Capillary Coatings: Flow and Drying Dynamics in Open Microchannels

Surface-Wetting Characteristics of DLP-Based 3D Printing Outcomes under Various Printing Conditions for Microfluidic Device Fabrication

In recent times, the utilization of three-dimensional (3D) printing technology, particularly a variant using digital light processing (DLP), has gained increasing fascination in the realm of microfluidic research because it has proven advantageous and expedient for constructing microscale 3D structures. The surface wetting characteristics (e.g., contact angle and contact angle hysteresis) of 3D-printed microstructures are crucial factors influencing the operational effectiveness of 3D-printed microfluidic devices. Therefore, this study systematically examines the surface wetting characteristics of DLP-based 3D printing objects, focusing on various printing conditions such as lamination (or layer) thickness and direction. We preferentially examine the impact of lamination thickness on the surface roughness of 3D-printed structures through a quantitative assessment using a confocal laser scanning microscope. The influence of lamination thicknesses and lamination direction on the contact angle and contact angle hysteresis of both aqueous and oil droplets on the surfaces of 3D-printed outputs is then quantified. Finally, the performance of a DLP 3D-printed microfluidic device under various printing conditions is assessed. Current research indicates a connection between printing parameters, surface roughness, wetting properties, and capillary movement in 3D-printed microchannels. This correlation will greatly aid in the progress of microfluidic devices produced using DLP-based 3D printing technology.

3D Assembly of MXene Networks using a Ceramic Backbone with Controlled Porosity

Transition metal carbides (MXenes) are novel 2D nanomaterials with exceptional properties, promising significant impact in applications such as energy storage, catalysis, and energy conversion. A major barrier preventing the widespread use of MXenes is the lack of methods for assembling MXene in 3D space without significant restacking, which degrades their performance. Here, this challenge is successfully overcome by introducing a novel material system: a 3D network of MXene formed on a porous ceramic backbone. The backbone dictates the network's 3D architecture while providing mechanical strength, gas/liquid permeability, and other beneficial properties. Freeze casting is used to fabricate a silica backbone with open pores and controlled porosity. Next, capilary flow is used to infiltrate MXene into the backbone from a dispersion. The system is then dried to conformally coat the pore walls with MXene, creating an interconnected 3D-MXene network. The fabrication approach is reproducible, and the MXene-infiltrated porous silica (MX-PS) system is highly conductive (e.g., 340 S m-1 ). The electrical conductivity of MX-PS is controlled by the porosity distribution, MXene concentration, and the number of infiltration cycles. Sandwich-type supercapacitors with MX-PS electrodes are shown to produce excellent areal capacitance (7.24 F cm-2 ) and energy density (0.32 mWh cm-2 ) with only 6% added MXene mass. This approach of creating 3D architectures of 2D nanomaterials will significantly impact many engineering applications.

Capillary Imbibition in a Diverging Flexible Channel

We study the imbibition of a wetting liquid between flexible sheets that are fixed at both ends. Assuming a narrow gap between the sheets, we solve the lubrication equation coupled with a slender body deformation. When the sheets are parallel, we find that the deformation initially speeds up the flow, as shown in previous studies, but only up to the middle of the channel. As the channel contracts, the hydrodynamic resistance increases and ultimately slows down the filling process. Below a threshold stiffness, the channel collapses and imbibition stops. We propose a scaling of the filling duration near this threshold. Next, we show that if the sheets are initially tilted with a minimal angle, the channel avoids collapse. The liquid front pulls the diverging sheets and spreads in a nearly parallel portion, which maintains the capillary propulsion and enhances the wicking. Therefore, while it is established that diverging rigid plates imbibe liquids slower than parallel ones do, we show that elasticity reverses this principle: diverging flexible sheets imbibe liquids faster than parallel ones. We find an optimal tilt angle that gives the shortest filling time.

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.

Capillary flow of liquids in open microchannels: overview and recent advances

Capillary flow is the spontaneous wicking of liquids in narrow spaces without the assistance of external forces. Examples of capillary flow can be found in numerous applications ranging from controlling and transporting fuel in spacecrafts to printed electronics manufacturing. Open rectangular microchannels often appear in these applications, with the lack of a top resulting in a complex free-surface morphology and evaporation. Here, we present a brief overview of this topic and discuss some recent advances.

Superwicking Functionality of Femtosecond Laser Textured Aluminum at High Temperatures

An advanced superwicking aluminum material based on a microgroove surface structure textured with both laser-induced periodic surface structures and fine microholes was produced by direct femtosecond laser nano/microstructuring technology. The created material demonstrates excellent wicking performance in a temperature range of 23 to 120 °C. The experiments on wicking dynamics show a record-high velocity of water spreading that achieves about 450 mm/s at 23 °C and 320 mm/s at 120 °C when the spreading water undergoes intensive boiling. The lifetime of classic Washburn capillary flow dynamics shortens as the temperature increases up to 80 °C. The effects of evaporation and boiling on water spreading become significant above 80 °C, resulting in vanishing of Washburn's dynamics. Both the inertial and visco-inertial flow regimes are insignificantly affected by evaporation at temperatures below the boiling point of water. The boiling effect on the inertial regime is small at 120 °C; however, its effect on the visco-inertial regime is essential. The created material with effective wicking performance under water boiling conditions can find applications in Maisotsenko cycle (M-cycle) high-temperature heat/mass exchangers for enhancing power generation efficiency that is an important factor in reducing CO2 emissions and mitigation of the global climate change.

Synchronization and control of capillary flows in rectangular microchannel with spacers

Liquid control in microchannels is quite important in microfluidic devices used in, for example, lab-on-a-chip and point-of-care applications. Capillary microfluidics, being self-powered, is especially advantageous for use in passive devices, and has attracted significant attention. In this paper, capillary flows in rectangular microchannels with spacers are studied experimentally and theoretically; in particular, capillary flow synchronization (or waiting) behavior is identified and investigated. Based on changes of channel walls, two basic synchronization modes are proposed for flows isolated by spacers in a channel. Experimental results show that the velocities of faster capillary flows are reduced by the liquid pinning effect and that the time delay between two capillary flows is automatically balanced. The synchronization behavior of capillary flows is explained by analyzing the time delay, contact angle variation, and capillary forces. In addition, the quantity of liquid flowing out of the waiting channels is estimated and verified. Then a model for the change in contact angle during synchronization is derived and verified. Finally, we conceive a series of studies of the control of capillary flows for different spacer designs and conduct an experiment to study the dynamic behaviors of a number of capillary flows by adding many spacers in a microchannel. This study expands the applications of capillary microfluidics.

Temperature Effect on Capillary Flow Dynamics in 1D Array of Open Nanotextured Microchannels Produced by Femtosecond Laser on Silicon

Capillary flow of water in an array of open nanotextured microgrooves fabricated by femtosecond laser processing of silicon is studied as a function of temperature using high-speed video recording. In a temperature range of 23-80 °C, the produced wicking material provides extremely fast liquid flow with a maximum velocity of 37 cm/s in the initial spreading stage prior to visco-inertial regime. The capillary performance of the material enhances with increasing temperature in the inertial, visco-inertial, and partially in Washburn flow regimes. The classic universal Washburn's regime is observed at all studied temperatures, giving the evidence of its universality at high temperatures as well. The obtained results are of great significance for creating capillary materials for applications in cooling of electronics, energy harvesting, enhancing the critical heat flux of industrial boilers, and Maisotsenko cycle technologies.

Droplet Incubation and Splitting in Open Microfluidic Channels

Droplet-based microfluidics enables compartmentalization and controlled manipulation of small volumes. Open microfluidics provides increased accessibility, adaptability, and ease of manufacturing compared to closed microfluidic platforms. Here, we begin to build a toolbox for the emerging field of open channel droplet-based microfluidics, combining the ease of use associated with open microfluidic platforms with the benefits of compartmentalization afforded by droplet-based microfluidics. We develop fundamental microfluidic features to control droplets flowing in an immiscible carrier fluid within open microfluidic systems. Our systems use capillary flow to move droplets and carrier fluid through open channels and are easily fabricated through 3D printing, micromilling, or injection molding; further, droplet generation can be accomplished by simply pipetting an aqueous droplet into an empty open channel. We demonstrate on-chip incubation of multiple droplets within an open channel and subsequent transport (using an immiscible carrier phase) for downstream experimentation. We also present a method for tunable droplet splitting in open channels driven by capillary flow. Additional future applications of our toolbox for droplet manipulation in open channels include cell culture and analysis, on-chip microscale reactions, and reagent delivery.

Capillary Flow with Evaporation in Open Rectangular Microchannels

Numerous applications rely upon capillary flow in microchannels for successful operation including lab-on-a-chip devices, porous media flows, and printed electronics manufacturing. Open microchannels often appear in these applications, and evaporation of the liquid can significantly affect its flow. In this work, we develop a Lucas-Washburn-type one-dimensional model that incorporates the effects of concentration-dependent viscosity and uniform evaporation on capillary flow in channels of a rectangular cross section. The model yields predictions of the time evolution of the liquid front down the length of the microchannel. For the case where evaporation is absent, prior studies have demonstrated better agreement between model predictions and experimental observations in low-viscosity liquids when using a no-slip rather than a no-stress boundary condition at the upper liquid-air interface. However, flow visualization experiments conducted in this work suggest the absence of a rigidified liquid-air interface. The use of the no-stress condition results in overestimation of the time evolution of the liquid front, which appears to be due to underestimation of the viscous forces from (i) the upper and front meniscus morphology, (ii) dynamic contact angle effects, and (iii) surface roughness, none of which are accounted for in the model. When high-viscosity liquids are considered, the large bulk viscosity is found to suppress these factors, resulting in better agreement between model predictions using the no-stress condition and experiments. Model predictions are also compared to prior experiments involving poly(vinyl alcohol) in the presence of evaporation by using the evaporation rate as a fitting parameter. Scaling relationships obtained from the model for the dependence of the final liquid-front position and total flow time on the channel dimensions and rate of uniform evaporation are found to be in good agreement with experimental observations.