Self-cleaning behavior in polyurethane/silica coatings via formation of a hierarchical packed morphology of nanoparticles

•Self-cleaning behavior was imparted to the hydrophilic polyurethane.•A hierarchical packed morphology is responsible for the superhydrophobicity.•Prolonged pressing process cannot lead to superhydrophobicity due to migration of TPU.•Samples exhibited excellent stability against media with a wide range of pH values. In the current research, a hierarchical morphology comprising of packed assembly of nanoparticles was induced in thermoplastic polyurethane (TPU)/silica nanocomposite coatings in order to achieve self-cleaning behavior. Moderately hydrophilic behavior of TPU hinders its transforming to a superhydrophobic material. In the presented method, a very thin layer of silica nanoparticles is applied to the surface of TPU sheets under elevated temperature and pressure. As temperature and pressure of the process remain unchanged, processing time was considered as a main variable. Based on scanning electron microscopy and confocal microscopy results, it was found that at a certain processing time, nanoparticles can form an utterly packed morphology leading to a self-cleaning behavior. Once the process was prolonged, TPU macromolecules found the chance to migrate onto the coating's top layer due to the enhanced mobility of chains at high temperature. This observation was further proved by X-ray photoelectron spectroscopy analysis and cross-sectional morphology. The presented method has promising potentials in transforming intrinsically hydrophilic polymers into superhydrophobic materials with self-cleaning behavior.