Solventless Polymer-Grafted Mesh for Rapid and Efficient Oil–Water Separation

We report a solventless bilayer strategy for grafting hydrophilic poly(methacrylic acid) (PMAA) onto metal meshes. The bilayer nanocoating consisted of ultrathin PMAA brushes grafted onto a highly crosslinked primer that binds to each mesh wire. The enrichment of hydrophilic functionalities on the PMAA-grafted mesh surface improved the surface hydration and underwater oil repellency over the PMAA-crosslinked mesh, which contributed to the formation and stabilization of continuous water films between mesh wires to reject oil penetration in repeated uses. The vapor-based nanocoating process maximized the retention of pore openings for high-flux oil–water separation. The retained permeability, together with the enhanced oil repellency, enabled the PMAA-grafted mesh to achieve excellent gravity-driven oil–water separation, with an oil rejection rate higher than 99%, water flux exceeding 50,000 L m –2 h –1, and flux decay less than 3% after 20 cycles of reuse. More importantly, the PMAA-grafted mesh preserved high separation efficiency and flux stability under conditions of high salinity and extreme pH.