Large-Scale Spraying Fabrication of Robust Fluorine-Free Superhydrophobic Coatings Based on Dual-Sized Silica Particles for Effective Antipollution and Strong Buoyancy

With the rapid development of bionic science and manufacturing technology, superhydrophobic surfaces have received extensive attention and research. However, the cumbersome steps, high cost, fluorine pollution, and poor durability greatly restrict its commercial promotion and application. Here, a simple spraying method is used to construct wear-resistant superhydrophobic coatings on various substrates such as glass, filter paper, copper sheets, and polyethylene terephthalate films, using an integrated fluorine-free suspension consisting of silica micropowder, nanofumed silica, epoxy resin, and polydimethylsiloxane. The prepared superhydrophobic coating can withstand 75 sandpaper abrasion cycles and can still maintain good superhydrophobic performance after other physical tests (e.g., hand kneading and tape peeling after knife scraping). In addition, the coating is extremely water-repellent under harsh conditions such as strong UV irradiation and extreme chemical corrosive media. In the buoyancy test, the coated filter paper can bear 39 times its own gravity. This water-repellent interface also has the ability to self-clean in air and oil environments due to its ultralow adhesion to water droplets. Thanks to its simplicity, cheapness, and environmental friendliness, this superhydrophobic coating has promising applications in the fields of construction, chemicals, transportation, and electronics.