The fabrication of highly durable superhydrophobic MF-impregnated paper decorated laminate by embossing method.

Surface decorated wood-based panels with melamine formaldehyde resin (MF) impregnated paper is highly favored by consumers due to its outstanding appearance and durable performance. However, the laminated composites would encounter hygroscopic expansion and damage that affect its service and aesthetics in long-term humid environments. This study aims to construct highly durable superhydrophobic surface to address this issue. Firstly, a controlled micro rough structure on stainless steel plates which were built with sandblasting was successfully duplicated onto the surface of MF impregnated paper laminated medium density fiberboard (MDF) using the embossing method. Following that, a spray treatment with hydrophobic nanoparticles was employed to the laminated composite surface, ultimately resulting in a superhydrophobic coating with a contact angle up to 163°. To confirm the durability of the fabricated superhydrophobic layer, linear abrasion test, water droplet impact test, sand impact test, and tape peeling test were carried out. The results demonstrated that even after severe processed conditions, the contact angle of the decorated surface remained above 150°. And the decorated laminate successfully passed both self-cleaning and dirt resistance challenge, clearly indicating the outstanding durability of superhydrophobic structure. Furthermore, water absorption thickness expansion measurement was done to verify the dimensional stability of the laminate in humid conditions. This research presented a straightforward and cost-effective approach to fabricate highly durable superhydrophobic MF impregnated paper decorated laminates, offering a dependable strategy for research and applications in related domains. [ABSTRACT FROM AUTHOR]