Ice protection coating and bonding methods thereof

A method for bonding an icephobic coating layer to an exterior surface of a substrate, the method comprising:

• roughening the exterior surface of the substrate to provide a roughened substrate surface;
• roughening a backside surface of the icephobic coating layer to provide a roughened icephobic coating layer surface;
• placing a pressure sensitive adhesive film layer on the roughened icephobic coating layer surface;
• placing the icephobic coating layer and the pressure sensitive adhesive film layer on the roughened substrate surface such that the pressure sensitive adhesive film layer is in contact with the roughened substrate surface, thereby providing a layered stack;
• enclosing the layered stack in a vacuum bag;
• applying a vacuum to the layered stack enclosed in the vacuum bag;
• releasing the vacuum;
• and
• removing the layered stack from the vacuum bag to provide an icephobic-coated substrate.

A method for bonding an icephobic coating layer to an exterior surface of an airfoil, the method comprising:

• roughening the exterior surface of the airfoil to provide a roughened airfoil surface;
• roughening a backside surface of the icephobic coating layer to provide a roughened icephobic coating surface;
• placing an epoxy film adhesive layer on the roughened airfoil surface to cover at least a part of the exterior surface of the airfoil;
• placing the roughened icephobic coating layer on the epoxy film adhesive layer such that the roughened icephobic coating surface is in contact with the epoxy film adhesive layer, thereby providing a layered stack;
• enclosing the layered stack in a vacuum bag;
• applying a vacuum to the vacuum bag, and heating the layered stack enclosed in the vacuum bag;
• cooling the layered stack;
• releasing the vacuum;
• and
• removing the layered stack from the vacuum bag to provide an icephobic-coated airfoil;
• wherein the icephobic coating layer comprises:
• a first polymer;
• a second polymer that is a fluoropolymer;
• an isocyanate;
• and
• a curative composition.