Facile fabrication of durable and flexible superhydrophobic surface with polydimethylsiloxane and silica nanoparticle coating on a polyethylene terephthalate film by hot-roll lamination

Abstract

Practical applications of superhydrophobic surfaces have been limited by several disadvantages such as complex fabrication processes, high modification cost, and low mechanical durability. In this study, we present a facile and low-cost fabrication method to make flexible superhydrophobic films by a hot-roll lamination process. The film consists of a hydrophobic polydimethylsiloxane (PDMS) and hydrophobic silica nanoparticle (SNP) composite coating layer on a polyethylene terephthalate (PET) film. The coated film displayed excellent superhydrophobic properties with an apparent water droplet contact angle of 176.3° and a sliding angle of 2.4°. The surface morphology, roughness, and cross-section chemical composition of the coated films were investigated by field emission scanning electron microscopy and confocal laser scanning microscopy. The mechanical durability of the coated films was evaluated using several tests such as scratching with sandpaper, repeated bending deformation, and adhesion tape tests. The fabricated superhydrophobic films still showed superhydrophobic behavior after 20 tape tests. In addition, the fabricated superhydrophobic films exhibited strong mechanical durability, which preserved their very high contact angle >160° and very small sliding angle <10° after a 350 cm abrasion test with 240 grit sandpaper and a pressure of 1.2 kPa. Also, the coated sample exhibited very stable superhydrophobicity after 100 bending cycles due to the elasticity of PDMS. The chemical stability of flexible PDMS/SNP coated PET films was also investigated in acidic, neutral, and alkaline solutions and showed excellent chemical stability in acidic and neutral media in contrast to the alkaline medium. The obtained results demonstrated the outstanding robustness of the fabricated flexible superhydrophobic films that are promising for self-cleaning and water droplet bouncing performance. • Superhydrophobic surfaces were fabricated by a facile method without toxic chemicals. • The durability of the superhydrophobic films was demonstrated by abrasion and tape tests. • The fabricated films exhibited good flexibility in bending tests. • The self-cleaning property of the fabricated coated surfaces was also observed.