreover, the controlled scrapping of ice, infrared thermal treat-
addition of PTFE powder to PDMS improves the water-repellency, mechanical ments, chemical treatments, and the
strength, and surface roughness of the coating. The self-formation of the use of antifreeze solutions and salts.[5]
superhydrophobic state of the PDMS/PTFE composite is achieved by However, these methods are ineffective,
time-consuming, energy-consuming,
sprinkling SiO2 NPs. The sprinkled SiO2 NPs are protected by the expensive, and harmful to the environ-
PDMS/PTFE composite, which serves as a stress concentrator to achieve low ment. Thus, over the last five decades,
ice adhesion. Furthermore, freezing at low temperatures can be delayed by substantial research efforts have been
controlling the heat flow rate, interfacial contact area, and surface texture. devoted to the design of durable passive
This indicates the feasibility of the proposed method for various promising icephobic surfaces.[6,7] Icephobicity can
be achieved in several ways, such as by
anti-icing applications.
lowering the ice adhesion strength (IAS,
𝜏ice), minimizing the interfacial contact
area between supercooled water/ice with
1. Introduction coating, delaying the ice nucleation, reducing the rate of heat
transfer at solid/liquid interface, and preventing the transition
Ice formation and accretion are inevitable phenomena in ex- from the Cassie–Baxter (CB) state to the Wenzel state.[8–11] Such
tremely cold environments.[1] Ice accumulation and proliferation passive icephobic coatings are expected to address long-term

A. H. Patil, N. L. Trinh, H. Gaiji, Y. Kang, H.-B.-R. Lee A. H. Patil, J. Lee, C. Chung


Department of Materials Science and Engineering Center of Technology Development
Incheon National University Korea Polar Research Institute
Incheon 22012, Republic of Korea Incheon 21990, Republic of Korea
E-mail: hbrlee@inu.ac.kr E-mail: ch.chung@kopri.re.kr
H. Do
Division of Life Sciences
The ORCID identification number(s) for the author(s) of this article Korea Polar Research Institute
can be found under https://doi.org/10.1002/admi.202300919 Incheon 21990, Republic of Korea
© 2024 The Authors. Advanced Materials Interfaces published by
Wiley-VCH GmbH. This is an open access article under the terms of the
Creative Commons Attribution License, which permits use, distribution
and reproduction in any medium, provided the original work is properly
cited.
DOI: 10.1002/admi.202300919

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issues with undesired ice formation by allowing ice to be re- presence of the fluorinated ligand (─CF2 ) within PVDF signif-
moved by simple perturbations of natural forces such as gravity icantly contributed to the reduction in IAS. However, aiming to
and wind.[12] reduce the surface energy of the coating further and enhance me-
To date, various research groups have used poly(dimethy- chanical strength, we have chosen PTFE, which is recognized as a
lsiloxane) (PDMS) to develop passive low ice adhesion superior fluoropolymer compared to PVDF. PTFE exhibits excep-
coatings[13–16] because of its tunable mouldability, hydropho- tional properties, such as excellent hydrophobicity, low surface
bicity, low surface energy (19–21 mN m−1 ),[17] and viscoelastic energy, and robust mechanical strength derived from its unique
nature.[13] These exceptional properties of PDMS render it molecular structure composed solely of ─CF2 ligands.[26,27] Thus,
a promising material for applications in the fields of super- to address limitations regarding surface roughness improvement
hydrophobicity and icephobicity. However, PDMS has low and surface energy reduction, we introduced SiO2 NPs along with
mechanical strength, which restricts the ice prevention from its PTFE. Subsequently, PDMS/PTFE/SiO2 NPs composite coatings
coating to considerably fewer icing and de-icing cycles.[18] To were prepared and investigated to assess the effect of SiO2 NP
overcome this issue, it is necessary to improve the mechanical sizes on superhydrophobicity, freezing delay time, and icepho-
strength of the coating without losing its softness and elastic bicity (Table 1).
nature.[19] Soft elastic coatings produce deformation incompati- In this study, a simple method is developed to prepare su-
bility at the ice/coating interface owing to the mismatch of the perhydrophobic/icephobic coatings on Al substrate by coating
elastic moduli, which promotes easy detachment of ice from the PDMS/PTFE composite through the spin-coating method, fol-
coating surface.[20] In addition, the mechanical strength of the lowed by sprinkling of SiO2 NPs on it. A controlled amount
coating is a crucial factor for maintaining the superhydrophobic of PTFE powder was added to the viscous PDMS to lower the
CB state for several icing and de-icing cycles under prolonged surface energy, improve mechanical strength, and maintain the
exposure to extremely low temperatures and harsh conditions. viscoelasticity of the coating. Additionally, we demonstrated ex-
In the literature, there are reports on the integration perimentally and theoretically that the electrostatically driven
of polymers such as poly(vinylidene fluoride) (PVDF),[21] induced dipole-dipole interactions between the H atoms (pos-
poly(tetrafluoroethylene) (PTFE),[22] and polyhedral oligomeric itively charged) of PDMS and F atoms (negatively charged) of
silsesquioxane (POSS)[23] into PDMS, which improved the me- PTFE were responsible for the binder-free adhesion in PDMS
chanical strength and superhydrophobicity/icephobicity of the and PTFE. Surface morphology analysis revealed that the for-
coatings. Moreover, the covalent bonding strategy has also been mation of porous 3D micro-nanostructured surfaces of the
implemented to improve the mechanical robustness of the super- PDMS/PTFE/SiO2 NPs composite were highly textured surfaces
hydrophobic state. Particularly, the hydrolyzed glycidoxypropy- with several trapped air voids. These air voids minimized the sur-
ltrimethoxysilane was used as a connecting layer for coating the face contact area with water droplets or ice, thereby improving
hexamethyldisilazane-modified SiO2 NPs on a hydrophilic Al the water contact angle (WCA) and reducing the IAS. Moreover,
substrate.[24] Among them, PTFE is the best fluoropolymer with the relationship between IAS and surface wettability was inves-
high mechanical strength, low surface energy (18 mN m−1 ),[25] tigated for various coating surfaces. Furthermore, we provide ex-
hydrophobic nature, and low frictional coefficient.[26] Addition- perimental insights into the ice freezing delay time (FDT) for var-
ally, PTFE (Teflon) is widely used in the non-stick cookware ious surface wettabilities.
industry.[27] Owing to its unique characteristics, PTFE is an
excellent candidate for lowering ice adhesion, improving me-
chanical strength, and maintaining the thermal stability of coat- 2. Results and Discussion
ings at extremely low temperatures. Various approaches, includ-
ing RF-sputtering,[28] plasma treatment,[29] and chemical vapor 2.1. Density Functional Theory Calculations and Structural
deposition,[30] have been employed to prepare PDMS/PTFE com- Analyses
posites. However, these techniques are expensive and unfeasible
for large-scale applications. The impact of the relative orientation of the PDMS and PTFE
In our previous work, we successfully developed simple polymeric chains on the adhesive and mixing properties was ex-
methods for preparing superhydrophobic and icephobic coat- amined using DFT calculations. Different possible orientations
ings by sprinkling micron-sized SiO2 particles onto PDMS and of the polymeric chains were used to compute the interaction en-
PDMS/PVDF surfaces.[21,31] These studies demonstrated that the ergies between
sprinkling of SiO2 particles was responsible for the creation of PDMS and PTFE. The interaction energy was calculated using
micro-nanoscale surface roughness. Moreover, self-formation of Equation (1).
superhydrophobic surfaces was achieved through interfacial en- ( )
ergy engineering between the PDMS solution and SiO2 parti- Einteraction = EPTFE+PDMS − EPDMS + EPTFE (1)
cles. Coatings with smaller particle sizes exhibited higher sur-
face roughness and lower corresponding IAS. However, because As shown in Figure 1a, DFT calculations illustrate that the in-
we used micro-sized SiO2 particles, which produced only limited teraction energy mainly depends on the relative orientation of the
surface roughness, we could not further reduce the IAS. Particu- PDMS and PTFE chains. The oriented geometry with the highest
larly, the PDMS/PVDF/SiO2 composite coating with 1.3 μm size possibility of interactions between the F and H atoms exhibited
of SiO2 particles showed an IAS of 46 kPa at −35 °C and 55% hu- the lowest physisorption energy of −0.5 eV (configurations #2
midity. The integration of PVDF into PDMS resulted in improved and #5). This phenomenon is attributed to the positive charge
hydrophobicity and mechanical strength of the coating.[21] The of the H atom and the negative charge of the F atom. However,

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Table 1. Comparison of present work with relevant previous reports.

Coating Synthesis technique Temperature WCA [°] IAS [kPa] Reference


[°C]

PDMS/PTFE/SiO2 NPs Self-formation of porous 3D −15 ± 1 163.9 ± 0.2 27 ± 3 Present work


micro-nanostructure by sprinkling SiO2 NPs
on PDMS/PTFE surface
PDMS/PVDF/SiO2 microparticles Self-formation of superhydrophobic surface by −35 161 ± 0.5 46 [21]
sprinkling micron-sized SiO2 on the
PDMS/PVDF
Porous PDMS Curing and phase separation method −18 120.3 40 [32]
Carbon nanowire/PDMS composite Laser etching −10 155.4 ± 0.5 39.55 [33]
Carbon nanotube/PDMS composite Shear dispersion and ambient curing −10 ± 2.6 160.7 ± 1.5 38.4 [34]
1H,1H,2H,2H-heptadecafluorodecyl)- Acid etching and thermal treatment −20.5 170.5 ± 1 25.3 [35]
trimethoxysilane and PDMS

when F and O atoms face each other, the interaction energy be- 0.025a0 −3 , shown in Figure 1b. Specifically, for configuration #5,
tween PDMS and PTFE is observed slightly higher (−0.2 eV; con- the electrostatic potential ranges from −10.81 Ry (blue) to +1.97
figurations #4 and #6). This is because F and O atoms are neg- Ry (red). The electrostatic potentials around the H atoms in both
atively charged. Moreover, the electron density isosurface is col- polymeric chains are relatively low; the color is close to green, in-
ored based on electrostatic potentials, with an isosurface level of dicating hydrogen is positively charged. Whereas, those around
the F and O sites are higher; the color is close to red, indicating
they are negatively charged. Overall, DFT calculations reveal that
PDMS and PTFE polymeric molecules are attracted to each other
via induced dipole-dipole electrostatic interactions between F and
H atoms.[36]
The microstructure and chemical composition of the
PDMS/PTFE composite were analyzed using X-ray diffrac-
tion (XRD), Fourier-transform infrared (FTIR) spectroscopy,
and X-ray photoelectron spectroscopy (XPS). Figure 2a shows
the XRD patterns of PDMS, PTFE, and the PDMS/PTFE com-
posite. In the XRD pattern of bare PDMS, the presence of a
low-intensity wide single peak at 11.77° confirms the formation
of amorphous PDMS.[37] In the XRD pattern of the bare PTFE,
the diffraction peaks at 18.03°, 31.50°, and 36.59° correspond to
the (100), (110), and (107) crystal planes of the hexagonal crystal
structure of PTFE, respectively.[37] Moreover, in the XRD pattern
of the PDMS/PTFE composite, the amorphous peak of PDMS
is present at 11.77°; other diffraction peaks of PTFE are also
present. The XRD results are well consistent with previously
published reports.[37,38]
Figure 2b shows the FTIR spectra of PDMS, PTFE, and the
PDMS/PTFE composite. The peaks located at 867 and 914 cm−1
correspond to the asymmetric rocking of the ─CH3 groups of
PDMS. The peaks at 1008 and 1255 cm−1 are assigned to silox-
ane backbone Si-O-Si asymmetrical stretching vibrations and
bending vibrations of the CH3 groups of PDMS. Importantly, in
the FTIR spectra of the PDMS/PTFE composite, the absorption
peaks at 1208 and 1160 cm−1 correspond to the ─CF2 bond of
PTFE.[36] In PDMS/PTFE composite spectra, the peaks at 2160
and 2962 cm−1 are attributed to the C─H asymmetric and CH3
asymmetric stretch respectively, which are assigned to PDMS.[36]
The FTIR and DFT results demonstrate that no primary bonds
are formed between PDMS and PTFE, indicating that the com-
posite is formed owing to secondary interactions between them.
Figure 1. Results of DFT calculations a) Interaction energies (in eV) for six
possible configurations, and b) the interaction between PDMS and PTFE Furthermore, XPS analysis was performed to obtain informa-
polymeric chains and their electron-density isosurfaces colored according tion on the chemical valence states and corresponding binding
to electrostatic potentials, with an isosurface level of 0.025a0 −3 . energies (BEs) of PDMS, PTFE, and the PDMS/PTFE composite.

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Figure 2. a) XRD, b) FTIR, c) XPS survey spectra of PDMS, PTFE, and PDMS/PTFE composite d) C1s spectra e) F1s spectra of PTFE and PDMS/PTFE
composite, and f) schematic for secondary interaction between PDMS and PTFE.

As shown in Figure 2c, the survey spectrum of the PDMS/PTFE slightly shifted toward a lower BE of ≈0.58 eV, compared with
composite confirms the presence of Si2p, Si2s, C1s, O1s, and bare PTFE, as shown in Figure 2d. Additionally, in the high-
F1s characteristic peaks corresponding to the BEs of 98.31, resolution F1s spectra of PTFE and the PDMS/PTFE composite,
150.97, 281.38, 529.54, and 687.80 eV, respectively.[39] As shown the F1s peak is observed at 688.14 and 687 eV, respectively, as
in Figure 2d, the core-level spectrum of C1s (PDMS/PTFE shown in Figure 2e. The F1s peak of the PDMS/PTFE composite
composite) reflects two peaks at BEs of 282.22 and 290.27 eV, is shifted toward the lower BE of 1.14 eV as compared to bare
corresponding to the Si─C bond of PDMS and ─CF2 bond of PTFE. The BEs of the characteristic peaks of bare PDMS, bare
PTFE, respectively.[40,41] The peak corresponding to the ─CF2 PTFE, and the PDMS/PTFE composite are summarized in Table
bond in the C1s spectrum of the PDMS/PTFE composite is S1 (Supporting Information). In particular, shifts in the F1s and

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Figure 3. a) FESEM images of bare PDMS and 9:1 to 5:5 weight percent ratio of PDMS to PTFE, b) WCA and WSA, and c) RMS surface roughness and
ice adhesion strength.

C1s (─CF2 bond) spectra are observed because of the interaction PDMS contains C, O, and Si, whereas the PDMS/PTFE compos-
of the H atom of PDMS with the highly electronegative F atom ite contains F from PTFE in addition to C, O, and Si (see Figure
of PTFE.[36] These shifts in the BE positions of the characteristic S2a,b, Supporting Information). The weight percentage of F in
peaks suggest that the PTFE particles interact with the PDMS the composite coatings increased from 5.74% to 35.12% as the
chains through secondary interactions, which is consistent with weight ratio of PDMS to PTFE changed from 9:1 to 5:5. The FE-
the DFT calculation results shown in Figure 2f. SEM results showed good dispersion of the PTFE particles in the
PDMS chains, as expected from the DFT calculations and struc-
tural analysis results.
2.2. PDMS/PTFE Composites Figure 3b shows the WCA and water sliding angle (WSA) of the
bare PDMS and PDMS/PTFE composite coatings. The WCA and
Figure 3a shows the surface morphology and elemental mapping WSA of the bare PDMS coating were 114.8 ± 0.7° and 23 ± 1°, re-
analysis of the bare PDMS and PDMS/PTFE coatings with vari- spectively. As the amount of PTFE increased in PDMS, the WCA
ous weight percent ratios in the range of 9:1–5:5. The surface of increased linearly from 114.8 ± 0.7° to 118.2 ± 0.5°. This sug-
the bare PDMS coating is observed flat, uniform, and smooth, as gests that the addition of PTFE to PDMS results in a slight in-
shown in Figure 3a. crement in the hydrophobicity of the composite. However, no
As the weight percent ratio of PDMS to PTFE varied from 9:1 significant change is observed in the WSA after the addition of
to 5:5, bright-contrast PTFE particles are observed in the field PTFE to PDMS. Figure 3c depicts the root mean square (RMS)
emission scanning electron microscopy (FESEM) images. The surface roughness and IAS of bare PDMS and PDMS/PTFE com-
average particle size of bare PTFE particles determined using posite coatings with various weight percent ratios (9:1–5:5). The
FESEM analysis is ≈166 ± 3 nm (see Figure S1, Supporting In- bare PDMS coating exhibited a considerably low surface RMS
formation). The elemental mapping images revealed that bare roughness of 8.55 nm and IAS of 225 ± 3.6 kPa. The bare Al

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Figure 4. FESEM images of a) PDMS/SiO2 NPs, b) PDMS/PTFE/SiO2 NPs (8:2), and c) PDMS/PTFE/SiO2 NPs (6:4).

substrate exhibited the highest IAS of 614 ± 4 kPa because of microscale SiO2 powder, PDMS, and PDMS/PVDF composites.
the high contact angle hysteresis, hydrophilic nature, and hard- Similar to our previous studies,[21,31] SiO2 NPs with various sizes
ness properties of the Al substrate (see Table S2, Supporting In- were added to the PDMS/PTFE composite samples at mixing
formation). In contrast, the PDMS/PTFE (6:4) coating showed ratios of 8:2 and 6:4. Figure 4a–c shows the FESEM images of
IAS of 202 ± 3.6 kPa. The IAS of PDMS/PTFE (6:4) is reduced PDMS, PDMS/PTFE (8:2), and PDMS/PTFE (6:4), respectively.
by approximately three times compared to that of bare Al, likely As shown in Figure 4a, the SiO2 NPs are perfectly covered by
owing to the elastic nature,[42] hydrophobicity, and low surface PDMS of all sizes, and the morphological features of the NPs are
energy ─CF2 and ─CH3 ligands of the PDMS/PTFE composite. still observed on the surface. For both the PDMS/PTFE samples
The elastic nature of the coating promotes the easy detachment as shown in Figure 4b,c, the SiO2 NPs are also covered by the
of ice by creating deformation incompatibility at the coating and composite layer, but the surface roughness from the morpholog-
ice interface.[13] Additionally, as the amount of PTFE in the com- ical features is considerably higher than that of the PDMS sam-
posite increased from 9:1 to 5:5 weight percent ratio, the corre- ple.
sponding surface roughness increased gradually from 13.32 to Surface roughening was achieved by sprinkling SiO2 NPs
63.22 nm. The increase in surface roughness can be attributed to over the PDMS/PTFE composite surface, and the interactions
the higher volume fraction of PTFE particles creating nanoscale between them were theoretically calculated to understand the
peaks and valleys at the coating surface.[43] This slight change in self-formation mechanism. The interaction and self-formation
surface roughness due to the addition of PTFE to PDMS also af- mechanism of the porous 3D micro-nanostructure of the
fected the IAS. Moreover, the coating with a PDMS:PTFE weight PDMS/PTFE/SiO2 NPs composite is described based on Stokes’
ratio of 5:5 exhibited superior properties, such as hydrophobic- law and the Washburn equation. We assumed the interaction of a
ity and IAS, compared to the other composites. However, as ob- single SiO2 particle with viscous PDMS. After the SiO2 NPs were
served in synthesis, after mixing a 5:5 weight percent ratio of sprinkled onto the surface of the viscous PDMS, the SiO2 parti-
PDMS (viscous) to PTFE (solid), the viscosity of the resulting mix- cles started to sediment because of their higher density. The sedi-
ture was highly increased. Owing to its high viscosity, it was not mentation velocity of a single SiO2 particle in viscous PDMS was
appropriate to produce a uniform film by spin-coating. calculated using Stokes’ law of viscosity (Equation 2) as follows.
[ ]
𝜌s − 𝜌l
v = g D2 (2)
2.3. Synthesis Mechanism and Surface Morphology 18𝜇

As described in the Introduction, we reported an easy process Where v is the terminal (sedimentation) velocity of SiO2 NPs in
for fabricating superhydrophobic and icephobic surfaces using m s−1 , 𝜌s and 𝜌l are the densities of SiO2 NPs (2.4 g cm−3 ) and

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PDMS (0.965 g cm−3 ), respectively, μ is the viscosity of PDMS and ─CF2 ligands within the PDMS/PTFE composite.[21] As de-
(3.5 Pa s), g is the acceleration due to gravity (9.8 m s−2 ), and scribed in the mechanism of self-formation superhydrophobic
D is the diameter of SiO2 NPs in nm. The calculated sedimen- surface, the sprinkling of SiO2 NPs is mainly responsible for
tation velocities for SiO2 NPs with diameters of 65, 25, 15, and creating a porous 3D micro-nanostructured surface. Owing to
10 nm were ≈0.94, 0.14, 0.05, and 0.022 pm s−1 , respectively. the sprinkling of SiO2 NPs over viscous PDMS/PTFE composite,
Moreover, another interaction mechanism involves the drawing- the surface morphology significantly altered from flat to rough
up of PDMS into the stacked SiO2 NPs due to the capillary imbi- (Figures 3 and 4). This significant change in the surface rough-
bition phenomenon. The capillary penetration length (L in μm) of ness is attributed to the creation of interconnected peaks and val-
PDMS was calculated using Washburn’s Equation (3) as follows. leys within the interface of the PDMS/PTFE/SiO2 NPs composite
(Figure 4c). The presence of several trapped air voids within the
√ composite surface reduces the physical contact area with the wa-
𝛾rtCos𝜃 ter droplet. Overall, this formation of a rough surface, coupled
L = (3)
2𝜇 with the low surface energy PDMS/PTFE, leading to the com-
posite surface with a high WCA and low contact angle hysteresis,
Where, 𝛾, r, t, μ, and 𝜃 are the surface tension of PDMS facilitates the easy roll-off capabilities to water droplets.
(22.1 mJ m−2 ), average pore radius (nm), time (s), dynamic vis-
cosity (3.5 Pa s), and contact angle (0°) between the viscous PDMS
and the solid SiO2 NPs, respectively. After sprinkling SiO2 NPs
on the PDMS surface, the viscous PDMS immediately begins to 2.4. Surface Wettability and Ice Adhesion Strength
penetrate under capillarity action and drawing up to the stacked Measurements
SiO2 NPs. The calculated penetration lengths for SiO2 NPs with
diameters of 65, 25, 15, and 10 nm were ≈7.94, 5.62, 3.93, and Figure 5a depicts the WCA analysis of the 10, 15, 25, and 65 nm
1.68 μm, respectively. The calculated sedimentation velocities and sizes of SiO2 NPs sprinkled on PDMS and the PDMS/PTFE com-
penetration lengths are summarized in Table S3 (Supporting In- posites. The PDMS/SiO2 NP coatings exhibited the WCA greater
formation). Overall, from comparing the calculated sedimenta- than 150° for all the sizes of SiO2 NPs. The WCA was increased
tion velocity and penetration length values for PDMS and SiO2 slightly for the PDMS/PTFE/SiO2 (8:2) samples compared to the
NP systems, the capillary imbibition dominates the sedimenta- PDMS/SiO2 samples. The coatings with a 6:4 weight ratio ex-
tion velocity. The SiO2 NPs attain considerably low sedimentation hibited the highest WCA of 153.6°, 159.3°, 163.9 ± 0.2°, and
velocity in the order of 10−12 m s−1 ; however, the excellent dis- 156.9 ± 0.6° for 10, 15, 25, and 65 nm SiO2 NPs, respectively.
persion of PDMS and SiO2 was observed. This is because of the Additionally, the WSA of the PDMS/PTFE/SiO2 NP (6:4) coating
excellent wetting nature of PDMS and the larger specific surface was reduced by approximately twofold compared to that of the
area (130–600 m2 g−1 ) of smaller spherical SiO2 NPs.[44] There- PDMS/SiO2 NPs (Figure 5b). Overall, the results imply that by
fore, it is clearly seen that SiO2 NPs of all sizes are completely increasing the amount of PTFE in PDMS, the coatings exhibited
covered by PDMS and the SiO2 particles are seen underneath the an increase in WCA and a decrease in WSA. As the volume frac-
PDMS, as shown in Figure 4a. tion of PTFE in PDMS increases, the quantity of ─CF2 ligands
In the case of the PDMS/PTFE composite, owing to the pres- from PTFE on the surface also increases. PTFE is a widely rec-
ence of solid PTFE, the viscosity of the mixture increases com- ognized polymer with exceptional hydrophobicity and extremely
pared to that of bare PDMS. Therefore, the viscosity of the low surface energy, which is attributed to the presence of ─CF2
PDMS/PTFE mixture exerts an upthrust force on the SiO2 NPs, ligands and its non-polar nature.[26] When the interaction of wa-
which affects their sinking rate. For 65 nm SiO2 NPs, the calcu- ter molecules occurs at the coating interface, these low surface
lated sedimentation velocity is in the order of 10−12 m s−1 and the energy ─CF2 ligands which have a surface energy of 18 mJ m−2
penetration length L is 7.94 μm (for t = 1 s). This suggests that the create a large interfacial energy difference with water molecules
sinking velocity is negligible compared with the penetration rate. (water-air interfacial energy 𝛾 wa = 72.8 mJ m−2 ).[6] Thus, a signif-
Therefore, capillary imbibition dominates over sedimentation for icant energy difference is generated at the coating-water interface
all particle sizes. Consequently, viscous PDMS quickly covers the owing to the PTFE particles, which facilitates an increase in the
SiO2 NPs. Additionally, it could be possible that the secondary- WCA and easy roll-off of the water droplet capabilities of coating.
induced electrostatic interactions between the PDMS and PTFE As shown in Figure 5a, the WCA was increased gradually
particles cause the PDMS chains to pull the PTFE particles.[36] as the size of SiO2 NPs increased from 10 to 25 nm; however,
Hence, the SiO2 NPs are confined within the PDMS/PTFE com- above 25 nm, the WCA decreased. Particularly, the coatings with
posite. Thus, capillary imbibition is the driving force responsible 10 nm SiO2 NPs exhibited lower WCA and higher WSA than
for the self-formation of the porous 3D micro-nanostructure of those with other sizes. This is due to the 10 nm size of SiO2
the PDMS/PTFE/SiO2 NP composite, as shown in Figure 4b,c. NPs sprinkled over PDMS and PDMS/PTFE composite surfaces,
Furthermore, a similar but compact formation of porous 3D created comparatively more closely packed and flatter micro-
micro-nanostructures is observed for the 6:4 weight ratio, as nanostructured surfaces owing to their smaller size and larger
shown in Figure 4c. Additionally, the superhydrophobic nature of surface area, as shown in Figure 4. However, the WCA was de-
PDMS/PTFE/SiO2 NPs coatings is discussed as follows: the main creased for the 65 nm size of SiO2 NPs. This is likely due to the
reason for the superhydrophobic nature lies in the synergistic change in surface roughness over a specific size range of the SiO2
effects aroused by the porous 3D micro-nanostructured surface NPs. As shown in Figure 4, for 65 nm particles, the surface rough-
morphology coupled with low surface energy properties of ─CH3 ness is slightly reduced compared to that of the 25 nm samples.

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Figure 5. a) WCA, b) WSA, c) ice adhesion strength of PDMS/SiO2 NPs, PDMS/PTFE/SiO2 NPs (8:2), and PDMS/PTFE/SiO2 NPs (6:4) coatings, and
d) Schematic of the interaction of minimized contact area of a frozen water droplet on superhydrophobic surface.

Figure 5c shows the IAS analysis of PDMS and PDMS/PTFE Furthermore, as shown in Figure 5c, the IAS of the coatings
composites integrated with 10, 15, 25, and 65 nm SiO2 NPs. varied with the particle size of the SiO2 NPs; the IAS reduced
The PDMS/SiO2 NPs coatings exhibited IAS of 101 ± 5, 76 ± 5, as the particle size increased from 10 to 25 nm but increased
60 ± 5, and 87 ± 5 kPa for 10, 15, 25, and 65 nm sprinkled slightly to 65 nm. This is primarily due to changes in the surface
NPs, respectively. However, the IAS was reduced slightly for morphology, effectiveness in the formation of interconnected air
PDMS/PTFE/SiO2 (8:2) coatings, as compared to PDMS/SiO2 voids, and the contact area between the coating surface and ice at
NPs coatings. In comparison, the PDMS/PTFE/SiO2 (6:4) coat- the interface with variations in particle sizes of SiO2 NPs. Specif-
ings exhibited the lowest IAS of 38 ± 2, 31 ± 7, 27 ± 3, and ically, the 10 nm size of SiO2 NPs exhibited the highest IAS in
29 ± 2 kPa for 10, 15, 25, and 65 nm SiO2 NPs, respectively. comparison with the other particle sizes. The 10 nm size of SiO2
From Figure 5c, it is evident that increasing the amount of NPs created more compact, densely packed, and flatter surfaces,
PTFE in PDMS leads to a decrease in IAS. This is because of as shown in Figure 4, owing to their smaller particle size and
the increased volume fraction of PTFE particles in PDMS, re- larger surface area. Such compact surface microstructures failed
sulting in more ─CF2 ligands on the coating surface. The ─CF2 to create effective air voids on the coating surface, resulting in
ligands from PTFE exhibit excellent characteristics, such as hy- an increase in the contact area with ice. Hence, the coatings with
drophobicity, low surface energy, low frictional coefficient, and 10 nm particle size exhibited relatively higher IAS. The 25 nm
non-polar nature, which facilitate low interfacial shearing stress particle size produced a more porous 3D micro-nanostructured
at the coating/ice interface.[26] Additionally, when freezing initi- rough surface with highly effective air voids, resulting in a greater
ates, the interaction between ─CF2 ligand with the surface en- reduction in the contact area compared with the 10 nm particles,
ergy of 18 mJ m−2 and ice with the interfacial energy of 𝛾 ia ≅ as shown in Figure 5d. The particle sizes of 10, 15, 25, and 65 nm
75 mJ m−2 occurs at the coating interface, resulting in a signif- with coating layers have occupied the contact areas with 10 μL wa-
icant interfacial energy difference at the coating/ice interface.[6] ter droplets of ≈0.23, 0.15, 0.1, and 0.18 mm2 , respectively (see
Thus, the increased volume fraction of PTFE in PDMS generates Table S4, Supporting Information). The PDMS/PTFE/SiO2 (6:4)
a significant energy difference at the coating/ice interface, which coatings exhibited the IAS of 38 ± 2, 31 ± 7, 27 ± 3, and 29 ± 2 kPa
promotes the easy detachment of ice from the 6:4 weight ratio’s for 10, 15, 25, and 65 nm SiO2 NPs, respectively. The contact areas
coating surface. at the interface between the water and coating, calculated from

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the volume of water droplet, WCA, and surface roughness, are higher release rate of latent heat (good thermal conductivity, e.g.,
consistent with the IAS results. From Figure 5a–c, a consistent bare Al), leading to a rapid freezing rate, and vice versa (e.g.,
correlation is observed between the IAS measured at low tem- PDMS/PTFE/SiO2 superhydrophobic surfaces).
peratures and the surface wettability analysis performed at room As shown in Figure 6, the FDT for bare Al, PDMS,
temperature for parameters, such as the WCA and WSA.[45] and PDMS/PTFE (6:4) composite were recorded ≈28 ± 4.16,
Overall, after sprinkling SiO2 NPs of various sizes over 93.5 ± 5.67, and 108 ± 3 s, respectively. Bare Al substrate is
PDMS and the PDMS/PTFE composite, the surface topogra- a metal with excellent thermal conductivity of 167 W mK−1 ,[48]
phy significantly changed from flat to rougher and more porous hydrophilic nature, and high surface energy. Hence, the water
3D micro-nanotextures. Thus, for the superhydrophobic sur- droplet on the Al surface freezes within a very short span, and
faces, the contact area between the coating surface and the wa- the freezing rate is rapid. Although the PDMS and PDMS/PTFE
ter droplet is significantly reduced compared to that for the composite coatings are hydrophobic in nature, the PDMS/PTFE
PDMS and PDMS/PTFE hydrophobic flat/smooth surfaces (see composite exhibited a slightly higher FDT than PDMS. This can
Table S4, Supporting Information). Additionally, from the high- be attributed to the slight change in the contact area and the
magnification inset images shown in Figure 4a–c, the forma- reduction in the heat transfer rate of the water droplet on the
tion of interconnected peaks and valleys in the porous 3D micro- PDMS/PTFE composite surface. The graphical representation
nanostructures is observed. The peaks are attributed to the SiO2 of FDT versus WCA for distinct thermal conductivities is illus-
NPs confined in the PDMS/PTFE composite, which serves as a trated in Figure S7 (Supporting Information). On the other hand,
stress concentrator. When a water droplet freezes on a superhy- for superhydrophobic surfaces, the FDT values of 357 ± 8.83,
drophobic CB surface, it exerts an adhesive force on its peaks. As 452 ± 7.12, 441.32 ± 12, and 404 ± 4.24 s were recorded for SiO2
illustrated in Figure 5d the schematic of a frozen water droplet particles with sizes of 10, 15, 25, and 65 nm, respectively.
interacting with the peaks of an elastic superhydrophobic sur- As shown in Figure 6, the FDT for 10 μL water droplets
face. Therefore, most of the adhesive force (stress) of the ice is on different surfaces follows the order of PDMS/PTFE/SiO2 >
concentrated on the peaks of PDMS/PTFE/SiO2 . The peaks bear PDMS/PTFE > PDMS > Al. The bare Al, PDMS, and PTFE
most of the stress and induce deformation incompatibility as well have thermal conductivities of 167, 0.16, and 0.25 W mK−1 ,
as the presence of air voids, which reduce the surface contact respectively.[48–50] The calculated contact areas for bare Al,
area with water droplets or ice.[20,46] Thus, such porous 3D micro- PDMS, and PDMS/PTFE (6:4) composite are ≈15.43, 5.45, and
nanostructured morphologies are favorable for minimizing the 5.19 mm2 , respectively (see Table S4, Supporting Information).
contact area of water/ice with the coating surface, which facili- Whereas, for superhydrophobic surfaces, the PDMS/PTFE com-
tates an overall reduction in the ice shearing stress. posite with SiO2 NPs of sizes 10, 15, 25, and 65 nm have occu-
pied the contact areas of ≈0.23, 0.15, 0.1, and 0.18 mm2 , respec-
tively (see Table S4, Supporting Information). Based on quanti-
2.5. Freezing Delay Time fied terms such as the thermal conductivity of coatings and the
contact area of a water droplet with the surface, it is worth point-
FDT experiments were performed to investigate the freezing de- ing out that the FDT mainly depends on the rate of heat transfer
dQ
lay performance of water droplets for various surface wettabilities ( dt ), interfacial contact area between the water droplet and coat-
and material compositions. Figure 6 shows the photographs of ing surface (A), thermal conductivity of the coated material (k),
the phase transition of water to ice at −15°C with respect to time. and temperature gradient ( dT dx
). Equation (5) depicts the Fourier’s
Photographs of different stages of water droplets until freezing law of heat transfer rate.[51]
and producing a sharp spike shape on the top of the ice and ( )
the WCA at room temperature are compared. In ice FDT mea- dQ dT
= −kA (5)
surements, it is necessary to consider the differences between dt dx
real freezing and experimental FDT analysis conditions. The sur-
rounding temperature is an important factor that can affect the Overall, the PDMS/PTFE/SiO2 (6:4) coated Al samples exhib-
ice growth and freezing time. Thus, it is important to consider ited around fourfold increment in FDT compared to that of the
Equation (4),[47] which relates the effect of the temperature dif- PDMS/PTFE composite. This is because of the formation of
ference between the surrounding and freezing temperatures on porous 3D micro-nanostructures and the creation of interfacial
the ice growth. air voids. The presence of air between the water droplet and the
micro-textured coating surface lowers the thermal conductivity
ΔT T f − Ta and decreases the heat transfer rate. Therefore, a significant in-
V̇ ∝ Q̇ ∝ = (4) crease in the FDT for superhydrophobic surfaces is observed be-
R R
cause a reduction in the contact area due to an increase in air
Where V, ̇ Q,
̇ and R are the volumetric growth of ice, heat flux, voids between the water droplet and the coating surface results
and thermal resistance at the ice front, respectively. Moreover, in a reduced rate of heat transfer.
∆T = Tf – Ta , ∆T is the difference between the freezing tem- Additionally, when the freezing process begins at the water
perature (Tf ) and the surrounding temperature (Ta ). During and CB surface interface, the air present in the voids initiates
FDT analysis for all the samples, ∆T maintained remains con- upward migration into the water droplet owing to the Marangoni
stant. If ∆T is constant, then the FDT of ice mainly depends force,[52] which arises because of the surface-tension gradient at
on thermal resistance (R). As, V̇ is inversely proportional to R; the interface between distinct fluids at low temperatures.[52] In
therefore, a surface with a lower thermal resistance provides a the present case, water and air are the two fluids present at the

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Figure 6. The comparison of water contact angle and photographs of freezing delay time at −15 °C temperature of bare Al, PDMS, PDMS/PTFE (6:4),
PDMS/PTFE/SiO2 (10 nm), PDMS/PTFE/SiO2 (15 nm), PDMS/PTFE/SiO2 (25 nm), and PDMS/PTFE/SiO2 (65 nm).

coating interface. When the temperature of the stage reaches if the spacing between peaks or grooves exceeds 20 μm, the
−15 °C, some air dissolves into the water droplet because air possibility of permeating water droplets into the voids of rough
solubility increases at low temperatures, and the remaining surfaces is enhanced significantly.[46] Therefore, the utilization
air escapes from the water droplet. This reveals that, at low of SiO2 NPs of size less than 65 nm in PDMS/PTFE/SiO2 NPs
temperatures, the permeation of water into the air voids of composite favorably maintained the spacings between peaks or
the microstructure is possible. However, the spacings between grooves at approximately less than 2 μm, as shown in Figure 4.
peaks or grooves on the microtextured surface morphology of Thus, the smaller spacing minimized the possibility of water
superhydrophobic surfaces play a crucial role.[46] Specifically, droplets permeation into the voids. Moreover, during freezing,

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ice embryos begin heterogeneous nucleation on the coating PDMS played a vital role in improving the hydrophobicity, and
surface, attempting to adhere to it by establishing van der Waals mechanical strength, and decreasing the surface energy of the
and electrostatic bonds with the surface.[53] However, the elastic composite coatings. Surface morphology studies revealed that
moduli of PDMS/PTFE composite and ice are 3.2 MPa and the formation of porous 3D micro-nanostructured surfaces re-
3.6 GPa,[54] respectively, which results in deformation incompat- duced the water/ice contact area by creating air voids. Further-
ibility due to a mismatch of elastic moduli. This capability of the more, we successfully demonstrated that the ice FDT mechanism
composite may be favorable for the easy detachment of ice from mainly depended on the rate of heat transfer, thermal conductiv-
the coating surface. After dethatching the ice from the coating ity, and interfacial contact area of the coating surface. Overall,
surface, the coating maintains its original dimensional stability the PDMS/PTFE/SiO2 coatings of size 25 nm exhibited the min-
and durability owing to its reasonable mechanical strength. imum IAS of 27 ± 3 kPa at −15 ± 1 °C. The proposed approach is
facile, cost-effective, and suitable for the large-scale preparation
of icephobic coatings.
2.6. Mechanical Property Analysis

The mechanical properties of icephobic coating are vital param- 4. Experimental Section
eters because coating should withstand challenging conditions
Materials: All coatings were applied on the Al substrate. The Sylgard
such as extremely cold weather, frosting destruction, and high-
184 base and curing agent were purchased from Dow Corning. PTFE pow-
speed wind. The stress–strain curve of the bare PDMS and 9:1 der (free-flowing) with a particle size of 1 μm was purchased from Sigma–
to 5:5 weight ratios of PDMS to PTFE coatings are depicted in Aldrich. SiO2 NPs with sizes of 10, 15, 25, and 65 nm were obtained from
Figure S9 (Supporting Information). The bare PDMS coatings Sigma–Aldrich and US Research Nanomaterials, Inc. In this work, the
have shown 48% tensile strain and 0.9 MPa tensile stress. Fur- fumed SiO2 NPs of all sizes were utilized without any additional function-
thermore, as the quantity of PTFE from 1 to 4 weight percent alization. All chemicals used in the experiments were of analytical grade
and used as received.
was added to the PDMS, the tensile strain and tensile stress of
Coating of PDMS/PTFE/SiO2 NPs: All coatings were fabricated under
the resulting PDMS/PTFE composite increased gradually. The ambient conditions (24 °C and 60% humidity). Before coating, the Al sub-
PDMS: PTFE (6:4) coating sample exhibited tensile stress and strate (20 mm × 20 mm × 2 mm) was polished with #2000-grit metal-
tensile strain of 3.2 MPa and 129%, respectively. The tensile lographic abrasive paper and cleaned by ultrasonication. Subsequently, it
fracture strength and stress-bearing capacity of the PDMS/PTFE was washed with ethanol and deionized (DI) water, and dried at 80 °C for
(6:4) composite were enhanced by 174% and 170%, respec- 30 min. All coatings were deposited using a laboratory-scale spin coater
tively, compared to bare PDMS. The bare PTFE has an excel- (HS-EZ4, Zhengzhou TCH Instrument Co., Ltd.).
First, a Sylgard 184 base and a curing agent were mixed in the weight
lent Young’s modulus of 766 ± 29 MPa[55] and a low frictional percent ratio of 10:1 to prepare the PDMS viscoelastic solution. This mix-
coefficient of 0.04–0.2.[56] In this study, the reinforcement of ture was homogeneously mixed by hand for 5 min using a spatula. Bub-
PTFE particles into the matrix of polymeric PDMS chains con- bles were generated during mixing, and degassing was performed at am-
sequently improved the mechanical strength of the PDMS/PTFE bient conditions for 20 min. Thereafter, 400 μL of the PDMS solution was
composite.[57,58] As the composite coating withstood with 3.2 MPa dropped on the Al substrate, and it was spin-coated at 400 rpm for 90 s.
of optimum elastic moduli, it provides the deformation incom- To improve the mechanical strength of the coating, a controlled quantity
of PTFE powder (density = 2.15 g cm−3 ) was added to the PDMS solu-
patibility owing to the elastic moduli mismatch of the hard and
tion (density = 0.965 g cm−3 ). PDMS-to-PTFE weight-to-weight % ratios
brittle nature of ice (Young’s modulus of ice is 0.3–3.6 GPa)[54] of 9:1, 8:2, 7:3, 6:4, and 5:5 were prepared to optimize PTFE addition as
and the soft elastic nature of PDMS/PTFE composite. This mis- a thixotropic agent to maintain the viscosity of the PDMS/PTFE compos-
match in elastic modulus between ice and PDMS/PTFE coat- ite for uniform film formation. Subsequently, each weight percent ratio of
ing can result in significant deformation incompatibility under the PDMS/PTFE composite was dropped onto the Al substrate and spin-
stress during ice removal. Additionally, the mechanical strength coated for 90 s at 500 rpm. The complete scheme of coatings fabrication
is depicted in Figure S3 (Supporting Information). Homogeneous film for-
of superhydrophobic surfaces is also a serious concern for long-
mation of the PDMS/PTFE composite was observed (see Figure S4, Sup-
term exposure to extreme cold conditions. Thus, owing to the porting Information). To create the micro-nanoscale surface roughness on
excellent mechanical strength of PTFE, the integration of PTFE the PDMS and PDMS/PTFE viscoelastic composites, SiO2 NPs with sizes
into PDMS improves the coatings mechanical strength. Conse- of 10, 15, 25, and 65 nm were sprinkled individually on bare PDMS and
quently, it maintains the robustness of the superhydrophobic CB PDMS/PTFE composites with different weight percent ratios (8:2 and 6:4).
state. A #60 copper mesh was used to sprinkle SiO2 NPs. The samples were then
kept under ambient conditions for 1 h to promote sedimentation and self-
formation of PDMS, PDMS/PTFE, and SiO2 NPs. After the sedimentation
of the SiO2 NPs in the PDMS and PDMS/PTFE composites, the loosely
3. Conclusion bound SiO2 NPs were gently detached by blowing nitrogen air. Finally, all
of the coatings were cured in an oven for 12 h at 80 °C in the air.
This study conveys new insights into the fabrication of icepho- Theoretical Calculation: To investigate the secondary interactions
bic coatings based on the self-formation of superhydrophobic between PDMS and PTFE, DFT calculations were performed using
surfaces using SiO2 NPs, surface wettability analysis, ice FDT, the Vienna ab initio simulation package (version 5.4.4).[59–63] Van der
and stress concentrator concepts. DFT calculations and struc- Waals (vdW) interactions are crucial for molecular adsorption on solid
surfaces. Therefore, the Perdew–Burke–Ernzerhof exchange-correlation
tural studies revealed that the adhesion in PDMS and PTFE function[64,65] was employed with vdW interactions using the DFT-D2
originated from the stable induced dipole-dipole electrostatic in- method.[66,67] The projector-augmented wave method was used with a
teraction between them; therefore, siloxane and the fluoropoly- cut-off energy of 400 eV. All the slab models included at least a 10 Å
mer exhibited excellent miscibility. The integration of PTFE with vacuum region to avoid interaction between periodic atomic images along

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the vertical direction. A (2 × 2 × 1) Monkhorst–Pack mesh[68] was used Data Availability Statement
for k-point sampling after convergence testing. All the atomic structures
were relaxed until all atomic forces became less than 10−2 eV Å−1 and the The data that support the findings of this study are available from the cor-
wave function converged to 10−6 eV. responding author upon reasonable request.
Analysis: The surface property measurements, such as WCA, WSA,
contact angle receding (𝜃 rec ), and contact angle hysteresis were performed
on a contact angle goniometer (SDL200TEZED, Femtobiomed). Each Keywords
measurement was conducted by pouring 10 μL of DI water on the coat-
ing surface. The anti-icing performance of all the coatings was recorded freezing delay time, icephobicity, PDMS/PTFE, SiO2 NPs, superhydropho-
by analyzing the IAS and FDT. IAS measurements of all the coatings were bicity
performed as described in the previous report.[21] The temperatures for
the ice adhesion test were maintained at −15 ± 1 and −2 ± 1 °C for the Received: November 2, 2023
cold Peltier plate and ice chamber (refrigerator), respectively. The real-time Revised: January 12, 2024
temperature and humidity in the ice chamber were monitored using a tem- Published online:
perature and humidity sensor (UA10 RADIONODE, DEKIST Co., Ltd.).
Throughout the measurement process, the humidity of the ice chamber
varied in the range of 35–95 ± 5% (see Figure S5, Supporting Informa-
tion).
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