Bulk synthesis of ordered macroporous silica particles for superhydrophobic coatings

[Display omitted] ► Ordered macroporous particles were produced in bulk from emulsions with polymer beads and inorganic nanoparticles. ► The mean size of macroporous particles was controlled depending on emulsification conditions. ► The film of ordered macroporous particles was used for the self-cleaning superhydrophobic coatings. We report the bulk synthesis of ordered macroporous ceramic particles by the emulsion templating process. Large polystyrene (PS) beads and small silica nanoparticles were assembled simultaneously inside an emulsion, which formed composite structured particles during the evaporation of droplets. Then, by burning out PS beads, macroporous ceramic particle films were produced on substrate. The size of ordered macroporous particles could be controlled by adjusting the emulsification condition for confining emulsions. As well, the pore size could be controlled by changing the diameter of PS beads. The surface of the ordered macroporous particle films was coated with fluorinated molecules, which have shown superhydrophobic property due to multi-scale roughness.