A simple strategy towards construction of copper foam-based robust superhydrophobic coating based on perpendicular nanopins for long-lasting delayed icing and reduced frosting

Icing/frosting poses a significant problem for materials used in everyday applications. In recent years, anti-icing methods utilizing superhydrophobic materials have become popular. These materials have superhydrophobic surfaces with air-solid composite structures, which can prevent icing/frosting by creating air cushions in the micro- and nano-scales of the rough structure. However, long-term protection of the substrate is challenging due to air leakage from the air cushion and the breakdown of the superhydrophobic coating. The use of superhydrophobic materials in cold environments is also greatly limited by this shortcoming. In this paper, superhydrophobic copper foam (SHS CF) was created by using electrochemical oxidation and impregnation techniques and subsequent modified by fluorosilane coupling agent on the copper foam surface to reduce surface particle activity through condensation reactions, achieving a superhydrophobicity with a water contact angle of up to 170±2°. Furthermore, gas was utilized to form a specific rough structure by combining with Cu(OH)2 micro-nanopins, leading to the development of long-lasting gas in SHS CF (LAG-SHS CF). The LAG-SHS CF exhibited impressive anti-frost characteristics, with a delayed icing time of approximately 2171 s. Notably, the SHS CF retained strong wetting capabilities and excellent resistance to abrasion, UV, acid, and alkali even after the removal of LAG, which was ascribed to the fact that the composite structure effectively reduces the solid-liquid contact area and has a high roughness. These properties provide a solid foundation for the application of LAG-SHS CF. The findings of this study contribute to the creation of new materials with anti-icing and anti-frost properties.