Creating superhydrophobic, abrasion-resistant and breathable coatings from water-borne polydimethylsiloxane-polyurethane Co-polymer and fumed silica

The high surface area and branched structure of fumed silica (FS) can be exploited in concert with the hydrophobic properties of polydimethylsiloxane (PDMS) and robustness of polyurethane (PU) to create PDMS-PU and FS grafted coatings with hierarchical structures and enhanced functionalities. The structural features of FS would add to superhydrophobicity; its open-branchlike characteristics would provide air permeability; the use of a tiered coating approach involving a FS-only layer on top of the PDMS-PU coat would create interlocking and strong abrasion-resistance, leading to a multifunctional coating with potential application in filtration and personal protection equipment (PPE). PDMS-PU and PDMS-PU-Si copolymer dispersions are synthesized with different monomer molecular weights and FS concentration. Hydrophobicity is measured via water contact angle and wetting resistance measurements. Abrasion resistance is compared by investigating the fiber morphology and hydrophobicity of the coated fabrics after various abrasion cycles. Air flow versus pressure drop experiments are used to measure breathability. Interaction mechanism between substrate/components are explored using infrared spectroscopy. The interactions between the substrate, FS, and PDMS-PU can be manipulated to create a novel, tiered coating that exhibits superhydrophobicity, strong abrasion resistance together with desirable air-permeability, thereby providing a versatile and unique coating platform.