Rinse-resistant superhydrophobic block copolymer fabrics by electrospinning, electrospraying and thermally-induced self-assembly

An inherent problem that restricts the practical application of superhydrophobic materials is that the superhydrophobic property is not sustainable; it can be diminished, or even lost, when the surface is physically damaged. In this work, we present an efficient approach for the fabrication of superhydrophobic fibrous fabrics with great rinse-resistance where a block copolymer has been electrospun into a nanofibrous mesh while micro-sized beads have been subsequently electrosprayed to give a morphologically composite material. The intricate nano- and microstructure of the composite was then fixed by thermally annealing the block copolymer to induce self-assembly and interdigitation of the microphase separated domains. To demonstrate this approach, a polystyrene-b-poly(ethylene-co-butylene)-b-polystyrene (SEBS) nanofibrous scaffold was produced by electrospinning before SEBS beads were electrosprayed into this mesh to form a hierarchical micro/nanostructure of beads and fibers. The effects of type and density of SEBS beads on the surface morphology and wetting properties of composite membranes were studied extensively. Compared with a neat SEBS fibrous mesh, the composite membrane had enhanced hydrophobic properties. The static water contact angle increased from 139 degrees (+/- 3 degrees) to 156 degrees (+/- 1 degrees), while the sliding angle decreased to 8 degrees (+/- 1 degrees) from nearly 90 degrees. In order to increase the rinse-resistance of the composite membrane, a thermal annealing step was applied to physically bind the fibers and beads. Importantly, after 200 h of water flushing, the hierarchical surface structure and superhydrophobicity of the composite membrane were well retained. This work provides a new route for the creation of superhydrophobic fabrics with potential in self-cleaning applications. (C) 2017 Elsevier B.V. All rights reserved.