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Superhydrophobic surfaces, or those with a water contact angle above 150°, are currently
attracting great attention in the scientific community. Such surfaces are known as Lotus Effect
leaves of the Lotus plant (see fig. 1). Due to the self-cleaning
in the creation of hydrophobic surfaces. Two methods of creating these surfaces are proposed.
In the first, hydrophobic polymer particles are prepared via emulsion polymerization
using monomers with hydrophobic side chains. These are coated onto a surface, creating a
polymer film with rough surface morphology. The surface roughness combined with the low
surface energy of the polymer result in very high water contact angles. Since pure polymer
coatings tend to be soft and easily deformed or removed, composite particles, specifically
polymer/silica particles, can be used. This method was used successfully to produce a 140°
contact angle, and to produce polymer/silica composite particles with almost all silica being
incorporated into the polymer. Emulsion polymerization has been used before to synthesize
specific particle types. Synthesis of structured PnBA/PMMA copolymer particles was reported
by Pfau, Sander, and Kirschii of BASF. BASF also has a spray on coating product that consists of
a PtBA polymer colloid, but this coating is not considered superhydrophobic. Meneghetti and
The second application involves using the polymer particles as a template for porous
silica, aiming to create self cleaning superhydrophobic surfaces. First, a polymer dispersion is
prepared with embedded TiO2 nanoparticles. The polymer is mixed with a silica colloid, and the
mixture is deposited as a coating. The coating is then heated, decomposing the polymer and
leaving the remaining silica coating porous. Finally, the silica coating is treated with flourosilane,
attaching hydrophobic chains to the silica molecules on the surface. Each depression in the silica
surface also has a TiO2 particle in it, left from the decomposed polymer particle. The treatment
makes the surface hydrophobic, the depressions left from the polymer give surface roughness
and cause superhydrophobicity, and the remnant TiO2 particles have a photocatalytic effect that
oxidizes any organic materials that get trapped in the depressions. These, once oxidized, are
picked up by water rolling off the surface in the self-cleaning effect shown by all lotus effect
surfaces. TiO2/polymer composite particles were synthesized that could be used in this process to
obtain a self cleaning, durable superhydrophobic coating. No previous research has been reported
2. Theory
2.1. Contact Angle and Hydrophobicity. Hydrophobicity can be measured by the
contact angle of a small water droplet on a level surfacev. The angle is measured from the line
tangent to where the drop touches the surface to the flat plane of the surface. Contact angle can
where γSL, γSV, and γLV are the interfacial free energies per unit area of the solid-liquid, solid-gas,
and liquid-gas interfaces, respectively. This equation can only be used for flat surfaces, not rough
ones. The highest contact angle achievable on a flat surface can be calculated from the lowest
surface energy value ever recorded, 6.7 mJ/m2, and amounts to about 120°. Therefore,
surface area than is apparent. Since r is always larger than one, surface roughness improves both
the hydrophilicity of hydrophilic surfaces and the hydrophobicity of hydrophobic ones. This
shows that when surface roughness is present on a hydrophobic, low energy surface,
Another model for contact angle on a rough surface was proposed by Cassie. This
equation describes the contact angle θ at a surface composed of solid and air. The equation is as
follows:
f is defined as the area fraction of solid surface to total surface (solid + air). This equation
assumes that air is trapped in the depressions on the rough surface, creating a smaller liquid-solid
interface, which has higher energy, and a larger liquid-air interface, which has an assumed
contact angle of 180°. This applies to hydrophobic surfaces, showing another mechanism by
emulsion polymerization can be used to make small polymer particles in a colloid. These, after
polymerization, the components can either be mixed together in preparation for a batch reaction,
or kept separate and continuously added to the reactor to better control reaction rate. In either
case, the surfactant is first dissolved in water. When enough surfactant is added, the critical
micelle concentration (CMC) is reached, and micelles form. Micelles are spheres of oriented
surfactant molecules. Each molecule consists of a hydrophobic tail attached to a hydrophilic head,
which often has a positive or negative charge. In a micelle, the tails point inward while the heads
are outside, close to the water. In both batch and continuous reactions, when the monomer is
added to the reactor, it first exists in relatively large droplets, due to its insolubility in water.
Some monomer moves into the micelles, where it finds more favorable conditions surrounded by
the hydrophobic tails of the surfactant. The initiator, which is added as a solution in water during
continuous reactions, remains dissolved in the water, and begins the polymerization when the
temperature is raised and the mixture is agitated by stirring. With heating and agitation, the
initiator generates free-radicals, which start the polymerization chain reaction. Due to the much
larger surface area of the micelles compared to the monomer droplets, the initiator reacts with
monomer inside the micelles. The free radical attacks the double bond on a monomer molecule,
bonding to it and causing the combined molecule to have a free radical on the end. This reacts
with another monomer molecule, and the process continues until another initiator free radical
terminates the chain. Typically there is one growing chain per micelle at a time, leading to
polymer particles with nearly identical molecular weights. Heat produced by the reaction is
readily absorbed by the water, eliminating any chance of a runaway reaction. When all monomer
has been consumed, what remains is a colloidal dispersion of solid polymer particles in water.
Surfactant remains in the dispersion, so when coating a glass slide, surfactant must be removed
by washing with water. This residual surfactant coats the polymer surface in the dispersion,
repelling other coated (therefore similarly charged) particles and preventing the agglomeration
that would otherwise result due to van der waals forces between the polymer particles.
3. Experimental Section
3.1. Chemicals. In the experiments, n-butyl acrylate (nBA), tert-butyl acrylate (tBA), and
methyl methacrylate (MMA) were used as monomers, Sodium dodecyl sulfate (SDS) and
and Ammonium persulfate (APS) and Sodium persulfate (SPS) were used as initiators. In some
reactions small amounts of Triton X-100 (TX-100) surfactant were also used. TX-100 is a
nonionic surfactant, having no charge on its hydrophilic head, and acts as a steric stabilizer for
the polymer particles. Due to its lack of charge, the TX-100 can coat the polymer particles even
after they are dried, allowing for easy restabilization as a dispersion in water.
3.2. Materials, Equipment, and Suppliers. MMA, tBA, SDS, CTAB, SPS, APS, AIBN
were supplied by Aldrich Chemical Inc. and used as is. TX-100 is a product by Union Carbide,
and the colloidal silica used was Ludox HS-40, a Grace Davidson product. The TiO2
nanoparticle powder was PC 105, supplied by Millennium Chemicals. HCl was supplied by JT
Baker and diluted to 1 M concentration with deionized water before use. NH4OH was obtained
from Fisher Scientific, and also diluted to 1 M concentration with deionized water before use.
Chemicals were massed on a Mettler AE 260 DeltaRange electronic balance. Reactions were
heated and stirred on a Corning Stirrer/Hotplate, and glass slides were spincoated with polymer
dispersion on a Directview 1000 spincoater by Specialty Coating Systems, Inc. Two sonicators
were used for sonic stirring: a VWR Scientific Products Aquasonic model 75HT, and a Misonix
Sonicator 3000. Continuous reations were performed using a Thermo Separation Products
ConstaMetric 4100 pump to control rates of addition of chemicals. Contact angles were
Analyzer by TA Instruments.
the reactor, and MMA pre-emulsion was continuously added, followed by nBA pre-emulsion.
addition of nBA pre-emulsion after an initial emulsion polymerization of MMA at 80°C for 2 h.
PtBA particles were prepared by batch emulsion polymerization, performed at 80°C with
TiO2 nanoparticles, which were first dispersed in water, then used as seeds for emulsion
polymerization of MMA using SDS or CTAB and various initiators. TiO2 nanoparticles were
dispersed at various pH values, and the best dispersion was determined by observation and
The general procedure for creating TiO2/PMMA composite particles involved a batch
emulsion polymerization with periodic addition of 20% wt. TiO2 dispersion. The dispersion was
prepared by mixing TiO2 nanoparticle powder with water adjusted to the desired pH, then
placing this in a sonic stirrer for 1 h. The polymerization was carried out in a 200 mL flask with
magnetic stirring at 750 rpm, heated in a water bath. 15g of MMA was added to 50g of water
with initiator, surfactant, and .05g TX-100 dissolved in it. Different combinations of SDS and
CTAB surfactants and SPS/APS and AIBN initiators were used, each involving different
amounts, depending on the chemicals used. The pH of the water was adjusted beforehand to the
desired value by addition of HCl. This mixture was stirred in a sonic stirrer for 30 minutes, and
then placed in the water bath with stirring, beginning the reaction. TiO2 dispersion was added
periodically at intervals of either 30 min or 1 h. Also, a continuous reaction was performed
where MMA pre-emulsion was added at a constant rate to 20% wt. TiO2 dispersion at the desired
Exp 19:
PMMA/PnBA copolymer
In the first stage, 5g of MMA was added to a 200 mL flask containing .08g of SDS
and .1209g of SPS dissolved in 30g of water. This was polymerized in a water bath at
80°C for 2 h with magnetic stirrer running at 400 rpm. In the second stage of the
reaction, nBA pre-emulsion was added to the PMMA dispersion in 3 1g portions at
different time intervals. The nBA pre-emulsion consisted of 1g of nBA, and .005g of
SDS dissolved in 2g of water. After addition of the first portion of pre-emulsion, the
mixture was reacted in an 80°C water bath for 40 minutes with constant stirring. After
the second pre-emulsion addition, the mixture was reacted for 80 minutes under the
same conditions. The final pre-emulsion was then added, and the mixture was reacted
for an additional 40 minutes.
dispersion was spincoated onto a glass slide, dried, rinsed with distilled water, and dried again. A
water contact angle of 111.4° was measured on the surface. This angle was a result of the
structure of each polymer particle, combined with the inherent roughness of the polymer surface.
Each particle had a core-shell structure that was created by the two step reaction. In the first step,
PMMA core particles were synthesized. Then, in the second part of the reaction, each particle
was coated with a shell of PnBA. The surface only has a contact angle of around 111.4°, and a
higher contact angle cannot be achieved using this procedure due to 1) the surfactant adsorbed on
Exp 24:
Composite Silica/PnBA/PMMA copolymer
7.5g of 30% wt. silica colloid and 10 mL of .0475 M SPS initiator solution were added to a 200 mL flask. This
was placed in an 80°C water bath with magnetic stirring at 400 rpm, and pre-emulsion and initiator solution were
fed in continuously using a pump. The first stage pre-emulsion consisted of 3g of MMA mixed with .03g of SDS
and .1g of TX-100 dissolved in 10g water. This was fed into the reaction mixture at a rate of .2 mL/min, along
with a .0238 M solution of SPS initiator fed at .1 mL/min. When all of the first stage pre-emulsion had been
added, the second stage was fed in at a rate of .2 mL/min, while the initiator solution continued to be added at .1
mL/min. The second stage pre-emulsion was prepared from 1g nBA mixed with .03g of SDS and .1g of TX-100
dissolved in 10g water.
Experiment 24 produced PMMA core, PnBA shell polymer particles with embedded
silica nanoparticles intended to harden the polymer. And the polymer coating, obtained by
spincoating the dispersion on a glass slide at 500 rpm for 10 sec, had an average water contact
angle of less than 20.0°. SEM pictures showed silica nanoparticles adhered to the polymer
surface. The hydrophilic silica particles on the surface of the polymer, hydrophilic due to the
hydroxyl groups on the silica surface, combined with inherent surface roughness to cause the
coating’s very hydrophilic nature, according to Cassie’s equation. The minimization of Gibbs
free energy explains the appearance of silica particles on the polymer surface. During the
reaction, the hydrophilic silica particles migrated to the polymer-water interface due to the van
der Waals force attraction. When at the interface, the attraction force of water acted on the
particles to prevent them from embedding in the polymer. Still stuck to the polymer surface, they
were present after coating, and drastically lowered the contact angle.
Exp 25:
poly(tert-butyl acrylate)
Synthesis was performed as a batch reaction in
a 200 mL flask with magnetic stirrer running at
400 rpm. 15g of tBA, .15g of SDS (.026
M), .1159g of APS (.025 M), and 20g of water
were reacted at 80°C for 1 h 45 min, yielding a
white colored dispersion of PtBA particles. This
was spincoated onto a glass slide at 500 rpm for
10 seconds, then dried and rinsed with distilled
water to remove surfactant. After re-drying, a
water contact angle of 140.4° was measured on
the surface.
Contact angle: 140.4°
In the PtBA systhesis, a white colored colloid was formed. The spherical polymer
particles in the dispersion adhered to the glass slide during drying, creating a somewhat rough
surface film when the particles agglomerated on the substrate. The tert-butyl groups caused a
low surface energy that combined with the roughness of the surface to create the high contact
angle.
tert-butyl acrylate n-butyl acrylate
tBA has a distinct advantage over nBA in single polymer nanocomposite particle coatings. The
tert-butyl group’s shape of 3 CH3 groups oriented around one carbon atom makes for a harder
and more hydrophobic polymer than does the straight hydrocarbon chain of the n-butyl group.
The hardness allows for easier coating of substrates, and the lower surface energy of tert-butyl
4.4.1. Preparation of TiO2 dispersion. Forming a good TiO2 dispersion in water required the
gradient was found to depend on the pH of the solution. 1M HCl was used to make acidic
solutions, and 1M NH4OH was used for basic solutions. Acidic conditions were found to be
better for TiO2 nanoparticle dispersion, although too low of a pH caused more precipitation. A
pH of 1.58 provided the best dispersion of TiO2. A neutral solution failed to disperse any TiO2,
having complete precipitation within 24 h. Basic solutions showed a visible gradient in particle
concentration, caused by gravity, and were decided to be undesirable for TiO2 dispersion.
Two tests were performed to find the best pH for TiO2 dispersion. First, 0.2% wt.
solutions of TiO2 in water were prepared at various pH values, including 10.25, 10.1, 10.0, 9.8, 7,
2.25, 1.6, and 1.3. These were left standing for a period of 4 days. All 4 basic solutions
developed a concentration gradient over the 4 days, and most of the TiO2 particles precipitated to
the bottom. The neutral pH had complete precipitation of added TiO2. The two higher acidic pH
values had apparently good dispersions by observation, and the lowest pH had partial
precipitation and appeared clearer than the other acidic dispersions. Because of the better results
for acidic solutions, but the lack of a visually obvious best pH, another test was performed. 5
20% wt. TiO2 dispersions were prepared, each at a different acidic pH. Values of 2.23, 2.07, 1.94,
1.58, and 1.29 were tested, as well as pH 7 as a control. First, the dispersions were mixed by
agitation followed by 1 h in a sonic stirrer (sonicator). The dispersions were then left standing for
24 h, and were subsequently weighed. The liquid dispersion was then poured out; the remaining
precipitate was dried, and then weighed again. Finally, each container was cleaned, dried, and
weighed again to obtain the empty container weight. From this data, the remaining wt. % of TiO2
12.00%
10.00%
8.00%
TiO2 wt. %
6.00%
4.00%
2.00%
0.00%
1 1.5 2 2.5
pH
Figure 3
Clearly, a pH of 1.58 had the best retention of dispersed TiO2. Thus, several polymerizations
were performed at this pH using TiO2, to try to incorporate TiO2 nanoparticles into a polymer. It
was not possible in the experiments to obtain a dispersion with no precipitation, because of larger
embedded TiO2, each sample was spincoated onto a glass slide at 1000 rpm for 10 seconds, then
dried and rinsed with distilled water to remove surfactant. These were then cut to small size,
mounted for the SEM, then sputter coated with gold. Also, a small amount of polymer dispersion
from each experiment was dried on a hotplate, and then put into the TGA for analysis of TiO2
1 12.00%
10.00%
0.8
Exp 28
weight fraction
8.00%
0.6 Exp 30
Exp 31
Exp 32 6.00%
0.4 Exp 33
4.00%
0.2
2.00%
0
0 100 200 300 400 500 600 700 800 0.00%
28 30 31 32 33
Temperature, C
TiO2 wt.% 3.05% 7.34% 10.37% 1.85% 2.98%
Experiment 28 was carried out at a higher pH, at which less TiO2 could disperse.
Therefore, as can be seen in the SEM picture, TiO2 particles exist on the polymer coating surface.
This accounts for the 3.05% TiO2 wt. percent value obtained by the TGA. In experiment 30 a
thick paste was formed, which consisted of TiO2 mixed with heavily agglomerated polymer,
visible in the SEM picture. This led to the conclusion that the reaction rate was too high, and the
H+ ions were causing the polymer to agglomerate. A slower initiator was needed to facilitate a
stable reaction. A large amount of TiO2 was incorporated into the polymer particles, however,
and agglomeration only occurred during the last hour of the reaction. Next, in experiment 31,
AIBN initiator was used, which creates free radicals more slowly than persulfate initiators
(APS/SPS). AIBN had to be dissolved in the monomer, but this was achieved using the same
general procedure as the previous reactions. A very large chunk of TiO2 and polymer formed
around the magnetic stirbar. The remaining dispersion, when left unagitated overnight,
completely precipitated. The SDS had been prevented from functioning correctly by the H+ ions
in solution, since SDS is an anionic (-) surfactant. This led to massive agglomeration of polymer,
which had a negatively charged coating of SDS, because of attraction imparted by oppositely
charged H+ ions. The polymer itself consisted of a wide range particle sizes, some as large as 1
micron in diameter, visible in the SEM photo. This further demonstrates the faulty functioning of
SDS. This experiment showed that cationic surfactant needed to be used in acidic conditions, to
keep the polymer colloid stable. The next reaction, experiment 32, produced more uniform
particles but failed to incorporate much TiO2 into the polymer. This was due to a fast reaction
rate, similar to what was seen in experiment 30, resulting from the use of SPS. Experiment 33
was carried out slightly differently, using a continuous reaction setup that improved TiO2 content
in the polymer. Also, CTAB and AIBN were used, combining the advantageous effects of both
slower reaction rate and cationic surfactant. This experiment had good TGA results, but still did
not have as much incorporated polymer as desired. Results indicate that TiO2 particles cannot be
5. Conclusion
Emulsion polymerization was used in two methods toward the goal of obtaining a
stable coating but midrange contact angle. Polymer/silica composite particles were produced,
incorporating much of the colloidal silica into the polymer. PtBA particles were prepared that
created a very hydrophobic coating, showing the superiority of the tert-butyl group over the n-
butyl group in hydrophobic polymer coating preparation. The optimal pH for dispersion of TiO2
nanoparticles was determined, and dispersions at this were used in reactions. Low pH was shown
to negatively affect the function of SDS, and possibly the incorporation of TiO2 particles into the
polymer. Slightly higher pH showed good results, but agglomeration occurred in the last hour of
the reaction. Modification of this reaction’s procedure could lead to composite particles with up
to 10% wt. TiO2, allowing further research into the creating of a templated silica surface, to
I thank Prof. C.P Wong and Yonghao Xiu for their mentorship throughout the research,
and specifically Yonghao for teaching me several of the concepts which are discussed in this
paper. I also thank the Georgia Tech Packaging Research Center for giving me the opportunity to
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Pfau, A.; Sander, R.; Kirsch, S. Orientational Ordering of Structured Polymeric Nanoparticles at Interfaces;
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Meneghetti, P.; Qutubuddin, S. Synthesis of Poly(methyl methacrylate) Nanoparticles via Emulsion
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