PLUNGER AND METHODS OF PRODUCING

HYDROPHOBIC SURFACES

BACKGROUND

Priority Data & incorporation Ry Reference

[0001] This international application claims the benefit of priority to U.S. Provisional Patent

Application No. 61/3 14, 137, filed March 15, 2010, entitled "Plunger and Methods of Producing Hydrophobic Surfaces" which is incorporated by reference in its entirety.

[0002] A plunger is the most common household article used to clear clogged plumbing fixtures such as drains, toilets, and sinks. As seen in Fig. 1 , the plunger generally consists of two parts: (1 ) a cup and (2) a handle. With a slightly modified cup, which has a skirt (3) protruding from the cup (Fig. 2), the plunger is used for industrial applications such as in hotels. The plunger cup typically consists of rubber or a flexible polyvinyl chloride (PVC) material. PVC is sometimes prepared as a composite with fillers such as thermoplastic rubber (TPR), and up to 35% of the fillers is added to the PVC for optimizing flexibility and hardness of the plunger cup. The handle is typically wood or solid plastic, but other materials such as clear acrylic are used.

[0003] Regardless of the materials used to construct a plunger or the exact form of the cup, plungers operate by making a seal with the plumbing fixture's surfaces after which the application of pressure on the flexible cup through the handle creates a pressure that clears clogs. The number of times pressure must be applied to the handle to create a plunging action depends on the severity of the clog.

[0004] After use, the plunger (cup and handle) typical ly are covered in materials originally destined for the sewer, such as toilet water and/or other materials such as fecal matter. That water and other materials tend to drip onto the floor when the plunger is removed from the toilet and contaminate any surface it comes into contact with. Not only is the water dripping on the floor highly undesirable with regard to the cleanliness of the bathroom and damage to the floor's surface but it also creates sites for bacterial growth.

BRIEF DESCRIPTION OF THE DRAWINGS

[0005] Fig. 1 shows three views of a typical household drain plunger showing the cup ( 1 ) with an optional lip (8) and handle (2).

[0006] Fig. 2 shows three views of a typical industrial (heavy duty) plunger showing a handle and a cup with an optional lip (8) and skirt (3) protruding from the lower edge of the cup. [0007] Fig. 3 shows an embodiment of a plunger with a hydrophobic (superhydrophobic) coating applied to the cup and a portion (about one-half of the length) of the handle.

[0008] Fig. 4 shows another embodiment of a plunger with a hydrophobic (superhydrophobic) coating applied to the cup.

[0009] Fig. 5 shows another embodiment of an industrial plunger with a hydrophobic

(superhydrophobic) coating applied to the cup and a portion of the handle.

DESCRIPTION OF EMBODIMENTS OF THE DISCLOSURE

[00010] Embodiments of this disclosure, which are described herein, provide for a plunger coated in whole or in part with a hydrophobic or superhydrophobic coating that can be used to clear plumbing while advantageously resisting becoming wet and fouled with materials intended for disposal via the drain. The plunger resists wetting and fouling even after dozens or even hundreds of uses, which can be measured by individual compressions of the plunger cup via pressure applied to the handle. In some embodiments, less than about 0.2, about 0.5, about 1 , about 2, about 3, or about 4 grams of water remain bound by adhesion to the surface of the plunger after immersion in water at about 20°C, even after the plunger cup has been compressed more than about 300 tiroes by app lying force to the handle.

[00011 J Embodiments of the plungers described herein that resist wetting and fouling by materials intended for the sewer can provide one or more of a variety of advantages. For example, they can be removed from plum bing fixtures after use with little or no dripping of materials onto the floor and other nearby objects, thus keeping floors and nearby surfaces dry and clean. Embodiments of the plungers described herein also reduce or eliminate the odor associated with used plungers, in addition, bacterial (m icrobial) growth is less likely to occur on the hydrophobic coatings described herein, whether applied to plungers or other objects, as there will be a limited amount of accumulated water and/or other materials to support growth. Bacterial (microbial) growth can be further suppressed by incorporating a number of d ifferent antibacterial and/or antifungal agents into the coatings described herein including, but not limited to, zinc pyrithione, zinc di(lower alky])dithiocarbamate (e.g., zinc

dimethyldithiocarbamate) and silver (e.g. , colloidal silver or silver nanoparticles typically in the range of 1 -50 ppm or 1 0-30 ppm).

[00012] In some embod iments, the coatings applied to al l or a part of the plungers described herein will not only be hydrophobic, but also oleophobic. Plungers that are oleophobic in addition to being hydrophobic will further resist wetting and contamination by materials, including fecal matter, that are intended for the sewer. Such plungers will further limit the growth of bacteria by limiting the amount of material present to support its growth.

[00013] Embod iments of the plungers described herein are thus suitable for use in clearing plumbing includ ing clogged toilets, sinks and drain pipes connected to toilets and sinks, including embodiments that are adapted for industrial use. The shape of the cup (oval, circular etc.) may be made in a variety of widths adapted to clearing specific types of plumbing fixtures, in addition, the use of one or more rubbers to prepare cups having suitable stiffness and resilience can permit embodiments of the plungers described herein to adapt its contours to the surface of plumbing fixtures.

1.0 DEFINITIONS

[00014] For the purposes of this disclosure a hydrophobic coating is one that results in a water droplet forming a surface contact angle exceeding about 90° and less than about 150° at room temperature (about 18 to about 23 °C). Similarly, for the purposes of this disclosure a superhydrophobic coating is one that results in a water droplet forming a surface contact angle exceed ing about 150° but less than the theoretical maximum contact angle of about 1 80° at room temperature. The term hydrophobic includes superhydrophobic, and may be limited to superhydrophobic, unless stated otherwise,

[00015] For the purposes of this disclosure an oleophobic material or surface is one that results in a droplet of l ight mineral oil forming a surface contact angle exceeding about 25° and less than the theoretical maximum contact angle of about 1 80° at room temperature.

[00016] Durability, unless stated otherwise, refers to the resistance to loss of hydrophobic properties due to mechanical abrasion or flexing.

[00017] Moiety or moieties, for the purpose of this disclosure, refers to a chemical group (e.g. , alky] group, fluoroakiyl group, haloaklyl group) bound directly or indirectly (e.g. , covalently) to another part of a molecule or another substance or material (e.g., a first or second particle). A moiety also includes chemical components of materials that are associated with a material (e.g., components of first or second particles) that are not covalently bound to the particles (e.g. , siloxanes or silazanes associated with first or second particles).

[00018] Alky] as used herein denotes a linear or branched alky 1 radical . Alkyl groups may be independently selected from C | to C ₂₀ al kyl, Q to Q ₀ alkyl. Q to Q ₀ alkyl, C ₆ to Q ₈ alkyl, C ₆ to C| ₆ alkyl, or Q to C ₂₀ alkyl . Unless otherwise indicated, alkyl does not include cycloalkyl, Cyc!oa!ky! groups may be independently selected from: Q to Qo alkyl comprising one or two C ₄ to Q cycloalkyl functionalities; Q to o alkyl comprising one or two Q to Q cycloalkyl functionalities; Q o CM alkyl comprising one or two Q to Q cycloalkyl functional ities; Q to Q _¾ alkyl comprising one or two Q to Q cycloalkyl functionalities; and Q to Q ₆ alkyl comprising one or two Q to Q cycloalkyl functionalities. One or more hydrogen atoms of the alkyl groups may be replaced by fluorine atoms to form fluoroalkyl groups..

00019] Lower al ky] as used herein denotes a Q to Q alkyl group. [00020] Haloalkyl as used herein denotes an alky! group in which some or all of the hydrogen atoms present in an alk S group have been replaced by halogen atoms. Halogen atoms may be Iimited to chlorine or fluorine atoms in haloa!kyl groups.

[00021 ] Fluoroalkyi as used herein denotes an alkyi group in which some or ail of the hydrogen atoms present in an alky! group have been replaced by fluorine atoms.

[00022] Perfiuoroalkyl as used herein denotes an alkyi group in which fluorine atoms have been substituted for each hydrogen atom present in the alky] group.

[00023] For the purpose of this disclosure, when content is indicated as being present on a

"weight basis" the content is measured as the percentage of the weight of components indicated, relative to the tota l weight of the binder system. When a l iquid component such as a commercial binder product is used, the weight of the liquid component is used to caiculate the weight basis, without regard to the relative amounts of solute and solvent that might be present in the commercial product. Thus, for example, when Polane is used as a binder, the weight basis is calculated using the weight of the Polane prepared as instructed by the manufacturer, without regard to the proportions of polyurethane solute and organic solvents. Optional solvents that are separately added to a composition merely to, for example, d ilute the composition to a thickness suitable for spraying, are not included in the calculation of content on a weight basis.

[00024] Water-based as used herein to refer to binders refers to liquid compositions that comprise water or which can be diluted with water (e.g., to reduce viscosity). Water-based binder compositions include solutions, dispersion, suspensions, emulsion gels and the like.

[00025] The term metalloid includes the elements B, Si, Sb, Te and Ge. Oxides of metalloids or metalloid oxides include, but are not limited to, oxides of B, Si, Sb, Te, and Ge, such as Si0 ₂ .

2.0 PLUNGER CUPS

[00026] Referring now to Figure 1 , embod iments of plunger cups disclosed herein may take many forms. Generally, the cups are shaped to have a concave inner surface (4) and a convex outer surface (5) to which the handle is attached at a point that can be reinforced or built conform to an end of the handle (9). The inner surface and outer surface meet at a rim (7) that may have an optional lip attached (8). The point where the handle is attached may be reinforced to provide an adequate strength to the joint and to spread the force applied to the cup from the handle. The shape at the point where the handle attaches to the outer surface of the cup may thus depart from a convex shape. A cross section through the cup parallel to the rim and generally perpend icular to the long axis of the hand le (6) is generally circular, ova!, elliptical, or oblate, in add ition to the cups shown in the accompanying drawings, some examples of suitable cup shapes can be observed in U.S. Patent Nos. 4,622,702 and 4,768,237, the disclosures of which are incorporated herein by reference in terms of their disclosures of plunger-cup shapes.

[00027] Referring to Figure 2, in some embodiments, particularly industrial embodiments, the cup may be fitted with a "skirt" (3), which assists in conforming the plunger to the shape of the plumbing fixtures. The skirts are generally cylindrical sections of material that attach to, or just inside of, the rim of the cup. The skirt may narrow slightly as it extends away from the cup. Skirts, when present, are generally made from the same material as the cup, and in one piece with the cup, although they also can be made of a different material.

[00028] in embodiments described herein, plunger cups may be made from a resilient material that is resistant to water. In some embodiments the plunger consists of rubber (natural or synthetic) or a flexible polyvinyl chloride (PVC) material. Where PVC is employed, may be prepared as a composite with fillers such as thermoplastic rubber (TPR), which may be added in an amounts, e.g. , up to 35% (by weight) or more, to impart desirable properties such as increasing the flexibility of the PVC while providing appropriate hardness and resilience. In other embodiments, the cup may be made from a rubber selected from the group consisting of: nitriie rubber, acrylonitrile-butadiene (NBR), natural rubber, butadiene-type rubber, styrene-butadiene rubber, chloroprene, ethylene propylene diene modified rubber (EPDM), polyurethane rubber, butyl rubber, neoprene, isoprene, poiyisoprene, halobutyl rubber, fluoroelastomers, epichlorohydrin rubber, polyacrylate rubber, chlorinated polyethylene rubber, hydrogenated SBR, hydrogenated NBR, carboxylated NBR, silicone rubber, or mixtures, copolymers or terpolymers thereof.

3.0 HANDLES

[00029] Hand les of plungers are general ly attached to the outer surface of the cup at a point where the cup can be effectively compressed to provide pressure to water and material clogging a plumbing fixture. Where the plungers are circular in cross section the hand le is typically attached to the outer surface at a point that is approximately equidistant from the rim in all direction.

[00030] Hand les for use with plungers can be made of any suitable rigid material including, but not limited to, wood, plastic, and metal , in some embodiments, the handles can be made of clear plastic such as acrylic. In some embodiments, the handles may be hollow and fluid connection with the inside of the cup on one end, and at the other end connected to a source of water to supply pressure, as in U.S. Patent No. 4,768,237, the disclosure of which is incorporated herein by reference in terms of the use of a hollow handle and a fluid connection. The handle also may be provided with a hydrophobic coating as described herein .

4.Θ COATINGS

[00031] Coatings applied to the surfaces of the plungers described herein may be any coating that provides a hydrophobic coating that is sufficiently flexible to endure the repeated bending and flexing that the plunger cup wil l be exposed to during use without substantial loss of hydrophobicity [00032] In some embodiments, the hydrophobic coatings applied to the plungers, and optionally to the handles, comprise: i) a binder; ii) first partic les having a size of about 30 μιη to about 225 pm; and iii) second particles having a size of about 1 nanometer (nm) to about 25 μηι comprising one or more independently selected hydrophobic or oieophobic moieties,

[00033] In other embodiments, the hydrophobic coatings applied to the plungers comprise a base coat comprised of said binder and said first particles applied to said cup, and optionally applied to said handle, and a top coat comprised of second particles applied to the base coat after it has been applied to a surface (e.g., a surface of the plunger such as the cup or handle).

4,1 Binders

[00034] Binders used to prepare hydrophobic coatings may have a variety of compositions. One consideration in choosing a suitable binder is the compatibility between the surface to be coated and any soivent(s) used to apply the binder, Virtually any binder may be employed that is capable of adhering to the surface of the plunger while retaining sufficient flexibility that it does not appreciably chip, crack, or peal away from the plunge cup when subjected to repeated flexing due to pressure applied to the plunger handle to the point that the hydrophobic nature of the coating is substantial ly reduced (i. e. the coating hydrophobicity or ability to shed water is not substantial ly reduced by more than, 5%, 10%, 1 5%, 20% or 25% (e.g., where a 100 mg of water might adhere to a plunger before being subject to 100 depressions by applying pressure to the hand le, the plunger will not retain more than 105, 1 10, 1 25, 120, or 125 mg of water adhering to its surface). In some embodiments, the binders employed are hydrophobic in the absence of any added first or second particles, which can be advantageous in the preparation of hydrophobic and/or oieophobic coatings.

[00035] In some embodiments, the binders may be selected from lacquers, po!yurethanes

(including water based poSyurethanes), fluoropolymers, or epoxies. In other embodiments the binders may be selected from lacquers, polyurethanes, or fluoropolymers. Binders may be hydrophilic, hydrophobic, or hydrophobic and oieophobic in the absence of the first and second particles described herein that alters the durability, hydrophobic and oieophobic properties of the binder.

[00036] Where the binders employed are hydrophilic, the coating, including first and second particles, can be given an application of a silanizing agent after it has been applied to the plunger.

[00037] Hydrophobic coatings applied to the surfaces, such as the surfaces of the plungers described herein, may be formed with binders having a broad range of thicknesses. In some

embodiments the coatings will have a thickness in a range selected from about 10 pm to about 225 pm. Within this broad range are embodiments employing coatings of thicknesses that range from about 10 pm to about 25 pm, from about 25 pm to about 50 pm, from about 50 pm to about 75 pm, from about 75 μιη to about 100 pm, from about 100 pm to about 125 pm, from about 125 pm to about 1 50 pm, from about 150 pm to about 1 75 pm, from about 1 75 μπι to about 200 pm, from about 200 pm to about 225 pm, from about 15 urn to about 200 pm; from about 20 pm to about 150 pm; from about 30 pm to about 175 pm; and from about 50 pm to about 200 μπι, 4.1.1 Lacquer Binders

[00038] Embodiments of the plunger described herein may employ lacquer binders. Lacquers may be used on a variety of surfaces that may be employed to make plungers and/or plunger handles, and are particularly useful in forming coatings on plastics, woods and metals, including, but not limited to, metals (steel, stainless steel, and aluminum), plastics and rubbers. Lacquer binders typical ly are polymeric materials that are suspended or dissolved in carrier solvents and which dry to a hard finish, at least in part, by evaporation of the carrier solvents used to apply them. The polymeric binders present in lacquers include, but are not limited to, nitrocellu lose and acrylic lacquers; each of which are suitable for use in preparing hydrophobic coatings.

[00039] in embodiments of plungers herein, hydrophilic lacquers may be employed as binders; particularly where the coating will be given an application of a silanizing agent after it has been applied to the substrate, in other embodiments, lacquers that are hydrophobic in the absence of first or second particles described below may be employed to prepare the coatings described herein.

[00040] In addition to the polymeric materials and solvents present in lacquers, a variety of other materials that enhance the properties of lacquers also may be present to impart one or more desirable properties. For example, such materials can provide not on ly color but also increased adhesion between the lacquer and the surface of the plunger upon which it is applied (i. e. the cup or handle).

[00041 ] A variety of commercial lacquer preparations may be used to prepare the durable coatings described herein. Among the commercial acryl ic lacquers that may be employed are "Self- Etching Primer" (Eastwood Co., Pottstown, PA); DuPont VariPrime 615S (DuPont Performance Coatings, Wilmington, DE) and Nason 491 - 17 Etch Primer (DuPont Performance Coatings, Wi lmington, DE).

[00042] Lacquers may be used on a variety of surfaces, and are particularly useful in forming coatings on plastics, woods, and metals, including, but not limited to, metals (steel, stainless steel, and aluminum), plastics, and rubbers.

4.1.2 Polyurethane Binders

[00043] A wide variety of polyurethanes, including those prepared in organic solvent or in water may be used to prepare hydrophobic and/or oleophobic coatings described herein. Polyurethanes are polymers consisting of a chain of organic units joined by urethane (carbamate) l inkages. Polyurethane polymers are typically formed through polymerization of at least one type of monomer containing at least two isocyanate functional groups with at least one other monomer containing at least two hydroxyl (alcohol) groups. A catalyst may be employed to speed the polymerization reaction. Other components may be present in the polyurethane coating compositions to impart desirable properties including, but not limited to, surfactants and other additives that bring about the carbamate forming reaction(s) yielding a coating of the desired properties in a desired cure time.

[00044] In some embodiments, the polyurethane employed in the durable coatings may be formed from a polyisocyanate and a mixture of -OH (hydroxyl) and NH (amine) terminated monomers. In such systems the polyisocyanate can be a trimer or homopolymer of hexamethylene diisocyanate. (CH ₂ ) _e NCO (CH ₂ ) _e NCHOOR— --

HO-R-OH

OCN(H ₂ C)e ^(CH ₂ ) ₆ NCO OOHCN(H ₂ C)e Π iCH ₂ ) ₆ NCHOOR

HD! Trimer Polya!coho! Poiyurethane

[00045] Some solvents compatible with such systems include n-buty! acetate, toluene, xylene, ethyl benzene, cyciohexanone, isopropyl acetate, and methyl isobutyl ketone and mixtures thereof.

[00046] In some embodiments, polyurethanes that are hydrophobic as applied in the absence of first or second particles described below may be employed to prepare the coatings described herein. Among the commercial polyurethanes that may be employed are the POLANE® family of polyurethanes from Sherwin Williams (Cleveland, OH).

[00047] Polyurethanes may come as a single component ready to apply composition, or as a two or three part (component) system, as is the case with POLANE® products. For example POLANE® B can be prepared by mixing POLANE® B (typically six parts), to a catalyst (e.g., typically one part of V66V27 or V66V29 from Sherwin Wi lliams), and a reducer (typical ly 25 to 33% of R7K84 from Sherwin Wi ll iams). The "pot life" of mixed POLANE® B prepared in that manner is typically 6-8 hours.

[00048] A variety of water-based poiyurethane compositions (aqueous poiyurethane suspensions, emulsions, dispersions, gels etc.) may be employed may be used to prepare hydrophobic and/or oieophobic coatings described herein. Some commercially available water-based poiyurethane compositions include POLANE® 700T and KEM AQUA® (Sherwin-Williams), and Bayhydrol 124 (Bayer Material Science), which may be used alone or in combination.

[00049] Poiyurethane binders are compatible with, and show good adhesion to, a wide variety of surfaces. Using poiyurethane binders, hydrophobic coatings may be formed on many, if not most surfaces including, but not limited to, those of metals, glass, rubber and plastics.

4.1.3 F!i!orope!ymer Binders

[00050] In other embodiments, a wide variety of fluoropolymer compositions may be used as binders in the preparation of hydrophobic and/or oieophobic (HP/OP) coatings described herein.

Fluoropoiymers are polymers comprising one or more fluoroalkyl groups. In some embodiments, the fluoropolymers employed in the durable coatings may be formed from fluoroethylene/vinyl ether copolymer (FEVE). Fluoropoiymers that are hydrophobic as applied, in the absence of first or second particles which are described further below, may be employed to prepare the coatings described herein. Among the commercial fluoropoiymers that may be employed to prepare HP/OP coatings are

LUMiFLON ^® fami ly polymers (Asahi Glass Co., Toyko, Japan).

[00051] Fluoropolymers that may be employed as binders typical ly come as a two or three component system, as is the case with LUMIFLON ^® products. For example LUMIFLON* LF can be prepared by mixing 58 parts of LUMIFLON ^® LF-200, 6.5 parts of DESMODUR ^® N3300A (Bayer Material Sciences, Leverkusen, Germany) 2.5 parts of catalyst (DABCO T 12 ( 1 /10,000 part), DABCO ( l ,4-diazabicyclo[2.2.2]octane, 1 /10,000 part), 1 part xyiene), with 33 parts xyiene. Un less otherwise noted, references to LUMIFLON ^® , particularly in the Examples, refer to LUMIFLON® LF.

Fluropolymer coatings such as LUMIFLON ^® can be appl ied to a variety of surfaces including wood, metal, rubber, and plastic.

4.2 First Particles

[00052] Embodiments of the coatings disclosed herein may comprise particles that are added to the binder compositions to improve the mechanical properties of the coating, e.g. , the durability of the hydrophobic and/or oleophobic coatings. A wide variety of such particles, which are denoted herein as "first particles" because the coatings described herein optionally may have one or more additional types of particles, also are known as extenders or fillers, may be added to the binders. Such first particles that may be employed in the HP/OP coatings include, but are not limited to, particles comprising: wood (e.g. , wood dust), glass, metals (e.g. , iron, titanium, nickel, zinc, tin), alloys of metals, metal oxides, metalloid oxides (e.g. , silica), plastics (e.g. , thermoplastics), carbides, nitrides, borides, spinels, diamond, and fibers (e.g. , glass fibers).

[00053] Numerous variables may be considered in the selection of first particles. These variables include, but are not l imited to, the effect the first particles have on the resulting coatings, their size, their hardness, their compatibilit with the binder, the resistance of the first particles to the environment in which the coatings will be employed, and the environment the first particles must endure in the coating process, including resistance to temperature and solvent conditions.

[00054] in embodiments described herein, first particles have an average size in a range selected from about 1 micron (μηι) to about 250 μπι. Within such broader range, embodiments include ranges of first particles having an average size of from about 1 μτη to about 5 μτη, from about 5 μηι to about 30 μηι, from about 10 μηι to about 1 5 um, about 1 5 μηι to about 20 μπι, from about 20 μηι to about 25 μπι, from about 1 μτη to about 25 μιη, from about 5 μίη to about 25 μηι, from about 25 urn to about 50 μιη, from about 50 μηι to about 75 μηι, from about 75 μηι to about 1 00 μτη, from about 1 00 μτη to about 125 μιη, from about 125 μιη to about 1 50 μηι, from about 1 50 μηι to about 1 75 μτη, from about 1 75 μπι to about 200 μηι, from about 200 μιη to about 225 μτη, and from about 225 μπι to about 250 μπι. Also included within the broader range are embod iments employing particles in ranges of from about 10 μηι to about 100 μιη, from about 10 μτη to about 200 μηι, from about 20 μιτι to about 200 μηι, from about 30 μιτι to about 50 um, from about 30 μπι to about 1 00 μπι, from about 30 μπι to about 200 μηι, from about 30 μηη to about 225 μηι, from about 50 μηι to about 100 μηι, from about 50 μιη to about 200 μηι, from about 75 μιτ! to about 1 50 μηι, from about 75 μηι to about 200 μηι, from about 1 00 μηι to about 225 μηι, from about 100 μηι to about 250 μιη, from about 125 μπι to about 225 μπι, from about 1 25 μηι to about 250 μηι, from about 1 50 um to about 200 μηα, from about 1 50 μπι to about 250 μηι, from about 1 75 μιη to about 250 μηι, and from about 200 μηι to about 250 μηι.

[00055] First particles may be incorporated into binders at various ratios depending on the binder composition and the first particle's properties, in some embodiments, the first particles may have a content range selected from: about 1% to about 60% or more by weight, included within this broad range are embodiments in which the first particies are present, by weight, in ranges of from about 2% to about

5%, irom about 5% to about 10%, from about 10% to about 1 5°/o, from about 15% to about 20%, from about 20% to about 25%. from about 25% to about 30%, from about 30% to about 35%, from about 35% to about 40%, from about 40% to about 45%, from about 45% to about 50%, from about 50% to about 55%, from about 55% to about 60%, and greater than 60%. Also included within this broad range are embodiments in which the first particles are present, by weight, in ranges of from about 4% to about 30%, from about 5% to about 25%, from about 5% to about 35%, from about 10% to about 25%, from aboutl 0% to about 30%, from about 10% to about 40%, from about 1 0% to about 45%, from about 15% to about 25%, from about 15% to about 35%, from about 1 5% to about 45%, from about 20% to about 30%, from about 20% to about 35%, from about 20% to about 40%, from about 20% to about 45%, from about 20% to about 55%, from about 25% to about 40%, from about 25% to about 45%, from about 25% to about 55%, from about 30% to about 40%, from about 30% to about 45%, from about 30% to about 55%, from about 30% to about 60%, from about 35% to about 45%, from about 35% to about 50%, from about 35% to about 60%, or from about 40% to about 60% on a weight basis.

[00056] In some embodiments, where the first particles comprise or consist of glass spheres, the first particles may be present in any of the foregoing ranges or in a range of from about 1% to about 40%, from about 3% to about 45%, from about 10% to about 45%>, or from about 2% to about 15% on a weight basis.

[00057] In other embodiments where the first particles are a polyethylene or modified polyethylene, the particle may be present in a content range selected from any of the foregoing ranges, or in a range of from about 3% to about 20%, from about 3%> to about 15%o, or from about 3% to about 10% on a weight basis.

[00058] The incorporation of first particles can lead to a surface that is textured due to the presence of the first particles. In such embodiments, the presence of the first particles results in a surface texture that has elevations on the level of the coating formed. The height of the elevations due to the presence of the first particles can be from 0 (where the first partic le is just below the line of the binders surface) to a point where the first particles are almost completely above the level of the binder coating (although they may sti ll be coated with binder). Thus, the presence of first particles can result in a textured surface wherein the first particles cause such elevations in the binder that have maximum heights in a range of up to almost about 250 μηι, Accordingly, such elevations can be present in ranges of from about 1 μιτι to about 5 μηι, from about ί μιτ! to about 10 μιη, from about 1 μτη to about 15 μηι, about 1 μηι to about 20 μηι, from about 1 μηι to about 25 μηι, from about 1 am to about 50 μίη, from about 1 μίη to about 75 μηι, from about 1 μτη to about 100 μηι, from about 1 μηι to about 125 μιη, from about 1 μηι to about 1 50 μιη, from about 1 μηι to about 175 μιτι, from about 1 μηι to about 200 μηι, from about 1 μηι to about 225 μηι, from about 1 μηι to about 250 μηι, from about 1 0 μιη to about 80 μιη, from about 1 5 to about 80 μρη, from about 20 to about 100 μηι, and from about 30 to about 70 μηι.

[00059] The surface texture of coatings may also be assessed using the arithmetical mean roughness (Ra) or the ten point mean roughness (Rz) as a measure of the surface texture. In some embodiments, a coating described herein has an arithmetical mean roughness (Ra) in a range selected from: about 0.2 μηι to about 20 μηι; about 0.3 μπι to about 1 8 μπι; about 0.2 μπι to about 8 μπι; about 8 μΐΉ to about 20 μπι; or about 0.5 μιη to about 15 μπι. In other embodiments, a coating as described herein has a ten point mean roughness (Rz) in a range selected from: about 1 μπι to about 90 μΐϊΐ; about 2 μηι to about 80 μηι; about 3 μιη to about 70 μπι: about 1 μηι to about 40 μηι; about 40 μιη to about 80 μηι; about 10 μηι to about 65 μ ^ρ η; or about 20 μΐΉ to about 60 μηι.

[00060] First particles may optionally comprise moieties that make them hydrophobic and'or oleophobic. Where it is desirable to introduce such moieties the particles may be reacted with reagents that covalently bind moieties that make them hydrophobic and/or oleophobic. In some embodiments, the reagents may be silanizing agents, such as those that introduce alkyl, haloalkyl, fluoroa!kyl or perfluoroalky! moieties (functional ities). In some embodiments the silan izing agents are compounds of formula (I) {i.e., R4 _-n Si-X„), and the various embodiments of compounds of formula (I) described below for the treatment of second particles. The surface of many types of first partic les can be activated to react with silanizing agents by various treatments including exposure to acids, bases, plasma, and the l ike, where necessary to achieve functionalization of the particles.

[00061] In embod iments described herein, the first particles are not modified by adding functional groups that impart one or more of hydrophobic and/or oleophobic properties to the particles (e.g. , properties beyond the properties inherent to the composition forming the particles). In one such embodiment, first particles do not contain covalently bound alkyl, haloalkyl, fluoroalkyl or

perfluoroaikyl functionalities (moieties). In another such embodiment, the first particles are not treated with a silanizing agent (e.g., a compound of formula (I)).

4.3 Exem lary Sources of First Particles

[00062] First particles may be prepared from the diverse materials described above.

Alternatively, first particles may be purchased from a variety of suppliers. Some commercially available first particles that may be employed in the formation of the hydrophobic and/or oleophobic (HP/OP) coatings described herein include those in the accompanying Table I.

Table I First Particles

7 S32 Glass GPS ^e 0.32 20-80 White 2000 3M™ St. Paul Bubbles M

8 S35 Glass GPS" 0.35 10-85 White 3000 3M™ St. Paul

Bubbles MN

9 Κ.37 Glass GPS ¹¹ 0.37 20-85 White 3000 3M™ St. Paul,

Bubbles MN ί θ S38 Glass GPS° 0.38 15-85 White 4000 3M™ St. Paul,

Bubbles MN

3 1 S38HS Glass GPS ⁰ 0.38 35-85 White 5500 3M™ St. Paul,

Bubbles MN

32 Κ46 Glass GPS" 0.46 15-80 White 6000 3M™ St. Paul,

Bubbles MN

33 S60 Glass GPS ^fl 0.6 15-65 White 10000 3M™ St. Paul,

Bubbles MN

34 S60/HS Glass GPS" 0.6 1 1 -60 White 18000 3M™ St. Paul,

Bubbles MN

15 A S 6/500 Glass Floated 0.16 35- 135 White 500 3M™ St. Paul

Bubbles Series MN

36 Α20/3000 Glass Floated 0.2 30- 120 White 3000 3M™ St. Paul,

Bubbles Series MN

17 Η20/3000 Glass Floated 0.2 25-1 30 White 1000 3M™ St. Paul,

Bubbles Series MN

Ϊ8 D32/4500 G lass Floated 0.32 20-85 White 4500 3M™ St. Paul,

Bubbles Series MN

19 H50/ 1 0000 Glass Floated 0.5 20-60 White 30000 3M™ St. Paul, ΕΡΧ Bubbles Series MN 0 iMK Glass Floated 0.6 8.6- White 28000 3M™ St. Paul,

Bubbles Series 26.7 MN 1 G-3 I25 Z-Light CM ⁵ 0.7 50-125 Gray 2000 3M™ St. Paul,

Spheres™ MN 2 G-3 150 Z-Light CM ⁶ 0.7 55- 145 Gray 2000 3 ™ St. Paul,

Spheres™ MN 3 G-3500 Z-Light CM" 0.7 55-220 Gray 2000 3M™ St. Paul,

Spheres™ MN 4 G-600 Zeeo- CM* 2.3 1 -40 Gray >6000 3 ™ St. Paul, spheres™ 0 MN 5 G-800 Zeeo- CM* 2.2 2-200 Gray >6000 3M™ St, Paul, spheres™ 0 MN 6 G-850 Zeeo- CM* 2.3 12-200 Gray >6000 3M™ St. Paul, spheres™ 0 MN 7 W-610 Zeeo- CM* 2.4 1-40 White >6000 3 ™ St. Paul,

SphereS™ 0 MN 8 SG Extendo- HS ^r 0.72 30- 140 Gray 2500 Spher Chattano ^¬ sphere™ e One oga, TN 9 DSG Extendo- HS' ^' 0.72 30-140 Gray 2500 Spher Chattano

_sphere™ e One oga, TN 0 SGT Extendo- HS' ^' 0,72 30- 160 Gray 2500 Spher Chattano sphere™ e One oga. TN 3 TG Extendo- HS ^f 0.72 8-75 Gray 2500 Spher Chattano sphere™ e One oga, TN 2 SLG Extendo- HS' 0.7 1 0- 349 Off 3000 Spher Chattano sphere™ White e One oga, TN 3 SLT Extendo- HS ^C 0.4 30-90 Off 3000 Spher Chattano sphere™ White e One oga, TN4 SL- 550 Extendo- HS' ^' 0.62 70 Cream 3000 Spher Chattano sphere™ e One oga, TN 5 SLW-3 50 Extendo- HS" 0.68 8-80 White 3000 Spher Chattano

SDhere™ e One oga, TN 6 HAT Extendo- HS' ^' 0.68 10- 365 Gray 2500 Spher Chattano sphere™ e One oga, TN 7 HT- 150 Extendo- HS' 0.68 8-85 Gray 3000 Spher Chattano sphere™ e One oga, TN

38 LS-90 Extendo- 0.56 4-05 Light 1200 Spher Chattano sphere™ Grav e One oga, TN

39 KLS- 125 Exten do- ^c 0.56 4-55 Light 1200 Spher Chattano sphere™ Gray e One oga, TN

40 LS- 150 Extendo- HS ^£ 0.56 4-55 Light 1200 Spher Chattano sphere™ Gray e One oga, TN

41 LS-300 Extendo- ns ^c 0.56 4-55 Light 1200 Spher Chattano sphere™ Gray e One oga, TN

42 HA-300 Extendo- HS ^C 0.68 10- 146 Gray 2500 Spher Chattano sphere™ e One oga, TN

43 X!O 5 12 ThermoMPR" 0.96 10- 100 White 508 XIOM West

plastic Corp. Babylon,

NY

44 XIOM 5 12 ThermoMPR ^rf 0.96 10- 100 Black 508 XIOM West

plastic Corp. Babyion,

NY

45 CGRVEL™ Nylon 1.09 44-74 ROH Phiiadeip Black 78- ThermoPowder Black M & hia, PA 700 \ plastic Coating HASS

46 Microglass Fibers MMEG 1.05 16X 120 White Fibert Bridgew

3082 ec ater, MA

47 Microglass Fibers MMEG 0.53 10X 150 White Fiber! Bridgew 90Q7D Silane- ec ater, MA

Treated

4,4 Second Particles

[00063] Embodiments of the coatings disclosed herein also may employ second particles (e.g. , nanoparticles), including those which bear hydrophobic moieties. A variety of second panicles can be used to prepare the hydrophobic coatings applied to the plungers described herein. Suitable second particles have a size from about 1 nano meter (nm) to about 25 μπι and are capable of binding covaient!y to one or more chemical moieties( groups or components) that provide the second particles, and the coatings into which they are incorporated, hydrophobicity, and when selected to include f!uoroalky! groups, oleophobicity.

[00064] In some embodiments the second particles may have an average size in a range selected from about 1 nm to up to about 25 μπι or more. Included within this broad range are embod iments In which the second particles have an average size in a range of from about I nm to about 10 nm, from about 10 nm to about 25 nm, from about 25 nm to about, 50 nm, from about 50 nm to about 100 nm, from about 100 nm to about 250 nm, from about 250 nm to about 500 nm, from about 500 nm to about 750 nm, from about 750 nm to about 1 μηι, from about 1 μηι to about 5 μηι, from about 5 μπι to about 10 μπι, from about 10 μίτι to about 1 5 μηι, from about 1 5 μηι to about 20 μπι, from about 20 μπι to about 25 μπι, from 1 nm to about 100 nm, from about 2 nm to about 200 nm, from about 10 nm to about 200 nm, from about 20 nm to about 400 nm, from about 10 nm to about 500 nm; from about 40 nm to about 800 nm, from about 1 00 nm to about 1 μηι, from about 200 nm to about 1 ,5 μΐΐΐ, from about 500 nm to about 2 μιτι, from about 500 nm to about 2.5 μπι, from about 1.0 μπι to about 10 μπι, from about 2.0 μηι to about 20 μηι. from about 2,5 μηι to about 25 μηι, from about 500 nm to about 25 μπι, from about 400 nm to about 20 μιτί, and from about 3 00 nm to about 1 5 μπι, from about 1 nm to about 50 nm, from about 1 nm to about 400 nm, from about I nm to about 500 nm, from about 2 nm to about 120 nm, from about 5 nm to about 100 nm, from about 5 nm to about 200 nm; from about 5 nm to about 400 nm; about 10 nm to about 300 nm; or about 20 nm to about 400 nm..

[00065] In the above-mentioned embodiments, the lower size of second particles may be limited to particles greater than about 20 nm, about 25 nm, about 30 nm, about 35 nm, about 40 nm, about 45 nm, about 50 nm, or about 60 nm; and the upper size of second particles may be limited to particles less than about 20 μηι, about 10 μηι, about 5 μηι, about 1 μιτι, about 0.8 μπι, about 0.6 μιη, about 0.5 μηι, about 0.4 μπ\, about 0.3 μη\ or about 0.2 μπι. Limitations on the upper and lower size of second particles may be used alone or in combination with any of the above-recited size limits on particle composition, percent composition in the coatings, etc.

[00066] in some embodiments, the coatings may contain first particles in any of the above- mentioned ranges subject to either the proviso that the coatings do not contain only particles (e.g. , first or second particles) with a size of 25 μηι or less, or the proviso that the coatings do not contain more than an insubstantial amount of particles with a size of 25 μηι or less (recognizing that separation processes for particles of size that is greater than 25 μπι may ultimately provide an unintended, insubstantial amount of partic les that are 25 μπι or less).

[00067] In other embodiments, first particles have an average size greater than 30 μηι and less than 250 μηι, and do not contain substantial amounts of particles (e.g., first and second particles) with a size of 30 μιτ! or less. In yet other embodiments, the coatings do not contain only particles (e.g., first and second particles) with a size of 40 μηι or less, or particles with a size of 40 μηι or less in substantial amounts. And in still other embodiments, the coatings do not contain only particles (e.g., first and second particles) with a size of 50 μιτι or less, or particles with a size of 50 μτ or less in substantial amounts.

[00068] In other one embodiments, such as where the second particles are prepared by fuming

(e.g. , fumed silica or fumed zinc oxide), the second particles may have an average size in a range selected from about 1 nm to about 50 nm; about 1 nm to about 100 nm; about I nm to about 400 nm; about 1 nm to about 500 nm; about 2 nm to about 1 20 nm; about 5 nm to about 100 nm; about 5 nm to about 200 nm; about 5 nm to about 400 nm; about 10 nm to about 300 nm; or about 20 nm to about 400 nm.

[00069] Second particles having a wide variety of compositions may be employed in the durable coatings described and employed herein. In some embodiments the second particles will be particles comprising metal oxides (e.g. , aluminum oxides such as alumina, zinc oxides, nickel oxides, zirconium oxides, iron oxides, or titanium dioxides), or oxides of metal loids (e.g. , oxides of B, Si, Sb, Te and Ge) such as a glass, si licates (e.g. , fumed sil ica), or particles comprising combinations thereof. The particles are treated to introduce one or more moieties (e.g., groups or components) that impart hydrophobicity and/or oleophobicity to the particles, either prior to incorporation into the compositions that will be used to apply coatings or after incorporation into the coatings. In some embodiments, the second particles are treated with a silanizing agent, a si loxane or a si lazane to incorporate groups that will provide hydrophobic and/or oleophobic properties to the particles (in addition to any such properties already possessed by the particles). When treated after incorporation into the coatings, only those particles at or near the surface that can be contacted with suitable agents such as silanizing agents will have moieties that impart hydrophobicity and/or oleophobicity associated with them.

[00070] in some embodiments, second particles are silica (silicates), alumina (e.g. , AI7O3), titanium oxide, or zinc oxide, that are optionally treated with a silanizing agent.

[00071] in. embodiments, the second particles are si lica (silicates), glass, alumina (e.g., Al ₂ 0 ₃ ), a titanium oxide, or zinc oxide, which optionally may be treated with a silanizing agent, a siloxane or a silazane. In some embodiments, the second particles may be prepared by fuming (e.g. , fumed silica or fumed zinc oxide).

4.5 Some Sources of Second Particles

[00072] Second particles such as fumed sil ica may be purchased from a variety of suppliers, including but not limited to Cabot Corp., Bii!erica, MA (e.g., Nanogel TLD20 L CAB-O-SIL® TS-720, and M5 (untreated silica)) and Evonik Industries, Essen, Germany (e.g., ACEMATT® silica such as untreated HK400, AEROXIDE® Ti0 ₂ titanium dioxide, and AEROXIDE® Aiu alumina).

[00073] Some commercially available second particles are set forth in Scheme I.

Scheme I

Data from Cabot Corp. website.

Hexamethy!disilazane

Dlmethyldichlorosi!ane

H

V

Cl-Si— , ! O ! ..

Poiydimethy!si!oxane Ociyltrimeihoxysi!ane

As purchased, the second particles may be untreated (e.g. , M5 silica) and may not posses any HP/OP properties. Such untreated particles can be treated to covalently attach one or more groups or moieties to the particles that give them HP/OP properties, for example, by treatment with the silanizing agents discussed above. 5.0 HYDROPHOBIC AND OLEOPHOBIC MOIETIES OF FIRST AND/OR SECOND PARTICLES

[00074] As discussed above, both the first and second particles may comprise one or more independently selected moieties that impart hydrophobic and/ ^' or oleophobic properties to the particles, and the coatings into which they are incorporated. As also noted above, such chemical entities may be inherently associated with the particles themselves and/or added by way of treating the particies. Although first particles may be treated to make them hydrophobic and/or oleophobic either before or after incorporation into the coating compositions described herein, the second particies typically will be treated with agents that introduce such moieties before being incorporated into the coatings described herein, it is also possible to treat the coating after it is applied to a surface with agents that modify the second particles and introduce hydrophobic and/or oleophobic properties. In such circumstances, other components of the coating {e.g., the binder or first particles) may also become modified by the agent.

[00075] In some embodiments, the second particles will bear one or more alkyl, haloaikyl, fluoroalkyl, and perfluoroalkyl moieties. Such moieties can be covalently bound directly or indirectly bound to the second particle, such as through one or more intervening silicon or oxygen atoms.

[00076] In other embodiments, the second particles will bear one or more alkyl, haloaikyl, fluoroalkyl, and perfluoroalkyl moieties of the formula R.3 _-n Si-, where n is from 1 -3, that are directly or indirectly {e.g. , covalently bound) to the second particle, such as through one or more intervening atoms.

5.1 Silanizing Agents and their Use

[00077] A variety of silanizing agents {e.g., compounds of the formula R^Si-X,,) can be employed to introduce moieties, e.g. , R3 _-n Si- groups (where n is an integer from 0 to 2), to the first or second particles prior to or subsequent to their introduction into the coatings described herein. Suitable silanizing agents typically have both leaving groups and terminal functionalities. Terminal

functionalities are groups that are not displaced by reaction of a silanizing agent with silica second particles (e.g. , R groups of compounds of the formula (I)). Leaving groups are those groups that are displaced from silanizing agents upon reaction to form bonds with the second particies,

[00078] Prior to reacting first or second particles with silanizing agents, the particles may be treated with an agent that will increase the number of sites available for reaction with the silanizing agent (e.g., SiCI ₄ . Si(OMe) ₄ , Si(OEt) ₄ , SiCI ₃ CH ₃ , SiCl ₃ CH ₂ SiCl ₃ , SiCI ₃ CH ₂ CH ₂ SiCl _3! Si(OMe) ₃ CH ₂ Si(OMe) ₃ , Si(QMe) ₃ CH ₂ CH ₂ Si(OMe) ₃ , Si(OEt) ₃ CH ₂ Si(OEt) ₃ , or Si(OEt) ₃ CH ₂ CH ₂ Si(OEt) ₃ and the like).

Treatment with such agents is conducted, e.g., with a 1% to 5% solution of the agent in a suitable solvent (e.g. , hexane), although higher concentrations may be employed (e.g., about 5% to about 10%). Where agents such as SiCI ₄ or Si(OMe) ₄ are employed to increase the number of sites available for reaction with silanizing agents, the surface may first be treated with SiCl ₄ followed by reaction with water to replace the chlorines with OH groups thai react effectively with si!anizing agents such as those of formula (I). Reaction with si!anizing agents is typically conducted using a silanizing agent at in the range of about 1% to about 2% w/v. although concentrations in the range of about 2% to about 5% w/v may also be used . Depending on the reagents employed, the reaction, which often can be conducted at room temperature, is typically conducted for 1 hour to 6 hours, although reaction for as long as 24 hours may be desirable in some instances. Skilled artisans will appreciate that concentrations and reaction times and conditions other than those described above also m ight be able to be used.

[00079] in some embodiments, silanizing agents are compounds of the formula (I):

here n is an integer from 1 -3 ;

each R is independently selected from

(i) alkyl or cycloalky] group optional ly substituted with one or more fluorine atoms,

(ii) C; !o 2o alkyl optionally substituted with one or more independently selected substituents selected from fluorine atoms and C _6- i 4 aryl groups, which aryl groups are optionally substituted with one or more independently selected halo, C| _{!0 ]0} alkyl, C; , _{0 10} haloalkyl, C< _t0 ;o alkoxy, or C , _i0 ·,ο haloalkoxy substituents,

(iii) C6 io 20 alkyl ether optionally substituted with one or more substituents independently selected from fluorine and C6 _i0 u aryl groups, which aryl groups are optional ly substituted with one or more independently selected halo, C. , _{0 10} alkyi, C; , ₀ so haloalkyl, C\ _t0 io alkoxy, or C ( _t0 so haloalkoxy substituents,

(iv) C ₆ io aryl, optional ly substituted with one or more substituents independently selected from halo or alkoxy, and haloalkoxy substituents;

(v) C ,o aikenyl or C _{10 20} alkynyl, optionally substituted with one or more substituents independently selected from haio, alkoxy, or haloalkoxy; and

(vi) -Z-((CF2) _q (CF ₃ )),., wherein Z is a C-, _{t0 n} divalent alkane radical or a C ₂ „ _!2 divalent alkene or alkyne radical, q is an integer from 1 to 12, and r is an integer from 1 -4:

each X is an independently selected -H, -CI, -I, -Br, -OH, -OR ² , -NHR ³ , or -N(R ³ ) ₂ group; each R ^" is an independently selected Q _{lo 4} alkyl or haloalkyl group; and

each R ^J is independently an independently selected H, Ci _{lo 4} alkyi, or haloalkyl group,

in some embodiments, R is an alkyl or fluoroalkyl group having from 6 to 20 carbon ato s.

00081] other embod iments, R is an alkyl or fluoroalkyl group having from 8 to 20 carbon atoms.

00082] other embodiments, R is an alkyl or fluoroalkyl group having from 10 to 20 carbon atoms.

[00083] in other embodiments, R is an alkyl or fluoroalkyl group having from 6 to 20 carbon atoms and n is 3. [00084] In other embodiments, R is an alky! or fluoroalkyl group having from 8 to 20 carbon atoms and n is 3.

[00085] In other embodiments, R is an alky] or fluoroalkyl group having from 10 to 20 carbon atoms and n is 3.

[00086] In other embodiments, R has the form -Z-((CF ₂ ) _q (CF ₃ )) _r , wherein Z is a C _{s l0 i 2} divalent alkane rad ical or a C _{2 t0} > ₂ divalent alkene or alkyne radical, q is an integer from 1 to 12, and r is an integer from 1 to 4,

[00087] In any of the previously mentioned embodiments of compounds of formula (I), the value of n may be varied such that 1 , 2 or 3 independently selected terminal functional ities are present in compounds of formu la (I). Thus, in some embodiments, n is 3. in other embodiments, n is 2, and in stil l other embod iments, n is 3 .

[00088] In any of the previously mentioned embodiments of compounds of formula (I), ai l halogen atoms present in any one or more R groups may be fluorine.

[00089] In any of the previously mentioned embodiments of compounds of formula (I), X may be independently selected from H, CI, -OR ² , -NHR ³ , -N(R ^J ) ₂ , or combinations thereof. In other embodiments, X may be selected from CI, -OR ² , -NHR ³ , -N(R ³ ) ₂ , or combinations thereof. In still other embodiments, X may be selected from, -CI, -NHR , -N(R ^J ) ₂ or combinations thereof.

[00090] Any coating described herein may be prepared with one, two, three, four or more compounds of formula (1) employed alone or in combination to modify the first or second particles, and/or other components of the coating. For example, the same or different compounds of formula (I) may be employed to modify both the first particles and the binder.

[00091] The use of siianizing agents of formula (I) to modify first or second particles, or any of the other components of the coatings, will introduce one or more R ₃ . _r ,X;,Si~ groups (e.g. , R ₃ Si- R ₂ X;Si-. or RX ₂ Si- groups) where R and X are as defined for a compound of formula (I). The value of n is 0, 1 , or 2, due to the displacement of at least one "X" substituent and formation of at least one bond between a particle and the Si atom (the bond between the particle and the silicon atom is indicated by a dash "-" (e.g. , R ₃ Si- R ₂ X| Si- or RX ₂ Si- groups).

[00092] Exemplary reagents that can be employed to prepare first or second particles with hydrophobic and/or oleophobic properties include siianizing agents such as those that are commercially available from Gelest, inc., Morrisvil le, PA. Such siianizing agents include, but are not limited to, the following compounds, which are identified by their chemical name followed by the commercial supplier reference number (e.g., their Gelest reference in parentheses): (tridecafluoro- 1 , 1 , 2, 2- tetrahydrooctyl)silane (SIT8173.0); (tridecafluoro- 1 , 1 ,2,2-tetrahydroocryi)trichiorosi lane (SIT8 174.0); (tridecafluoro- 1 , 1 ,2,2-tetrahydrooctyl)triethoxysilane (SIT8175.0); (tridecafluoro- 1 , 1 ,2,2- tetrahydrooctyi)trimethoxysilane (SIT8 1 76.0); (heptadecafluoro- 1 , 1 ,2,2- tetrahydrodecyl)dimethyl(dimethylamino)silane (S1H 840.5); (heptadecafluoro- 1 , 1 ,2,2- tetrahydrodecyl)tris(dimethylamino)siIane (SIH5841 .7); n-octadecyltrimethoxysilane (SI06645.Q); n- octyltriethoxysilane (SIO6715.0); and nonafluorohexyldimethyl(dimethylamino)silane (SIN6597.4). [00093] Two attributes of si lanizing agents that may be considered for the purposes of their reaction with first or second particles and the introduction of hydrophobic or oleophobic moieties are the leaving group (e.g. , X groups of compounds of the formula (I)) and the terminal functionality (e.g. , R groups of compounds of the formula (I)). A silanizing agent's leaving group(s) can determine the reactivity of the agent with the first or second particie(s) or other components of the coating. Where the first or second particles are a silicate (e.g. , fumed silica) the leaving group can be displaced to form Si-O- Si bonds. Leaving group effectiveness is ranked in the decreasing order as chloro > methoxy > hydro (H) > ethoxy (measured as trichloro > trimethoxy > trihydro > triethoxy). This ranking of the leaving groups is consistent with their bond dissociation energy. The terminal functionality determines the level of hydrophobicity that results from application of the siiane to the surface.

[00094] 3n addition to the silanizing agents recited above, a variet of other silanizing agents can be used to alter the properties of first or second particles and to provide hydrophobic and/or oleophobic properties, in some embodiments, second particles may be treated with an agent selected from

dimethyldichlorosi lane, hexamethyldisiiazane, octyltrimethoxysi lane, polydimethylsi loxane, or

tridecafluoro- l , l ,2,2-tetrahydrooctyl trichiorosilane. In such embodiments, the second particles may be silica. Silica second particles treated with such agents may have an average size in a range selected from: about 1 nm to about 50 nm, from about 1 nm to about 100 nm, from about 1 nm to about 400 nm, from about 1 nm to about 500 nm, from about 2 nm to about 120 n, from about 5 nm to about 1 50 nm, from about 5 nm to about 400 nm, from about 10 nm to about 300 nm, from about 20 nm to about 400 nm, or from about 50 nm to about 250 nm.

[00095] in addition to the silanizing agents recited above, which can be used to modify any one or more components of coatings (e.g., first and/or second particles), other agents can be employed including, but not limited to, one or more of: gamma-aminopropyitriethoxysilane, Dynasylan ^® A

(tetraethylorthosilicate), hexamethyldisiiazane, and Dynasylan ^® F 8263 (fluoroa!ky!siiane), any one or more of which may be used alone or in combination with the silanizing agent recited herein.

5.2 Use of Compounds Other Than Silanizing Agents

[00096] Other agents also can be used to introduce hydrophobic and/or oleophobic moieties into second particles. The choice of such agents will depend on the functionalities available for forming chemical (covaient) l inkages between hydrophobic/oleophobic moieties and the functional groups present on the second particles surface. For example, where second particle surfaces have, or can be mod ified to have, hydroxy! or amino groups, then acid anhydrides and acid chlorides of a! kyi, fluoroaikyi, and perfiuoroaikyl compounds may be employed (e.g., the acid chlorides: C1-C(0)(CH ₂ ) , ₀ isCH ₃ ; Cl- C(0)(CH ₂ )4-io(CF ₂ )2 to MCF ₃ ; C1-C(0)(CF ₂ ) _{4 !0} i ₈ CF ₃ or the anhydrides of those acids).

5.3 Preparation of Plungers with Hydrophobic and Oleophobic Coatings.

[00097] As noted above, in addition to the hydrophobicity d isplayed against aqueous-based solutions, suspensions, and emulsions, the coatings described herein also have the abil ity to display oleophobic behavior, thereby further reducing the abi lity of materials destined for the sewer to attach to the surface of coated plungers. Oleophobicity wil l be exhibited by embodiments described herein, particularly when the coatings comprise fluorinated or perfluorinated alky I groups bound to first or second particles (e.g. , where the terminal functionality, that is the R group(s) of a silane of the formula R4. _n Si-X _r „ are fluorinated a!kyi or perfluoroalkyl).

6.0 METHODS OF APPLYING HYDROPHOBIC AND OLEOPHOBIC COATINGS

6.1 Portion of the Plunger Coated

[00098] Al l or only a portion of the cup and/or handle may be coated with a hydrophobic coating according to this disclosure. As the cup is the portion of the plunger with the most surface area that contacts standing water and other materials that are to enter sewage l ines, in some embod iments the cup is the only portion of the plunger that is coated with a hydrophobic coating. Likewise, as only a part of the handle is typically immersed in water during the unciogging operation, in other embodiments only the cup and the part of the handle closest to the cup are treated to provide them with a hydrophobic surface (e.g. , by coating them). In some embodiments, less than one-half of the handle's length will be treated, and in other embodiments greater than one-half of the handle will be treated. In yet other embodiments, the entire plunger (the cup and handle) is treated/coated so that the surface of the plunger is hydrophobic. The appl ication of hydrophobic coatings to household and industrial plungers are illustrated in Figs. 3-6.

6.2 Application of Coatings by One-Step and Two-Step Processes

[00099] The hydrophobic coatings described herein may be applied to substrates (e.g. , the surface of one or more parts of a plunger) using a variety of techniques, some of which can be grouped into one- step process and two-step processes. Within each of those categories numerous variations may be employed.

[000100] In one-step embodiments, the coating composition is substantial ly appl ied in a single step to the surfaces of an object (e.g., a plunger) on which a hydrophobic surface is desired, although coatings applied by a one step method may subsequently be treated in one or more steps with one or more agents to increase the hydrophobicity of the coating or to effect some other modification of the properties of the hydrophobic coating or plunger. Exemplary coating compositions that can be applied in one step comprise a binder and at least one type of first particle and at least one type of second particle bearing a hydrophobic moiety. In some such embodiments, the coating may be treated with an agent that comprises a silanizing agent (e.g. , compositions comprising a compound of formula (1)). In other embodiments, coating hydrophobic compositions that comprise a binder and a first particle may be appl ied in a single step and subsequently treated by an agent comprising second particles according to th is disclosure that, for example, bear hydrophobic and/or oleophobic chemical moieties such as fluoroalkyl groups.

[000101 ] In one embodiment, a one-step method of applying a coating to a substrate comprises applying a coating composition comprising: i) a binder; ii) first particles having a size of about 30 μτη to about 225 μπι; and iii) second particles having a size of about 1 nm to about 25 μτη bearing a hydrophobic moieties. Optionally, one or more independently selected alkyl, haloalkyl, or perfluoroalkyl groups may be covalentiy bound, either directly or indirectly, to the second particles prior to their incorporation into the coating composition. One-step coating compositions may be diluted with any compatible solvents/liquids to assist in the application process.

[000102] in two-step methods, the coating composition is applied to a surface in two steps that comprise, respectively, the application of a first composition followed by the application of a second composition, in embod iments of a two-step method, the first composition comprises a binder and at least one type of first particles, and does not contain second particles that bear hydrophobic moieties. Once applied to the substrate, the first coating composition is termed a "substrate coating" or a "base coat(ing)." Following the application of the first coating composition, a second composition that is sometimes referred to as a "second coat(ing)" or "top coai(ing)" is applied to the base coating. The second composition comprises second particles bearing hydrophobic moieties (e.g., alky! or fluoroaikyl groups such as those introduced by reacting second particles with siianizing agents such as those of formula (I)).

[000103] In another embodiment a two-step method of forming a coating on at least a portion of a surface comprises: i) applying a composition comprising a binder to said surface, and ii) applying to said binder on said surface second particles having a size of about 1 nm to about 25 μιτι, wherein said second particles comprise one or more independently selected hydrophobic or oleophobic moieties; and wherein said applying to said comprises spray coating said second particles using a stream of gas (the second particles typically comprise less than about 2% by weight of a VOC (e.g., a volatile solvent with a boiling point below 150° or 200° C at 1 atmosphere such as hexane, ethanoi, and the like), in one variation of that method the composition comprising a binder further comprises first particles, in such an embod iment the first particles may have a size of about 1 μη to about 100 p.m or of about 30 μιη to about 225 μιτη (either average diameter or minimum diameter in any dimension). First particles, and their dimensions, are described elsewhere in this disclosure.

[000104] Second particles appl ied as part of the second coating composition in a two-step method may be applied either as a suspension in a suitable solvent that is compatible with the binder system (e.g., hexane, xylene, and ethanoi) or without a solvent using a spray gun (air spray gun) supplied with a suitable supply of compressed air, nitrogen, or other compressed gas (e.g., a Binks Model 200 l or 2001 V spray gun air spray gun; Binks, inc., Glendale Heights, il^ supplied with air at about 50 psi may be employed).

[000105] In some embodiments a two-step method of applying a coating to a substrate comprises:

a) applying to the substrate a coating composition comprising i) a binder and ii) first particles having a size of about 30 μηι to about 225 μηι, to provide a base coating: and b) applying to this base coating a composition containing second particles having a size of about 1 nm to about 25 μτη.

[000106] The composition may also contain any necessary solvents/liquids to assist in the application process.

[000107] In one embodiment, the present specification includes and provides for a method of forming a hydrophobic coating on at least a portion of a surface comprising: i) applying a composition comprising a binder on said surface and ii) applying to said binder on said surface second particles a having a size of about 1 nm to 25 μιτι wherein said second partic les comprising one or more

independently selected hydrophobic or oleophobic moieties; wherein said applying to said binder comprises spray coating of said second particles using a stream of gas; and wherein said second particles comprise less than 2% by weight of a solvent.

[000108] In another embodiment, the present specification includes and provides for a method of forming a hydrophobic coating on at least a portion of a surface comprising: i) applying a composition comprising a binder and first particles on said surface and ii) applying to said binder and first particles on said surface second particles a having a size of about 1 nm to 25 μιτι, wherein said second particles comprising one or more independently selected hydrophobic or oleophobic moieties; wherein said applying to said binder and first particles comprises spray coating of said second particles using a stream of gas; and wherein said second particles comprise less than 2% by weight of a solvent,

[000109] In one-step or two-step processes, the coatings may be applied using high or low VOC compositions (e.g., water-based or aqueous binder compositions etc. ). Where two step processes are used, either the first step of applying the base coat, the second step of applying a composition comprising second particles, or both steps may employ low VOC compositions. Where high VOC compositions are employed to for hydrophobic/oleophobic surfaces, it can be advantageous to employ equipment that can capture the volatile solvents and reuse or recyc le them.

[000110] Coatings applied by a one-step or two-step methods may subsequently be treated with compositions comprising one or more agents to increase the hydrophobicity of the coating. In one embodiment, the agent is a silanizing agent (e.g. , the compositions comprising a compound of formu la (I)), In another embodiment, the coating resulting from a one-step process can be treated with a composition comprising second particles that have been treated so that they bear hydrophobic moieties (e.g., hydrophobic moieties or groups such as fluoroalkyi groups or dimethylsiloxanes). Where the coatings applied in one-step or two-step processes have not dried to the point that second particles can be incorporated, subsequent applications of second particles may be applied either in a binder compatible solvent, or with an air gun in the absence of a solvent as with the second step of a two-step process described above. In contrast, where coatings resulting from one-step or two-step process have already dried to the point where second particles cannot be incorporated into the coating in any significant amount (e.g. , an amount capable of altering the hydrophobicity of the coatings), second particles are generally applied in binder compatible solvents.

[00011 1 ] Coatings may be applied to substrates, or base coatings previously applied to substrates, by any method known in the art, including but not limited to: brushing, painting, dipping, spin coating, spraying, or electrostatic spraying.

6.3 Surface Preparation

[000112] To provide good adhesion of coatings (e.g., the base coat of a two-step coating) to a surface (e.g., the cup and handle parts of the plunger), the surfaces may be abraded to create some degree of surface roughness. For plungers, the surface roughness of the cup and hand le can be created by methods including: ( 1 ) scuffing with an abrasive pad (e.g. , Scotch-Brite™ pads), (2) fine sandblasting, (3) tumble blasting with small steel bails, and (4) coarse sandblasting. The surface roughness produced by different methods can be compared with the starting surface roughness. The surface roughness measured using a Mahr Pocket Surf PS 1 (Mahr Federal inc., Providence, RJ.) can be expressed using a variety of mathematical expressions including, but not l imited to, the arithmetical mean roughness (Ra) and ten-point mean roughness (Rz), which are described in Scheme 5Ϊ below.

[000113] Scuffing with abrasive materials such as Scotch-Brite™ pads increases the roughness values of plastics, such as those used in plunger handles, from an Ra of about 0.2-0.3 μηι to about 0.7-0.9 μιτι and the Rz from about 1 .4 to about 7 μηι. Sandblasting plastics with coarse sand produces a very rough surface where the Ra increases substantially into the range of about 5 to about 6 μπι and the Rz increases to the range of about .30 to about 37 μηι.

[000114] The surface of flexible materials, such as the cup of the plunger, can also be abraded to improve the adherence of the hydrophobic coatings. Scuffing with abrasive materials (e.g. Scotch- Brite™ pads) can increase the Ra of flexible materials such as rubber from the range of about 0.2 to about 0.35 μηι to the range of about 0.4 to about 0.5 μιτι and the Rz from about 2 μτη to the range of about 3 to about 4 μηι. Fine sandbiasting of flexible materials, such as rubber, increases the Ra into the range from about 0.60 to about 0.75 μηι and the Rz from about 2 μιτι to the range from about 6 to about 7 μιη. Tumbl ing with small steel bails can increase the Ra from about 0.28 to the range of about 0.3 to about 0.4 μηι and the Rz from about 2.043 to about .3.28 μιτι. Coarse sandblasting increases the Ra from 0.3 to the range of about 5 to about 6 μηι and the Rz. to the range of about 30 to about 35 μηι.

[0001 15] The adhesion of the base coat to the plunger cup and hand le is increased by any level of roughening. However, the surface roughness produced by coarse sandblasting with Ra values of about 5.662 μιτι for the handle and about 5.508 μηι for the cup or corresponding Rz values of about 33.05 and about 33. 150 μπι for the handle and cup, respectively, are considered too excessive, and they result in a less pleasing surface finish. Thus, surface roughening may be accomplished by a variety of techniques including, but not limited to: abrading with abrasive cloths or papers (e.g., scuffing with sandpaper or a Scotch-Brite™ pad), sandblasting with fine sand, sand blasting with coarse sand ( 10-20 mesh), or tumbling with small metal (e.g., steel) balls, fine sand (20-50 mesh), and fine alumina or other metal oxide or metalloid oxide powders. Scheme II

7.0 CERTAIN EMBODIMENTS

[0001 16] Embodiment 1 . A plunger for clearing clogged plumbing, having a hand le and a resi l ient collapsible cup comprising an outer surface and an inner surface, said outer and inner surface meeting at a rim, and said handle attaching to said outer surface, wherein said cup is coated with a hydrophobic coating, and wherein at least a portion of said handle is optional ly coated with a hydrophobic coating.

[000117] Embodiment 2. The plunger of embodiment 1 , wherein said hydrophobic coating comprises:

i) a binder; ii) first particles having a size of about 30 um to about 225 μητ; and iii) second particles having a size of about I nm to 25 μητ comprising one or more independently selected hydrophobic or oleophobic moieties; wherein said composition optionally contains 5% to 10% of a block copolymer on a weight basis.

[0001 18] Embodiment 3. The plunger of any of embodiments 1 or 2, wherein said hydrophobic coating comprises a base coat comprised of said binder and said first particles applied to said cup and optional ly applied to said handle, and a top coat applied to said base coat comprised of said second particles,

[0001.19] Embodiment 4. The plunger of any of embodiments 1 to 3, wherein the outer surface of the cup is generally convex and said inner surface is general ly concave.

[000120] Embodiment 5. The plunge of any of embodiments 1 to 4, wherein a cross section through the cup in a plane parallel to said rim is generally oval, elliptical, or oblate.

[000121] Embodiment 6. The plunger of any of embod iments 1 to 5, wherein a cross section through the cup in a plane paral lel to the rim is generally circular.

[000122] Embodiment 7. The plunger of embodiment 5, wherein said handle is attached to said outer surface at a point that is approximately equidistant from the rim in each direction. [000123] Embodiment 8. The plunger of any of embodiments 1 to 7, wherein plumbing is selected from a toilet, bathtub, shower, pipe, or sink,

[000124] Embodiment 9, The plunger according to embodiment 8, wherein said cup is adapted to conform to said plumbing.

[000125] Embodiment 10. The plunger of any of embodiments 1 to 9, wherein said hydrophobic coating is resistant to greater than 200, 250, 300, 350 or 400 abrasions cycles on Taber Model: 503 instrument using CS- 10 wheels with 250 g load .

[000126] Embodiment 1 1 . The plunger of any of embodiments 2 to 1 0, wherein said binder comprises a polyurethane.

[000,127] Embodiment 32. The plunger of embodiment 1 1 , wherein said polyurethane is a POLANE.

[000128] Embodiment 13. The plunger of any of embodiments 1 to 12, wherein said hydrophobic coating comprises about 5 to about 1 5% of first particles which are comprised of a material selected from: polymers, metals, glasses, glass bubbles, metal loid oxides, metal oxides, and cellulose.

[000129] Embodiment 14. The plunger of any of embodiments 2 to 13 , wherein said second particles comprise;

(i) a metal oxides (e.g. , aluminum oxides, zinc oxides, nickel oxide, zirconium oxides, iron oxides, or titanium dioxide such as alumina), an oxide of a metalloid (e.g. , oxides of B, Si, Sb, Te and Ge such silica or fumed silica), or one or more metal oxides, oxides of metal loids or combination thereof (e.g. , glass particles); and

(ii) a si iane, si !oxane or a si lizane, which may be covaientiy bound to said metal oxide, oxide of a metal loid, or a combination thereof.

[000130] Embodiment 15. The plunger of embodiment 14, wherein said siiane, siloxane or silazane are selected from po!ydimethyisiloxane (PDMS) and hexamethyldisilazane.

[000131 ] Embodiment 1 6. The plunger of any of embodiments 1 to 1 5, wherein said hydrophobic coating is resistant to 40, 50, 60, 70, 80, 90, or 100 abrasion cycles on a Taber Model: 503 instrument using CS- 10 wheels with 250 g load.

[000132] Embodiment 1 7. The plunger of any of embodiments 3 to 1 6, wherein said binder comprises an water-based polyurethane.

[000133] Embodiment 1 8. The plunger of embodiment 1 7, wherein said water-based polyurethane is a Polane ^tM

[000134] Embodiment 1 9. The plunger of any of embodiments 3 to 1 8, wherein said base coat comprises about 5 to about 15% of first particles which are comprised of a material selected from :

polymers, metals, giasses, glass bubbles, metal loid oxides, metal oxides, or cel lulose.

[000135] Embodiment 20. The plunger of any of embodiments 1 to 1 9, wherein said second particles are silica particles treated with a silanizing agent (e.g. , a compound of formula (I)). [000136] Embodiment 21 . The plunger of embodiment 20, wherein said si lanizing agent is selected from (tridecafluoro- 1 , 1 ,2,2-tetrahydrooctyl)silane (SITS 173.0); (tridecafluoro- 1 , 1 ,2,2- tetrahydrooctyl) trichlorosilane (SIT8 174.0); (tridecafluoro- 1 , 1 ,2,2-tetrahydroocty!)triethoxysilane

(SITS 1 75.0); (tridecafluoro- 1 , 1 ,2,2-tetrahydrooctyl)trimethoxysilane (SITS 176.0); (heptadecafluoro- 1 , i ,2,2-tetrahydrodecyl)dimethyl(dimethylamino)silane (SIH5840.5); (heptadecafluoro- 1 , 1 ,2,2- tetrahydrodecyl)tris(d imethylamino)silane (SIH5841 .7); n-octadecyltrimethoxysi lane (SIO6645.0); n- octyltriethoxysilane (SIO671 5.0); and nonafluorohexyldiinethyl(dimethylamino)silane (SIN6597.4).

[000137] Embodiment 22. The plunger of any of embodiments 1 to 21 , wherein the coating on said cup and/or at least a portion of said handle has an arithmetical roughness value from about 0.44 to about 5.5 1 urn or a ten point mean roughness from about 0.9 to about 5.7 μτη.

[000138] Embodiment 23. The plunger of any of embodiments ! -22, wherein less than about 0.2, 0.5, 1 , 2, 3 , or 4, grams of water remain bound to the surface after immersion in water at about 20°C.

[000139] Embod iment 24. The p lunger according to embod iment 23, wherein less than about 0.2, 0.5, 1 , 2, 3, or 4, grams of water remain bound to the surface after immersion in water at about 20°C after the handle has been used to compress the cup more than about 100, 200, or 300 times.

[000140] Embodiment 25. The plunger of any of embodiments 1 to 24, wherein the coating further comprises silver particles

[000141 ] Embodiment 26. The plunger of any of embodiments 3 to 25, wherein the base coat, top coat or both the base and top coat further comprise silver particles {e.g., silver nanoparticles for antibacterial action).

[000142] Embodiment 27. A method of forming a hydrophobic coating on at least a portion of a surface comprising:

i) applying a composition comprising a binder on said surface, wherein said binder optionally comprises one or more first particles; and

ii) applying to said binder on said surface second particles a having a size of about 1 nm to 25 μηι wherein said second particles comprising one or more independently selected hydrophobic or o!eophobic moieties; wherein said applying comprises spray coating of said second particles using a stream of gas; and wherein said second particles comprise less than 2% by weight of a solvent.

[000143] Embodiment 28. The method of embodiment 27, wherein said composition comprising a binder further comprises first particles having a size of about 30 μηι to about 225 μπι.

[000144] Embodiment 29. The method of any of embodiments 27 to 28, wherein said gas is air, nitrogen, or C0 ₂ .

[000145] Embodiment 30. The method of any of embodiments 27 to 29, wherein said second particles contain less than about 5%, 4%, 3%, 2%, or 1 % by weight of a volatile solvent as applied to the base coat.

[000146] Embodiment 3 1 . The method of any of embodiments 27 to 30, wherein said second particles comprise a metalloid oxide. [000147] Embodiment 32. The method of any of embod iments 27 to 3 i wherein said particles are silica particles,

[000148] Embod iment 33. The method of any of embodiments 27 to 32, wherein said coating composition comprises second particles in a range selected from: about 0.1 % to about 5%; about 0.2% to about 6%; about 4% to about 3 0%; about 6% to about 12%; about 8% to about 16%; about 1 % to about 1 6%; about 1 % to about 20%; about 10% to about 20% or about 1 5% to about 20% on a weight basis.

[000149] Embodiment 34. The method of any of embodiments 27 to 33 , wherein said coating has a surface in contact with said substrate and an exposed surface not in contact with said substrate, and said coating has a greater amount of second particles on, at, or adjacent to the exposed surface than on at or adjacent to the surface in contact with the substrate.

[000150] Embodiment 35. The method of embodiment 34, wherein said surface in contact with said substrate has, no second particles.

[000151] Embodiment 36. The method of embodiment 34, wherein the number of second particles on said surface in contact with said substrate is less than about I %, about 2%, about 5%, about 10%, about 20%, about 30%, about 40%, about 50%, about 60%, about 70%, about 80%, or about 90% of the number of second particles on at or adjacent to said exposed surface.

[000152] Embod iment 37. The method of any of embodiments 27 to 36, wherein the binder comprises a polyurethane, lacquer, fluoropolymer, or epoxy.

[000153] Embodiment 38. The method of any of embodiments 28 to 37, wherein the binder is hydrophilic or hydrophobic in the absence of said first particles and said second particles.

[000154] Embod iment 39. The method of any of embodiments 28 to 38, wherein said first particles comprise a material selected from the group consisting of: wood, cellulose, glass, metal oxides, metalloid oxides (e.g., silica), plastics, carbides, nitrides, borides, spinels, diamond, fly ash, hollow glass spheres, and fibers.

[000155] Embodiment 40, The method of any of embodiments 28 to 39, wherein the first particles have an average size in a range selected from: greater than about 5 μιτι to about 50 um; about 10 μηι to about 100 μ πΊ; about 10 μηι to about 200 μπι; about 20 μηι to about 200 μιτ about 30 μηι to about 100 μιη; about 30 μητ to about 200 μπι; about 50 μηι to about 100 μπι; about 50 μιτι to about 200 μιη; about 75 μπι to about 1 50 μηι; about 75 μιη to about 200 μπι; about 100 μηι to about 225 μηι; about 125 am to about 225 μιτ and about 1 00 μΐΌ to about 250 μιτι,

[000156] Embodiment 41 The method of any of embodiments 28 to 40, wherein the first particles have an average size greater than 30 μηι and less than 250 μιη.

[000157] Embodiment 42. The method of any of embodiments 38 to 4 1 , wherein the first particles have a size of 30 μιτι or greater in at least one dimension.

[000158] Embodiment 43. The method of any of embodiments 28 to 42, wherein said first particles do not comprise one or more independently selected hydrophobic and/or oleophobic moieties covalentiy bound to said first particle, or any hydrophobic or oleophobic moieties associated with said first particles as applied to (e.g., mixed with) said binder. [000159] Embodiment 44. The method of any of embodiments 28 to 43 , wherein said first particles comprises one or more independently selected hydrophobic and/or oieophobic moieties covalentiy bound to said first particle.

[000160] Embodiment 45. The method of any of embodiments 28 to 44, wherein said one or more hydrophobic and/or oieophobic moieties comprise one or more independently selected alkyl, fluoroalkyl or perfiuoroalkyi moieties.

[000161 ] Embodiment 46. The method of any of embodiments 27 to 45, wherein said first particles and/or second particles comprise one or more covalentiy bound hydrophobic or oieophobic moieties of the form:

R _3- „ X _n Si-*

where n is an integer from 0 to 2;

each R is independently selected from

(i) alkyl or cycloalkyl group optionally substituted one or more fluorine atoms,

(ii) C. _i0 20 alky l optionally substituted with one or more independently selected substituents selected from fluorine atoms and C6 _I0 u aryl groups, which ary! groups are optionally substituted with one or more independently selected halo, Ci , ₀ o alkyl, Q , ₀ io haloalkyl, Q _t0 [o alkoxy, or Ci , _{0 ) 0} haloalkoxy substituents,

(iii) Οή ιο 20 alkyl ether optionally substituted with one or more substituents independently selected from fluorine and C ₆ | ₀ ^yl groups, which aryl groups are optionally substituted with one or more independently selected halo, Cj _{l0 i0} alkyl, C| _l0 io haloalkyl, Q _!0 io alkoxy, or Ci ,o io haloalkoxy substituents,

(iv) C _{6 l0} aryl, optionally substituted with one or more substituents independently selected from halo or alkoxy, and haloalkoxy substituents;

(v) C ₄ , ₀ 2o alkenyl or C _{4 t0} 2o alkynyl, optionally substituted with one or more substituents independently selected from halo, alkoxy, or haloalkoxy;

(vi) -Z to ((CF2)q(CF ₃ )) _r , wherein Z is a C _{ , _{0 n} d ivalent alkane radical or a C ₂ io 12 divalent alkene or alkyne radical, q is an integer from 1 to 12, and r is an integer from I to 4);

each X is independently selected from -H, -Ci, -I, -Br, -OH, -OR ² , -NHR ³ , and -N(R ³ ) ₂ ;

each R is independently selected from C _\ alkyl and haloakiyl; and

each R ³ is independently an independently selected from H, C i _i0 ,\ alkyl and haloalkyl; where the open bond indicated by the * indicates a point of attachment to a particle.

[000162] Embod iment 47. The method of embodiment 46, wherein R is selected from: (a) an alkyl or fluoroalky! group having from 6 to 20 carbon atoms; (b) an alkyl or fluoroalky! group having from 8 to 20 carbon atoms; (c) an alky! or fluoroalkyl group having from 1 0 to 20 carbon atoms; (d) an alkyl or fluoroalkyl group having from 6 to 20 carbon atoms when n is 3 ; (e) an a!ky! or fluoroalkyl group having from 8 to 20 carbon atoms when n is 3 ; and (f) an alkyl or fluoroalkyl group having from 1 0 to 20 carbon atoms when n is 3. [000163] Embodiment 48. The method of any of embodiments 46 to 47, wherein R is -Z-

((CF ₂ ) _q (CF ₃ )),

[000164] Embodiment 49, The method of any of embodiments 46 to 48, wherein all halogen atoms present in any one or more R groups are fluorine atoms.

[000165] Embodiment 50. The method of any of embodiments 27 to 45, wherein said second particles are prepared by treating a particle having a size of about 1 nm to 25 μπι with a silanizing agent selected from: tridecafluoro- l , l ,2,2-tetrahydrooctyl)silane (SITS 173 ,0); (tridecafluoro- 1 , 1 , 2,2- tetrahydrooctyl) trichlorosi lane (SITS 1 74.0); (tridecafluoro- l , l ,2,2-tetrahydroocty])triethoxysilane

(SITS 175.0); (tridecafluoro- 1 , 1 ,2,2-tetrahydroocty l)trimethoxysiIane (SITS 176.0); (heptadecafluoro- l , l ,2,2-tetrahydiOdecy!)dimethy](dimethylamino)silane (SEH5840.5); (heptadecafluoro- 1 , 1 ,2,2- tetrahydrodecyl)tris(dimethylamino)silane (SIH5841 .7); n-octadecyltrimethoxysilane (SIO6645.0); n- octyltriethoxysilane (S3O6715.0); and nonafluorohexyldimethyl(dimethylamino)silane (SIN6597.4).

[000166] Embodiment 5 1 , The method of any of embodiments 27 to 45, wherein said second particles are particle having a size of about 3 nm to 25 μηι (e.g., silica particles) treated with a silanizing agent selected from: dimethyldichlorosilane, hexamethyldisilazane, octyitrimethoxysilane,

polydimethyisiloxane, or tridecafluoro- 1 , 1 , 2,2-tetrahydrooctyl trichlorosi lane.

[000167] Embodiment 52. The method of any of embodiments 27 to 45, wherein said second particles are silica particles prepared by treating said silica particles with an agent that will increase the number of sites on the si lica particles that can react with a silanizing agent prior to being treated with said silanizing agent.

[000168] Embodiment 53. The method of embodiment 52, wherein said agent that will increase the number of sites on the silica particles that can react with silanizing agents is selected from the group consisting of: SiCl ₄₎ SiCI _4, Si(OMe) ₄ , Si(OEt) ₄ , SiCl ₃ CH ₃ , SiCi ₃ CH ₂ SiCl ₃₎ SiCl ₃ CH ₂ CH ₂ SiCl ₎

Si(OMe) ₃ CH ₂ Si(OMe) ₃ , Si(OMe) ₃ CH ₂ CH ₂ Si(OMe) _3, Si(OEt) ₃ CH ₂ Si(OEt) ₃ , or Si(OEt) ₃ CH ₂ CH ₂ Si(OEt) ₃ .

[000169] Embodiment 54. The method of any of embodiments 27 to 53, wherein second particles have an average size in a range selected from about 1 nm to about 1 00 nm; about 10 nm to about 200 nm; about 20 nm to about 400 nm; about 10 nm to 500 nm; about 40 nm to about 800 nm; about 100 nm to about 1 micron; about 200 nm to about 1 .5 m icron; about 500 nm to about 2 micron; about 500 nm to about 2.5 μηι; about 1 .0 micron to about 1 0 μηι; about 2,0 micron to about 20 μπι; about 2.5 micron to about 25 μηι; about 500 nm to about 25 μιη; about 400 nm to about 20 μηι; and about i OOnrn to about 15 μηΊ,

[000170] Embodiment 55, The method of any of embodiments 27 to 54, wherein said second particles comprise: a metal oxide, an oxide of a metalloid, a silicate, or a glass.

[000171] Embodiment 56, The method of any of embodiments 27 to 55, wherein said second particles are comprised of silica and have an average size in a range selected from about i m to about 50 nm; about 1 nm to about 100 nm; about 1 nm to about 400 nm; about 1 nra to about 500 nrn; about 2 nm to about 120 nm; about 5 nm to about 1 50 nm; about 5 nm to about 400 nm; about 10 nm to about 300 nm; and about 20 nm to 400 nm.

[000172] Embodiment 57. The method of embodiment 56, wherein said second particles have an average size in the range of about 1 nm to about 1 00 nm or about 2 nm to about 200 nm.

[000173] Embodiment 58. The method of any of embodiments 27 to 57, further comprising treating said coating with a silanizing agent such as a compound of formula I.

[000174] Embodiment 59. The method of embodiment 58, wherein said si lanizing agent is selected from the group consisting of (tridecafluoro- l , l ,2,2-tetrahydrooctyl)silane (SIT8 1 73.0);

(tridecafluoro- 1 , 1 ,2,2-tetrahydrooctyl) trichlorosilane (SIT81 74.0); (tridecafluoro- 1 , 1 ,2,2- tetrahydrooctyljtriethoxysilane (SIT8 175.0); (tridecafluoro- 1 , 1 ,2,2-tetrahydrooctyl)trimethoxysi]ane (SIT8 1 76.0); (heptadecafluoro- l , l ,2,2-tetrahydrodecyl)dimethyl(dimethylamino)si lane (SIH5840.5); (heptadecafluoro- l , l ,2,2-tetrahydrodecyl)tris(dimethylamino)silane (SIH5841 .7); n- octadecyltrimethoxysilane (S1O6645.0); n-octyltriethoxysilane (SIO071 5.0); and

nonafluorohexyldimethyl(dimethylamino)silane (SIN6597.4).

[000175] Embodiment 60. An article having a surface coated with a hydrophobic coating prepared by the method of embodiments 27-59.

[000176] Embodiment 63. The article of embod iment 60, wherein said article is a plunger.

[000177] Embodiment 62. A plunger for clearing clogged plumbing having a hydrophobic coating on at least a portion of its surface, that when removed from sewage waste water is substantially free of any adhering water or drips and free of any solid or semi-solid particle(s) attached to the portion of the plunger coated with a hydrophobic coating (e.g., the plunger has less than about 0.1 , 0.2, 0.4. 0.5. 0.7,. 1 . 2. 3. or 5 grams of material adhering to the surface to the plunger).

[000178] Embodiment 63. The article of embodiment 60, or the plunger of embodiments 61 or 62, wherein the coating is resistant to bacterial growth.

[000179] Embodiment 64. The method of any of embodiments 27 to 59 or the article of any of embodiments 60 to 63, wherein the coating has an arithmetical roughness value from about 0.4 to about 5.6 μηι or a ten point mean roughness from about 0.8 to about 5.8 μηι.

[000180] Embodiment 65. The method of any of embodiments 27 to 59 or the article of any of embodiments 60 to 64, wherein the coating is resistant to greater than 20, 30, 40, 40, 60, 70, 80, 90, 100, 200, or 250 abrasion cycles on Taber Model: 503 instrument using CS- 10 wheels with 250 g load (e.g., tested as appl ied to a metal, such as alum inum, plate).

[000181] Embodiment 66. The plunger of embodiment 1 , wherein said hydrophobic coating comprises:

j) a binder; and ii) second particles having a size of about 1 nm to 25 μτη comprising one or more independently selected hydrophobic or oleophobic moieties; wherein said composition optional ly contains 5% to 1 0% of a block copolymer on a weight basis. [000182] Embodiment 67. The piunger of any of embodiments 1 or 66, wherein said hydrophobic coating comprises a base coat comprised of said binder (without added first particles) applied to said cup and optionally appiied to said handle, and a top coat applied to said base coat comprised of said second particles,

[000183] Embodiments also include one-step and two-step compositions for use in forming hydrophobic and/or oleophobic compositions. Those compositions may be in the form kits that include the coating component(s) and instructions for their use.

8.0 EXAMPLES

Example 1. High and Low Volatile Organic Compound (VOC) Coating processes Two-Step Coating Processes

Process A: Two-Step High VOC Process

[000184] This process consists of two steps each applying coatings via wet spray technique. In the first step a first or base coat is prepared comprising POLANE® B system from Sherwin Williams is formulated to a 6:3 : 1 volume ratio of POLANE® B, POLANE® Reducer and POLANE® A Catalyst as follows:

The first coat is prepared using a polyurethane binder, prepared as follows:

POLANE® B (F63W 13) 6 parts (strobe white, F63W 13, Sherwin Williams, PA)

Catalyst (V66V29) 1 part

Reducer (R7K84) 3 parts

POLANE® accelerator (V66VB 1 1 ) 0. 1 %

[000185] A ll ingredients are mixed by weight. The accelerator is used to speed the POLANE® curing process.

[000186] To the composition comprising the binder used in the first coat (base coat) a variety of different first particles can be added to enhance the durability and/or the bonding of the top coat to the base coat. First particles, some times referred to as fil lers herein, include, but are not l imited to glass bubbles (e.g. , 3M® glass bubbles, which are hol low glass microspheres of soda-l ime-borosilicate glass). Some glass bubbles suitable for use in the present coatings include: S60, K20, and K25 glass bubbles, whose particle sizes are given in Table 1 .1 .

[000187] The first coat is appiied to the article, and after about 60 to 120 seconds the second or top coat is appl ied. The second step comprises spraying a hexane slurry (4% w/v) of a hydrophobic second particles (e.g., treated fumed silca).

[000188] The base coat composition, without the first particles, contains about 30% solids, and releases about 7 grams of VOCs per 10 grams of wet coating, which is about the amount applied to some plungers described in later examples. Additionally the second step in the process, which util izes a hexane m ixture with fumed si lica releases about 13 grams of VOCs per 25ml applied to an article the size (surface area to be coated) of a plunger. This process therefore releases a total of about 20 grams of VOCs for per article the size of a plunger. Process B: Two-Step Low VOC Process

[000189] This process consists of two steps the first comprising a wet application of a first or base coat) followed by an appl ication of a second coating composition using materials that are not considered VOCs such as a stream of compressed air. In the first step a first coat (base coat) is prepared comprising a water borne polyurethane dispersion based on Bayer Material Science product Bayhydrol 124 and Sherwin Wi ll iams POLANE® 700T. That coating composition comprises about 35% solids and contains about 53% water and 12% «-methyl-2-pyrrolidone by weight, A 5%w/w loading of first particles (e.g., glass microspheres) is employed. The weight of glass microspheres used is determined based upon the weight of the coating composition as prepared,

[000190] To the composition comprising the binder used in the first coat a variety of different first particles can be added to enhance the durability and/or the bonding of the top coat to the base coat. First particles, some times referred to as fillers herein, include, but are not l imited to glass bubbles (e.g., 3M® glass bubbles, which are hollow glass microspheres of soda-iime-borosilicate glass ). Some glass bubbles suitabie for use in the present coatings include: S60, 20, and 25 glass bubbles, whose particle sizes are given in Table 1 .1 .

[000191 ] The first coat is appiied to the article, and after about 60 to 120 seconds the second or top coat is applied. The second step comprises applying an alcohol or acetone slurry (4% w/v) of hydrophobic second particles (e.g., treated fumed siica) on to the first coat by spraying or dipping.

Alternatively, a hydrophobic fumed si l ica can be appi ied to the surface using a stream of compressed gas typically at about 10 to 100 psi in the absence of VOCs.

[000192] The coating process would release about 1 .2 grams of VOC per article about the size of a plunger in the first step and 7 grams in the second step, bringing the total down to 8.2 g per article the size of a plunger if solvent is used in the second step and 1 .2 g if no solvent is used in the second step. Example 2. A Two-Step Hyd ophobic Coating Process as Applied to Plunger for Drains

[000193] Although the methods described herein can be applied to any suitable surface, this example uses the two step coating process to apply a hydrophobic coating to a plunger for clearing drains.

Surface Preparation

[000194] In order to obtain tight adhesion of the base coat to the a surface, such as the cup and hand le parts of a plunger, the surface roughness is increased by methods including: ( 1 ) scuffing with a Scotch Brite™ pad, (2) fine sandblasting, (3) tumble blasting with small steel bal ls, and (4) coarse sandblasting. The roughness can be expressed using a variety of mathematical expressions Including, but not limited to, the Arithmetical Mean Roughness (Ra) and Ten-Point Mean Roughness (Rz), which are described in Scheme II. Values for Ra and Rz surface roughness produced by different methods compared with the starting surface roughness, (measured using a Mahr Pocket Surf PS I by Mahr Federal Inc., Providence, RJ) are given in Table 2.1 . Table 2.1 : Plunger Roughness Produced by Different Methods

Coating process

[000195] The conversion of plunger parts (cup and handle) into hydrophobic surfaces is accomplished by application of surface coating using a two-step process, in the two-step process the first coat (base coat) generally serves as a base or binder coat to the substrate (cup and hand le of the plunger in this case) and the second coat (top coat) comprises hydrophobic second particles (hydrophobic fumed silica).

[000196] The first coat (base coat) is prepared using a polyiirethane binder, prepared as foilows from the following ingredients by weight:

POLANE® B (F63W 13) 6 parts (strobe white, F63W 13, Sherwin Will iams, PA)

Catalyst (V66V29) 1 part Reducer (R7K84) 3 parts

POLANE® accelerator (V66VB 1 1 ) 0. 1 %

[000197] All ingredients are m ixed. The accelerator is used to speed the POLANE® curing process.

[000198] A variety of different first particles can be added to enhance the durability of bonding of the top coat to the base coat. First particles, some times referred to as fillers herein, include, but are not l imited to glass bubbles (e.g., 3M ^® glass bubbles, which are hol low glass microspheres of soda-lime- borosilicate glass). Some glass bubbles suitable for use in the present coatings include: S60, K20, and 25 glass bubbles, whose particle sizes are given in Table 2,2.

Table 2.2: Particle Size Distribution of 3M™ Glass Bubbles

000199] The top coat comprises nano-sized (5-50 nm) fumed si lica particles, which are preireated with chemical moieties that impart hydrophobicity (e.g., a silazane or a siloxane). In one top coat of this example TS-720 (Cabot Corporation, Bi lierica, MA) is employed, in another top coat of this example

R812S (Evonik Degussa Corp., Parsippany, NJ) is employed.

Table 2.3: Properties of TS-720 and R812S Silicas

Both TS-720 and R812S are fumed silica of approximately the same surface area. However, they are treated with two different compounds whose molecular formulas are shown below, Poiydimethylsi!oxane Hexamethyldisilazane

in this example the top coats is applied by one of two methods:

[000201 ] Method ¾ : in this method, fumed silica particles are dispersed in a solvent (e.g., hexane) and sprayed. Typical dispersions obtained with TS-720 are prepared with 4 g of TS-720 in 100 ml of hexane. For R812S, the dispersion is employed uses 8 g of R8.12S in 100 ml of hexane. The fumed silica dispersion is sprayed onto the base coat using an air spray gun Binks Mode! 2001 or 2001 V spray gun air spray gun. [000202] Method 2: The fumed silica is delivered to the surface of the base coat without hexane. The fumed silica is sprayed on at a high air pressure (20 - 100 psi) onto the base coat. The pressure of spray is critical to get good bond with the base coat (Binks Model 200 l or 2001 V spray gun air spray gun.

[000203] In method 2 excess fumed silica Is recovered by a dust col lection system from the spray booth and can be reused.

Sample 1 : Plunger Prepared With Two-Step Coating Using a Base Coat (Containing no first panicles)

[000204] A plunger cup and a part of the handle adjacent to the cup (part most likely to contact water/sewage) are coated with the above-described strobe white POLANE™ containing base coat. A total of 10 g of the POLANE™ containing base coat is applied by spraying the inside and outside of the cup and part of the handle. The base-coated cup and handle are subsequently coated with a second (top) coat of 20 ml of composition comprising 4 g of TS-720 fumed silica suspended in 100 ml of hexane within 30 min after spraying the base coat to maximize the bonding of the fumed silica top coat to the base coat.

[000205] The coated plunger is cured at room temperature for 24 hours. After curing, the plunger is tested by inserting it in the toilet water. After 50 plunges, some water droplets remain on the edge of the top plunger and on the bottom side of the rim.

Sample 2: Two-Step Coating Employing Glass Bubble Second Particles ( 1 0% - 1 5% S60 Particles)

[000206] A plunger is coated using the process described for Sample 1 , except that the base coating of POLANE® contains 10% - 1 5% (by weight) of S60 glass bubbles (see Table 1 for detai Is). Quantities of the base and top coats are kept nearly the same. After curing, the plunger is tested in a toilet by repeated plunges. After about 100 plunges, some water droplets were seen on the bottom rim (7) and S ip (8) of the cup. No droplets were seen on the edge of the top of the plunger as was the case in Example I . The incorporation of S60 particles in the base coat approximately doubles the number of plunges with minimum droplet adherence at limited locations.

Sample 3 : Base Coat with 5% 25 Glass Bubbles as Filler

[000207] A plunger is coated using the process described for Sample 1 , except that the base coating of POLANE® contains 5% of the K25 glass bubbles (see Table 1 for details) as first particles. After applying the top coat and curing at room temperature for 24 hours, the plunger is tested in a toilet. After about 100 plunges only one or two droplets are seen on the inside of the cup near the rim and lip.

Sample 4: Base Coat with 10- 15% K25 Glass Bubbles

[000208] A plunger is coated using the process described for Sample 1 , except that the base coating of POLANE© contains 10- 15% K25. After curing at room temperature for 24 hours the plunger is tested by plunging 100 times in a toilet. This plunger, which has a slightly rougher surface than plunger in Sample 3 , shows no sticking of any water droplets in any location (outside or inside the cup). Sample 5 : Base Coat with 5% K20 Glass Bubbles and Top Coat using R81 25 -Treated Silica

[000209] A plunger is coated using the process described for Sample 1 , except that the base coating of POLANE® contains K20 glass bubbles (5%) to limit the coating roughness. After applying the base coat by spraying, the top coat, which is prepared by suspending 8 g of R812S-treated fumed silica (Evonik Industries) in 50 ml of hexane is appiied. Although the same quantity of top coat is used as in Sample 1 , it contains only half the amount of hexane. After curing at room temperature for 24 hours, the plunger is tested by plunging a toilet 250 times, after which no water droplets are noted on any of the surfaces. In addition, even following 250 plunges no indication of any cracking or flaking of the coating is noted.

Sample 6: Base Coat with 5% K20 Glass Bubbles as Fil ler and Pressure Applied Dry Top Coat of TS- 720

[000210] A plunger is coated with a base coating of POLANE® containing 5% K20 glass bubbles, as in Sample 5. A top coat of TS-720 fumed silica is appiied within 10 minutes by high pressure (50 psi) spraying using a Binks Model 2001 or 2001 V spray gun air spray gun air in an enclosed box with dust collection system. After curing at room temperature for 24 hours, the plunger is tested by plunging in a toilet 300 times, without the adherence of any water droplets.

Sample 7: Base Coat with 5% K20 Glass Bubble Filler and Pressure Applied Dry Top Coat of R8 12S

[000211] A plunger is coated with a base coating of POLANE® containing 5% K20 glass bubbles, as in Sample 6. However, the top coat of TS-720 applied by pressure spraying is replaced by a coating of R812S fumed silica appiied using the same air pressure (50 psi). After curing at room temperature for 24 hours, the plunger is tested in a toilet by plunging 250 times without the adherence of any water droplets. Example 3 Plunger Base and Coating and Top Coating Procedure:

[000212] A base coat is prepared using POLANE® ⁾ System and glass bubbles:

POLANE® B = 6 pans (Sherwin Williams (521 - 1404), Strobe White, F63 W 1 3)

POLANE® A Exterior Catalyst = 1 part (Sherwin Williams (500- 1417), V66V29)

POLANE® Reducer = 3 parts (Sherwin Williams (530-2641 ), R7K69)

K20 Glass Bubbles = 5.0% by weight to POLANE® mix (3M ^® , 70-0704-8403 -8)

[000213] To a plastic mixing container whose empty weight is determined is added POLANE® B (6 parts), POLANE® A ( 1 part) and POLANE® Reducer (3 parts) by volume. Hazardous Air Pollutants (HAPS) free POLANE® Reducer (R7K95) can be used in place of POLANE® Reducer (R7K96). The mixture is stirred for 3 minutes using a mechanical mixer/drill with mixing blade. The container and its contents are weighed and the weight of the POLANE® components determined by deducting the empty weight of the container. K20 glass bubbles are added (5% by weight) and the mixture is stirred for 5 minutes to ensure complete mixing of K20 glass bubbles into the liquid components to form a

K20/POLANE® base coat composition. The approximate pot-life of the base coat composition is 4-6 hours.

[000214] Plungers are prepared for the application of the base coat by Scuffing of handle and plunger head using an abrasive pad (e.g. Scotchbright pads), fine sandblast, and/or tumble blasting with aluminum oxide or steel ball bearings, The plunger is cleaned of debris from the scuffing process, for example using high pressure air or water fol lowed by drying.

[000215] The 20/POLANE® base coat composition is poured into a gravity fed spray gun (Central Pneumatic, 20 oz. (50-70 psi), item #47016) and sprayed on to the plunger head and at least the portion of the hand le closest to the plunger head (e.g., about 6 inches of the handle) (approximately 15- 20mL of K20/ POLANE® mixture per plunger is sprayed in the process. Including over spray, the coating amounts to about 3.0g of dried coating mixture. The thickness will depend upon the amount of material sprayed and the amount of overspray. Care must be taken to ensure complete coverage of all portions of the plunger cup, such as the inside of the cup and underneath parts of the rim/lip.

[000216] Top coats, such as those comprising silica and a hydrophobic moiety (e.g., a bound si lane group) can be appiied to the base coat after a period of about 60 to 120 seconds. The application of the top coat may be conducted by spraying the base coat with top coat composition comprising second particles using a stream of gas (e.g. air) in the presence or absence of a compatible solvent. Alternatively, the top coat may be applied by dipping a plunger into a coating composition comprising secondary particles.

Example 4 Abrasion Testing of Coatings

[000217] To assess the abrasion resistance of the hydrophobic coatings, and particularly the abrasion resistance of coatings that can be appl ied to flexible materials such as the cup of a plunger, a first coat binder composition as described in Example 2 including the indicated fil ler is applied to 4 inch by 4 inch aluminum plates. One of four different fillers (S60, 20, 5 12 B lack or K25 Black) is added to the coating composition applied to each plate. Following the application of the first coat, second coats are applied to the plates using compressed air at the indicated pressures to apply TS720 silica or R812S silica (see the columns marked "Dry Power Spraying") in the accompanying table. Control aluminum plates, where the second coat is applied by spraying them with a slurry comprising TS720 or R812S hydrophobic fumed silica (4g/ 100ml w/v) in hexane, are also prepared.

[000218] After air drying at room temperature for 24 hours the plates were subject abrasion testing. A lthough resistance to abrasion may be measured using any method known in the art, for the purpose of this application abrasion testing was conducted using a Taber Model: 503 instrument equipped with CS- 1 0 wheels with loads as indicated,

ABRASI ON TESTING T BLE

Dry Powder Spraying Dry Powder Spraying Hexane, Spr aying

(TS720) (R812S) (TS720 ) ^'

Taher

Filler Cycles (250g

S60 Glass (10-15%) load)

Spray Taber Cycles Spray Taber Cycles (250g S60 Glass ( 10-

Pressure (2S0g load) Pressure load) 15%) 200

10 psi 20 cycles 10 psi 20 cycles K20 Glass (5%) 350

20 psi 40 cycles 20 psi 40 cycles 25 Glass (5%) 450

512 White or

30 psi 80 cycles 30 psi 70 cycles Black ( 10-1 5%) 400

40 psi 100 cycles 40 psi 105 cycles

Hexane Spr aying

Filk T K20 Glass (5%) POLANE® Wh he/R812S

Taber Cycles

Filler (250g load)

Spray Taber Cycles Spray Taber Cycles (250g S60 Glass

Pressu e (2S0g load) Pressure load) ( 10- 15%) 180-220

10 psi 20 cycles 10 psi 20 cycles 20 Glass (5%) 400

20 psi 30 cycles 20 psi 40 cycles 25 Glass (5%) 400

512 White or

30 psi 50 cycles 30 psi 65 cycles Black ( 10- 15%) 375-425

40 psi 85 cycles 40 psi 90 cycles

K25 Black (10-15%)

Spray Taber Cycles Spray Taber Cycles {250g

Pressure (250g load) Pressure load)

10 psi 20 cycles 10 psi 15 cycles

20 psi 30 cycles 20 psi 30 cycles

30 psi 60 cycles 30 psi 55 cycles

40 psi 80 cycles 40 psi 80 cycles

512 Black (10-15%)

Spray Taber Cycles Spray Taber Cycles (250g

Pressure (250g load) Pressure load)

10 psi 125 cycles 10 psi 125 cycles

20 psi 150 cycles 20 psi 1 50 cycles

30 p.si 200 cycles 30 psi 200 cycles

40 psi 200 cycles 40 psi 200 cycles Example 5 One-Step Coating Process Employing Water-Based Po!yurethanes

[000219] A 40-g quantity of 40 :60 ratio by volume of POLANE® 700T (Sherwin-Williams Co., Cleveland, OH) and Bayhydrol 124 (Bayer Material Science, Pittsburg, PA) is prepared as a binder composition. Both 700T and Bayhydrol 124 are water-based polyurethanes. POLANE® 700T comes with pigment preloaded, whereas Bayhydrol 124 is provided from the manufactiirer as an un-pigmented coating composition to which pigment can be added at wil l. A 40:60 blend of POLANE® 7Θ0Τ to Bayhydrol 124 achieves a desirable pigment content. Optional components such as silver nanoparticles ( 10-30 ppm) may be added to the coating composition to provide antimicrobial action.

[000220] To the 40-g mixture of POLANE® and Bayhydrol described above, 2 g of S60, glass spheres (first particles), 4.5 g of TS-720 (second particles of fumed si lica treated with polyd imethyl- siloxane), and 15 g of water is added. The components are mixed extensively to achieve a good dispersion of TS-720 in the polyurethane binder composition and to form a one-step coating composition. The one-step-coating composition can be applied to surfaces by any suitable means including, but not limited to, spraying for several hours provided it is periodically mixed.

[000221] There are several advantages to the use of one-step processes, including one step process that employ water based binder systems to prepare hydrophobic and/or oleophobic coatings. One advantage is a minimization of the time that is needed to coat objects. Another advantage of the process described in this example is that it releases very low amounts of VOCs because essentially no solvents are used. Any VOCs released are associated with the water-based binder components (POLANE® 7Θ0Τ and/or Bayhydrol 124).

[000222] To prepare hydrophobic and/or oleophobic coated objects (e.g., plungers), the composition comprising binder, first, and second particles is sprayed on to the desired portions of the object after surface preparation (e.g., the plunger cup and part of the handle after roughening and cleaning) such as by using an air spray gun. The coating is left to dry for a suitable period depending on local conditions such as temperature and humidity (general ly about 3 to 4 hours for water based polyurethane compositions.

[000223] Two plungers treated by coating the plunger cup and a portion of the handle with the one-step Polane 700T -Bayhydrol composition described in this exampie are dried for 3-4 hours and tested. The coated plungers are tested by repeated plunging of a toi let. Each of the two plungers showed no water droplet sticking to any coated part of the plunger even after 500 plunges. The process yields hydrophobic and/or oleophobic coatings that are comparable in their ability to shed water to coatings that have been prepared by two step processes (e.g., the amount of water retained by the coating does not significantly increase even after repeated use such as in plunging tests).

Example 6 Two-Step Coating Process Employing Water-Based Polyurethanes

[000224] A mixture comprising a 40:60 ratio of POLANE® 700T and Bayhydrol 124 by volume is prepared. To that mixture water (7% by weight), K20 glass beads (5% by weight) and untreated M5 fumed silica ( 2.5% by weight) is added to form a base coating composition (i.e., to l OOg of the POLANE® /Bayhdrol mixture 7 g of water, 5 g of glass beads, and 2.5g of silica is added). The mixture is stirred and applied to prepared surfaces to form a base coat. After its application, the base coat is allowed to dry for a suitable period of time and a second coating (a 4% w/v mixture of TS-720 in acetone) is applied by for example by dipping. After appl ication of the second coating composition, the two-step coating can be given a subsequent treatment, for example with the second coating if desired or needed to produce a suitably hydrophobic and/or oleophobic surface. Optional components such as silver nanoparticles ( 1 0-30 ppm) may be added to the coating composition to provide antimicrobial action.

[000225] Four plungers are prepared for treatment using the two step process described above. Three of the plungers are prepared for coating by sandblasting and a fourth plunger is prepared by tumble blasting. Residue from the blasting step is removed by washing, and the plungers and drying them prior to any subsequent treatment. Each of the four plungers is sprayed with the above-described base coating composition. After the base coat, the three sand blasted plungers are left to dry for 45, 60, and 75 minutes, respectively; the tumble blast plunger is dried for about 70 minutes. After the specified drying time, the plunger is dipped into a second coating composition of 4% w/v mixture of TS-720 sil ica in acetone. After dipping, each plunger was allowed to dry and then given 3 to 5 minutes in acetone, after which it was sprayed with the same second coating composition in critical areas such as at the base of the cup and areas around the cup and both inside and outside the cup. The plungers are left to cure for two days prior to testing. The following test results are noted for each of the plungers:

[000226] Plunger # 1 (Sandblast, 45 minutes drying time before dipping in second coating): With the treatment used to apply the coating to this plunger, some tiny water droplets attach to the inside of the cup at points were cracking was observed after subjecting the plunger to testing. The cracking is apparently caused by the excess application of TS-720 during the dip application step. The first tiny droplets were observed to adhere to the plunger after about 50 plunges. Besides the adherence of droplets to that local area no other droplets were observed adhering to any other pail of the plunger for 400 plunges.

[000227] Plunger #2 (Sandblast, 60 minutes drying time before dipping in second coating): The base coat applied to this plunger is drier than the base coat applied to plunger # 3 at the time the second coating is applied by dipping. The cup stil l acquired excess TS-720 in small areas during the dipping process. With this plunger, the tiny droplets stick to the inside of the cup, but only after 100 plunges. Aside from this local effect, the plunger shows no additional droplets adhering to its surface for 400 plunges, at which point the testing stopped.

[000228] Plunger #3 (Sandblast, 75 minutes drying time before dipping in second coating): The drying time for this plunger permitted a more uniform coating with the second coating composition in the dipping process. As dipping the base coated plunger into the TS-720/acetone mixture does not cause any excess build-up in any areas of the plunger no cracking or water droplet adherence is observed . ^" No water droplets are observed adhering to the inside of the cup, or elsewhere, even after 400 plunges, as compared to plungers # 1 and #2. [000229] Plunger #4 (Tumble blast, 70 minutes drying time before dip): This plunger, performs in a manner similar to plunger #3, and does not show any excess pick-up of TS-720 during the dip process. The plunger can be subject to 400 plunges without any droplets sticking to the cup.

[000230] As with the one-stop process using water-based po!yurethanes described in Example 5, this two-step process advantageously limits the amount of VOCs released in the coating process (acetone is VOC exempt). For coatings applied after a drying time of about 60 to 70 minutes (for plungers), the plungers performed about as well as those prepared using the one step process regardless of the pretreatment of the surface (e.g., sandblasting or tumble blasting).