Withdrawing a solid from a bath: How much liquid is coated?

Deposition and alignment of fiber suspensions by dip coating

HYPOTHESIS

The dip coating of suspensions made of monodisperse non-Brownian spherical particles dispersed in a Newtonian fluid leads to different coating regimes depending on the ratio of the particle diameter to the thickness of the film entrained on the substrate. In particular, dilute particles dispersed in the liquid are entrained only above a threshold value of film thickness. In the case of anisotropic particles, in particular fibers, the smallest characteristic dimension will control the entrainment of the particle. Furthermore, it is possible to control the orientation of the anisotropic particles depending on the substrate geometry. In the thick film regime, the Landau-Levich-Derjaguin model remains valid if one account for the change in viscosity.

EXPERIMENT

To test the hypotheses, we performed dip-coating experiments with dilute suspensions of non-Brownian fibers with different length-to-diameter aspect ratios. We characterize the number of fibers entrained on the surface of the substrate as a function of the withdrawal velocity, allowing us to estimate a threshold capillary number below which all the particles remain in the liquid bath. Besides, we measure the angular distribution of the entrained fibers for two different substrate geometries: flat plates and cylindrical rods. We then measure the film thickness for more concentrated fiber suspensions.

FINDINGS

The entrainment of the fibers on a flat plate and a cylindrical rod is primarily controlled by the smaller characteristic length of the fibers: their diameter. At first order, the entrainment threshold scales similarly to that of spherical particles. The length of the fibers only appears to have a minor influence on the entrainment threshold. No preferential alignment is observed for non-Brownian fibers on a flat plate, except for very thin films, whereas the fibers tend to align themselves along the axis of a cylindrical rod for a large enough ratio of the fiber length to the radius of the cylindrical rod. The Landau-Levich-Derjaguin law is recovered for more concentrated suspension by introducing an effective capillary number accounting for the change in viscosity.

Measurement of Capillary Forces Using Two Fibers Dynamically Withdrawn from a Liquid: Evidence for an Enhanced Cheerios Effect

We study the capillary attraction force between two fibers dynamically withdrawn from a bath. We propose an experimental method to measure this force and show that its magnitude strongly increases with the retraction speed by up to a factor of 10 compared to the static case. We show that this remarkable increase stems from the shape of the dynamical meniscus between the two fibers. We first study the dynamical meniscus around one fiber and obtain experimental and numerical scaling of its size increase with the capillary number, which is not captured by the classical Landau-Levich-Derjaguin theory. We then show that the shape of the deformed air-liquid interface around two fibers can be inferred from the linear superposition of the interface around a single fiber. These results yield an analytical expression for the capillary force which compares well with the experimental data. Our study reveals the critical role of the retraction speed to create stronger capillary interactions, with potential applications in industry or biology.

Viscous-capillary entrainment on bioinspired millimetric structure for sustained liquid transfer

Liquid entrainment with a solid architecture passing through the fluid-fluid interface is ubiquitous and widely used in industrial processes as a liquid transfer method. Besides liquid properties, solid structures play a core role in entrainment. Although the influence of its macroscopic curvatures and microscale roughness has attracted years of research, the effect and potential of the commonly seen millimetric structures have not been sufficiently explored and exploited. Here, we demonstrate enhanced liquid entrainment on the millimetric structured surface by the co-effect of viscosity and capillarity for sustained liquid transfer of small deviation, including high-quantity uptake and practically operational drainage with small and relatively uniform droplet dripping time of varied liquid viscosities. With the overall process of viscous-capillary entrainment, we achieve stable cyclical arrayed liquid transport, showing its potential for sustained liquid transfer in intractable situations in laboratory, industry, and even daily life.

Development of branched polyphenolic poly(beta amino esters) to facilitate post-synthesis processing

Given their versatility and formability, polymers have proven to be a viable platform facilitating a controlled and tuned release for a variety of therapeutic agents. One growing area of polymer drug delivery is polymeric prodrugs, which covalently link active pharmaceutical ingredients to a polymeric form to enhance stability, delivery, and pharmacology. One such class of polymeric prodrugs, poly(beta amino esters) (PβAEs) can be synthesized into crosslinked, or "thermoset," networks which greatly limits their processability. An antioxidant-PβAE polymer prodrug that is soluble in organic solutions would permit enhanced processability, increasing their utility and manufacturability. Curcumin PβAEs were synthesized to be soluble in organic solvents while retaining the release and activity properties. To demonstrate the polymer processability, curcumin PβAEs were further synthesized into nanoparticles and thin films. Control over nanoparticle size and film thickness was established through variance of dope solution concentration and withdrawal speed, respectively. Layering of polymeric films was demonstrated through inkjet printing of thin films. Polymer function was characterized through curcumin release and antioxidant activity. The processing of the polymer had a drastic impact on the curcumin release profiles indicating the polymer degradation was influenced by surface area and porosity of the final product. Previously, release was controlled primarily through the hydrophobicity of the polymer. Here, we demonstrate a novel method for further tuning the degradation by processing the polymer.

Particulate suspension coating of capillary tubes

The displacement of a suspension of particles by an immiscible fluid in a capillary tube or in porous media is a canonical configuration that finds application in a large number of natural and industrial applications, including water purification, dispersion of colloids and microplastics, coating and functionalization of tubings. The influence of particles dispersed in the fluid on the interfacial dynamics and on the properties of the liquid film left behind remain poorly understood. Here, we study the deposition of a coating film on the walls of a capillary tube induced by the translation of a suspension plug pushed by air. We identify the different deposition regimes as a function of the translation speed of the plug, the particle size, and the volume fraction of the suspension. The thickness of the coating film is characterized, and we show that similarly to dip coating, three coating regimes are observed, liquid only, heterogeneous, and thick films. We also show that, at first order, the thickness of films thicker than the particle diameter can be predicted using the effective viscosity of the suspension. Nevertheless, we also report that for large particles and concentrated suspensions, a shear-induced migration mechanism leads to local variations in volume fraction and modifies the deposited film thickness and composition.

The Thickness and Structure of Dip-Coated Polymer Films in the Liquid and Solid States

Films formed by dip coating brass wires with dilute and semi-dilute solutions of polyvinyl butyral in benzyl alcohol were studied in their liquid and solid states. While dilute and semi-dilute solutions behaved as Maxwell viscoelastic fluids, the thickness of the liquid films followed the Landau-Levich-Derjaguin prediction for Newtonian fluids. At a very slow rate of coating, the film thickness was difficult to evaluate. Therefore, the dynamic contact angle was studied in detail. We discovered that polymer additives preserve the advancing contact angle at its static value while the receding contact angle follows the Cox–Voinov theory. In contrast, the thickness of solid films does not correlate with the Landau-Levich-Derjaguin predictions. Only solutions of high-molecular-weight polymers form smooth solid films. Solutions of low-molecular-weight polymers may form either solid films with an inhomogeneous roughness or solid polymer domains separated by the dry substrate. In technological applications, very dilute polymer solutions of high-molecular-weight polymers can be used to avoid inhomogeneities in solid films. These solutions form smooth solid films, and the film thickness can be controlled by the experimental coating conditions.

Quantitative imaging and modeling of colloidal gelation in the coagulant dipping process

Many common elastomeric products, including nitrile gloves, are manufactured by coagulant dipping. This process involves the destabilization and gelation of a latex dispersion by an ionic coagulant. Despite widespread application, the physical chemistry governing coagulant dipping is poorly understood. It is unclear which properties of an electrolyte determine its efficacy as a coagulant and which phenomena control the growth of the gel. Here, a novel experimental protocol is developed to directly observe coagulant gelation by light microscopy. Gel growth is imaged and quantified for a variety of coagulants and compared to macroscopic dipping experiments mimicking the industrial process. When the coagulant is abundant, gels grow with a t1/2 time dependence, suggesting that this phenomenon is diffusion-dominated. When there is a finite amount of coagulant, gels grow to a limiting thickness. Both these situations are modeled as one-dimensional diffusion problems, reproducing the qualitative features of the experiments including which electrolytes cause rapid growth of thick gels. We propose that the gel thickness is limited by the amount of coagulant available, and the growth is, therefore, unbounded when the coagulant is abundant. The rate of the gel growth is controlled by a combination of a diffusion coefficient and the ratio of the critical coagulation concentration to the amount of coagulant present, which in many situations is set by the coagulant solubility. Other phenomena, including diffusiophoresis, may make a more minor contribution to the rate of gel growth.

The Wavelength-Shifting Optical Module

The Wavelength-shifting Optical Module (WOM) is a novel photosensor concept for the instrumentation of large detector volumes with single-photon sensitivity. The key objective is to improve the signal-to-noise ratio, which is achieved by decoupling the photosensitive area of a sensor from the cathode area of its photomultiplier tube (PMT). The WOM consists of a transparent tube with two PMTs attached to its ends. The tube is coated with wavelength-shifting paint that absorbs ultraviolet photons with nearly 100% efficiency. Depending on the environment, e.g., air (ice), up to 73% (41%) of the subsequently emitted optical photons can be captured by total internal reflection and propagate towards the PMTs, where they are recorded. The optical properties of the paint, the geometry of the tube, and the coupling of the tube to the PMTs have been optimized for maximal sensitivity based on theoretical derivations and experimental evaluations. Prototypes were built to demonstrate the technique and to develop a reproducible construction process. Important measurable characteristics of the WOM are the wavelength-dependent effective area, the transit time spread of detected photons, and the signal-to-noise ratio. The WOM outperforms bare PMTs, especially with respect to the low signal-to-noise ratio with an increase of a factor up to 8.9 in air (5.2 in ice). Since the gain in sensitivity is mostly in the UV regime, the WOM is an ideal sensor for Cherenkov and scintillation detectors.

Microfluidics-Enabled Soft Manufacture of Materials with Tailorable Wettability

Microfluidics and wettability are interrelated and mutually reinforcing fields, experiencing synergistic growth. Surface wettability is paramount in regulating microfluidic flows for processing and manipulating fluids at the microscale. Microfluidics, in turn, has emerged as a versatile platform for tailoring the wettability of materials. We present a critical review on the microfluidics-enabled soft manufacture (MESM) of materials with well-controlled wettability and their multidisciplinary applications. Microfluidics provides a variety of liquid templates for engineering materials with exquisite composition and morphology, laying the foundation for precisely controlling the wettability. Depending on the degree of ordering, liquid templates are divided into individual droplets, one-dimensional (1D) arrays, and two-dimensional (2D) or three-dimensional (3D) assemblies for the modular fabrication of microparticles, microfibers, and monolithic porous materials, respectively. Future exploration of MESM will enrich the diversity of chemical composition and physical structure for wettability control and thus markedly broaden the application horizons across engineering, physics, chemistry, biology, and medicine. This review aims to systematize this emerging yet robust technology, with the hope of aiding the realization of its full potential.

An Extensive Review of Natural Polymers Used as Coatings for Postharvest Shelf-Life Extension: Trends and Challenges

Global demand for minimally processed fruits and vegetables is increasing due to the tendency to acquire a healthy lifestyle. Losses of these foods during the chain supply reach as much as 30%; reducing them represents a challenge for the industry and scientific sectors. The use of edible packaging based on biopolymers is an alternative to mitigate the negative impact of conventional films and coatings on environmental and human health. Moreover, it has been demonstrated that natural coatings added with functional compounds reduce the post-harvest losses of fruits and vegetables without altering their sensorial and nutritive properties. Furthermore, the enhancement of their mechanical, structural, and barrier properties can be achieved through mixing two or more biopolymers to form composite coatings and adding plasticizers and/or cross-linking agents. This review shows the latest updates, tendencies, and challenges in the food industry to develop eco-friendly food packaging from diverse natural sources, added with bioactive compounds, and their effect on perishable foods. Moreover, the methods used in the food industry and the new techniques used to coat foods such as electrospinning and electrospraying are also discussed. Finally, the tendency and challenges in the development of edible films and coatings for fresh foods are reviewed.

Dip coating of cylinders with Newtonian fluids

HYPOTHESIS

The Landau-Levich-Derjaguin (LLD) theory is widely applied to predict the film thickness in the dip-coating process. However, the theory was designed only for flat plates and thin fibers. Fifty years ago, White and Tallmadge attempted to generalize the LLD theory to thick rods using a numerical solution for a static meniscus and the LLD theory to forcedly match their numeric solution with the LLD asymptotics. The White-Talmadge solution has been criticized for not being rigorous yet widely used in engineering applications mostly owing to the lack of alternative solutions. A new set of experiments significantly expanding the range of White-Tallmadge conditions showed that their theory cannot explain the experimental results. We then hypothesized that the results of LLD theory can be improved by restoring the non-linear meniscus curvature in the equation. With this modification, the obtained equation should be able to describe static menisci on any cylindrical rods and the film profiles observed at non-zero rod velocity.

EXPERIMENT

To test the hypothesis, we distinguished capillary forces from viscous forces by running experiments with different rods and at different withdrawal velocities and video tracking the menisci profiles and measuring the weight of deposited films. The values of film thickness were then fitted with a mathematical model based on the modified LLD equation. We also fitted the meniscus profiles.

FINDINGS

The results show that the derived equation allows one to reproduce the results of the LLD theory and go far beyond those to include rods of different radii. A new set of experimental data together with the White-Tallmadge experimental data are explained with the modified LLD theory. A set of simple formulas approximating numeric results have been derived. These formulas can be used in engineering applications for the prediction of the coating thickness.

Polymer-infiltrated nanoplatelet films with nacre-like structure via flow coating and capillary rise infiltration (CaRI)

Alignment of highly anisotropic nanomaterials in a polymer matrix can yield nanocomposites with unique mechanical and transport properties. Conventional methods of nanocomposite film fabrication are not well-suited for manufacturing composites with very high concentrations of anisotropic nanomaterials, potentially limiting the widespread implementation of these useful structures. In this work, we present a scalable approach to fabricate polymer-infiltrated nanoplatelet films (PINFs) based on flow coating and capillary rise infiltration (CaRI) and study the processing-structure-property relationship of these PINFs. We show that films with high aspect ratio (AR) gibbsite (Al (OH)3) nanoplatelets (NPTs) aligned parallel to the substrate can be prepared using a flow coating process. NPTs are highly aligned with a Herman's order parameter of 0.96 and a high packing fraction >80 vol%. Such packings show significantly higher fracture toughness compared to low AR nanoparticle (NP) packings. By depositing NPTs on a polymer film and subsequently annealing the bilayer above the glass transition temperature of the polymer, polymer infiltrates into the tortuous NPT packings though capillarity. We observe larger enhancement in the modulus, hardness and scratch resistance of NPT films upon polymer infiltration compared to NP packings. The excellent mechanical properties of such films benefit from both thermally promoted oxide bridge formation between NPTs as well as polymer infiltration increasing the strength of NPT contacts. Our approach is widely applicable to highly anisotropic nanomaterials and allows the generation of mechanically robust polymer nanocomposite films for a diverse set of applications.

The challenge of lubricant-replenishment on lubricant-impregnated surfaces

Lubricant-impregnated surfaces are two-component surface coatings. One component, a fluid called the lubricant, is stabilized at a surface by the second component, the scaffold. The scaffold can either be a rough solid or a polymeric network. Drops immiscible with the lubricant, hardly pin on these surfaces. Lubricant-impregnated surfaces have been proposed as candidates for various applications, such as self-cleaning, anti-fouling, and anti-icing. The proposed applications rely on the presence of enough lubricant within the scaffold. Therefore, the quality and functionality of a surface coating are, to a large degree, given by the extent to which it prevents lubricant-depletion. This review summarizes the current findings on lubricant-depletion, lubricant-replenishment, and the resulting understanding of both processes. A multitude of different mechanisms can cause the depletion of lubricant. Lubricant can be taken along by single drops or be sheared off by liquid flowing across. Nano-interstices and scaffolds showing good chemical compatibility with the lubricant can greatly delay lubricant depletion. Often, depletion of lubricant cannot be avoided under dynamic conditions, which warrants lubricant-replenishment strategies. The strategies to replenish lubricant are presented and range from spraying or stimuli-responsive release to built-in reservoirs.

Stability of a directional Marangoni flow

Marangoni flows result from surface-tension gradients, and these flows occur over finite distances on the surface, but the subsequent secondary flows can be observed on much larger lengthscales. These flows play major roles in various phenomena, from foam dynamics to microswimmer propulsion. We show here that if a Marangoni flow of soluble surfactants is confined laterally, the flow forms an inertial surface jet. A full picture of the flows on the surface is exhibited, and the velocity profile of the jet is predicted analytically, and is successfully compared with the experimental measurements. Moreover, this straight jet eventually destabilizes into meanders. A quantitative comparison between the theory and our experimental observations yields a very good agreement in terms of critical wavelengths. The characterization and understanding of the 2D flows generated by confined Marangoni spreading is a first step to understand the role of inertial effects in the Marangoni flows with and without confinement.

Drawing-Based Manufacturing of Shear-Activated Reversible Adhesives

Although biomimetic technologies for dry reversible adhesion seem to be maturing, the costs, complexity, and time expenditures associated with the current template-based molding techniques call for research on other fabrication methods. In this paper, we report a novel cost-effective, simple, and flexible drawing-based technique for manufacturing the soft elastomeric thin-film-based microstructures needed for successful implementation of the principles of biological shear-activated adhesion. Several different types of adhesive microstructures are fabricated, and the best of them demonstrate shear-driven amplification of pull-off force by a factor of 40, which significantly outperforms known molded analogues. A simple gripper based on a manual center-clamping vise is shown to enable pick-and-place manipulation of various flat and curved objects of everyday use.

A Novel Simple Anti-Ice Aluminum Coating: Synthesis and In-Lab Comparison with a Superhydrophobic Hierarchical Surface

A simple process to obtain a slippery surface with anti-ice and ice-phobic properties has been developed and characterized in laboratory. The coating is realized by growing a nanostructured pseudo-boehmite on an aluminum substrate and applying an environmentally compatible final functionalization consisting of a fluorine-free oligomeric short-chain alkylfunctional silane. The resulting surface is conceptually similar to a slippery liquid infused porous surface (SLIP) material, but the porous infrastructure is inorganic and the process to generate it is very simple, rapid and economic. The coating performance in terms of hydrophobicity at room and low temperatures, ice nucleation temperature and ice adhesion forces were assessed in laboratory. Moreover, hydrophobicity persistence was tested after prolonged immersion in acid, basic and saline solutions while the durability of ice-phobic behavior was assessed by repeated shear stress tests. Results are compared with those of a superhydrophobic hierarchical aluminum surface obtained with a fluorinated siloxane. The novel coating shows very good anti-ice properties and relevant durability, with some differences from the fluorinated surface. The novel slippery coating process is promising for industrial applications, also taking into account its environmental compatibility, simplicity and low cost.

Self-Cleaning Mechanism: Why Nanotexture and Hydrophobicity Matter

Dust particles can adhere to surfaces, thereby decreasing the efficiency of diverse processes, such as light absorption by solar panels. It is well known that superhydrophobicity reduces the friction between water droplets and the surface, thus allowing water drops to slide/roll and detach (clean) particles from surfaces. However, the forces that attach and detach particles from surfaces during the self-cleaning mechanism and the effect of nanotextures on these forces are not fully understood. To shed light on these forces and the effect of nanotexture on them, we prepared four Si-based samples (relevant to solar panels): (1) smooth or (2) nanotextured hydrophilic surfaces and (3) smooth or (4) nanotextured hydrophobic surfaces. In agreement with previous publications, it is shown that the efficiency of particle removal increases with hydrophobicity. Furthermore, nanotexture enhances the hydrophobicity, whereby particle removal is further increased. Specifically, hydrophilic particle removal increased from ∼41%, from hydrophilic smooth Si wafers to 98% from superhydrophobic Si-based nanotextured surfaces. However, the reason for the increased particle removal is not low friction between the droplets and the superhydrophobic surfaces; it is the reduction of the adhesion force between the particle and the surface and the altered geometry of the water-particle-air line tension acting on the particles on superhydrophobic surfaces, which increases the force that can detach particles from the surfaces. The experimental methods we used and the criterion for particle removal we derived can be implemented to engineer self-cleaning surfaces using other surfaces and dust particles, exhibiting different chemistries and/or textures.

Stress Field inside the Bath Determines Dip Coating with Yield-Stress Fluids in Cylindrical Geometry

We study experimentally and theoretically the thickness of the coating obtained by pulling out a rod from a reservoir of yield-stress fluid. Opposite to Newtonian fluids, the coating thickness for a fluid of large enough yield stress is determined solely by the flow inside the reservoir and not by the flow inside the meniscus. The stress field inside the reservoir determines the thickness of the coating layer. The thickness is observed to increase nonlinearly with the sizes of the rod and of the reservoir. We develop a theoretical framework that describes this behavior and allows us to precisely predict the coating thickness.

Collection of nectar by bumblebees: how the physics of fluid demonstrates the prominent role of the tongue's morphology

Bumblebees and some other tiny animals feed on nectar by visiting flowers in their neighborhood. Some bee species appear to be highly specialized, their tongue being adapted to specific flowers. Bombus terrestris in contrast is able to feed on a wide variety of flowers and can thus be considered as a kind of universal nectar catcher. Since plant nectars show highly variable sugar content, Bombus terrestris have developed a capture mechanism that works for almost any fluid viscosity. Their tongues are decorated with very elongated papillae forming a hairy coating surrounding a rod-like main stalk. When settled on a flower, Bombus rapidly dip their tongue into the inflorescence to catch the highly sought-after nectar. To determine the physical mechanism at the origin of this outstanding ability, the capture dynamics was followed from videos recorded during viscous fluid ingestion. Surprisingly, the volume per lap and the lapping frequency are independent of the fluid viscosity over three orders of magnitude. To explain this observation, we designed a physical model of viscous dipping with structured rods. Predictions of the model compared to observations for bees showed that the nectar is not captured with the help of viscous drag, as proposed in the Landau-Levich-Derjaguin model, but thanks to the hairy structure that traps the viscous fluid, capillary forces drastically limiting the drainage. Our approach can be transposed to others nectar foragers such as bats and hummingbirds.

Dextran as a Resorbable Coating Material for Flexible Neural Probes

In the quest for chronically reliable and bio-tolerable brain interfaces there has been a steady evolution towards the use of highly flexible, polymer-based electrode arrays. The reduced mechanical mismatch between implant and brain tissue has shown to reduce the evoked immune response, which in turn has a positive effect on signal stability and noise. Unfortunately, the low stiffness of the implants also has practical repercussions, making surgical insertion extremely difficult. In this work we explore the use of dextran as a coating material that temporarily stiffens the implant, preventing buckling during insertion. The mechanical properties of dextran coated neural probes are characterized, as well as the different parameters which influence the dissolution rate. Tuning parameters, such as coating thickness and molecular weight of the used dextran, allows customization of the stiffness and dissolution time to precisely match the user's needs. Finally, the immunological response to the coated electrodes was analyzed by performing a histological examination after four months of in vivo testing. The results indicated that a very limited amount of glial scar tissue was formed. Neurons have also infiltrated the area that was initially occupied by the dissolving dextran coating. There was no noticeable drop in neuron density around the site of implantation, confirming the suitability of the coating as a temporary aid during implantation of highly flexible polymer-based neural probes.

Dip-coating of suspensions

Withdrawing a plate from a suspension leads to the entrainment of a coating layer of fluid and particles on the solid surface. In this article, we study the Landau-Levich problem in the case of a suspension of non-Brownian particles at moderate volume fraction 10% < φ < 41%. We observe different regimes depending on the withdrawal velocity U, the volume fraction of the suspension φ, and the diameter of the particles 2a. Our results exhibit three coating regimes. (i) At small enough capillary number Ca, no particles are entrained, and only a liquid film coats the plate. (ii) At large capillary number, we observe that the thickness of the entrained film of suspension is captured by the Landau-Levich law using the effective viscosity of the suspension η(φ). (iii) At intermediate capillary numbers, the situation becomes more complicated with a heterogeneous coating on the substrate. We rationalize our experimental findings by providing the domain of existence of these three regimes as a function of the fluid and particles properties.