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.