Plasma-Polymerized Polystyrene Coatings for Hydrophobic and Thermally Stable Cotton Textiles

Dielectric barrier discharge (DBD) plasma provides a solvent-free and energy-efficient approach for the in situ polymerization of styrene on cotton textiles. Traditional methods for polystyrene (PS) coating often require elevated temperatures, chemical initiators, or organic solvents, conditions that are incompatible with porous, heat-sensitive substrates such as cotton. In this work, we demonstrate that DBD plasma can initiate and sustain styrene polymerization directly on cotton fibers under ambient conditions. FT-IR spectroscopy confirms the consumption of the vinyl C=C bond and the formation of atactic, amorphous polystyrene. Thermogravimetric analysis indicates that the cotton coated with DBD polymerized PS exhibits enhanced thermal stability compared to cotton coated with commercial PS. Additionally, UV aging tests confirm that the plasma-deposited coating maintains its hydrophobicity after exposure to light. Together, these findings highlight DBD plasma as a sustainable and effective approach for producing hydrophobic, thermally robust, and UV-stable textile coatings without the need for solvents, initiators, or harsh processing conditions.