Ultrafast Flame-Induced Pyrolysis of Poly(dimethylsiloxane) Foam Materials toward Exceptional Superhydrophobic Surfaces and Reliable Mechanical Robustness

Rational Design of Oil-Resistant and Electrically Conductive Fluorosilicone Rubber Foam Nanocomposites for Sensitive Detectability in Complex Solvent Environments

Recent years have witnessed the explosive development of highly sensitive smart sensors based on conductive polymer foam materials. However, the design and development of multifunctional polymeric foam composites as smart sensors applied in complex solvent and oil environments remain a critical challenge. Herein, we design and synthesize vinyl-terminated polytrifluoropropylmethylsiloxane through anionic ring-opening polymerization to fabricate fluorosilicone rubber foam (FSiRF) materials with nanoscale wrinkled surfaces and reactive Si-H groups via a green and rapid chemical foaming strategy. Based on the strong adhesion between FSiRF materials and consecutive oxidized ketjen black (OKB) nano-network, multifunctional FSiRF nanocomposites were prepared by a dip-coating strategy followed by fluoroalkylsilane modification. The optimized F-OKB@FSiRF nanocomposites exhibit outstanding mechanical flexibility in wide-temperature range (100 cycle compressions from -20 to 200 °C), structure stability (no detached particles after being immersed into various aqueous solutions for up to 15 days), surface superhydrophobicity (water contact angle of 154° and sliding angle of ∼7°), and tunable electrical conductivity (from 10-5 to 10-2 S m-1). Additionally, benefiting from the combined actions of multiple lines of defense (low surface energy groups, physical barriers, and "shielding effect"), the F-OKB@FSiRF sensor presents excellent anti-swelling property and high sensitivity in monitoring both large-deformation and tiny vibrations generated by knocking the beaker, ultrasonic action, agitating, and sinking objects in weak-polar or nonpolar solvents. This work conceivably provides a chemical strategy for the fabrication of multifunctional polymeric foam nanocomposite materials as smart sensors for broad applications.

Superhydrophobic Non-Metallic Surfaces with Multiscale Nano/Micro-Structure: Fabrication and Application

Multiscale nano/micro-structured surfaces with superhydrophobicity are abundantly observed in nature such as lotus leaves, rose petals and butterfly wings, where microstructures typically reinforce mechanical stability, while nanostructures predominantly govern wettability. To emulate such hierarchical structures in nature, various methods have been widely applied in the past few decades to the manufacture of multiscale structures which can be applied to functionalities ranging from anti-icing and water-oil separation to self-cleaning. In this review, we highlight recent advances in nano/micro-structured superhydrophobic surfaces, with particular focus on non-metallic materials as they are widely used in daily life due to their lightweight, abrasion resistance and ease of processing properties. This review is organized into three sections. First, fabrication methods of multiscale hierarchical structures are introduced with their strengths and weaknesses. Second, four main application areas of anti-icing, water-oil separation, anti-fog and self-cleaning are overviewed by assessing how and why multiscale structures need to be incorporated to carry out their performances. Finally, future directions and challenges for nano/micro-structured surfaces are presented.

Stereo-complex polylactide composite aerogel for crude oil adsorption

Adsorption materials are a cost-effective and simple method for oil spill remediation, but their efficiency is limited by high crude oil viscosity. Additionally, non-degradable materials pose another risk of secondary pollution, such as microplastic debris. Here, an environmentally-friendly stereo-complex polylactide composite (SCC) aerogel were developed via water-assisted thermally induced phase separation. The SCC with 3 wt% carbon nanotubes had a hierarchical structure of micro/nanoscale pores and high content of stereo-complex crystallites (35.7 %). Along with the excellent water repellency (water contact angle: 157°), SCC aerogel was 2.7 times as resistant to hydrolysis than poly(l-lactide) aerogel (Ph = 13, 37 °C). Additionally, a maximum absorption capacity of 41.2 g g-1 and over 97 % oil/water separation efficiency after 10 cycles were obtained in low viscosity conditions; while in high viscosity conditions, it displayed excellent photothermal performance, reaching a surface temperature of 85 °C under 1 sunlight, reducing crude oil absorption time from 42 min to 60 s (97.6 %-time savings). Moreover, it facilitated continuous crude oil spill recovery under sunlight with an adsorption rate of 3.3 × 104 kg m-3 h-1. The SCC aerogel presents a potential route for utilizing solar energy in crude oil adsorption applications without additional environmental burden.

Facilitate the preparation of naturally modified and self-healing superhydrophobic/superoleophilic biochar-based foams for efficient oil-water separation

Oil spills are sudden, complex, and long-term hazardous, and the existing adsorption materials still have the disadvantages of small selective adsorption capacity, easy secondary contamination, and difficult to repair after breakage in practical applications. Herein, melamine foam (MF) coated by ball milled biochar (BMBC) and natural beeswax (Wax@BMBC@MF) was prepared by a bio-inspired functionalization method and further added with self-healing function (SH-Wax@BMBC@MF) to cope with complex environments, and applied to oil-water separation for oil adsorption. SEM and FTIR results showed that BMBC and natural beeswax nanoparticles successfully encapsulated the smooth surface of the melamine foam skeleton. The loading of natural beeswax increased the foam's ability to absorb oil and organic solvents from 0.6108-1.134 g to 0.850-1.391 g, and the oil-absorbing capacity of the foam remained at 0. 758-1.263 g after being cut by a knife and self-healing. The oil-absorbing capacity of SH-Wax@BMBC@MF remained in the range of 0.936-1.336 g under acid/alkali environment (pH =1-13). The surface functional groups of BMBC improved the surface roughness of the material and strengthen the MF skeleton to adsorb oils and organic solvents by capillary action. The generation of the di-coordinated structure by Fe3+ and catechol group contributed the restoration of SH-Wax@BMBC@MF structure and oil absorption capacity. SH-Wax@BMBC@MF has superiority of superhydrophobic, superoleophilic, self-healing after damage, and environmental friendliness, which provides a promising solution for the treatment of oil spills at sea.

Natural microfibrils/regenerated cellulose-based carbon aerogel for highly efficient oil/water separation

Cellulose-based carbon aerogels as biodegradable and renewable biomass materials have presented potential applications in oil/water separation. Herein, a novel carbon aerogel composed of natural microfibrils/regenerated cellulose (NM/RCA) was directly prepared by economical hardwood pulp as raw material using a novel co-solvent composed of deep eutectic solvent (DES) and N-methyl morpholine-N-oxide monohydrate (NMMO·H₂O). In addition, the morphology and structure of the filiform natural microfibers could be remained after carbonized at 400 ℃, which resulted in a low density (8-10 mg cm^-3), high specific surface area (768.89 m² g^-1) and high sorption capability. In addition, the aerogel exhibited high compressibility, outstanding elasticity, excellent fatigue resistance, and recyclability (80.5% height recovery after repeating 100 cycles at the strain of 80%). Due to the morphology and composition of the carbonized microfiber surface, the superhydrophobic materials with a water contact angle of 151.5°, could sorb various oils and organic solvents with 65-133 times its own weight and maintain 91.9% sorption capacity after 25 cycles. In addition, the aerogels could achieve the continuous separation of carbon tetrachloride (CCl₄) from water with a high flux rate of 11,718.8 L m^-2 h^-1. Therefore, our prepared NM/RCA aerogels are anticipated to have broad potential applications in oil purification and contaminant remediation.

Facile, green and scalable preparation of low-cost PET-PVDF felts for oil absorption and oil/water separation

3D felt materials with pore structures have the advantages of high absorption performance and recyclability in oily wastewater treatment and chemical leakage. However, most of them were fabricated using either toxic organic solvents or complicated procedures. Herein, we report a facile, green, and scalable route for the fabrication of 3D composite felts with large pore structures by sequentially stirring and heating polyethylene terephthalate (PET) fibers and polyvinylidene fluoride (PVDF). The resulting PET-PVDF felt exhibits high oil absorption capacity to a variety of oil and organic solvents with a maximum saturated absorption capacity of 32 g/g. Additionally, it can be used to separate oil/water mixtures with a separation efficiency of 99.9% and separation flux of 89570 L m^-2 h^-1. Moreover, this felt shows excellent mechanical durability and chemical stability under acid, base, salt solution, and other harsh environments. The current study provides a promising approach for large-scale industrial oily wastewater separation.

Ultrafast materials synthesis and manufacturing techniques for emerging energy and environmental applications

Energy and environmental issues have attracted increasing attention globally, where sustainability and low-carbon emissions are seriously considered and widely accepted by government officials. In response to this situation, the development of renewable energy and environmental technologies is urgently needed to complement the usage of traditional fossil fuels. While a big part of advancement in these technologies relies on materials innovations, new materials discovery is limited by sluggish conventional materials synthesis methods, greatly hindering the advancement of related technologies. To address this issue, this review introduces and comprehensively summarizes emerging ultrafast materials synthesis methods that could synthesize materials in times as short as nanoseconds, significantly improving research efficiency. We discuss the unique advantages of these methods, followed by how they benefit individual applications for renewable energy and the environment. We also highlight the scalability of ultrafast manufacturing towards their potential industrial utilization. Finally, we provide our perspectives on challenges and opportunities for the future development of ultrafast synthesis and manufacturing technologies. We anticipate that fertile opportunities exist not only for energy and the environment but also for many other applications.

Highly Multifunctional Performances of Boron Nitride Nanosheets/Polydimethylsiloxane Composite Foams

Although this kind of hexagonal boron nitride (h-BN)-filled polydimethylsiloxane (PDMS) multifunctional composite foam has been greatly expected, its development is still relatively slow as a result of the limitation of synthetic challenge. In this work, a new foaming process of BNNSs-PDMS, alcohol, and water three-phase emulsion system is employed to synthesize a series of high-quality BNNSs/PDMS composite foams (BSFs) filled with highly functional and uniformly distributed BNNSs. As a result of well-bonded interfaces between the BNNSs and PDMS, enhanced multiple functions of BSFs appeared. The BSFs can show complete resilience at a compressive strain of 90% and only 3.99% irreversible deformation after 100,000 compressing-releasing hyperelastic cycles at a strain of 60%. On the basis of their outstanding shape-memory properties, the maximum voltage value of compression-driven piezo-triboelectric (CDPT) responses of the BSFs is up to ∼20 V. Depending on the remarkable super-elastic and CDPT performances, the BSFs can be used for sensitive sensing of temperature difference and electromechanical responses. Also, in the range of 12-40 GHz, the BSF materials display ultralow dielectric constants between 1.1 and 1.4 with proper dielectric loss tangent values of <0.3 and exhibit an enhanced and broadened sound adsorption capacity ranging from 500 to 6500 Hz. Although BSFs have high porosities of >65%, their thermal conductivities can still reach up to 0.407 ± 0.039 W m^-1 K^-1. Moreover, the BSF materials display favorable thermal stability, obviously reduced coefficient of thermal expansion, and good flame retardancy. All of these properties render the BSFs as a new category of excellent multifunctional material.

High performance flexible and antibacterial strain sensor based on silver‑carbon nanotubes coated cellulose/polyurethane nanofibrous membrane: Cellulose as reinforcing polymer blend and polydopamine as compatibilizer

In this study, ethyl cellulose was used as the second-phase polymer blended with polyurethane to make nanofibrous membrane as antibacterial strain sensor. The results indicated that ethyl cellulose could regulate the morphology of polyurethane through strong hydrogen bonding, which observably enhanced the nanofiber uniformity of polyurethane. Furthermore, rigid cellulose also remarkably improved the mechanical strength and thermal stability of the nanofibrous membrane. After being coated with silver nanoparticles and carbon nanotubes assisted by polydopamine (PDA), the membrane with outstanding bacteria inhibition performance exhibited outstanding sensitivity toward external mechanical stretching, as well as real-time motion of human body parts. The conductive composite membrane possessed sensitive and regular resistance feedback to 100 cycles of varied human motions. The cellulose in the nanofiber structure ensured the shape recovery and longtime use stability of the membrane. This study proposed a novel thinking for the construction of high performance strain sensor by rational introduction of rigid polysaccharide into the polymer matrix.

Functional Microtextured Superhydrophobic Surface with Excellent Anti-Wear Resistance and Friction Reduction Properties

The wear-resistant superhydrophobic (SHB) surfaces with excellent water-repellency ability were prepared by constructing a microtextured armor on an aluminum surface. With the assistance of laser-induced microtextures, the SHB surface could keep a longer water-repellency ability and a lower friction coefficient even after repeated friction tests under different loads and at different speeds. The mechanism of microtexture-protecting SHB coating is revealed based on both theoretical and elemental analysis. Additionally, we explore the relationship between the three-dimensional topography parameters (ISO 25178) and variation of water contact angles under different test recycles. The results show that the rough surface with appropriate S_a and higher S_ku exhibits a better wear resistance, which is mainly related to the storing ability of SHB coating inside the microtextures. Moreover, the surface with appropriate S_tr exhibits excellent wear resistance, which is mainly associated with better chip-removal ability. Finally, the tribological properties of the microtextured SHB surface are researched. It is worth noting that compared with the microtextured surface without SHB coating and the SHB-coated surface without microtextures, the microtextured SHB surface has the lowest friction coefficient under dry friction because the SHB coating would largely decrease the surface energy of the interface, so the adhesion friction decreases. The microtexture armor on the surfaces would protect the wear of SHB coating, so the SHB coating inside the microtexture could continuously play the role of a particle lubricant at the sliding interface and decrease the friction force of the sliding interface. We believe that the present study would contribute to the further understanding of the constructing mechanism of anti-wear SHB surfaces and provide a new strategy for topography design of engineering surfaces with friction reduction properties.

Bio-Based Porous Aerogel with Bionic Structure and Hydrophobic Polymer Coating for Efficient Absorption of Oil/Organic Liquids

Increasing contamination risk from oil/organic liquid leakage creates strong demand for the development of absorbents with excellent hydrophobicity and absorption capacity. Herein, bagasse was carbonized to form porous char with a special structure of array-style and vertically perforated channels, and then the activation process enlarged the pore volume of the char. With the cooperation of low-surface-energy polydimethylsiloxane and diatomaceous earth particles, the modified activated carbon aerogel (MACA) was fabricated by modifying the surface coating and mastoid structure on the bagasse char. Moreover, the MACA demonstrates high porosity oil-water separation, hydrophobicity, and considerable absorption capacity (4.06–12.31 g/g) for gasoline and various organic solvents. This work converts agricultural waste into an efficient porous adsorbent, offering a scalable and commercially feasible solution to solving the leakages of oil/organic solvents.

Recent advances of bio-inspired anti-icing surfaces

The need for improved anti-icing surfaces is the demand of the time and closely related to many important aspects of our lives as surface icing threatens not only industrial production but also human safety. Freezing on a cold surface is usually a heterogeneous nucleation process induced by the substrate. Creating an anti-icing surface is mainly achieved by changing surface morphology and chemistry to regulate the interaction between the surface and the water/ice to inhibit freezing on the surface. In this paper, recent research progress in the creation of biomimetic anti-icing surfaces is reviewed. Firstly, basic strategies of bionic anti-icing are introduced, and then bionic anti-icing surface strategies are reviewed according to four aspects: the process of ice formation, including condensate self-removing, inhibiting ice nucleation, reducing ice adhesion, and melting accumulated ice on the surface. The remaining challenges and the direction of future development of biomimetic anti-icing surfaces are also discussed.

Fabrication of Carbon Aerogels Derived from Metal-Organic Frameworks/Carbon Nanotubes/Cotton Composites as an Efficient Sorbent for Sustainable Oil–Water Separation

Due to the continuous occurrence of water pollution problems, practical separation methods for oil–water mixtures have attracted more and more attention. To date, different kinds of materials have been developed with good hydrophobic properties and strong separation ability. Carbon aerogels, as a promising ideal adsorbent for dealing with oil-spill accidents, have received extensive attention. In this work, zeolitic imidazolate frameworks (ZIFs), nanoparticles, and carbon nanotubes (CNTs) in the three-dimensional (3D) interconnected network structure of cotton balls (CBs) were successfully prepared by a simple and scalable process. The as-prepared carbonized CBs with carbonized ZIF-8 and CNTs (CZIF-8/CNTs/CCBs) were characterized. The oil–water separation performance of the composite was also measured. The results show that the ZIF-8 clusters intercalated with abundant CNTs are fully loaded into the porous structure of the CBs after the in situ synthesis process. Additionally, ZIF-8/CNTs/CBs was carbonized in nitrogen, leading to the formation of CZIF-8/CNTs/CCBs. The prepared material possesses excellent hydrophobicity with a water contact angle of 152.7°, showing good absorption capacities Q1 in the range of 48 to 84 times its original weight for oil and organic liquids. In addition, CZIF-8/CNTs/CCBs exhibits good recyclability in the absorption–distillation test. In summary, this study proposes a novel and simple method for the preparation of a superhydrophobic material that could have wide application in the separation of oil–water mixtures.

One-Step Fabrication of Hot-Water-Repellent Surfaces

Hot-water repellency is of great challenge on traditional superhydrophobic surfaces due to the condensation of tiny droplets within the cavities of surface textures, which builds liquid bridges to connect the substrate and hot water and thus destroys the surface water-repellence performance. For the unique structural features and scales, current approaches to fabricate surfaces with hot-water repellency are always complicated and modified by fluorocarbon. Here, we propose a facile and fluorine-free one-step vapor-deposition method for fabricating excellent hot-water-repellent surfaces, which at room temperature even repel water droplets of temperature up to 90 °C as well as other normal-temperature droplets with surface tension higher than 48.4 mN/m. We show that whether the unique hot-water repellency is achieved depends on a trade-off between the solid–liquid contact time and hot-vapor condensation time, which determines the probability of formation of liquid bridges between the substrate and hot-water. Moreover, the designed surfaces exhibit excellent self-cleaning performance in some specific situations, such as oil medium, hot water and condensation environments. We envision that this facile and fluorine-free strategy for fabricating excellent hot-water-repellent surfaces could be valuable in popularizing their practical applications.

Facile Construction and Fabrication of a Superhydrophobic and Super Oleophilic Stainless Steel Mesh for Separation of Water and Oil

The fluoride-free fabrication of superhydrophobic materials for the separation of oil/water mixtures has received widespread attention because of frequent offshore oil exploration and chemical leakage. In recent years, oil/water separation materials, based on metal meshes, have drawn much attention, with significant advantages in terms of their high mechanical strength, easy availability, and long durability. However, it is still challenging to prepare superhydrophobic metal meshes with high-separation capacity, low costs, and high recyclability for dealing with oil–water separation. In this work, a superhydrophobic and super oleophilic stainless steel mesh (SSM) was successfully prepared by anchoring Fe₂O₃ nanoclusters (Fe₂O₃-NCs) on SSM via the in-situ flame synthesis method and followed by further modification with octadecyltrimethoxysilane (OTS). The as-prepared SSM with Fe₂O₃-NCs and OTS (OTS@Fe₂O₃-NCs@SSM) was confirmed by a field emission scanning electron microscope (FESEM), transmission electron microscope (TEM), energy dispersive spectrometer (EDS), X-ray photoelectron spectrometer (XPS), and X-ray diffractometer (XRD). The oil–water separation capacity of the sample was also measured. The results show that the interlaced and dense Fe₂O₃-NCs, composed of Fe₂O₃ nanoparticles, were uniformly coated on the surface of the SSM after the immerging-burning process. Additionally, a compact self-assembled OTS layer with low surface energy is coated on the surface of Fe₂O₃-NCs@SSM, leading to the formation of OTS@Fe₂O₃-NCs@SSM. The prepared OTS@Fe₂O₃-NCs@SSM shows excellent superhydrophobicity, with a water static contact angle of 151.3°. The separation efficiencies of OTS@Fe₂O₃-NCs@SSM for the mixtures of oil/water are all above 98.5%, except for corn oil/water (97.5%) because of its high viscosity. Moreover, the modified SSM exhibits excellent stability and recyclability. This work provides a facile approach for the preparation of superhydrophobic and super oleophilic metal meshes, which will lead to advancements in their large-scale applications on separating oil/water mixtures.

Superhydrophobic nanohybrid sponges for separation of oil/ water mixtures

The industrial revolution has led to different types of environmental pollution, including frequent leakage of crude oil to marine waters and the contamination of wastewater with immiscible or emulsified oils and organic liquids from various industrial residues. Hence, developing multifunctional materials for oil/water separation is a field of high significance for the remediation of oil-polluted water. Recently, advanced superwetting materials have been employed for oily wastewater treatment. This review summarizes the recent development in fabricating superhydrophobic/superoleophilic nanohybrid polyurethane, melamine, and cellulose sponges for oil/water separation. The use of organic and/or inorganic nanohybrid materials opens the horizon for designing a diverse and wide range of superhydrophobic sponges due to the synergistic effect between the surface roughness and chemical composition. The discussion is organized based on different classes of low surface energy materials including thermoplastics, thermosets, elastomers, fluorinated polymers, conductive polymers, organosilanes, long alkyl chain compounds, and hydrophobic carbon-based materials. Recent examples for the separation of both immiscible and emulsified oil/water mixtures are presented, with a focus on fabrication strategies, separation efficiency, recyclability, mechanical performance, and durability. Currently, most studies did not focus on the mechanical/chemical stability of the fabricated sponges, and hence, future research directions shall address the fabrication of robust and long-term durable superhydrophobic sponges with proper guidelines. Similarly, more research focus is required to design superhydrophobic sponges for the separation of emulsified oil/water mixtures and heavy crude oil samples. Superhydrophobic sponges can be employed for treatment of oily wastewater, emulsion separation, and cleanup of crude oil spills.

Green and Rapid Preparation of Fluorosilicone Rubber Foam Materials with Tunable Chemical Resistance for Efficient Oil-Water Separation

Polydimethylsiloxane (PDMS) foam materials with lightweight, excellent oil resistance and mechanical flexibility are highly needed for various practical applications in aerospace, transportation, and oil/water separation. However, traditional PDMS foam materials usually present poor chemical resistance and easily swell in various solvents, which greatly limits their potential application. Herein, novel fluorosilicone rubber foam (FSiRF) materials with different contents of trifluoropropyl lateral groups were designed and fabricated by a green (no solvents used) and rapid (<10 min foaming process) foaming/crosslinking approach at ambient temperature. Typically, vinyl-terminated poly(dimethyl-co-methyltrifluoropropyl) siloxanes with different fluorine contents of 0−50 mol% were obtained through ring-opening polymerization to effectively adjust the chemical resistance of the FSiRFs. Notably, the optimized FSiRF samples exhibit lightweight (~0.25 g/cm−3), excellent hydrophobicity/oleophilicity (WCA > 120°), reliable mechanical flexibility (complete recovery ability after stretching of 130% strain or compressing of >60%), and improved chemical resistance and structural stability in various solvents, making them promising candidates for efficient and continuous oil−water separation. This work provides an innovative concept to design and prepare advanced fluorosilicone rubber foam materials with excellent chemical resistance for potential oil−water separation application.

Two-step facile fabrication of superamphiphilic biomimic membrane with micro-nano structure for oil-water emulsion separation on-demand

Superamphiphilic materials have attracted much attention due to their different wettability in different media. Through a simple two-step method, we fabricated a smart separation membrane with super-amphiphilic wettability. Under the...

Review on the recent development of durable superhydrophobic materials for practical applications

Biomimetic superhydrophobic surfaces show great potential in oil-water separation, anti-icing and self-cleaning. However, due to the instability caused by its fragile structure and non-durable superhydrophobicity, it is difficult to apply them in the actual field. Here, by introducing surface wettability and analysing the mechanism of superhydrophobic failure, it is concluded that the reason for the failure of the superhydrophobic surface comes from the transition of the surface energy and the hysteresis of the contact angle (CA). On the basis of this analysis, it is concluded that the principle of designing a durable superhydrophobic surface is to satisfy one of the following three points: improving the binding force between molecules, introducing durable materials and improving chemical durability. On this basis, a variety of preparation methods are proposed, such as assembly method and spray/dip coating method, and the design and preparation of a self-healing surface inspired by nature will also be included in the introduction. Last but not least, the preparation and application of a durable super-hydrophobic surface in oil-water separation, anti-icing and self-cleaning are also introduced in detail. This review reveals the conclusions and prospects of durable superhydrophobic surfaces, and aims to inspire more researchers to invest in this research.