Leveraging the water electrolysis reaction in bipolar electrophoresis to form robust and defectless chitosan films

•Bipolar pulsing for robust chitosan film.•Negative bias for chitosan electrophoresis.•Positive bias for surface conditioning.•Reduction of surface cavity and pores. Electrophoresis of chitosan and its composites are widely used to form a coating on selective substrates, but the parasitic water electrolysis causes structural defects that weaken the resulting film. In this work, we demonstrate a bipolar electrophoresis technique that leverages the water electrolysis to produce a chitosan film with less porosity and surface cavities. The process involves a negative bias to deposit the protonated chitosan molecules from the solution, followed by a positive bias to remove the entrapped hydrogen bubbles via the re-protonation of chitosan deposit. Since water electrolysis occurs for both positive and negative bias, the bipolar profile is designed to engender pH changeup near the electrode for “surface conditioning” of chitosan film. The bipolar electrophoresis route demonstrates better coulomb efficiency than that of conventional potentiostatic electrophoresis, resulting in a free-standing chitosan film with sufficient mechanical strength and large area.