A simple immersion method is proposed to develop durable superhydrophobic cotton fabric from low-cost, fluorine and silane-free eco-friendly materials, to address the growing environmental concerns led by hazardous surface modifiers. Herein, silica sand nanoparticles (SS NPs) were synthesized by mechanical ball-milling approach, from a least reported silica abundant natural source, Cherthala sand. Cherthala a small town in the Alappuzha district of Kerala is noted for its high quality sand with 96.5% silica. The synthesis of SS NPs was optimized based on ball-to-powder weight ratio (BPR) and milling time using Central Composite Design of response surface methodology. Minimum crystallite size (∼26 nm) and maximum turbidity (355 NTU) were obtained for the trial loaded with 20:1 BPR and processed for 10 hours. In a traditional nano-coating approach, the milled SS NP was employed as the roughness-enhancer along with polymeric binder for adhesion; silicone oil and stearic acid to lower the surface energy. The standardized coating mixture exhibited maximum water contact angle 158.9 ± 7.6°, long-term water repellency, chemical stability after 12 hours standing in acidic and alkaline pH and more than five detergent washing cycles. The coated fabrics were resilient to O2-plasma, UV-irradiation and adhesive peel test. The study also presented the practical scope of the developed eco-friendly coatings for oil-water separation and in wearable smart textiles. Thus, the present work offers a scalable sustainable route to develop silica NP-based functional textiles with same comfort, touch-proof, and breathability.
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