This study developed a human-friendly energy-efficient superhydrophobic polypropylene (PP) fabric by oxygen plasma etching and short-term thermal aging without additional chemicals. The effect of the microroughness on the superhydrophobicity was examined by adjusting the weave density. After the PP fabric was treated with oxygen plasma etching for 15 min and thermal aging at 120 °C for 1 h (E15H120 1 h), the static contact and shedding angles were 162.7° ± 2.4° and 5.2° ± 0.7° and the energy consumption was 136.4 ± 7.0 Wh. Oxygen plasma etching for 15 min and thermal aging at 120 °C for 24 h (E15H120 24 h) resulted in a static contact and shedding angle of 180.0° ± 0.0° and 1.8° ± 0.2° and energy consumption of 3628.5 ± 82.6 Wh. E15H120 1 h showed a lower shedding angle but had a higher sliding angle of 90°. E15H120 24 h exhibited shedding and sliding angles of less than 10°. Regardless of the thermal aging time, superhydrophobicity was higher in high-density fabrics than in low-density fabrics. The superhydrophobic PP fabric had a similar water vapor transmission rate and air permeability with the untreated PP fabric, and it showed a self-heading property after washing followed by tumble drying and hot pressing.
Keywords: energy-efficient; plasma etching; polypropylene; self-cleaning; superhydrophobicity; thermal aging; weave density.