Water-based acrylate copolymer/silica hybrids for facile preparation of robust and durable superhydrophobic coatings

Highlights: • Robust superhydrophobic surfaces were facilely constructed with a water-based formula. • Low free energy particles were incorporated into an aqueous system without surfactant. • The coatings can stand abrasion up to 1200 cycles even with a rough sand paper. • Good water resistance and promising oil/water separation function were achieved. • Content of low free energy particles were reduced to form superhydrophobic coatings. Resin based superhydrophobic coatings are effective to construct robust superhydrophobic surfaces on large scale without limitation of substrates. However, for most of the common resin based superhydrophobic coatings, it is inevitable to deteriorate environmental or health problems due to release of a large amount volatile solvents. In this work, a kind of water-based organic/inorganic hybrid consisted of acrylate copolymers and superhydrophobic silica nanoparticles were synthesized. The highly water-repellent silica nanoparticles were successfully involved into the aqueous dispersion of acrylate copolymers without additional surfactants. The as-synthesized hybrids simultaneously retain the excellent film-forming property of acrylate resins and amplify the contributions of low surface energy nanoparticles to the superhydrophobicity. Robust superhydrophobic coatings (CA > 160°, CA < 7°) with high adhesion strength, good scratch-resistance and excellent abrasion-resistance were constructed using the synthesized hybrids with significantly reduced content of low surface energy particles and organic solvent. The hybrid coating can stand abrasion up to 300 cycles with a fine sand paper and up to 1200 cycles under rough sand paper abrasion. Benefited from its good water-repellence property, the hybrid coating with a water-based formula not only showed improved water-resistance in comparison with commercial products; but also displayed attractive performances in self-cleaning and oil/water separation processes.