Porous bulk superhydrophobic nanocomposites for extreme environments

Robust superhydrophobic materials providing protections from harsh weather events such as hurricanes, high temperatures, and humid/frigid conditions have proven challenging to achieve. Here, we report a porous bulk nanocomposite comprising carbon nanotube (CNT)-reinforced polytetrafluoroethylene (PTFE). The nanocomposites are prepared using a templated approach by infusing a CNT/PTFE dispersion into a sponge followed by thermal annealing and decomposition of the sponge template. Importantly, an excess accretion of CNT/PFFE particle mixture on the sponge resulted in nanocomposites with unique and hierarchical porous microstructure, featuring nanochannels near the surface connected to microscale pores inside. The superhydrophobic nanocomposite could resist liquid jets impacting at a velocity of ∼85.4 m s−1 (Weber number of ∼202,588) and exhibits excellent high-temperature resistance as well as mechanochemical robustness. The porous nanocomposites display excellent icephobicity both with and without infusion with polydimethylsiloxane/silicone oil. These properties should facilitate exploitation as stiff/strong structural polymeric foams used in a variety of fields.