Hydrogel Coated Mesh with Controlled Flux for Oil/Water Separation

Superwetting surfaces are often applied in oil/water separation. Hydrogels have been widely prepared as superhydrophilic/underwater superoleophobic materials for oil/water separation since they are naturally hydrophilic. Hydrogels usually need to be combined with porous substrates such as stainless steel mesh (SSM) due to their poor mechanical properties. However, it is usually inevitable that the pores of the substrate are clogged during the actual preparation process, leading to a significant decrease in the flux, which limits its effective application. In this study, acrylic acid (AA), chitosan (CS) and modified silica were utilized to form a layer of dual-network PAA/CS@SiO₂ hydrogel by photopolymerization on SSM, followed by a simple and novel ultrasonic-assisted pore-making method to generate numerous pores in situ on the surface of the hydrogel-coated mesh, which led to an increase in water flux from 0 to 70,000 L m^-2 h^-1 without decreasing the separation efficiency. After 100 separations of a mixture of n-hexane and water, the flux was still higher than 50,000 L m^-2 h^-1 with a separation efficiency above 99%, which is superior to most of hydrogel-coated meshes reported so far. Moreover, the prepared PAA/CS@SiO₂ hydrogel-coated mesh also has good environmental stability, low swelling, and self-cleaning properties. We believe that the strategy of this study will provide a simple new perspective when hydrogels block the substrate pores, resulting in low water flux.