Dual Scale Roughness Driven Perfectly Hydrophobic Surfaces Prepared by Electrospraying a Polymer in Good Solvent-Poor Solvent Systems

We demonstrated a facile method to produce perfectly hydrophobic surfaces (advancing and receding angles both 180 degrees) via electrospraying. When a copolymer of styrene and a perfluoroacrylate monomer was electrosprayed in good solvents, surfaces composed of micrometer size beads were formed and fairly low threshold water sliding angles could be achieved. Addition of high boiling point poor solvents to the solutions resulted nanoscale roughness on the beads due to a possible phase separation that occurs in a predominantly poor solvent environment. However, sliding angles were not zero even on the nanoscale roughness dominated topographies achieved by this method. On the other hand, when the electrospraying process parameters were set such that micrometer size hills of nanoscopically rough beads were formed, 0 degrees sliding angles were measured. Videos of droplets recorded and the adhesive forces measured during a contact and release experiment revealed that these dual scale rough surfaces were indeed perfectly hydrophobic. Application of the method with other binary good solvent-poor solvent systems also resulted in perfect hydrophobicity. Overall results showed how the differences in surface topology affected the wettability of surfaces within a very narrow range between perfect and extreme hydrophobicity (advancing and receding angles both close to 180 degrees).