One-step sprayable durable superhydrophobic coatings based on discrete epoxy binders: fabrication and performance

Superhydrophobic coatings demonstrate considerable application potential across diverse fields, including architecture, transportation, energy, and marine engineering. Among various preparation techniques, the one-step spraying method has emerged as a highly attractive strategy for fabricating superhydrophobic coatings owing to its significant advantages for large-scale production and operational simplicity. However, the superhydrophobic coatings currently prepared via the one-step spraying typically suffer from critical limitations of inadequate mechanical robustness and poor environmental durability, which severely constrain their practical deployment. This study innovatively proposes and employs a discrete epoxy resin adhesive system, aiming to effectively address the durability challenges inherent to one-step sprayed superhydrophobic coatings. Research findings demonstrate that the coatings fabricated using this approach retain exceptional superhydrophobicity (contact angle >150°, rolling angle <10°) even after rigorous testing regimes, including sandpaper abrasion, tape peeling, chemical corrosion, and ultraviolet (UV) aging. Consequently, their durability is significantly enhanced. This work provides an effective solution for developing high-performance superhydrophobic coatings that simultaneously feature a straightforward preparation process (one-step spraying) and excellent durability. It thereby holds significant value for advancing the large-scale practical application of this technology.