Superhydrophobic Fabrics Produced by Electrospinning and Chemical Vapor Deposition

Electric field-induced, reversible lotus-to-rose transition in nanohybrid shish kebab paper with hierarchical roughness

Nature uses a variety of strategies to tune wetting behavior for biological applications. By artificially mimicking these strategies, a variety of different wetting conditions can be achieved. Numerous examples exist of designed surfaces that can mimic the wetting behavior of lotus leaves or rose petals, but few surfaces that may reversibly transition between the two have been reported. In this paper, a combination of topological control over conductive, carbon-based nanomaterials and low surface energy coating was used to tune the wetting properties between "lotus" and "rose." The topological control was imparted by a hierarchical "nanohybrid shish kebab" structure, which uses solution-grown polymer single crystals on carbon nanotubes to tune the surface roughness of the latter. The low surface energy polytetrafluoroethylene (PTFE) coating was deposited by the initiated chemical vapor deposition technique. Application of electric potential on these unique nanostructures allows the surfaces to reversibly transition between "lotus" and "rose" behavior. A further irreversible transition between "rose" and the fully wetted Wenzel wetting state was also predicted and shown. These materials show remarkable promise for lab-on-a-chip devices and surface passivation for biological studies.

Fog-harvesting potential of lubricant-impregnated electrospun nanomats

Hydrophobic PVDF-HFP nanowebs were fabricated by a facile electrospinning method and proposed for harvesting fog from the atmosphere. A strong adhesive force between the surface and a water droplet has been observed, which resists the water being shed from the surface. The water droplets on the inhomogeneous nanomats showed high contact angle hysteresis. The impregnation of nanomats with lubricants (total quartz oil and Krytox 1506) decreased the contact angle hysteresis and hence improved the roll off of water droplets on the nanomat surface. It was found that water droplets of 5 μL size (diameter = 2.1 mm) and larger roll down on an oil-impregnated surface, held vertically, compared to 38 μL (diameter = 4.2 mm) on a plain nanoweb. The contact angle hysteresis decreased from ~95 to ~23° with the Krytox 1506 impregnation.

25th anniversary article: CVD polymers: a new paradigm for surface modification and device fabrication

Well-adhered, conformal, thin (<100 nm) coatings can easily be obtained by chemical vapor deposition (CVD) for a variety of technological applications. Room temperature modification with functional polymers can be achieved on virtually any substrate: organic, inorganic, rigid, flexible, planar, three-dimensional, dense, or porous. In CVD polymerization, the monomer(s) are delivered to the surface through the vapor phase and then undergo simultaneous polymerization and thin film formation. By eliminating the need to dissolve macromolecules, CVD enables insoluble polymers to be coated and prevents solvent damage to the substrate. CVD film growth proceeds from the substrate up, allowing for interfacial engineering, real-time monitoring, and thickness control. Initiated-CVD shows successful results in terms of rationally designed micro- and nanoengineered materials to control molecular interactions at material surfaces. The success of oxidative-CVD is mainly demonstrated for the deposition of organic conducting and semiconducting polymers.

Effect of surface tension, viscosity, and process conditions on polymer morphology deposited at the liquid-vapor interface

We have observed that the vapor-phase deposition of polymers onto liquid substrates can result in the formation of polymer films or particles at the liquid-vapor interface. In this study, we demonstrate the relationship between the polymer morphology at the liquid-vapor interface and the surface tension interaction between the liquid and polymer, the liquid viscosity, the deposition rate, and the deposition time. We show that the thermodynamically stable morphology is determined by the surface tension interaction between the liquid and the polymer. Stable polymer films form when it is energetically favorable for the polymer to spread over the surface of the liquid, whereas polymer particles form when it is energetically favorable for the polymer to aggregate. For systems that do not strongly favor spreading or aggregation, we observe that the initial morphology depends on the deposition rate. Particles form at low deposition rates, whereas unstable films form at high deposition rates. We also observe a transition from particle formation to unstable film formation when we increase the viscosity of the liquid or increase the deposition time. Our results provide a fundamental understanding about polymer growth at the liquid-vapor interface and can offer insight into the growth of other materials on liquid surfaces. The ability to systematically tune morphology can enable the production of particles for applications in photonics, electronics, and drug delivery and films for applications in sensing and separations.

A Mechanistic Study of Wetting Superhydrophobic Porous 3D Meshes

Superhydrophobic, porous, 3D materials composed of poly( ε -caprolactone) (PCL) and the hydrophobic polymer dopant poly(glycerol monostearate- co- ε -caprolactone) (PGC-C18) are fabricated using the electrospinning technique. These 3D materials are distinct from 2D superhydrophobic surfaces, with maintenance of air at the surface as well as within the bulk of the material. These superhydrophobic materials float in water, and when held underwater and pressed, an air bubble is released and will rise to the surface. By changing the PGC-C18 doping concentration in the meshes and/or the fiber size from the micro- to nanoscale, the long-term stability of the entrapped air layer is controlled. The rate of water infiltration into the meshes, and the resulting displacement of the entrapped air, is quantitatively measured using X-ray computed tomography. The properties of the meshes are further probed using surfactants and solvents of different surface tensions. Finally, the application of hydraulic pressure is used to quantify the breakthrough pressure to wet the meshes. The tools for fabrication and analysis of these superhydrophobic materials as well as the ability to control the robustness of the entrapped air layer are highly desirable for a number of existing and emerging applications.

Superhydrophobic surfaces on light alloy substrates fabricated by a versatile process and their corrosion protection

After hydrothermally treated in H2O (for Mg alloy and Al alloy) or H2O2 (for Ti alloy), microstructured oxide or hydroxide layers were formed on light alloy substrates, which further served as the active layers to boost the self-assembling of 1H,1H,2H,2H-perfluorooctyltriethoxysilane (PFOTES) and finally endowed the substrates with unique wettability, that is, superhydrophobicity. For convenience, the so-fabricated superhyrdophobic surfaces (SHS) were abridged as HT-SHS. For comparison, SHS coded as CE-SHS were also prepared based on chemical etching in acid and succedent surface passivation with PFOTES. To reveal the corrosion protection of these SHS, potentiodynamic polarization measurements in NaCl solution (3.5 wt %) were performed. Moreover, to reflect the long-term stability of these SHS, SHS samples were immersed into NaCl solution and the surface wettability was monitored. Experimental results indicated that HT-SHS was much more stable and effective in corrosion protection as compared with CE-SHS. The enhancement was most likely due to the hydrothermally generated oxide layer by the following tow aspects: on one hand, oxide layer itself can lower the corrosion due to its barrier effect; on the other hand, stronger interfacial bonding is expected between oxide layer and PFOTES molecules.

Effect of Electric Current on Beads Formation in Electrospinning of Poly(Vinyl Alcohol)

We investigate effects of electric current on formations of beads in electrospinning by changing an electric conductivity of a poly(vinyl alcohol) (PVA) aqueous solution and spinning conditions, such as applied voltage, distance between a tip of needle and a collector, and relative humidity. From the results of experiments done by changing the conductivity of PVA aqueous solution and spinning conditions, we found that a beads formation is suppressed at a lower electric current. Furthermore, when the electrospinnings are performed at a certain constant electric current in various spinning conditions where the applied voltage and tip-collector distance are changed so as to give the same constant electric current, resultant PVA fibers have no beads and almost the same distribution of fiber diameter.

Superhydrophobic surfaces by electrochemical processes

This review is an exhaustive representation of the electrochemical processes reported in the literature to produce superhydrophobic surfaces. Due to the intensive demand in the elaboration of superhydrophobic materials using low-cost, reproducible and fast methods, the use of strategies based on electrochemical processes have exponentially grown these last five years. These strategies are separated in two parts: the oxidation processes, such as oxidation of metals in solution, the anodization of metals or the electrodeposition of conducting polymers, and the reduction processed such as the electrodeposition of metals or the galvanic deposition. One of the main advantages of the electrochemical processes is the relative easiness to produce various surface morphologies and a precise control of the structures at a micro- or a nanoscale.

Facile fabrication of robust superhydrophobic epoxy film with polyamine dispersed carbon nanotubes

Nanocomposite films of superhydrophobic surface are fabricated from the dispersion of unmodified carbon nanotubes (CNTs) and hydrophobic poly(isobutylene)-amine (PIB-amine). The PIB-amine prepared from the amidation of poly(isobutylene)-succinic anhydride and poly(oxypropylene)-amines is essential for dispersing the originally entangled CNTs into the debundled CNTs as observed by TEM. A robust CNTs/epoxy nanocomposite film with high dimensional stability is made by subsequent curing with epoxy resin. The self-standing film exhibits a superhydrophobic property, with water droplet contact angle > 152° due to the CNTs controlled alignment on the surface forming micrometer-size plateaus, as observed by SEM. The preparation of PIB-amine/CNTs dispersion and subsequently curing into a superhydrophobic CNTs/epoxy film is relatively simple and can potentially be applied to large surface coating.

Highly efficient wettability control via three-dimensional (3D) suspension of titania nanoparticles in polystyrene nanofibers

Electrospinning is a simple and highly versatile method for the large-scale fabrication of polymeric nanofibers. Additives or fillers can also be used to functionalize the nanofibers for use in specific applications. Herein, we demonstrate a novel and efficient way to fabricate superhydrophobic to hydrophilic tunable mats with the combined use of electrospinning and electrospraying that may be suitable for mass production on the merits of rapid deposition. The tunable nanocomposite mats were comprised of hydrophobic polystyrene nanofibers and hydrophilic titania nanoparticles. When the electrical conductivity of the electrospinning solution was increased, the surface morphology of the mats changed noticeably from a bead-on-string structure to an almost bead-free structure. Polystyrene (PS)-titania nanocomposite mats initially yielded a static water contact angle as high as 140° ± 3°. Subsequently exposing these mats with relatively weak ultraviolet irradiation (λ = 365 nm, I = 0.6 mW/cm²) for 2 h, the unique 3D suspension of the photoactive titania nanoparticles maximized the hydrophilic performance of the mats, reducing the static water contact angle to as low as 26° ± 2°. The tunable mats were characterized by scanning electron microscopy (SEM), static water contact angle (WCA) measurements, and energy-dispersive X-ray spectroscopy (EDX). Our findings confirmed that the tunable mats fabricated by the simultaneous implementation of electrospraying and electrospinning had the most efficient ultraviolet (UV)-driven wettability control in terms of cost-effectiveness. Well-controlled tunable hydrophobic and hydrophilic mats find potential applications in functional textiles, environmental membranes, biological sensors, scaffolds, and transport media.

Tailored fibro-porous structure of electrospun polyurethane membranes, their size-dependent properties and trans-membrane glucose diffusion

The aim of this study was to develop polyurethane (PU) based fibro-porous membranes and to investigate the size-effect of hierarchical porous structure on permeability and surface properties of the developed electrospun membranes. Non-woven Selectophore™ PU membranes having tailored fibre diameters, pore sizes, and thickness were spun using electrospinning, and their chemical, physical and glucose permeability properties were characterised. Solvents, solution concentration, applied voltage, flow rate and distance to collector, each were systematically investigated, and electrospinning conditions for tailoring fibre diameters were identified. Membranes having average fibre diameters - 347, 738 and 1102 nm were characterized, revealing average pore sizes of 800, 870 and 1060 nm and pore volumes of 44, 63 and 68% respectively. Hydrophobicity increased with increasing fibre diameter and porosity. Effective diffusion coefficients for glucose transport across the electrospun membranes varied as a function of thickness and porosity, indicating high flux rates for mass transport. Electrospun PU membranes having significantly high pore volumes, extensively interconnected porosity and tailorable properties compared to conventional solvent cast membranes can find applications as coatings for sensors requiring analyte exchange.

Carbon nanotube-directed polytetrafluoroethylene crystal growth via initiated chemical vapor deposition

Initiated chemical vapor deposition (iCVD) has been shown to be suitable for blanketing surfaces with thin polymer coatings of ≈1-2 nm and greater. In this work, iCVD coatings of polytetrafluoroethylene (PTFE) deposited on carbon nanotube (CNT)-based surfaces show CNT-templated PTFE single crystal growth. While the coating forms disoriented agglomerates when deposited on an amorphous carbon background, "shish-kebab" structures are observed when grown on single-walled carbon nanotubes (SWCNT) as well as CNT buckypaper. It is shown that the shish-kebab structure is composed of PTFE lamellae arranged with the chain backbones running parallel to the SWCNT axis. This result allows one to control not only the surface chemistry using PTFE but also the coating surface topology.

Condensation and polymerization of supersaturated monomer vapor

Initiated chemical vapor deposition (iCVD) of poly(glycidyl methacrylate) from supersaturated monomer vapor is reported. Rapid film growth rates, up to 600 nm/min, were observed. Films grown from supersaturated monomer exhibited distinct surface undulations. The temporal evolution of surface features during film growth was studied and is explained by monomer condensation followed by droplet coalescence and film growth. High droplet densities were observed at the early times and are attributed to rapid polymerization of monomer within condensed liquid nuclei. Droplet nucleation resulting in surface undulations can be avoided by first depositing a thin, cross-linked film from ethylene glycol diacrylate monomer followed by deposition of supersaturated monomer vapors.

Fabrication of superhydrophobic surface of stearic acid grafted zinc by using an aqueous plasma etching technique

A stable superhydrophobic surface of stearic acid grafted zinc was fabricated with two steps, that is, the zinc surface was firstly treated with glow discharge electrolysis plasma (GDEP) and then followed by a grafted reaction of stearic acid onto the treated zinc surface. Results indicated that the wettability of zinc substrate changed from superhydrophily to superhyphodrobicity with a water contact angle (CA) up to 158° and a water sliding angle (SA) less than 5°. The surface morphology and composition were characterized by scanning electron microscopy (SEM) and X-ray diffraction (XRD), respectively.

Dual scale roughness driven perfectly hydrophobic surfaces prepared by electrospraying a polymer in good solvent-poor solvent systems

We demonstrated a facile method to produce perfectly hydrophobic surfaces (advancing and receding angles both 180°) via electrospraying. When a copolymer of styrene and a perfluoroacrylate monomer was electrosprayed in good solvents, surfaces composed of micrometer size beads were formed and fairly low threshold water sliding angles could be achieved. Addition of high boiling point poor solvents to the solutions resulted nanoscale roughness on the beads due to a possible phase separation that occurs in a predominantly poor solvent environment. However, sliding angles were not zero even on the nanoscale roughness dominated topographies achieved by this method. On the other hand, when the electrospraying process parameters were set such that micrometer size hills of nanoscopically rough beads were formed, 0° sliding angles were measured. Videos of droplets recorded and the adhesive forces measured during a contact and release experiment revealed that these dual scale rough surfaces were indeed perfectly hydrophobic. Application of the method with other binary good solvent-poor solvent systems also resulted in perfect hydrophobicity. Overall results showed how the differences in surface topology affected the wettability of surfaces within a very narrow range between perfect and extreme hydrophobicity (advancing and receding angles both close to 180°).

Creation of superhydrophobic stainless steel surfaces by acid treatments and hydrophobic film deposition

In this work, we present a method to render stainless steel surfaces superhydrophobic while maintaining their corrosion resistance. Creation of surface roughness on 304 and 316 grade stainless steels was performed using a hydrofluoric acid bath. New insight into the etch process is developed through a detailed analysis of the chemical and physical changes that occur on the stainless steel surfaces. As a result of intergranular corrosion, along with metallic oxide and fluoride redeposition, surface roughness was generated on the nano- and microscales. Differences in alloy composition between 304 and 316 grades of stainless steel led to variations in etch rate and different levels of surface roughness for similar etch times. After fluorocarbon film deposition to lower the surface energy, etched samples of 304 and 316 stainless steel displayed maximum static water contact angles of 159.9 and 146.6°, respectively. However, etching in HF also caused both grades of stainless steel to be susceptible to corrosion. By passivating the HF-etched samples in a nitric acid bath, the corrosion resistant properties of stainless steels were recovered. When a three step process was used, consisting of etching, passivation and fluorocarbon deposition, 304 and 316 stainless steel samples exhibited maximum contact angles of 157.3 and 134.9°, respectively, while maintaining corrosion resistance.

Grafted crystalline poly-perfluoroacrylate structures for superhydrophobic and oleophobic functional coatings

This report describes the preparation of superhydrophobic and oleophobic surfaces by grafting of poly(perfluorodecylacrylate) chains with initiated chemical vapor deposition on silicon substrates. The grafting enhances the formation of a semicrystalline phase. The crystalline structures reduce the polymer chain mobility, resulting in nonwetting surfaces with both water and mineral oil. On the contrary, the same contacting liquid easily wets the amorphous ungrafted polymer.

Influence of flow on longevity of superhydrophobic coatings

Previous studies have demonstrated the capability of superhydrophobic surfaces to produce slip flow and drag reduction, which properties hold considerable promise for a broad range of applications. However, in order to implement such surfaces for practical utilizations, environmental factors such as water movement over the surface must be observed and understood. In this work, experiments were carried out to present a proof-of-concept study on the impact of flow on longevity of polystyrene fibrous coatings. The time-dependent hydrophobicity of a submerged coating in a pressure vessel was determined while exposing the coating to a rudimentary wall-jet flow. Rheological studies were also performed to determine the effect of the flow on drag reduction. The results show that the longevity of the surface deteriorates by increasing the flow rate. The flow appears to enhance the dissolution of air into water, which leads to a loss of drag reduction.

Diblock-copolymer-coated water- and oil-repellent cotton fabrics

A diblock copolymer consisting of a sol-gel-forming block and a fluorinated block was used to coat cotton fabrics, yielding textiles that were highly oil- and water-repellent. The coating procedure was simple. At grafted polymer amounts of as low as 1.0 wt %, water, diodomethane, hexadecane, cooking oil, and pump oil all had contact angles surpassing 150° on the coated cotton fabrics and were readily rolled. The liquids were not drawn into the interfiber space by the coated fabrics. Rather, droplets of the nonvolatile liquids such as cooking oil retained their beaded shapes for months with minimal contact angle changes. When forced into water, the coated fabrics trapped an air or plastron layer and this plastron layer was stable for months. In addition, the coating had high stability against simulated washing, and the mechanical properties were essentially identical to those of uncoated cotton fabrics.

Functionalized synthetic biodegradable polymer scaffolds for tissue engineering

Scaffolds (artificial ECMs) play a pivotal role in the process of regenerating tissues in 3D. Biodegradable synthetic polymers are the most widely used scaffolding materials. However, synthetic polymers usually lack the biological cues found in the natural extracellular matrix. Significant efforts have been made to synthesize biodegradable polymers with functional groups that are used to couple bioactive agents. Presenting bioactive agents on scaffolding surfaces is the most efficient way to elicit desired cell/material interactions. This paper reviews recent advancements in the development of functionalized biodegradable polymer scaffolds for tissue engineering, emphasizing the syntheses of functional biodegradable polymers, and surface modification of polymeric scaffolds.

Design parameters for a robust superhydrophobic electrospun nonwoven mat

Electrospun nonwoven mats exhibiting extreme hydrophobicity have recently attracted much attention for their use in a wide range of applications. These materials are highly heterogeneous and irregular in structure, and accordingly, the design parameters of such materials need to be carefully chosen for obtaining higher apparent contact angles along with the robust composite solid-liquid-vapor interface. Here, we present two dimensionless design parameters, namely, the spacing ratio and pressure difference across the liquid-vapor interface, for enhancing the stability of the Cassie regime. These design parameters are essentially dependent upon the structural characteristics of the electrospun mat and equilibrium contact angle of the liquid. Interestingly, the stability of the composite interface is a trade-off between these dimensionless parameters. Moreover, the pressure difference across the interface can significantly increase by reducing the fiber diameter to nanoscale. The stability of the Cassie state in an electrospun nonwoven mat consisting of lower fiber volume fractions at the nanostructural scale can restore superhydrophobicity even after the impact of a rainfall.