A Green Formulation for Superhydrophobic Coatings Based on Pickering Emulsion Templating for Anti-Biofilm Applications

This study reports significant steps toward developing anti-biofilm surfaces based on superhydrophobic properties that meet the complex demands of today's food and medical regulations. It presents inverse Pickering emulsions of water in dimethyl carbonate (DMC) stabilized by hydrophobic silica (R202) as a possible food-grade coating formulation and describes its significant passive anti-biofilm properties. The final coatings are formed by applying the emulsions on the target surface, followed by evaporation to form a rough layer. Analysis shows that the final coatings exhibited a Contact Angle (CA) of up to 155° and a Roll-off Angle (RA) lower than 1° on the polypropylene (PP) surface, along with a relatively high light transition. Dissolving polycaprolactone (PCL) into the continuous phase enhanced the average CA and coating uniformity but hindered the anti-biofilm activity and light transmission. Scanning electron microscopy (SEM) and atomic force microscopy (AFM) showed a uniform coating by a "Swiss-cheese" like structure with high nanoscale and microscale roughness. Biofilm experiments confirm the coating's anti-biofilm abilities that led to the reduction in survival rates of S.aureus and E.coli, by 90-95% respectively, compared to uncoated PP surfaces.