Hierarchical cotton surface engineering via mesoporous silica integration and in situ copper stearate growth for durable superhydrophobicity and enhanced antibacterial activity

The development of cotton fabrics with multifunctional properties such as superhydrophobicity, self-cleaning, and antibacterial activity without compromising intrinsic characteristics like flexibility, breathability, and comfort remains a significant challenge. In this study, a multifunctional superhydrophobic cotton fabric with amplified antimicrobial activity was fabricated by integrating multiple bactericidal mechanisms into a single platform. The process involved the deposition of copper-doped mesoporous silica nanoparticles (CuMSNs) onto cotton fabrics (CF), followed by in situ synthesis and deposition of copper stearate (CuSA) to impart durable superhydrophobicity. The incorporation of copper in two forms, embedded within the mesoporous structure for sustained release and long-term efficacy, and as copper stearate for immediate contact killing, produces a complementary dual-action effect that enhances both antibacterial performance and durability. Surface characterization by scanning electron microscopy, elemental analysis, and Fourier-transform infrared spectroscopy confirmed the successful surface modifications. The modified cotton exhibited excellent superhydrophobicity with a water contact angle of 152° and a sliding angle of 7°, along with outstanding antibacterial activity, achieving 99.99% bacterial reduction against both Gram-positive and Gram-negative strains after 24 h. Self-cleaning and air permeability tests further demonstrated the material's suitability for practical and protective applications. This multifunctional coating offers sustained antibacterial performance and robust durability, making it highly promising for advanced medical textiles and protective fabrics. • Facile in situ growth of hierarchical CuSA/CuMSN on cotton surfaces. • Durable superhydrophobicity with 152° contact and 7° sliding angles. • Simultaneous bacterial repellence with dual-mode contact/release killing • 99.99% antibacterial activity against Gram-positive/negative bacteria. • Superior breathability with minimal change in air permeability.