Condensation Induced Blistering as a Measurement Technique for the Adhesion Energy of Nanoscale Polymer Films

Bridging the Gap-Thermofluidic Designs for Precision Bioelectronics

Bioelectronics, the merging of biology and electronics, can monitor and modulate biological behaviors across length and time scales with unprecedented capability. Current bioelectronics research largely focuses on devices' mechanical properties and electronic designs. However, the thermofluidic control is often overlooked, which is noteworthy given the discipline's importance in almost all bioelectronics processes. It is believed that integrating thermofluidic designs into bioelectronics is essential to align device precision with the complexity of biofluids and biological structures. This perspective serves as a mini roadmap for researchers in both fields to introduce key principles, applications, and challenges in both bioelectronics and thermofluids domains. Important interdisciplinary opportunities for the development of future healthcare devices and precise bioelectronics will also be discussed.

Ultra-resilient multi-layer fluorinated diamond like carbon hydrophobic surfaces

Seventy percent of global electricity is generated by steam-cycle power plants. A hydrophobic condenser surface within these plants could boost overall cycle efficiency by 2%. In 2022, this enhancement equates to an additional electrical power generation of 1000 TWh annually, or 83% of the global solar electricity production. Furthermore, this efficiency increase reduces CO2 emissions by 460 million tons /year with a decreased use of 2 trillion gallons of cooling water per year. However, the main challenge with hydrophobic surfaces is their poor durability. Here, we show that solid microscale-thick fluorinated diamond-like carbon (F-DLC) possesses mechanical and thermal properties that ensure durability in moist, abrasive, and thermally harsh conditions. The F-DLC coating achieves this without relying on atmospheric interactions, infused lubricants, self-healing strategies, or sacrificial surface designs. Through tailored substrate adhesion and multilayer deposition, we develop a pinhole-free F-DLC coating with low surface energy and comparable Young's modulus to metals. In a three-year steam condensation experiment, the F-DLC coating maintains hydrophobicity, resulting in sustained and improved dropwise condensation on multiple metallic substrates. Our findings provide a promising solution to hydrophobic material fragility and can enhance the sustainability of renewable and non-renewable energy sources.

Interfacial Nanoblisters Formed in Water Serving as Freestanding Platforms for Measuring Elastic Moduli of Polymeric Nanofilms

Polymeric nanofilms have been widely utilized in diverse cutting-edge technologies, yet accurately determining their elastic moduli remains challenging. Here we demonstrate that interfacial nanoblisters, which are produced by simply immersing substrate-supported nanofilms in water, represent natural platforms for assessing the mechanical properties of polymeric nanofilms using the sophisticated nanoindentation method. Nevertheless, high-resolution, quantitative force spectroscopy studies reveal that the indentation test must be performed on an effective freestanding region around the nanoblister apex and meanwhile under an appropriate loading force, to obtain load-independent, linear elastic deformations. The nanoblister stiffness increases with either decreasing its size or increasing its covering film thickness, and such size effects can be adequately rationalized by an energy-based theoretical model. The proposed model also enables an exceptional determination of the film elastic modulus. Given that interfacial blistering is a frequently occurring phenomenon for polymeric nanofilms, we envision that the presented methodology would stimulate broad applications in relevant fields.

Direct Measurement of Solid-Liquid Interfacial Energy Using a Meniscus

Solid-liquid interactions are central to diverse processes. The interaction strength can be described by the solid-liquid interfacial free energy (γ_{SL}), a quantity that is difficult to measure. Here, we present the direct experimental measurement of γ_{SL} for a variety of solid materials, from nonpolar polymers to highly wetting metals. By attaching a thin solid film on top of a liquid meniscus, we create a solid-liquid interface. The interface determines the curvature of the meniscus, analysis of which yields γ_{SL} with an uncertainty of less than 10%. Measurement of classically challenging metal-water interfaces reveals γ_{SL}∼30-60  mJ/m^{2}, demonstrating quantitatively that water-metal adhesion is 80% stronger than the cohesion energy of bulk water, and experimentally verifying previous quantum chemical calculations.

Film Instability Induced by Swelling and Drying

Poly(2-vinyl pyridine), P2VP, films display a surface pattern of craters in a dried state after being immersed in aqueous solutions containing HAuCl₄ and its mixtures with low contents of K₂CO₃. The morphologies of craters indicate that the formation of craters involves three stages through film blistering and drying: (i) the permeability of water and solutes to swell P2VP films, (ii) partial wetting of liquid droplets near the substrate interface in the presence of the P2VP film, and (iii) evaporation-driven flows. The three stages produce the swelling pressure, Laplace pressure, and interplays among capillary flows, Marangoni flows, and pinning effects, respectively, by which craters of different dimensions and morphologies are obtained. The first stage softens the P2VP films and produces swelling pressure. This stage relies on interactions between AuCl₄^- ions, water, and protonated P2VP chains. The second stage produces liquid droplets inside the film and near the substrate interface. The surface tensions of those liquid droplets at contact lines deform swollen P2VP films. Changing film thicknesses or substrate types alters craters' lateral dimension and depth. The results indicate that film thicknesses and substrate interface energies influence the shape and dimension of liquid droplets on the substrate interface. The third stage determines morphologies of craters through interplays among capillary flows, Marangoni flows, and pinning/depinning events.

A Lipid-Inspired Highly Adhesive Interface for Durable Superhydrophobicity in Wet Environments and Stable Jumping Droplet Condensation

Creating thin (<100 nm) hydrophobic coatings that are durable in wet conditions remains challenging. Although the dropwise condensation of steam on thin hydrophobic coatings can enhance condensation heat transfer by 1000%, these coatings easily delaminate. Designing interfaces with high adhesion while maintaining a nanoscale coating thickness is key to overcoming this challenge. In nature, cell membranes face this same challenge where nanometer-thick lipid bilayers achieve high adhesion in wet environments to maintain integrity. Nature ensures this adhesion by forming a lipid interface having two nonpolar surfaces, demonstrating high physicochemical resistance to biofluids attempting to open the interface. Here, developing an artificial lipid-like interface that utilizes fluorine-carbon molecular chains can achieve durable nanometric hydrophobic coatings. The application of our approach to create a superhydrophobic material shows high stability during jumping-droplet-enhanced condensation as quantified from a continual one-year steam condensation experiment. The jumping-droplet condensation enhanced condensation heat transfer coefficient up to 400% on tube samples when compared to filmwise condensation on bare copper. Our bioinspired materials design principle can be followed to develop many durable hydrophobic surfaces using alternate substrate-coating pairs, providing stable hydrophobicity or superhydrophobicity to a plethora of applications.

The apparent surface free energy of rare earth oxides is governed by hydrocarbon adsorption

The surface free energy of rare earth oxides (REOs) has been debated during the last decade, with some reporting REOs to be intrinsically hydrophilic and others reporting hydrophobic. Here, we investigate the wettability and surface chemistry of pristine and smooth REO surfaces, conclusively showing that hydrophobicity stems from wettability transition due to volatile organic compound adsorption. We show that, for indoor ambient atmospheres and well-controlled saturated hydrocarbon atmospheres, the apparent advancing and receding contact angles of water increase with exposure time. We examined the surfaces comprehensively with multiple surface analysis techniques to confirm hydrocarbon adsorption and correlate it to wettability transition mechanisms. We demonstrate that both physisorption and chemisorption occur on the surface, with chemisorbed hydrocarbons promoting further physisorption due to their high affinity with similar hydrocarbon molecules. This study offers a better understanding of the intrinsic wettability of REOs and provides design guidelines for REO-based durable hydrophobic coatings.

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REOs are intrinsically hydrophilic but become hydrophobic as they adsorb hydrocarbons

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Our results demonstrate that both physisorption and chemisorption occur on the surface

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The adsorption of hydrocarbons was confirmed by multiple surface chemistry analysis

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Our work offers a better fundamental understanding of the intrinsic wettability of REO

Robust and durable liquid-repellent surfaces

This review provides a comprehensive summary of characterization, design, fabrication, and application of robust and durable liquid-repellent surfaces.

Role of Thin Film Adhesion on Capillary Peeling

The capillary force can peel off a substrate-attached film if the adhesion energy (G_w) is low. Capillary peeling has been used as a convenient, rapid, and nondestructive method for fabricating free-standing thin films. However, the critical value of G_w, which leads to the transition between peeling and sticking, remains largely unknown. As a result, capillary peeling remains empirical and applicable to a limited set of materials. Here, we investigate the critical value of G_w and experimentally show the critical adhesion (G_w,c) to scale with the water-film interfacial energy (≈0.7γ_fw), which corresponds well with our theoretical prediction of G_w,c = γ_fw. Based on the critical adhesion, we propose quantitative thermodynamic guidelines for designing thin film interfaces that enable successful capillary peeling. The outcomes of this work present a powerful technique for thin film transfer and advanced nanofabrication in flexible photovoltaics, battery materials, biosensing, translational medicine, and stretchable bioelectronics.

Dropwise condensation: From fundamentals of wetting, nucleation, and droplet mobility to performance improvement by advanced functional surfaces

As a ubiquitous vapor-liquid phase-change process, dropwise condensation has attracted tremendous research attention owing to its remarkable efficiency of energy transfer and transformative industrial potential. In recent years, advanced functional surfaces, profiting from great progress in modifying micro/nanoscale features and surface chemistry on surfaces, have led to exciting advances in both heat transfer enhancement and fundamental understanding of dropwise condensation. In this review, we discuss the development of some key components for achieving performance improvement of dropwise condensation, including surface wettability, nucleation, droplet mobility, and growth, and discuss how they can be elaborately controlled as desired using surface design. We also present an overview of dropwise condensation heat transfer enhancement on advanced functional surfaces along with the underlying mechanisms, such as jumping condensation on nanostructured superhydrophobic surfaces, and new condensation characteristics (e.g., Laplace pressure-driven droplet motion, hierarchical condensation, and sucking flow condensation) on hierarchically structured surfaces. Finally, the durability, cost, and scalability of specific functional surfaces are focused on for future industrial applications. The existing challenges, alternative strategies, as well as future perspectives, are essential in the fundamental and applied aspects for the practical implementation of dropwise condensation.

Ultra-thin self-healing vitrimer coatings for durable hydrophobicity

Durable hydrophobic materials have attracted considerable interest in the last century. Currently, the most popular strategy to achieve hydrophobic coating durability is through the combination of a perfluoro-compound with a mechanically robust matrix to form a composite for coating protection. The matrix structure is typically large (thicker than 10 μm), difficult to scale to arbitrary materials, and incompatible with applications requiring nanoscale thickness such as heat transfer, water harvesting, and desalination. Here, we demonstrate durable hydrophobicity and superhydrophobicity with nanoscale-thick, perfluorinated compound-free polydimethylsiloxane vitrimers that are self-healing due to the exchange of network strands. The polydimethylsiloxane vitrimer thin film maintains excellent hydrophobicity and optical transparency after scratching, cutting, and indenting. We show that the polydimethylsiloxane vitrimer thin film can be deposited through scalable dip-coating on a variety of substrates. In contrast to previous work achieving thick durable hydrophobic coatings by passively stacking protective structures, this work presents a pathway to achieving ultra-thin (thinner than 100 nm) durable hydrophobic films.

Nanostructured jumping-droplet thermal rectifier

Analogous to an electrical rectifier, a thermal rectifier (TR) can ensure that heat flows in a preferential direction. In this paper, thermal transport nonlinearity is achieved through the development of a phase-change based TR comprising an enclosed vapor chamber having separated nanostructured copper oxide superhydrophobic and superhydrophilic functional surfaces. In the forward direction, heat transfer is facilitated through evaporation on the superhydrophilic surface and self-propelled jumping-droplet condensation on the superhydrophobic surface. In the reverse direction, heat transfer is minimized due to condensate film formation within the superhydrophilic condenser and inability to return the condensed liquid to the superhydrophobic evaporator. We examine the coupled effects of gap size, coolant mass, heat transfer rate, and applied electric field on the thermal performance of the TR. A maximum thermal diodicity, defined as the ratio of forward to reverse heat transfer, of 39 is achieved.

Vapor-deposited functional polymer thin films in biological applications

Functional polymer coatings have become ubiquitous in biological applications, ranging from biomaterials and drug delivery to manufacturing-scale separation of biomolecules using functional membranes. Recent advances in the technology of chemical vapor deposition (CVD) have enabled precise control of the polymer chemistry, coating thickness, and conformality. That comprehensive control of surface properties has been used to elicit desirable interactions at the interface between synthetic materials and living organisms, making vapor-deposited functional polymers uniquely suitable for biological applications. This review captures the recent technological development in vapor-deposited functional polymer coatings, highlighting their biological applications, including membrane-based bio-separations, biosensing and bio-MEMS, drug delivery, and tissue engineering. The conformal nature of vapor-deposited coatings ensures uniform coverage over micro- and nano-structured surfaces, allowing the independent optimization of surface and bulk properties. The substrate-independence of CVD techniques enables facile transfer of surface characteristics among different applications. The vapor-deposited functional polymer thin films tend to be biocompatible because they are free of remnant toxic solvents and precursor molecules, potentially lowering the barrier to clinical success.

Breaking Droplet Jumping Energy Conversion Limits with Superhydrophobic Microgrooves

Coalescence-induced droplet jumping has the potential to enhance the performance of a variety of applications including condensation heat transfer, surface self-cleaning, anti-icing, and defrosting to name a few. Here, we study droplet jumping on hierarchical microgrooved and nanostructured smooth superhydrophobic surfaces. We show that the confined microgroove structures play a key role in tailoring droplet coalescence hydrodynamics, which in turn affects the droplet jumping velocity and energy conversion efficiency. We observed self-jumping of individual deformed droplets within microgrooves having maximum surface-to-kinetic energy conversion efficiency of 8%. Furthermore, various coalescence-induced jumping modes were observed on the hierarchical microgrooved superhydrophobic surface. The microgroove structure enabled high droplet jumping velocity (≈0.74U) and energy conversion efficiency (≈46%) by enabling the coalescence of deformed droplets in microgrooves with undeformed droplets on adjacent plateaus. The jumping velocity and energy conversion efficiency enhancements are 1.93× and 6.67× higher than traditional coalescence-induced droplet jumping on smooth superhydrophobic surfaces. This work not only demonstrates high droplet jumping velocity and energy conversion efficiency but also demonstrates the key role played by macroscale structures on coalescence hydrodynamics and elucidates a method to further control droplet jumping physics for a plethora of applications.