Optimizing Superhydrophobic Coatings: The Role of Catalysts, Additives, and Composition on UV and Thermal Stability of Inverse Vulcanization Polymers

Abstract

Inverse vulcanization (IV) enables the production of sustainable polymer from sulfur waste, offering hydrophobic, fluorine-free, and superhydrophobic coatings. However, these materials need adhesion improvements for enhanced durability. This study has developed an epoxy-, fluorine-, and metal-free superhydrophobic coating using the spray-coating of carbon nanofibers (CNFs), silica nanoparticles, and IV polymers on glass. An optimized formula of 28% sulfur, 20 mg/mL CNFs, 25 mg/mL silica, and 80 mg/mL polymer-was established. Zn(DTC)2-catalyzed coatings retained superhydrophobicity for 150 tape peeling cycles, up to 250 °C, and 6 h of UV-C exposure, demonstrating a straightforward, eco-friendly approach to durable, versatile superhydrophobic coatings.