Next-generation coatings: formulation and functionality

Coatings are critical to our daily lives. They protect our buildings and structures against damage from the weather, chemicals, corrosion, and fire. They prolong the life of our food. They enable and enhance the production of renewable energy by wind turbines and solar panels. They improve fuel efficiency of various transportation methods. And, notably, they protect us from infections. However, translating state-of-the-art scientific advances for the improvement of coatings is frequently unsuccessful. One of the main reasons for these failures is the poor fundamental understanding of the dynamics and interactions of the coating ingredients within its liquid formulation. In this project, we will develop experimental and theoretical tools to advance such understanding and apply them to translate a novel particle assembly method into fully formulated and functional coatings. We will take antibacterial coatings as a case study. Healthcare-associated infections (HCAIs), acquired at a hospital or other healthcare facility, are an enormous burden to public health and finances. It is estimated that 653,000 adult inpatients in NHS hospitals acquire an HCAI and 22,800 die as a result of their infection per year in England. Most of these infections are associated to the accumulation of bacteria on surfaces. Therefore, the development of novel antimicrobial coatings to prevent the adhesion of bacteria and/or kill them upon attachment to surfaces is imperative. We have been developing a method to obtain coating surfaces on demand which segregates formulation ingredients by size during drying. We will harness this strategy to achieve control over the distribution of the different formulation ingredients to enhance the performance of antibacterial coatings and prevent the growth of bacteria on them. We will combine state-of-the-art experimental techniques, soft matter theory, and computational modelling to establish the foundation for a science-based formulation framework that would eventually replace the current trial-and-error approaches. We will go up the innovation ladder to increase the technology readiness level of our size segregation technology. This will involve demonstrating the approach in a fully formulated product, testing its antibacterial activity against HCAI-relevant bacteria, and ensuring its stability upon the action of the photocatalytic nanoparticles which give the coating its functionality. The uptake of the size segregation technology by industry and its application in healthcare settings would help to mitigate the burden of healthcare-associated infections, saving lives and reducing their financial burden. Importantly, our technology would give the UK an advantage to become a global leader in functional coatings. Developing a science-based approach to replace the current trial-and-error formulations methods would make UK industry more adaptable and responsive to external challenges. For example, it would help to improve the sustainability of liquid formulated products, conserving natural resources and minimising pollution and waste.