Durable superhydrophobic PTFE films through the introduction of micro- and nanostructured pores

•Durable PTFE superhydrophobic films have been prepared by a simple process.•The new method for preparing superhydrophobic films is based on the introduction of micro- and nanoscale pores.•Micro- and nanoscale pore formation in superhydrophobic films has been characterized by SEM.•The mechanical durability of PTFE superhydrophobic films is attributed to the presence of micro- and nanoscale pores. A superhydrophobic surface, highly water repellant and self-cleaning, is typically made by introducing micro- and nanoscale roughness onto the surface of a low surface energy material. Herein, we offer a new process of superhydrophobic film formation, accomplishing the same thing through the production of micro- and nanoscale surface porosities. Such a material is prepared by introducing zinc acetate (ZnAc2) and sodium chloride (NaCl) into a commercially available PTFE (polytetrafluoroethylene) emulsion. On drying, baking and washing with acetic acid, the PTFE film produced from the emulsion had both micro- and nanoscale surface porosities, and demonstrated superhydrophobic properties, with a static contact angle >150° and a slide angle 150°, but with a slide angle >10°. Based on XPS and SEM data, we explore herein the affect of chemistry and porosity on the mechanism of superhydrophobic surface formation, and the durability of that surface under abrasion.