Surfaces with combined microscale and nanoscale structures: a route to mechanically stable superhydrophobic surfaces?

Superhydrophobic Non-Metallic Surfaces with Multiscale Nano/Micro-Structure: Fabrication and Application

Multiscale nano/micro-structured surfaces with superhydrophobicity are abundantly observed in nature such as lotus leaves, rose petals and butterfly wings, where microstructures typically reinforce mechanical stability, while nanostructures predominantly govern wettability. To emulate such hierarchical structures in nature, various methods have been widely applied in the past few decades to the manufacture of multiscale structures which can be applied to functionalities ranging from anti-icing and water-oil separation to self-cleaning. In this review, we highlight recent advances in nano/micro-structured superhydrophobic surfaces, with particular focus on non-metallic materials as they are widely used in daily life due to their lightweight, abrasion resistance and ease of processing properties. This review is organized into three sections. First, fabrication methods of multiscale hierarchical structures are introduced with their strengths and weaknesses. Second, four main application areas of anti-icing, water-oil separation, anti-fog and self-cleaning are overviewed by assessing how and why multiscale structures need to be incorporated to carry out their performances. Finally, future directions and challenges for nano/micro-structured surfaces are presented.

Designing Versatile Superhydrophilic Structures via an Alginate-Based Hydrophilic Plasticene

The rational design of superhydrophilic materials with a controllable structure is a critical component in various applications, including solar steam generation, liquid spontaneous transport, etc. The arbitrary manipulation of the 2D, 3D, and hierarchical structures of superhydrophilic substrates is highly desirable for smart liquid manipulation in both research and application fields. To design versatile superhydrophilic interfaces with various structures, here we introduce a hydrophilic plasticene that possesses high flexibility, deformability, water absorption, and crosslinking capabilities. Through a pattern-pressing process with a specific template, 2D prior fast spreading of liquids at speeds up to 600 mm/s was achieved on the superhydrophilic surface with designed channels. Additionally, 3D superhydrophilic structures can be facilely designed by combining the hydrophilic plasticene with a 3D-printed template. The assembly of 3D superhydrophilic microstructure arrays were explored, providing a promising route to facilitate the continuous and spontaneous liquid transport. The further modification of superhydrophilic 3D structures with pyrrole can promote the applications of solar steam generation. The optimal evaporation rate of an as-prepared superhydrophilic evaporator reached ~1.60 kg·m^-2·h^-1 with a conversion efficiency of approximately 92.96%. Overall, we envision that the hydrophilic plasticene should satisfy a wide range of requirements for superhydrophilic structures and update our understanding of superhydrophilic materials in both fabrication and application.

Arylazopyrazole-Modified Thiolactone Acrylate Copolymer Brushes for Tuneable and Photoresponsive Wettability of Glass Surfaces

Photoswitches have long been employed in coatings for surfaces and substrates to harness light as a versatile stimulus to induce responsive behavior. We previously demonstrated the viability of arylazopyrazole (AAP) as a photoswitch in self-assembled monolayers (SAMs) on silicon and glass surfaces for photoresponsive wetting applications. We now aim to transfer the excellent photophysical properties of AAPs to polymer brush coatings. Compared to SAMs, polymer brushes offer enhanced stability and an increase of the thickness and density of the functional organic layer. In this work, we present thiolactone acrylate copolymer brushes which can be post-modified with AAP amines as well as hydrophobic acrylates, making use of the unique chemistry of the thiolactones. This strategy enables photoresponsive wetting with a tuneable range of contact angle change on glass substrates. We show the successful synthesis of thiolactone hydroxyethyl acrylate copolymer brushes by means of surface-initiated atom-transfer radical polymerization with the option to either prepare homogeneous brushes or to prepare micrometer-sized brush patterns by microcontact printing. The polymer brushes were analyzed by atomic force microscopy, time-of-flight secondary ion spectrometry, and X-ray photoelectron spectroscopy. Photoresponsive behavior imparted to the brushes by means of post-modification with AAP is monitored by UV/vis spectroscopy, and wetting behavior of homogeneous brushes is measured by static and dynamic contact angle measurements. The brushes show an average change in static contact angle of around 13° between E and Z isomer of the AAP photoswitch for at least five cycles, while the range of contact angle change can be fine-tuned between 53.5°/66.5° (E/Z) and 81.5°/94.8° (E/Z) by post-modification with hydrophobic acrylates.

Bio-inspired and metal-derived superwetting surfaces: Function, stability and applications

Due to their exceptional anti-icing, anti-corrosion, and anti-drag qualities, biomimetic metal-derived superwetting surfaces, which are widely employed in the aerospace, automotive, electronic, and biomedical industries, have raised significant concern. However, further applications in other domains have been hampered by the poor mechanical and chemical durability of superwetting metallic surfaces, which can result in metal fatigue and corrosion. The potential for anti-corrosion, anti-contamination, anti-icing, oil/water separation, and oil transportation on surfaces with superwettability has increased in recent years due to the advancement of research in biomimetic superwetting interface theory and practice. Recent developments in functionalized biomimetic metal-derived superwetting surfaces were summarized in this paper. Firstly, a detailed presentation of biomimetic metal-derived superwetting surfaces with unique capabilities was made. The problems with the long-term mechanical and chemical stability of biomimetic metal-derived superwetting surfaces were then examined, along with potential solutions. Finally, in an effort to generate fresh concepts for the study of biomimetic metal-derived superwetting surfaces, the applications of superwetting metallic surfaces in various domains were discussed in depth. The future direction of biomimetic metal-derived superwetting surfaces was also addressed.

Micro-Nano-Nanowire Triple Structure-Held PDMS Superhydrophobic Surfaces for Robust Ultra-Long-Term Icephobic Performance

Anti-icing superhydrophobic surfaces have attracted tremendous interests due to their repellency to water and extremely low ice affinity, whereas the weak durability has been the bottleneck for further applications. Surface durability is especially important in long-term exposure to low-temperature and high-humidity environments. In this study, a robust micro-nano-nanowire triple structure-held PDMS superhydrophobic surface was fabricated via a hybrid process: ultrafast-laser-prepared periodic copper microstructures were chemically oxidized, followed by modification of PDMS. The hedgehog-like surface structure was composed of microcones, densely grown nanowires, and tightly combined PDMS. The capillary force difference in micro-nanostructures drove PDMS solutions to distribute evenly, bonding fragile nanowires to form stronger composite cones. PDMS replaced the commonly used fragile fluorosilanes and protected nanowires from breaking, which endowed the surfaces with higher robustness. The ductile PDMS-nanowire composites possessed higher resiliency than brittle nanowires under a load of 1 mN. The surface kept superhydrophobic and ice-resistant after 15 linear abrasion cycles under 1.2 kPa or 60 icing-deicing cycles under -20 °C or 500 tape peeling cycles. Under a higher pressure of 6.2 kPa, the contact angle (CA) was maintained above 150° until the abrasion distance exceeded 8 m. In addition, the surface exhibited a rare spontaneously optimized performance in the icing-deicing cycles. The ice adhesion strength of the surface reached its lowest value of 12.2 kPa in the 16th cycle. Evolution of surface roughness and morphology were combined to explain its unique U-shaped performance curves, which distinguished its unique degradation process from common surfaces. Thus, this triple-scale superhydrophobic surface showed a long-term anti-icing performance with high deicing robustness and low ice adhesion strength. The proposed nanostructure-facilitated uniform distribution strategy of PDMS is promising in future design of durable superhydrophobic anti-icing surfaces.

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.

One-level microstructure-arrayed hydrophobic surface with low surface adhesion and strong anti-wetting function

To achieve both a low surface adhesion function and a high anti-wetting function, it is generally necessary to introduce multi-level micro-nano-structures on a surface. However, this will bring the difficulty of preparation technology, and the functions will fail due to the fact that the nanostructures can easily be damaged. In this research, the surface adhesion and anti-wetting properties of several typically one-level microstructure-arrayed hydrophobic surfaces are analyzed with the dynamics theory, including a square pillar-arrayed three-dimensional microstructure, a conical table-arrayed microstructure, and square frustum-arrayed microstructure. It is found that the anti-adhesion performance and anti-wetting property cannot achieve the best performance simultaneously on the one-level microstructure arrayed surfaces. Either the critical pressure of anti-wetting is finite when the surface adhesion is the lowest, or both the anti-adhesion and anti-wetting capacities are finite. However, an interesting phenomenon is found in that the square frustum-arrayed surface can not only achieve an almost infinite anti-wetting capacity when the distance between neighboring microstructures vanishes, but also reach near-zero adhesion when the square frustum reduces to a square pyramid. All the theoretical predictions are further verified by precise numerical simulations. The results of this paper should be helpful for the design of surfaces with low surface adhesion and strong anti-wetting functions in practical engineering.

Long-Lived T-Shaped Micropillars with Submicron-Villi on PP/POE Surfaces with Grinding-Enhanced Water Repellency Fabricated via Hot Compression Molding

Superhydrophobic properties are derived from the roughness of the surface of micro/nanostructures and low-surface-energy materials. However, they are both easy to damage on superhydrophobic surfaces after mechanical abrasion in practical applications, resulting in the transition from the Cassie-Baxter state to the Wenzel state and even the loss of water repellency. In this work, the mechanical properties of polypropylene (PP) toughened with poly(ethylene-co-octene) (POE) were improved for the fabrication of long-lived T-shaped micropillars with submicron-villi on top by a combined method of compression molding and grinding. A universal testing machine was modified as equipment for the precise control of the traveling distance of specimens on sandpaper in precise. The PP/POE blend possessed high tensile strength of up to ∼23.84 MPa as well as elongation at break of ∼533.60%. The abrasive grains on sandpaper reshaped their surface morphologies from micropillars to T-shaped microstructures, on which the submicron-villi as secondary structures formed. The abraded microstructured PP/POE surface exhibited the highest contact angle of 154.4° and the most stable wetting state with a bouncing height of 7.68 mm (3.2 times the diameter of the 7-μL droplet) after a traveling distance of 1000 mm on 3000-grit sandpaper among the abraded and unabraded PP/POE surfaces.

Robust superhydrophobicity: mechanisms and strategies

Superhydrophobic surfaces hold great prospects for extremely diverse applications owing to their water repellence property. The essential feature of superhydrophobicity is micro-/nano-scopic roughness to reserve a large portion of air under a liquid drop. However, the vulnerability of the delicate surface textures significantly impedes the practical applications of superhydrophobic surfaces. Robust superhydrophobicity is a must to meet the rigorous industrial requirements and standards for commercial products. In recent years, major advancements have been made in elucidating the mechanisms of wetting transitions, design strategies and fabrication techniques of superhydrophobicity. This review will first introduce the mechanisms of wetting transitions, including the thermodynamic stability of the Cassie state and its breakdown conditions. Then we highlight the development, current status and future prospects of robust superhydrophobicity, including characterization, design strategies and fabrication techniques. In particular, design strategies, which are classified into passive resistance and active regeneration for the first time, are proposed and discussed extensively.

Challenges and Prospects of Bio-Inspired and Multifunctional Transparent Substrates and Barrier Layers for Optoelectronics

Bio-inspiration and advances in micro/nanomanufacturing processes have enabled the design and fabrication of micro/nanostructures on optoelectronic substrates and barrier layers to create a variety of functionalities. In this review article, we summarize research progress in multifunctional transparent substrates and barrier layers while discussing future challenges and prospects. We discuss different optoelectronic device configurations, sources of bio-inspiration, photon management properties, wetting properties, multifunctionality, functionality durability, and device durability, as well as choice of materials for optoelectronic substrates and barrier layers. These engineered surfaces may be used for various optoelectronic devices such as touch panels, solar modules, displays, and mobile devices in traditional rigid forms as well as emerging flexible versions.

Bioadhesion in the oral cavity and approaches for biofilm management by surface modifications

BACKGROUND

All soft and solid surface structures in the oral cavity are covered by the acquired pellicle followed by bacterial colonization. This applies for natural structures as well as for restorative or prosthetic materials; the adherent bacterial biofilm is associated among others with the development of caries, periodontal diseases, peri-implantitis, or denture-associated stomatitis. Accordingly, there is a considerable demand for novel materials and coatings that limit and modulate bacterial attachment and/or propagation of microorganisms.

OBJECTIVES AND FINDINGS

The present paper depicts the current knowledge on the impact of different physicochemical surface characteristics on bioadsorption in the oral cavity. Furthermore, it was carved out which strategies were developed in dental research and general surface science to inhibit bacterial colonization and to delay biofilm formation by low-fouling or "easy-to-clean" surfaces. These include the modulation of physicochemical properties such as periodic topographies, roughness, surface free energy, or hardness. In recent years, a large emphasis was laid on micro- and nanostructured surfaces and on liquid repellent superhydrophic as well as superhydrophilic interfaces. Materials incorporating mobile or bound nanoparticles promoting bacteriostatic or bacteriotoxic properties were also used. Recently, chemically textured interfaces gained increasing interest and could represent promising solutions for innovative antibioadhesion interfaces. Due to the unique conditions in the oral cavity, mainly in vivo or in situ studies were considered in the review.

CONCLUSION

Despite many promising approaches for modulation of biofilm formation in the oral cavity, the ubiquitous phenomenon of bioadsorption and adhesion pellicle formation in the challenging oral milieu masks surface properties and therewith hampers low-fouling strategies.

CLINICAL RELEVANCE

Improved dental materials and surface coatings with easy-to-clean properties have the potential to improve oral health, but extensive and systematic research is required in this field to develop biocompatible and effective substances.

Superhemophobic and Antivirofouling Coating for Mechanically Durable and Wash-Stable Medical Textiles

Medical textiles have a need for repellency to body fluids such as blood, urine, or sweat that may contain infectious vectors that contaminate surfaces and spread to other individuals. Similarly, viral repellency has yet to be demonstrated and long-term mechanical durability is a major challenge. In this work, we demonstrate a simple, durable, and scalable coating on nonwoven polypropylene textile that is both superhemophobic and antivirofouling. The treatment consists of polytetrafluoroethylene (PTFE) nanoparticles in a solvent thermally sintered to polypropylene (PP) microfibers, which creates a robust, low-surface-energy, multilayer, and multilength scale rough surface. The treated textiles demonstrate a static contact angle of 158.3 ± 2.6° and hysteresis of 4.7 ± 1.7° for fetal bovine serum and reduce serum protein adhesion by 89.7 ± 7.3% (0.99 log). The coated textiles reduce the attachment of adenovirus type 4 and 7a virions by 99.2 ± 0.2% and 97.6 ± 0.1% (2.10 and 1.62 log), respectively, compared to noncoated controls. The treated textiles provide these repellencies by maintaining a Cassie-Baxter state of wetting where the surface area in contact with liquids is reduced by an estimated 350 times (2.54 log) compared to control textiles. Moreover, the treated textiles exhibit unprecedented mechanical durability, maintaining their liquid, protein, and viral repellency after extensive and harsh abrasion and washing. The multilayer, multilength scale roughness provides for mechanical durability through self-similarity, and the samples have high-pressure stability with a breakthrough pressure of about 255 kPa. These properties highlight the potential of durable, repellent coatings for medical gowning, scrubs, or other hygiene textile applications.

Crack growth-driven wettability transition on carbon black/polybutadiene nanocomposite coatings via stretching

Ordered topography patterns with a mechanical response are usually designed to achieve wettability switching by geometric parameter changes through mechanical stimuli. However, their fabrication often needs expensive and complicated micro/nano-fabrication processing (e.g. photolithography and ion etching). In this study, a nano-carbon black (CB)/polybutadiene (PB) coating with a Wenzel superhydrophobic state was prepared on a rubber substrate by a facile method combining solution mixing and spraying coating. By stretching the composite coating, the generated cracks divided the continuous coating into new micro-nano mastoids, resulting in the formation of new hierarchical roughness for Cassie superhydrophobicity. The Wenzel-to-Cassie transition behavior was dependent on the CB loading in the coating. During stretching, the cracks propagated more rapidly in the coating with higher CB loading and induced the desired hierarchical structure to consequently enable the Wenzel-to-Cassie transition earlier at a lower stretching strain. The stretched coating presented good anti-wetting (a sliding angle of 5°) and low water adhesion. After releasing, the coating returned to its original Wenzel state by structure recovery. Thus, the switchable wettability of the coating can be adopted for no-loss water droplet transfer by controlling the droplet adhesion through cyclic stretching-releasing, and exhibits good potential for microfluidic and biomedical applications.

One-Step Aqueous Spraying Process for the Fabrication of Omniphobic Fabrics Free of Long Perfluoroalkyl Chains

We report on a simple and versatile method for the preparation in one-step of omniphobic textiles, using only aqueous suspensions of silica particles and polyurethane devoid of long perfluoroalkyl chains (C8) that are now legally-banned because of severe environmental concerns. The omniphobic coatings can be applied on different substrates including fabrics, can resist acidic and basic conditions and a moderate number of washing cycles, and repel liquids such as n-octane, dodecane, hexadecane, ethylene glycol, glycerol, olive oil, and water. Analysis of the wetting properties of coated fabrics indicates that the liquid repellence results from the trapping of air in the re-entrant roughness created by aggregates of silica particles, together with the low surface tension of the polyurethane which bears legally accepted short perfluoroalkyl chains (C4). Our study is a significant step forward toward achieving more environmentally-friendly and robust omniphobic textiles.

Hierarchical Structures for Superhydrophobic and Superoleophobic Surfaces

Many surfaces possessing robust super liquid repellency are hierarchically structured on the nano- and micrometer scales. Several examples are found in nature, such as the self-cleaning leaves of lotus plants and anisotropic, water-guiding rice leaves. Each surface design has unique properties optimized for specific wetting conditions. In this invited feature article, we review both natural and artificial hierarchical surface structures and their function in repelling liquids. We discuss different types of structures needed in various wetting situations and draw some general conclusions as a guideline for designing robust superhydrophobic and superoleophobic surfaces.

Electric field mediated elastic contact lithography of thin viscoelastic films for miniaturized and multiscale patterns

Elastic contact lithography (ECL) and electric field lithography (EFL) have both shown significant potential to develop large-area micropatterns on polymeric surfaces. Recently, the major challenges associated with these processes have been the improvement of the aspect ratio and reduction in the size and periodicity of the patterns fabricated. Herein, with the help of non-linear simulations, we show that combining these methods can be one recipe to overcome these limitations. We consider a linear viscoelastic film for the linear and non-linear analyses. In this regard, we explore the role of the moving contactor to improve the aspect ratio of the patterns. The study uncovers that (i) combined destabilizing influences originating from van der Waals and electric field forces ensure smaller timescales and length scales for the instabilities, (ii) the aid from the electric field helps to improve the minimum separation distance so that the contact instability initiates at a larger separation distance, (iii) a long-range ordering can be inflicted on the patterns on the polymer surfaces when electrodes with periodic physicochemical patterns are used and (iv) the strength of the externally applied electric field and the ratio of elastic to viscous compliance of the film play crucial roles in deciding the different modes of debonding of the film - peeling, catastrophic or coalescence. The proposed method can improve the aspect ratio of patterns by ∼9-fold during the peeling mode of debonding. Furthermore, pathways to develop technologically important biomimetic surfaces with multiscale and hierarchical structures have been shown.

Environmentally Friendly Super-Water-Repellent Fabrics Prepared from Water-Based Suspensions

We report on a facile, versatile, and environmentally friendly method to prepare superhydrophobic fabrics by a simple dip-coating method in water-based suspensions and emulsions. All the materials used are fluorine-free and commercially available at a large scale. The method can be easily integrated into standard textile industrial processes and has a strong potential for the mass production of environmentally friendly superwater-repellent fabrics. The produced fabrics show good resistance to machine washing and acidic or alkaline treatments. In addition, it is shown that superhydrophobicity can be quantitatively predicted based on the combination of the roughness of the fabric and of the fiber coating.

Molting Materials: Restoring Superhydrophobicity after Severe Damage via Snakeskin-like Shedding

The nanostructures that are required to generate superhydrophobic surfaces are always sensitive to shear and are easily damaged, especially by scratching with sharp objects. As a result of this destruction, the water repellency will be lost. We introduce a novel approach to restoring the original surface properties after mechanical damage. In this approach, the damaged layer is shed like the skin of a snake. This is demonstrated with a three-layer stack as a proof-of-principle system: when the original, superhydrophobic surface layer is damaged, this leads to the dissolution of a sacrificial layer below it. Thus, the damaged layer is shed, a new unscathed surface is uncovered, and superhydrophobicity can easily be restored after a short washing.

Highly Stretchable Superhydrophobic Composite Coating Based on Self-Adaptive Deformation of Hierarchical Structures

With the rapid development of stretchable electronics, functional textiles, and flexible sensors, water-proof protection materials are required to be built on various highly flexible substrates. However, maintaining the antiwetting of superhydrophobic surface under stretching is still a big challenge since the hierarchical structures at hybridized micro-nanoscales are easily damaged following large deformation of the substrates. This study reports a highly stretchable and mechanically stable superhydrophobic surface prepared by a facile spray coating of carbon black/polybutadiene elastomeric composite on a rubber substrate followed by thermal curing. The resulting composite coating can maintain its superhydrophobic property (water contact angle ≈170° and sliding angle <4°) at an extremely large stretching strain of up to 1000% and can withstand 1000 stretching-releasing cycles without losing its superhydrophobic property. Furthermore, the experimental observation and modeling analysis reveal that the stable superhydrophobic properties of the composite coating are attributed to the unique self-adaptive deformation ability of 3D hierarchical roughness of the composite coating, which delays the Cassie-Wenzel transition of surface wetting. In addition, it is first observed that the damaged coating can automatically recover its superhydrophobicity via a simple stretching treatment without incorporating additional hydrophobic materials.

Multifunctional Nano-engineered Polymer Surfaces with Enhanced Mechanical Resistance and Superhydrophobicity

This paper presents a multifunctional polymer surface that provides superhydrophobicity and self–cleaning functions together with an enhancement in mechanical and electrical performance. These functionalities are produced by nanoimprinting high aspect ratio pillar arrays on polymeric matrix incorporating functional reinforcing elements. Two distinct matrix-filler systems are investigated specifically, Carbon Nanotube reinforced Polystyrene (CNT-PS) and Reduced Graphene Oxide reinforced Polyvinylidene Difluoride (RGO-PVDF). Mechanical characterization of the topographies by quantitative nanoindentation and nanoscratch tests are performed to evidence a considerable increase in stiffness, Young’s modulus and critical failure load with respect to the pristine polymers. The improvement on the mechanical properties is rationalized in terms of effective dispersion and penetration of the fillers into the imprinted structures as determined by confocal Raman and SEM studies. In addition, an increase in the degree of crystallization for the PVDF-RGO imprinted nanocomposite possibly accounts for the larger enhancement observed. Improvement of the mechanical ruggedness of functional textured surfaces with appropriate fillers will enable the implementation of multifunctional nanotextured materials in real applications.

Multifunctional hollow superhydrophobic SiO2 microspheres with robust and self-cleaning and separation of oil/water emulsions properties

Superhydrophobic materials have drawn great attention due to its' remarkable non-wetting properties and applications in many fields. In this paper, we synthesize a hollow superhydrophobic SiO₂ powder by typical template method and self-assembly functionalization. Robustness of many superhydrophobic surfaces has become the development bottleneck for industrial applications. Aiming at this problem, the adhesive epoxy resin is specially taken to use as the binding layer between superhydrophobic SiO₂ powder and substrates to create robust superhydrophobic coating. The mechanical durability of the obtained superhydrophobic coating is evaluated by a cyclic sandpaper abrasion. Also, the chemical stability of this superhydrophobic coating is assessed by exposuring it to different pH conditions and UV irradiation, respectively. Significantly, because of the special structure and superhydrophobicity/superoleophilicity of the hollow microspheres, these hollow superhydrophobic SiO₂ powders manifest great oil-adsorbing capacity, which thus can be used to separate oil/water mixtures and remove oil from oil-in-water emulsions.

Bio-inspired hierarchically structured polymer fibers for anisotropic non-wetting surfaces

A rice leaf-like hierarchically textured polymer fiber arrays for anisotropic non-wetting surfaces.

A Robust Epoxy Resins @ Stearic Acid-Mg(OH)2 Micronanosheet Superhydrophobic Omnipotent Protective Coating for Real-Life Applications

Superhydrophobic coating has extremely high application value and practicability. However, some difficult problems such as weak mechanical strength, the need for expensive toxic reagents, and a complex preparation process are all hard to avoid, and these problems have impeded the superhydrophobic coating's real-life application for a long time. Here, we demonstrate one kind of omnipotent epoxy resins @ stearic acid-Mg(OH)2 superhydrophobic coating via a simple antideposition route and one-step superhydrophobization process. The whole preparation process is facile, and expensive toxic reagents needed. This omnipotent coating can be applied on any solid substrate with great waterproof ability, excellent mechanical stability, and chemical durability, which can be stored in a realistic environment for more than 1 month. More significantly, this superhydrophobic coating also has four protective abilities, antifouling, anticorrosion, anti-icing, and flame-retardancy, to cope with a variety of possible extreme natural environments. Therefore, this omnipotent epoxy resins @ stearic acid-Mg(OH)2 superhydrophobic coating not only satisfies real-life need but also has great application potential in many respects.

Recent advances in the mechanical durability of superhydrophobic materials

Large majority of superhydrophobic surfaces have very limited mechanical wear robustness and long-term durability. This problem has restricted their utilization in commercial or industrial applications and resulted in extensive research efforts on improving resistance against various types of wear damage. In this review, advances and developments since 2011 in this field will be covered. As such, we summarize progress on fabrication, design and understanding of mechanically durable superhydrophobic surfaces. This includes an overview of recently published diagnostic techniques for probing and demonstrating tribo-mechanical durability against wear and abrasion as well as other effects such as solid/liquid spray or jet impact and underwater resistance. The review is organized in terms of various types of mechanical wear ranging from substrate adhesion, tangential surface abrasion, and dynamic impact to ultrasonic processing underwater. In each of these categories, we highlight the most successful approaches to produce robust surfaces that can maintain their non-wetting state after the wear or abrasive action. Finally, various recommendations for improvement of mechanical wear durability and its quantitative evaluation are discussed along with potential future directions towards more systematic testing methods which will also be acceptable for industry.

Fabrication of superhydrophobic fiber fabric/epoxy composites coating on aluminum substrate with long-lived wear resistance

A superhydrophobic coating with long-lived wear resistance was successfully prepared by integrating the hydrophobization of cotton fiber fabric and the curing of epoxy composites.

P. Mechanically stable superhydrophobic polymer films by a simple hot press lamination and peeling process

Mechanically stable superhydrophobic PP/UHMWPE polymer blend films prepared by a simple and facile hot-press lamination and peeling method.

Surface forces: surface roughness in theory and experiment

A method of incorporating surface roughness into theoretical calculations of surface forces is presented. The model contains two chief elements. First, surface roughness is represented as a probability distribution of surface heights around an average surface height. A roughness-averaged force is determined by taking an average of the classic flat-surface force, weighing all possible separation distances against the probability distributions of surface heights. Second the model adds a repulsive contact force due to the elastic contact of asperities. We derive a simple analytic expression for the contact force. The general impact of roughness is to amplify the long range behaviour of noncontact (DLVO) forces. The impact of the elastic contact force is to provide a repulsive wall which is felt at a separation between surfaces that scales with the root-mean-square (RMS) roughness of the surfaces. The model therefore provides a means of distinguishing between "true zero," where the separation between the average centres of each surface is zero, and "apparent zero," defined by the onset of the repulsive contact wall. A normal distribution may be assumed for the surface probability distribution, characterised by the RMS roughness measured by atomic force microscopy (AFM). Alternatively the probability distribution may be defined by the histogram of heights measured by AFM. Both methods of treating surface roughness are compared against the classic smooth surface calculation and experimental AFM measurement.

Mechanically robust superhydrophobic steel surface with anti-icing, UV-durability, and corrosion resistance properties

A superhydrophobic steel surface was prepared through a facile method: combining hydrogen peroxide and an acid (hydrochloric acid or nitric acid) to obtain hierarchical structures on steel, followed by a surface modification treatment. Empirical grid maps based on different volumes of H2O2/acid were presented, revealing a wettability gradient from "hydrophobic" to "rose effect" and finally to "lotus effect". Surface grafting has been demonstrated to be realized only on the oxidized area. As-prepared superhydrophobic surfaces exhibited excellent anti-icing properties according to the water-dripping test under overcooled conditions and the artificial "steam-freezing" (from 50 °C with 90% humidity to the -20 °C condition) test. In addition, the surfaces could withstand peeling with 3M adhesive tape at least 70 times with an applied pressure of 31.2 kPa, abrasion by 400 grid SiC sandpaper for 110 cm under 16 kPa, or water impacting for 3 h without losing superhydrophobicity, suggesting superior mechanical durability. Moreover, outstanding corrosion resistance and UV-durability were obtained on the prepared surface. This successful fabrication of a robust, anti-icing, UV-durable, and anticorrosion superhydrophobic surface could yield a prospective candidate for various practical applications.

Functional superhydrophobic surfaces made of Janus micropillars

We demonstrate the fabrication of superhydrophobic surfaces consisting of micropillars with hydrophobic sidewalls and hydrophilic tops, referred to as Janus micropillars. Therefore we first coat a micropillar array with a mono- or bilayer of polymeric particles, and merge the particles together to shield the top faces while hydrophobizing the walls. After removing the polymer film, the top faces of the micropillar arrays can be selectively chemically functionalised with hydrophilic groups. The Janus arrays remain superhydrophobic even after functionalisation as verified by laser scanning confocal microscopy. The robustness of the superhydrophobic behaviour proves that the stability of the entrapped air cushion is determined by the forces acting at the rim of the micropillars. This insight should stimulate a new way of designing super liquid-repellent surfaces with tunable liquid adhesion. In particular, combining superhydrophobicity with the functionalisation of the top faces of the protrusions with hydrophilic groups may have exciting new applications, including high-density microarrays for high-throughput screening of bioactive molecules, cells, or enzymes or efficient water condensation. However, so far chemical attachment of hydrophilic molecules has been accompanied with complete wetting of the surface underneath. The fabrication of superhydrophobic surfaces where the top faces of the protrusions can be selectively chemically post-functionalised with hydrophilic molecules, while retaining their superhydrophobic properties, is both promising and challenging.

Mechanical stability of surface architecture--consequences for superhydrophobicity

Wet chemistry methods such as sol-gel provide a facile means of preparing coatings with controlled surface chemistry and architecture. The manipulation of colloidal "building blocks," film constituents, and reaction conditions makes it a promising method for simple, scalable, and routine production of superhydrophobic coatings. Despite all of this, the practical application of superhydrophobic coatings remains limited by low mechanical durability. The translation of chemistry to mechanical strength within superhydrophobic films is severely hindered by the requisite physical structure. More specifically, porosity and the surface architecture of roughness in sol-gel-derived films contribute significantly to poor mechanical properties. These physical effects emphasize that collective structure and chemistry-based strategies are required. This challenge is not unique to superhydrophobics, and there are many principles that can be drawn upon to greatly improve performance. The delicate interplay between chemistry and physical structure has been highlighted through theory and characterization of porous and rough interfaces within and outside the framework of superhydrophobics. Insights can further be drawn from biology. Nature's capacity for self-repair remains extremely challenging to mimic in materials. However, nature does demonstrate strategies for structuring nano- and microbuilding blocks to achieve generally mutually exclusive properties. Difficulties with characterization and example mechanical characterization methods have also been emphasized.

Study of transitions between wetting states on microcavity arrays by optical transmission microscopy

In this article, we present a simple and fast optical method based on transmission microscopy to study the stochastic wetting transitions on micro- and nanostructured polymer surfaces immersed in water. We analyze the influence of immersion time and the liquid pressure on the degree of water intrusion in individual microcavities on these surfaces as well as the lifespan of their superhydrophobicity. We show that transitions among the three wetting states (Cassie, Cassie-impregnating, and Wenzel) occur with a certain pressure threshold (300 mbar for a microcavity diameter of 7.5 μm). Below this threshold, the transitions between the Cassie and the Cassie-impregnating states are reversible, whereas above this threshold, irreversible transitions to the Wenzel state start to occur. The transitions between the different wetting states can be explained by taking into account both the Young-Laplace equation for the water menisci in the cavities and the diffusion of dissolved gas molecules in the water. In addition, the wetting transitions had a stochastic nature, which resulted from the short diffusion distance for dissolved gas molecules in the water between neighboring cavities. Furthermore, we compared the contact angle properties of two polymeric materials (COC and PP) with moderate hydrophobicity. We attributed the difference in the water repellency of the two materials to a difference in the wetting of their nanostructures. Our experimental observations thus indicate that both the diffusion of gas molecules in water and the wetting properties of nanostructures are important for understanding the sustainability of superhydrophobicity of surfaces under water and for improving the structural design of superhydrophobic surfaces.

Microcones and nanograss: toward mechanically robust superhydrophobic surfaces

We describe the generation of mechanically robust superhydrophobic surfaces, which carry a hierarchical roughness that is composed of silicon microcones and silicon nanograss. Both micro and nanostructures were fabricated using mask-free dry etching processes. The microcones were obtained utilizing a cryogenic deep reactive ion etching (DRIE) process run in the overpassivation regime. By varying process parameters, surfaces with different microcones geometries and densities were achieved. The nanograss was fabricated using a modified DRIE process with alternating etching and passivation cycles ('BOSCH process'). All surfaces were covered with a layer of a fluorinated film so that superhydrophobic structures resulted. Depending on microcone geometry and density, the advancing contact angle ranged between 170° and 180°, and roll-off angles of 10 μL drops between 30' (0.5°) and 6° were observed. The samples were exposed to varying shear loads, and the changes in the morphology were recorded by using electron microscopy. The wetting angles of the mechanically challenged surfaces were recorded and correlated with the mechanical properties of the samples.

Mechanically robust superhydrophobic polymer surfaces based on protective micropillars

Considerable attention is currently being devoted less to the question of whether it is possible to produce superhydrophobic polymer surfaces than to just how robust they can be made. The present study demonstrates a new route for improving the mechanical durability of water-repellent structured surfaces. The key idea is the protection of fragile fine-scale surface topographies against wear by larger scale sacrificial micropillars. A variety of surface patterns was manufactured on polypropylene using a microstructuring technique and injection molding. The surfaces subjected to mechanical pressure and abrasive wear were characterized by water contact and sliding angle measurements as well as by scanning electron microscopy and roughness analysis based on optical profilometry. The superhydrophobic polypropylene surfaces with protective structures were found to maintain their wetting properties in mechanical compression up to 20 MPa and in abrasive wear tests up to 120 kPa. For durable properties, the optimal surface density of the protective pillars was found to be about 15%. The present approach to the production of water-repellent polymer surfaces provides the advantages of mass production and mechanical robustness with practical applications of structurally functionalized surfaces.

Mechanically robust superamphiphobic aluminum surface with nanopore-embedded microtexture

A simple fabrication technique was developed for preparing a mechanically robust superamphiphobic surface on an aluminum (Al) plate. Dual geometric architectures with micro- and nanoscale structures were formed on the surface of the Al plate by a combination of simple chemical etching and anodization. This proposed methodology involves (1) fabrication of irregular microscale plateaus on the surface of the Al plate, (2) formation of nanopores, and (3) fluorination. Wettability measurements indicated that the fabricated Al surface became super-repellent toward a broad range of liquids with surface tension in the range 27.5-72 mN/m. By varying the anodization time, we measured and compared the effects of morphological change on the wettability. The adhesion property and mechanical durability of the fabricated superamphiphobic Al surface were evaluated by the Scotch tape and hardness tests, respectively. The results showed that the fabricated Al surface retained mechanical robustness because the down-directed surface made by nanopores on the microtextured surface was durable enough even after high force was applied. Almost no damage of the film was observed, and the surface still exhibited superamphiphobicity after the tests. The fabricated superamphiphobic surface also remained stable after long-term storage. The simple and time-saving fabrication technique can be extended to any large-area three-dimensional surface, making it potentially suitable for large-scale industrial fabrications of mechanically robust superamphiphobic surfaces.