Photothermal superhydrophobic coatings are supposed promising to prevent ice accumulation on infrastructures but often experience significant performance degradation in real icing conditions and lack mechanical robustness. Here, we report design of robust photothermal superhydrophobic coatings with three-tier hierarchical micro-/nano-/nanostructures by deposition of nanosized MOFs on natural attapulgite nanorods, fluorination, controlled phase separation of a hydrophobic adhesive and spraying assembly. Phase separation degree and adhesive content significantly influence the coatings’ properties by regulating the structural parameters and morphology. In simulated/real icing environments, the coatings simultaneously show (i) high superhydrophobicity and stable Cassie-Baxter states due to their low-surface-energy, three-tier micro-/nano-/nanostructure, (ii) excellent photothermal effect primarily due to nanosized MOFs, and (iii) good mechanical robustness by the phase-separated adhesive, reinforcement with attapulgite and the coatings’ self-similar structure. Accordingly, combined with low thermal conductivity, the coatings exhibit remarkable anti-icing/frosting (e.g., no freezing in at least 150 min and almost free of frost in 25 min) and de-icing/frosting performances (e.g., fast de-icing in 12.7 min and fast de-frosting in 16.7 min) in such environments. Furthermore, we realize large-scale preparation of the coatings at reasonable costs. The coatings have great application potential for anti-icing and de-icing in the real world by efficiently using natural sunlight.

Superhydrophobic coatings are expected to solve the rain attenuation issue of 5G radomes. However, it is very challenging to design and construct such superhydrophobic coatings with good impalement resistance, mechanical robustness, and weather resistance, which remains as one of the main bottlenecks hindering their practical applications. Here, we report the design of superhydrophobic coatings with all these merits mentioned above by spray-coating a suspension of adhesive/fluorinated silica core/shell microspheres onto substrates. The core/shell microspheres are formed by phase separation of the adhesive and adhesion between the adhesive and fluorinated silica nanoparticles. The coatings have an approximately isotropic three-tier hierarchical micro-/micro-/nanostructure, a dense but rough surface at the nanoscale, and chemically inert composition with low surface energy. Consequently, the coatings show excellent impalement resistance, mechanical robustness and weather resistance compared with previous studies, and the mechanisms are revealed. Furthermore, we realize large-scale preparation, extension, and practical application of the coatings for efficiently preventing rain attenuation of 5G/weather radomes. By taking these advantages, we believe that the superhydrophobic coatings have great application potential and market prospect. The findings here will boost preparation and real-world applications of superhydrophobic coatings.

Superhydrophobic (SH) surfaces have progressed rapidly in fundamental research over the past 20 years, but their practical applications lag far behind. In this perspective, we first present the findings of a survey on the current state of SH surfaces including fundamental research, patenting, and commercialization. On the basis of the survey and our experience, this perspective explores the challenges and strategies for commercialization and widespread practical applications of SH surfaces. The comprehensive performances, preparation methods, and application scenarios of SH surfaces are the major constraints. These challenges should be addressed simultaneously, and the actionable strategies are provided. We then highlight the standard test methods of the comprehensive performances including mechanical stability, impalement resistance, and weather resistance. Last, the prospects of SH surfaces in the future are discussed. We anticipate that SH surfaces may be widely commercialized and used in practical applications around the year 2035 through combination of the suggested strategies and input from both academia and industry.

Mechanisms, progress, commercialization, and testing methods of mechanically robust adhesive-based superhydrophobic coatings are summarized, while highlighting current challenges and future research directions.

Superamphiphobic coatings have widespread application potential in various fields, e.g., anti-icing, anti-corrosion and self-cleaning, but are seriously limited by poor mechanical stability. Here, mechanically stable superamphiphobic coatings were fabricated by spraying the suspension composed of phase-separated silicone-modified polyester (SPET) adhesive microspheres with fluorinated silica (FD-POS@SiO₂) on them. The effects of non-solvent and SPET adhesive contents on the superamphiphobicity and mechanical stability of the coatings were studied. Due to the phase separation of SPET and the FD-POS@SiO₂ nanoparticles, the coatings present a multi-scale micro-/nanostructure. Combined with the FD-POS@SiO₂ nanoparticles of low surface energy, the coatings present outstanding static and dynamic superamphiphobicity. Meanwhile, the coatings present outstanding mechanical stability due to the adhesion effect of SPET. In addition, the coatings present outstanding chemical and thermal stability. Moreover, the coatings can obviously delay the water freezing time and decrease the icing adhesion strength. We trust that the superamphiphobic coatings have widespread application potential in the anti-icing field.