Abstract: The process of the present invention significantly increases the durability of superhydrophobic surfaces, while retaining similar optical properties to those of the original surface. The process uses velocity and heat to take freshly formed nano- and ultrafine particles and can partially embed and chemically bond them to the substrate, creating a strongly bonded nano-to-submicron textured surface. This nanotextured surface can then be modified to have desirable surface properties; for example, it can be hydrophobic, oliophobic, or hydrophilic. The high points of the coating made with this process protect the remainder of the surface from abrasion, thus greatly increasing product life in many uses. In preferred embodiments, the process is used to coat transportation vehicle windshields.

Abstract: The process of the present invention significantly increases the durability of superhydrophobic surfaces, while retaining similar optical properties to those of the original surface. The process uses velocity and heat to take freshly formed nano- and ultrafine particles and can partially embed and chemically bond them to the substrate, creating a strongly bonded nano-to-submicron textured surface. This nanotextured surface can then be modified to have desirable surface properties; for example, it can be hydrophobic, oliophobic, or hydrophilic. The high points of the coating made with this process protect the remainder of the surface from abrasion, thus greatly increasing product life in many uses. In preferred embodiments, the process is used to coat transportation vehicle windshields.

Abstract: To form an ionomer-based catalytic layer on a porous substrate, a heat source (40) is used to dry an ionomer-containing spray (46) so that it does not substantially liquid flow on the substrate (14). The ionomer spray (46) may contain a catalyst. A spray (46) of mixed material for forming the catalytic layer is entrained by a gas stream and is heated and directed to a substrate surface (12). For hydrogen/oxygen fuel cells, catalytic material is incorporated into the proton-conducting membrane (56) to convert diffusing oxygen and hydrogen to water to reduce potential loss at the electrodes and maintain hydration of the proton-conducting membrane (56).