Controlling condensation and frost growth with chemical micropatterns

Multi-Scale Superhydrophobic Surface with Excellent Stability and Solar-Thermal Performance for Highly Efficient Anti-Icing and Deicing

Ice accretion can significantly impact the efficiency and safety of outdoor equipment. Solar-thermal superhydrophobic surface is an effective strategy for anti-icing and deicing. However, droplets easily turn to the Wenzel state during the icing and melting cycle processes, significantly increasing the adhesion and making the droplets difficult to remove from the surface. In this work, a triple-scale solar-thermal superhydrophobic surface is prepared on stainless steel 304 by etching, in situ oxidation, and spin-coating TiN nanoparticles for highly efficient deicing and anti-icing. The multi-scale structure enabled the droplets to recover the Cassie state completely after melting. The contact angle decreased from 162.5° to 136.7° during the icing process and gradually increased to 162.1° during the melting process. In addition, metal oxides and TiN nanoparticles enabled the superhydrophobic surface to exhibit a high solar absorptivity (α ¯ solar ${{\bar{\alpha }}_{{\mathrm{solar}}}}$ = 0.925). The synergistic effect of the superhydrophobicity and the solar-thermal performance endowed the designed multi-scale surface with excellent anti-icing and deicing performance. This work contributed to the practical development of anti-icing and deicing applications based on solar-thermal superhydrophobic surfaces.

Role of Molecular Water Layer State on Freezing Front Propagation Rate and Mode Studied with Thermal Imaging

In this work, we study the relationship between the molecular water layer (MWL) and frost freezing onset and propagation. The progression of frost has been reported to be governed by various localized icing phenomena, including interdroplet ice bridging, dry zones, and frost halos. Reports studying the state of water on surfaces have revealed the presence of a thin nanometer water layer on a range of surfaces. Regardless of further investigations that show environmental humidity, temperature, and surface energy to affect the thickness of the MWL on surfaces, the influence of the MWL on frost nucleation and propagation has not yet been previously addressed in the literature. To study the effect of the MWL on surface freezing events, a range of surface-functionalized glass substrates were prepared. In situ monitoring of freezing events with thermal imaging allowed studying the effect of surface chemistry and environmental relative humidity (RH) on the thickness and continuity of the MWL. We argue that the observed icing nucleation and propagation kinetics are directly related to the presence and continuity of the MWL, which can be manipulated by controlling the environmental humidity and surface chemistry.

Controlled condensation by liquid contact-induced adaptations of molecular conformations in self-assembled monolayers

Surface condensation control strategies are crucial but commonly require relatively tedious, time-consuming, and expensive techniques for surface-chemical and topographical engineering. Here we report a strategy to alter surface condensation behavior without resorting to any molecule-type or topographical transmutations. After ultrafast contact of liquids with and removal from surfaces, the condensation rate and density of water droplets on the surfaces decrease, the extent of which is positively correlated with the polarity of the liquid and the duration of contact. The liquid contact-induced condensation rate/density decrease (LCICD) can be attributed to the decrease of nucleation site density resulted from the liquid contact-induced adaption of surface molecular conformation. Based on this, we find that LCICD is applicable to various surfaces, on condition that there are flexible segments capable of shielding at least part of nucleation sites through changing the conformation under liquid contact induction. Leveraging the LCICD effect, we achieve erasable information storage on diverse substrates. Furthermore, our strategy holds promise for controlling condensation of other substances since LCICD is not specific to the water condensation process.

Icephobic Gradient Polymer Coatings Deposited via iCVD: A Novel Approach for Icing Control and Mitigation

Materials against ice formation and accretion are highly desirable for different industrial applications and daily activities affected by icing. Although several concepts have been proposed, no material has so far shown wide-ranging icephobic features, enabling durability and manufacturing on large scales. Herein, we present gradient polymers made of 1,3,5,7-tetravinyl-1,3,5,7-tetramethylcyclotetrasiloxane (V4D4) and 1H,1H,2H,2H-perfluorodecyl acrylate (PFDA) deposited in one step via initiated chemical vapor deposition (iCVD) as an effective coating to mitigate ice accretion and reduce ice adhesion. The gradient structures easily overcome adhesion, stability, and durability issues of traditional fluorinated coatings. The coatings show promising icephobic performance by reducing ice adhesion, depressing the freezing point, delaying drop freezing, and inhibiting ice nucleation and frost propagation. Icephobicity correlates with surface energy discontinuities at the surface plane resulting from the random orientation of the fluorinated groups of PFDA, as confirmed by grazing-incidence X-ray diffraction measurements. The icephobicity could be further improved by tuning the surface crystallinity rather than surface wetting, as samples with random crystal orientation show the lowest ice adhesion despite high contact angle hysteresis. The iCVD-manufactured coatings show promising results, indicating the potential for ice control on larger scales and various applications.

Unified description over time of heterogeneous condensation with quenched disorder

We report experimental results on breath figures (BFs) observed on substrates with quenched disorder. The evolution of BFs is found to be primarily influenced by global parameters associated with boundary conditions. We investigate classical statistical measures and explore topological properties using persistent homology techniques based on a modified Vietoris-Rips complex. Our findings reveal that the evolution of the number surface density of condensed droplets plays a crucial role in determining various condensation stages previously considered distinct. This evolution is significantly influenced by the distribution of nucleation sites and the individual growth law governing water droplets when coalescence does not occur. Ultimately, we demonstrate the capability to predict coalescence events based on the topological characteristics of BFs at a given point in time.

Defect-Density-Controlled Phase-Change Phenomena

Juxtaposing hydrophilicity and hydrophobicity on the same surface, known as hybrid surface engineering, can enhance phase-change heat transfer. However, controlling hydrophilicity on hybrid surfaces in a scalable fashion is a challenge, limiting their application. Here, using widely available metal meshes with variable dimensions and by controlling the patterning pressure, we scalably fabricate hybrid surfaces having spot and gridlike patterns using stamping. Using fog harvesting in a controlled chamber, we show that optimized hybrid surfaces have a ∼37% higher fog harvesting rate when compared to homogeneous superhydrophobic surfaces. Furthermore, condensation frosting experiments reveal that, on grid-patterned hybrid surfaces, frost propagates at ∼160% higher velocity and provides ∼20% less frost coverage when compared to homogeneous superhydrophobic surfaces. During defrost, our hybrid surfaces retain more water when compared to superhydrophobic surfaces due to the presence of hydrophilic patterns and melt water pinning. We adapt our fabrication technique to roll-to-roll patterning, demonstrating wettability contrast on round metallic geometries via atmospheric water vapor condensation. This work provides guidelines for the rapid, substrate-independent, and scalable fabrication of hybrid wettability surfaces for a wide variety of applications.

Design of Nanostructured Surfaces for Efficient Condensation by Controlling Condensation Modes

To meet the different needs of various industrial fields, it is of great application value to find a feasible method for controlling the condensation mode on the surface. Inspired by biological surfaces, tuning the surface structure and wettability is considered as a potential way to control the surface condensation behavior. Herein, the coupling effect of the geometric parameters and wettability distribution of the surface on the condensation process has been investigated systematically at the nanoscale. The results illustrate that the condensation mode is primarily determined by the nanopillar wettability when the nanopillars are densely distributed, while the substrate wettability dominates the condensation mode when the nanopillars are sparsely distributed. Besides, the effective contact area fraction is proposed, which more accurately reflects the influence of geometric parameters on the condensation rate of the nanopillar surface at the nanoscale. The condensation rate of the nanopillar surface increases with the increase of the effective contact area fraction. Furthermore, three surface design methods are summarized, which can control the condensation mode of water vapor on the surface into the dropwise condensation mode that generates Cassie-Baxter droplets, and this condensation process is very attractive for many practical applications.

Frost formation through super-cooled water within micron gap of galvanic coupled arrays

Frost is considered one of the key factors that negatively affects numerous daily life aspects all over the globe such as growth of crops, safety of aviation and transportation vehicles, working efficiency of air circulating systems and many others. Therefore, monitoring and early detection of frost are crucially needed to avoid such drastic effects. In this study, we used the micron gap of our newly developed galvanic coupled arrays named as moisture sensor chip (MSC) for the early detection of frost formation from super-cooled water droplets. The early frost formation was monitored via the tiny ice crystals formed on the cooled MSC surface at four different humidity levels using simultaneous electrochemical and optical microscopic detection tools. Experimental results revealed for the first time a remarkable increase in the detected galvanic current due to the condensation frosting mechanism of super-cooled water droplets via liquid transition transformation even at very low relative humidity which was believed to be responsible for de-sublimation frosting. Moreover, the super-cooled droplets formed ice bridges along their boundary domains due to the accumulation of the acquired water vapour that was evidenced by the release of the heat of solidification. These findings demonstrated that the MSC could be used as a promising platform for the early detection of frost formation considering the appropriate protective measures against its adverse effects.

Spray-Coated Superhydrophobic Overlayer with Photothermal and Electrothermal Functionalities for All-Weather De/anti-icing Applications

High-performance de/anti-icing overlayers which can be deposited on diverse surfaces offer great potential in many industrial settings and daily life, yet a versatile overlayer applicable to all-weather conditions (high humidity, low temperature, raining, snowing, etc.) is in high demand for practical applications. This study presents the fabrication and application of a superhydrophobic overlayer with a bioinspired hierarchical surface which additionally possesses photothermal and electrothermal functionalities, so it can operate as a de/anti-icing layer in extreme environments. The overlayer, with a papilla-like microstructure similar to that of a lotus leaf, features polydopamine-decorated layered basic zinc acetate microparticles distributed in the framework of multiwalled carbon nanotubes. Specifically, the overlayer is superhydrophobic, and its capability of suppressing the condensation of water droplets and growth of ice crystals is verified by both in situ environmental scanning electron microscopy observations and freezing experiments. Moreover, the overlayer can be warmed up to 74 and 105 °C under the excitation of sunlight and direct current bias, respectively, which is sufficiently high for deicing in severe weather. It is worth mentioning that the overlayer is produced by a spray-coating technique; therefore, it is suitable for large-scale deployment on arbitrary substrate materials. The findings provide insights into a new strategy for engineering multifunctional overlayers and can lead to expanding applications of composite coatings.

Icephobic/anti-icing properties of superhydrophobic surfaces

In the winter, icing on solid surfaces is a typical occurrence that may create a slew of hassles and even tragedies. Anti-icing surfaces are one of the effective solutions for this kind of problem. The roughness of a superhydrophobic surface traps air and weakens the contact between the solid surface and liquid water, allowing water droplets to be removed before freezing. At present, the conventional anti-icing methods including mechanical or thermal technology are not only surface structure unfriendly but also have the obsessions of low efficiency, high energy consumption and high manufacturing costs. Hence, developing a way to remove ice by just modifying the surface shape or chemical composition with a low surface energy is extremely desirable. Numerous attempts have been made to investigate the evolution of ice nucleation and icing on superhydrophobic surfaces under the direction of the ice nucleation hypothesis. In this paper, the research progress of ice nucleation in recent years is reviewed from theoretical and application. The icephobic surfaces are described using the wettability and classical nucleation theories. The benefits and drawbacks of anti-icing superhydrophobic surface are summarized, as well as deicing methods. Finally, several applications of ice phobic materials are illustrated, and some problems and challenges in the research field are discussed. We believed that this review will be useful in guiding future water freezing initiatives.

Frost Delay of a Water-Absorbing Surface with Engineered Wettability via Nonfreezing Water

Frost is common when a solid surface is subjected to a humid and cold environment. It can cause various inconveniences, complications, or fatal accidents. Water-repellent surfaces have demonstrated an antifreezing capability by enabling the water droplets to roll or bounce off before they freeze. However, these surfaces are often limited by their inability to shed the small water condensates, which can eventually grow and freeze. Recently, surfaces that can rapidly absorb and hydrogen bond with these water condensates have demonstrated significant delay in frost formation and growth. This is attributed to a lower freezing temperature of the absorbed water which makes it stay in a nonfreezing state. Herein, we report a surface with preferential wettability of water over oil (i.e., superhydrophilic and oleophobic wettability) that can significantly delay frost formation. The surface is fabricated by copolymerizing poly(ethylene glycol) diacrylate (PEGDA) and perfluorinated acrylate (1H,1H,2H,2H-heptadecafluorodecyl acrylate, HDF-acrylate) applied to a silane-grafted glass substrate (HDF-PEGDA). An HDF-PEGDA surface can quickly absorb condensed water which enables it to delay frost formation and growth for up to 20 min at a surface temperature of -35 °C. Also, the surface demonstrates that its frost-resistant capability remains almost unaffected even after being submerged in an oil bath due to its in-air oil repellency. Differential scanning calorimetry (DSC) measurements reveal that the significant quantity of absorbed water in an HDF-PEGDA surface remains in a nonfreezing state with a T_m value as low as -33 °C. A mathematical model that can predict the time at which the surface begins to be covered with frost is developed. Finally, an HDF-PEGDA is layered with a PEGDA copolymerized with sodium acrylate (Na-acrylate) that enables the continuous release of the absorbed water by posing forward osmotic pressure and regeneration of an HDF-PEGDA surface.

Fabrication Optimization of Ultra-Scalable Nanostructured Aluminum-Alloy Surfaces

Aluminum and its alloys are widely used in various industries. Aluminum plays an important role in heat transfer applications, where enhancing the overall system performance through surface nanostructuring is achieved. Combining optimized nanostructures with a conformal hydrophobic coating leads to superhydrophobicity, which enables coalescence induced droplet jumping, enhanced condensation heat transfer, and delayed frosting. Hence, the development of a rapid, energy-efficient, and highly scalable fabrication method for rendering aluminum superhydrophobic is crucial. Here, we employ a simple, ultrascalable fabrication method to create boehmite nanostructures on aluminum. We systematically explore the influence of fabrication conditions such as water immersion time and immersion temperature, on the created nanostructure morphology and resultant nanostructure length scale. We achieved optimized structures and fabrication procedures for best droplet jumping performance as measured by total manufacturing energy utilization, fabrication time, and total cost. The wettability of the nanostructures was studied using the modified Cassie-Baxter model. To better differentiate performance of the fabricated superhydrophobic surfaces, we quantify the role of the nanostructure morphology to corresponding condensation and antifrosting performance through study of droplet jumping behavior and frost propagation dynamics. The effect of aluminum substrate composition (alloy) on wettability, condensation and antifrosting performance was investigated, providing important directions for proper substrate selection. Our findings indicate that the presence of trace alloying elements play a previously unobserved and important role on wettability, condensation, and frosting behavior via the inclusion of defect sites on the surface that are difficult to remove and act as pinning locations to increase liquid-solid adhesion. Our work provides optimization strategies for the fabrication of ultrascalable aluminum and aluminum alloy superhydrophobic surfaces for a variety of applications.

Droplet Dynamics and Freezing Delay on Nanoporous Microstructured Surfaces at Condensing Environment

Superhydrophobic surfaces have aroused great interest for being promising candidates in applications such as self-cleaning, anti-icing, and corrosion resistance. However, most of the superhydrophobic surfaces lose their anti-wettability in low surface temperature and high humidity. The loss of superhydrophobicity by condensed liquid is a very common practical incident, yet to be understood properly. Here we report the wettability of the superhydrophobic nanoporous surfaces in condensation and freezing environments. Various structured surfaces fabricated with carbon nanotubes (CNT) and coated by an ultrathin, conformal, and low surface energy layer of poly (1H,1H,2H,2H-perfluorodecylacrylate) (pPFDA) are exploited in humid conditions. Droplet impact dynamics, condensate characteristics, and freezing time delays are investigated on the CNT micropillars with various geometries along with the CNT forest and two commercially available anti-wetting coatings, NeverWet and WX2100. Nanoporous microstructured CNT pillars with the favorable topological configuration demonstrated complete droplet bouncing, significant freezing delays, and considerable durability during several icing/de-icing cycles. This study provides an understanding on the preferable geometry of the highly porous CNT micropillars for retaining hydrophobicity and preventing ice formation, which is of practical importance for the rational development of anti-wetting surfaces and their applications in low temperatures and humid conditions.

Vapor Flux on Bumpy Surfaces: Condensation and Transpiration on Leaves

Drop condensation and evaporation as a result of the gradient in vapor concentration are important in both engineering and natural systems. One of the interesting natural examples is transpiration on plant leaves. Most of the water in the inner space of the leaves escapes through stomata, whose rate depends on the surface topography and a difference in vapor concentrations inside and just outside of the leaves. Previous research on the vapor flux on various surfaces has focused on numerically solving the vapor diffusion equation or using scaling arguments based on a simple solution with a flat surface. In this present work, we present and discuss simple analytical solutions on various 2D surface shapes (e.g., semicylinder, semiellipse, hair). The method of solving the diffusion equation is to use the complex potential theory, which provides analytical solutions for vapor concentration and flux. We find that a high mass flux of vapor is formed near the top of the microstructures while a low mass flux is developed near the stomata at the leaf surface. Such a low vapor flux near the stomata may affect transpiration in two ways. First, condensed droplets on the stomata will not grow due to a low mass flux of vapor, which will not inhibit the gas exchange through the stomatal opening. Second, the low mass flux from the atmosphere will facilitate the release of highly concentrated vapor from the substomatal space.

Bioinspired wettable-nonwettable micropatterns for emerging applications

Superhydrophilic and superhydrophobic surfaces are prevalent in nature and have received tremendous attention due to their importance in both fundamental research and practical applications. With the high interdisciplinary research and great development of microfabrication techniques, artificial wettable-nonwettable micropatterns inspired by the water-collection behavior of desert beetles have been successfully fabricated. A combination of the two extreme states of superhydrophilicity and superhydrophobicity on the same surface precisely, wettable-nonwettable micropatterns possess unique functionalities, such as controllable superwetting, anisotropic wetting, oriented adhesion, and other properties. In this review, we briefly describe the methods for fabricating wettable-nonwettable patterns, including self-assembly, electrodeposition, inkjet printing, and photolithography. We also highlight some of the emerging applications such as water collection, controllable bioadhesion, cell arrays, microreactors, printing techniques, and biosensors combined with various detection methods. Finally, the current challenges and prospects of this renascent and rapidly developing field are proposed and discussed.

Suppressing Condensation Frosting Using an Out-of-Plane Dry Zone

The vapor pressure above ice is lower than that above supercooled water at the same temperature. This inherent hygroscopic quality of ice has recently been exploited to suppress frost growth by patterning microscopic ice stripes along a surface. These vapor-attracting ice stripes prevented condensation frosting from occurring in the intermediate regions; however, the required presence of the sacrificial ice stripes made it impossible to achieve the ideal case of a completely dry surface. Here, we decouple the sacrificial ice from the antifrosting surface by holding an uncoated aluminum surface in parallel with a prefrosted surface. By replacing the overlapping in-plane dry zones with a uniform out-of-plane dry zone, we show that even an uncoated aluminum surface can stay almost completely dry in chilled and supersaturated conditions. Using a blend of experiments and numerical simulations, we show that the critical separation required to keep the surface dry is a function of the ambient supersaturation.

Condensation Frosting on Micropillar Surfaces - Effect of Microscale Roughness on Ice Propagation

Microscale surface structures have been widely explored as a promising tool for antifreezing or frost avoidance on heat transfer surfaces. Despite studies of many surface feature designs, the mechanisms associated with condensation freezing and ice propagation on microstructured surfaces have yet to be thoroughly elucidated, espectially when it comes to quantitative understanding. In this work, condensation freezing on circular micropillar surfaces is investigated, with varying pillar spacing and height (layout/microscale roughness) but a constant pillar diameter. The pillar layout is found to have significant effects on both liquid nucleation and neighboring droplet interactions, as reflected by the condensation droplet distribution prior to soilidification and eventually the freezing front propagation area velocity. In general, nucleation is preferred on the pillar top rather than the bottom of the pillared surface unless there is a large distance between the pillars. Interactions between neighboring droplets solely on pillar tops (or bottom surfaces) can induce heterogeneity in the droplet distribution and slow freezing front propagation. Based on the roles the pillars play in nucleation, droplet coalescence, and ice bridging, four different condensation states are identified and related to the layout of the pillars, and the freezing front area propagation velocity is found to be different in each state. The findings provide a quantitative basis for designing antifreezing surfaces, applicable to a wide range of thermal systems.

Double-Sided Microwells with a Stepped Through-Hole Membrane for High-Throughput Microbial Assays

To improve the throughput of microwell arrays for identifying immense cellular diversities even at a single-bacteria level, further miniaturization or densification of the microwells has been an obvious breakthrough. However, controlling millions of nanoliter samples or more at the microscale remains technologically difficult and has been spatially restricted to a single open side of the microwells. Here we employed a stepped through-hole membrane to utilize the bottom as well as top side of a high-density nanoliter microwell array, thus improving spatial efficiency. The stepped structure shows additional effectiveness for handling several millions of nanoliter bacterial samples in the overall perspectives of controllability, throughput, simplicity, versatility, and automation by using novel methods for three representative procedures in bacterial assays: partitioning cells, manipulating the chemical environment, and extracting selected cells. As a potential application, we show proof-of-concept isolation of rare cells in a mixed ratio of 1 to around 10⁶ using a single chip. Our device can be further applied to various biological studies pertaining to synthetic biology, drug screening, mutagenesis, and single-cell heterogeneity.

Delayed Frost Growth on Nanoporous Microstructured Surfaces Utilizing Jumping and Sweeping Condensates

Self-propelled jumping of condensate droplets (dew) enables their easy and efficient removal from surfaces and is essential for enhancing the condensation heat transfer coefficient and for delaying the frost growth rate on supercooled surfaces. Here, we report the droplet-jumping phenomenon using nanoporous vertically aligned carbon nanotube (VA-CNT) microstructures grown on smooth silicon substrates and coated with poly-(1H, 1H, 2H, 2H-perfluorodecylacrylate) (pPFDA). We also report droplet-sweeping phenomenon on horizontally mounted surfaces, concluding that the frost surface coverage area and the frost growth rates observed with the droplet-sweeping phenomenon are much lower than those that are observed with the droplet-jumping phenomenon alone. We also investigate the fundamentals of droplet-jumping and the frost growth phenomena using line-shaped, hollow-cylindrical, and cylindrical microstructures, comparing the frost surface coverage area and the ice-bridging times during condensation-frosting, prolonged condensation-frosting, and direct-frosting. We find that the closely spaced thin line-shaped microstructures and hollow-cylindrical microstructures are optimal for frost coverage reduction because of their ability to exhibit droplet-jumping and droplet-sweeping phenomena. We observe that adding nonuniform roughness on top of the microstructures leads to jumping-associated droplet-sweeping on supercooled surfaces. Here, we report the evaporation of an already frozen droplet because of freezing of a supercooled condensate droplet in its close vicinity, enabling the Cassie-Baxter state frost growth and enhancing defrosting efficiency. Finally, we discuss the dynamic defrosting behavior of the pPFDA-coated VA-CNT microstructures, concluding that the small gaps (spacings) between the microstructures not only enable dewetting transitions of droplets but also promote the Cassie-Baxter state frost formation.

Topography-Regulated Disorder-to-Order Transition of Condensation Droplets

Condensation of water vapor is a random, transient, and multiscale process prevalent in a variety of natural and industrial processes. Here, we demonstrate that it is possible to transform the disordered distribution of condensate droplets into temporary ordered arrays on chemically homogeneous but physically heterogeneous surfaces, a phenomenon that has not been systematically investigated in a previous study. We show that such a disorder-to-order transition demands an exquisite competition between the length scales of droplets and cavities. In particular, the confinement effect imposed by the patterned cavities should be well controlled to allow the energetically favorable transition.

Modified Voronoi Analysis of Spontaneous Formation of Interfacial Droplets on Immersed Oil-Solid Substrates

The nucleation and growth of liquid droplets on solid substrates have received much attention because of the significant relevance of these multiphase processes to both nature and practical applications. There have been extensive studies on the condensation of water from the air phase on solid substrates. Here, we focus on water diffusion through the oil phase and subsequent settlement on solid substrates because such interfacial droplets are formed. Voronoi diagram analysis is proposed to statistically characterize the size distribution of the growing droplets. It is found that modification of the standard Voronoi diagram is required for systems of interfacial droplets which have a noncircular shape and/or whose centers change with time. The modified Voronoi analysis of the growing droplets provides an automatic quantification of the droplet distribution and reveals that (i) during the nucleation stage, the interfacial droplets do not nucleate at the same time because the nucleation of newly formed droplets competes with the growth of the existing ones; (ii) the growth of interfacial droplets comes from water diffusion from the bulk water layer, and/or from adjacent interfacial droplets, and/or from coalescence of interfacial droplets; and (iii) the sizes of interfacial droplets become more polydispersed on P-glass but more monodispersed on OTS-glass as time goes. This work opens a new perspective on the formation of interfacial droplets at the interface between oil and the solid substrate and demonstrates the capability of an automatic analysis method, which can be potentially applied to similar interfacial multiphase systems.

Mechanisms of ice formation and propagation on superhydrophobic surfaces: A review

Icephobic surfaces, used as passive anti-icing materials, are in high demand due to the costs, damage, and loss of equipment and lives related to ice formation on outdoor surfaces. The proper design of icephobic surfaces is intertwined with the need for a profound understanding of ice formation processes and how ice propagates over a surface. Ice formation (ice nucleation) and interdroplet freezing propagation are processes that determine the onset of freezing and complete ice coverage on a surface, respectively. Evaluating the nature of these phenomena, along with their interactions with substrate and environmental factors, can offer a step toward designing surfaces having an improved icephobic performance. This review paper is organized to discuss ice nucleation and rate, preferable locations of nucleation, and favorable pathways of freezing (desublimation and condensation-freezing) on superhydrophobic surfaces. Furthermore, as the propagation of ice over a substrate plays a more deterministic role for the complete freezing coverage of a surface than that of ice formation, this review also elucidates possible mechanisms of ice propagation, theoretical backgrounds, and strategies to control this propagation using surface characteristics.

Inhibiting Condensation Freezing on Patterned Polyelectrolyte Coatings

Condensation freezing inhibition is of great practical importance for anti-icing applications; however, no coatings with this performance have been reported. Here, we report the inhibition of condensation freezing on patterned polyelectrolyte coatings, including polyelectrolyte brush (PB), polyelectrolyte multilayer (PEM), and polyelectrolyte hydrogel (PH) surfaces, benefiting from their feature in regulating ice nucleation and propagation via changing counterions. On the reported surfaces, ice nucleation can be initiated exclusively at the domains with the polyelectrolytes; moreover, spontaneous ice propagation can be achieved atop the patterned polyelectrolyte surface. Consequently, condensed water surrounding the frozen drops on the patterned polyelectrolyte surface evaporates due to the instantaneously released latent heat in the course of ice propagation. Afterward, ice grows specifically on polyelectrolyte surfaces via desublimation as the saturated vapor pressure of ice is smaller than that of condensed water drops. As such, an ice-free region up to 96% of the entire surface area can be accomplished. We demonstrate that various polyelectrolyte coatings can be easily introduced on almost all surfaces, revealing great promise for anti-icing applications.

Characterizing Hygroscopic Materials via Droplet Evaporation

Hygroscopic materials are widely used as desiccants for applications including food production, packaging, anti-icing, and gas storage. Current techniques for quantifying the hygroscopicity of materials, such as the use of a tandem differential mobility analyzer or a gravimetric vapor sorption analyzer, require complex and expensive setups. Here, we show that the hygroscopicity of any bulk material can be simply characterized by suspending it above a deposited droplet and measuring the droplet's evaporation rate. By controlling the temperature of the droplet to correspond to the dew point, we ensured that any evaporation was directly correlated with diffusive transport into the low-pressure hygroscopic material. Using Fick's law, the effective water vapor concentration of each material was extracted and nondimensionalized by the saturation concentration to obtain a hygroscopic index. This nondimensional index ranges from 0 (no hygroscopicity) to 1 (null vapor pressure) and can also be conceptualized as 1 - a_w, where a_w is the material's water activity.

How ice bridges the gap

When supercooled dew droplets form on a chilled surface, the subsequent freezing process is driven by a fascinating phenomenon of propagating inter-droplet ice bridges. Here, we explore the range of conditions under which an individual ice dendrite can successfully bridge the gap from a frozen droplet to its nearest liquid neighbor. Ranging the droplet sizes from 1 μm-10 mm, we find that the criterion for ice bridging is purely geometric and independent of temperature, ambient humidity, and surface wettability. We model the growth of individual ice bridges as well as the global speed of percolating fronts sweeping across large droplet populations. We also give a dynamical law for dry zone formation when ice fails to bridge the gap.

From Extremely Water-Repellent Coatings to Passive Icing Protection—Principles, Limitations and Innovative Application Aspects

The severe environmental conditions in winter seasons and/or cold climate regions cause many inconveniences in our routine daily-life, related to blocked road infrastructure, interrupted overhead telecommunication, internet and high-voltage power lines or cancelled flights due to excessive ice and snow accumulation. With the tremendous and nature-inspired development of physical, chemical and engineering sciences in the last few decades, novel strategies for passively combating the atmospheric and condensation icing have been put forward. The primary objective of this review is to reveal comprehensively the major physical mechanisms regulating the ice accretion on solid surfaces and summarize the most important scientific breakthroughs in the field of functional icephobic coatings. Following this framework, the present article introduces the most relevant concepts used to understand the incipiency of ice nuclei at solid surfaces and the pathways of water freezing, considers the criteria that a given material has to meet in order to be labelled as icephobic and clarifies the modus operandi of superhydrophobic (extremely water-repellent) coatings for passive icing protection. Finally, the limitations of existing superhydrophobic/icephobic materials, various possibilities for their unconventional practical applicability in cryobiology and some novel hybrid anti-icing systems are discussed in detail.

An integrative bioinspired venation network with ultra-contrasting wettability for large-scale strongly self-driven and efficient water collection

Collection of water from the atmosphere is a potential route to alleviate the global water shortage. However, it is still difficult to find a strategy to collect sufficient water on a large surface and transport it all off the surface without additional energy input. Inspired by redbud leaves, herein, we proposed a new water-collecting configuration. This configuration utilizes an ultra-contrasting wettability venation network with hierarchical micro-nano structures as the skeleton and integrates the strategies evolved by cacti and beetles. This venation network was fabricated by the technology based on ultra-fast lasers. We achieved a near-unity efficiency in collecting and centralizing the condensed water on the entire surface with a large area. Remarkable water collection and centralization capability were obtained. The venation networks manifested the notable enhancements of ∼166%, ∼352% and ∼644% in water collection efficiency when compared with conventional superhydrophobic surfaces at the tilt angles of 90°, 60° and 30°, respectively. This configuration can work continuously at all tilt angles, even against gravity at a negative tilt angle of 90°. In addition, the venation network can maintain excellent water collecting capability even under very arid conditions. The principle and fabrication technology of this venation network make it possible to scale up a practical network device for mass water collection and may be useful for water desalination, heat transfer, microfluidics, lab-on-a-chip, distillation and many other applications.

Biological and Engineered Topological Droplet Rectifiers

The power of the directional and spontaneous transport of liquid droplets is revealed through ubiquitous biological processes and numerous practical applications, where droplets are rectified to achieve preferential functions. Despite extensive progress, the fundamental understanding and the ability to exploit new strategies to rectify droplet transport remain elusive. Here, the latest progress in the fundamental understanding as well as the development of engineered droplet rectifiers that impart superior performance in a wide variety of working conditions, ranging from low temperature, ambient temperature, to high temperature, is discussed. For the first time, a phase diagram is formulated that naturally connects the droplet dynamics, including droplet formation modes, length scales, and phase states, with environmental conditions. Parallel approaches are then taken to discuss the basic physical mechanisms underlying biological droplet rectifiers, and a variety of strategies and manufacturing routes for the development of robust artificial droplet rectifiers. Finally, perspectives on how to create novel man-made rectifiers with functionalities beyond natural counterparts are presented.

Resistant energy analysis of self-pulling process during dropwise condensation on superhydrophobic surfaces

Recently the development of superhydrophobic surfaces with one-tier or hierarchical textures has drawn increasing attention because enhanced condensation heat transfer has been observed on such biomimetic surfaces in well-tailored supersaturation or subcooling conditions. However, the physical mechanisms underlying condensation enhancement are still less understood. Here we report an energy-based analysis on the formation and growth of condensate droplets on two-tier superhydrophobic surfaces, which are fabricated by decorating carbon nanotubes (CNTs) onto microscale fluorinated pillars. Thus-formed hierarchical surfaces with two tier micro/nanoscale roughness are proved to be superior to smooth surfaces in the spatial control of condensate droplets. In particular, we focus on the self-pulling process of condensates in the partially wetting morphology (PW) from surface cavities due to intrinsic Laplace pressure gradient. In this analysis, the self-pulling process of condensate tails is resisted by adhesion energy, viscous dissipation, contact line dissipation and line tension in a combined manner. This process can be facilitated by adjusting the configuration and length scale of the first-tier texture. The optimum design can not only lower the total resistant energy but also favor the out-of-plane motion of condensate droplets anchored in the first-tier cavity. It is also shown that engineered surface with hierarchical roughness is beneficial to remarkably mitigating contact line dissipation from the perspective of molecular kinetic theory (MKT). Our study suggests that scaling down surface roughness to submicron scale can facilitate the self-propelled removal of condensate droplets.

Finely Tunable Surface Wettability by Two-Dimensional Molecular Manipulation

Local molecular environment governs material interface properties, especially the substrate's exposing behavior and overall functionality expression. Although current techniques can provide efficient surface property modification, challenges in molecule spatial distribution and composition controls limited the generation of homogeneous and finely tunable molecular environment. In this study, Au-thiolate rupturing operation in chemical lift-off lithography (CLL) is used to manipulate the substrate interface molecular environment. The creation of randomly distributed artificial self-assembled monolayer defects generates vacancies for substrate property modification through back-insertion of molecules with opposite functionalities. Surface wettability adjustment is utilized as an example, where well-controllable molecule distribution provides finely tunable substrate affinity toward liquids with different physical properties. The distinct property difference between two surface regions assists microdroplet formation when liquids flow through, not only water solution but also low-surface-tension organic liquids. These microdroplet arrays become a template to guide material assembly in its formation process and act as pH-sensitive platforms for high-throughput detection. Furthermore, the tunability of the molecular pattern in this approach helps minimize the coffee-ring effect and the sweet-spot issue in matrix-assisted laser desorption/ionization mass spectrometry. Two-dimensional molecular manipulation in the CLL operation, therefore, holds the capability toward controlling homogeneous material surface property and toward exhibiting behavior adjustments.

Cascade Freezing of Supercooled Water Droplet Collectives

Surface icing affects the safety and performance of numerous processes in technology. Previous studies mostly investigated freezing of individual droplets. The interaction among multiple droplets during freezing is investigated less, especially on nanotextured icephobic surfaces, despite its practical importance as water droplets never appear in isolation, but in groups. Here we show that freezing of a supercooled droplet leads to spontaneous self-heating and induces strong vaporization. The resulting, rapidly propagating vapor front causes immediate cascading freezing of neighboring supercooled droplets upon reaching them. We put forth the explanation that, as the vapor approaches cold neighboring droplets, it can lead to local supersaturation and formation of airborne microscopic ice crystals, which act as freezing nucleation sites. The sequential triggering and propagation of this mechanism results in the rapid freezing of an entire droplet ensemble, resulting in ice coverage of the nanotextured surface. Although cascade freezing is observed in a low-pressure environment, it introduces an unexpected pathway of freezing propagation that can be crucial for the performance of rationally designed icephobic surfaces.

Tuning Ice Nucleation and Propagation with Counterions on Multilayer Hydrogels

Ice formation on solid surfaces includes heterogeneous ice nucleation and ice propagation processes. However, no study has been focused on tuning of both ice nucleation and ice propagation via a simple anti-icing coating method. In this work, we have prepared multilayer hydrogels based on simple layer-by-layer (LBL) deposition approach and discover the ion-specific effect on both ice nucleation and ice propagation. A large ice nucleation temperature window of 11 °C is controlled via changing different counterions; meanwhile, the differences in ice propagation time can be tuned up to 4 orders of magnitude. Through synergistically controlling of ice nucleation and propagation delay times, we can tune the freezing delay time of water droplets on multilayer hydrogel surfaces up to 3 orders of magnitude via changing various counterions. Considering the application requirements, these multilayer hydrogels are stable under different conditions and can be coated on various materials without destroying the existing surface. This new insight can inspire the design of anti-icing surfaces based on regulating both ice nucleation and ice propagation.

Passive Antifrosting Surfaces Using Microscopic Ice Patterns

Despite exceptional recent advances in tailoring the wettability of surfaces, to date, no engineered surface can passively suppress the in-plane growth of frost that invariably occurs in humid, subfreezing environments. Here, we show that up to 90% of a surface can exhibit passive antifrosting by using chemical or physical wettability patterns to template "ice stripes" across the surface. As ice exhibits a depressed vapor pressure relative to liquid water, these sacrificial ice stripes siphon the supersaturated water vapor to keep the intermediate surface areas dry from dew and frost. Further, we show that when these sacrificial ice stripes are elevated atop microfins, they diffusively coarsen in a suspended state above the surface. The suspended state of the coarsening ice results in a diffusive growth rate an order of magnitude slower than frost coarsening directly on a solid substrate and should also minimize its adhesive strength to the surface.

Desublimation Frosting on Nanoengineered Surfaces

Ice nucleation from vapor presents a variety of challenges across a wide range of industries and applications including refrigeration, transportation, and energy generation. However, a rational comprehensive approach to fabricating intrinsically icephobic surfaces for frost formation-both from water condensation (followed by freezing) and in particular from desublimation (direct growth of ice crystals from vapor)-remains elusive. Here, guided by nucleation physics, we investigate the effect of material composition and surface texturing (atomically smooth to nanorough) on the nucleation and growth mechanism of frost for a range of conditions within the sublimation domain (0 °C to -55 °C; partial water vapor pressures 6 to 0.02 mbar). Surprisingly, we observe that on silicon at very cold temperatures-below the homogeneous ice solidification nucleation limit (<-46 °C)-desublimation does not become the favorable pathway to frosting. Furthermore, we show that surface nanoroughness makes frost formation on silicon more probable. We experimentally demonstrate at temperatures between -48 °C and -55 °C that nanotexture with radii of curvature within 1 order of magnitude of the critical radius of nucleation favors frost growth, facilitated by capillary condensation, consistent with Kelvin's equation. Our findings show that such nanoscale surface morphology imposed by design to impart desired functionalities-such as superhydrophobicity-or from defects can be highly detrimental for frost icephobicity at low temperatures and water vapor partial pressures (<0.05 mbar). Our work contributes to the fundamental understanding of phase transitions well within the equilibrium sublimation domain and has implications for applications such as travel, power generation, and refrigeration.

Distinct ice patterns on solid surfaces with various wettabilities

No relationship has been established between surface wettability and ice growth patterns, although ice often forms on top of solid surfaces. Here, we report experimental observations obtained using a process specially designed to avoid the influence of nucleation and describe the wettability-dependent ice morphology on solid surfaces under atmospheric conditions and the discovery of two growth modes of ice crystals: along-surface and off-surface growth modes. Using atomistic molecular dynamics simulation analysis, we show that these distinct ice growth phenomena are attributable to the presence (or absence) of bilayer ice on solid surfaces with different wettability; that is, the formation of bilayer ice on hydrophilic surface can dictate the along-surface growth mode due to the structural match between the bilayer hexagonal ice and the basal face of hexagonal ice (ice I_h), thereby promoting rapid growth of nonbasal faces along the hydrophilic surface. The dramatically different growth patterns of ice on solid surfaces are of crucial relevance to ice repellency surfaces.

Dynamic Defrosting on Scalable Superhydrophobic Surfaces

Recent studies have shown that frost can grow in a suspended Cassie state on nanostructured superhydrophobic surfaces. During defrosting, the melting sheet of Cassie frost spontaneously dewets into quasi-spherical slush droplets that are highly mobile. Promoting Cassie frost would therefore seem advantageous from a defrosting standpoint; however, nobody has systematically compared the efficiency of defrosting Cassie ice versus defrosting conventional surfaces. Here, we characterize the defrosting of an aluminum plate, one-half of which exhibits a superhydrophobic nanostructure while the other half is smooth and hydrophobic. For thick frost sheets (>1 mm), the superhydrophobic surface was able to dynamically shed the meltwater, even at very low tilt angles. In contrast, the hydrophobic surface was unable to shed any appreciable meltwater even at a 90° tilt angle. For thin frost layers (≲1 mm), not even the superhydrophobic surface could mobilize the meltwater. We attribute this to the large apparent contact angle of the meltwater, which for small amounts of frost serves to minimize coalescence events and prevent droplets from approaching the capillary length. Finally, we demonstrate a new mode of dynamic defrosting using an upside-down surface orientation, where the melting frost was able to uniformly detach from the superhydrophobic side and subsequently pull the frost from the hydrophobic side in a chain reaction. Treating surfaces to enable Cassie frost is therefore very desirable for enabling rapid and low-energy thermal defrosting, but only for frost sheets that are sufficiently thick.

Spatial Control of Condensation on Chemically Homogeneous Pillar-Built Surfaces

The random nature of dropwise condensation impedes spatial control hereof and its use for creating microdroplet arrays, yet here we demonstrate the spatial control of dropwise condensation on a chemically homogeneous pillar array surface, yielding ∼8000 droplets/mm² under normal atmospheric pressure conditions. The studied pillar array surface is defined by photolithography and etched in silicon by deep reactive ion etching. Subsequently, the surface is covered with a self-assembled monolayer of perfluorodecyltrichlorosilane (FDTS) to render the surface hydrophobic. To obtain a perfect droplet array, with one droplet per pillar, we exploit a phenomenon where the water vapor flux is focused on the apexes of surface asperities by diffusion while matching the nucleation point density to the array dimensions. Matching is here achieved through the variation of interpillar distance and vapor flow conditions.

Fast Dynamics of Water Droplets Freezing from the Outside In

A drop of water that freezes from the outside in presents an intriguing problem: the expansion of water upon freezing is incompatible with the self-confinement by a rigid ice shell. Using high-speed imaging we show that this conundrum is resolved through an intermittent fracturing of the brittle ice shell and cavitation in the enclosed liquid, culminating in an explosion of the partially frozen droplet. We propose a basic model to elucidate the interplay between a steady buildup of stresses and their fast release. The model reveals that for millimetric droplets the fragment velocities upon explosion are independent of the droplet size and only depend on material properties (such as the tensile stress of the ice and the bulk modulus of water). For small (submillimetric) droplets, on the other hand, surface tension starts to play a role. In this regime we predict that water droplets with radii below 50  μm are unlikely to explode at all. We expect our findings to be relevant in the modeling of freezing cloud and rain droplets.

Suppression of Frost Nucleation Achieved Using the Nanoengineered Integral Humidity Sink Effect

Inhibition of frost formation is important for increasing efficiency of refrigeration systems and heat exchangers, as well as for preventing the rapid icing over of water-repellant coatings that are designed to prevent accumulation of rime and glaze. From a thermodynamic point of view, this task can be achieved by either increasing hydrophobicity of the surface or decreasing the concentration of water vapor above it. The first approach has been studied in depth, but so far has not yielded a robust solution to the problem of frost formation. In this work, we systematically explore how frost growth can be inhibited by controlling water vapor concentration using bilayer coatings with a porous exterior covering a hygroscopic liquid-infused layer. We lay the theoretical foundation and provide experimental validation of the mass transport mechanism that governs the integral humidity sink effect based on this coating platform as well as reveal intriguing sizing effects about this system. We show that the concentration profile above periodically spaced pores is governed by the sink and source concentrations and two geometrical parameters: the nondimensional pore size and the ratio of the pore spacing to the boundary layer thickness. We demonstrate that when the ratio of the pore spacing to the boundary layer thickness vanishes, as for the nanoporous bilayer coatings, the entire surface concentration becomes uniform and equal to the concentration set by the hygroscopic liquid. In other words, the surface concentration becomes completely independent of the nanopore size. We identified the threshold geometrical parameters for this condition and show that it can lead to a 65 K decrease in the nucleation onset surface temperature below the dew point. With this fundamental insight, we use bilayer coatings to nanoengineer the integral humidity sink effect to provide extreme antifrosting performance with up to a 2 h delay in nucleation onset at 263 K. The nanoporous bilayer coatings can be designed to combine optimal antifrosting functionality with a superhydrophobic water repelling exterior to provide coatings that can robustly prevent frost, rime, and glaze accumulation. By minimizing the required amount of antifreeze, this anti-icing method can have minimal operational cost and environmental impact.

Large scale generation of micro-droplet array by vapor condensation on mesh screen piece

We developed a novel micro-droplet array system, which is based on the distinct three dimensional mesh screen structure and sintering and oxidation induced thermal-fluid performance. Mesh screen was sintered on a copper substrate by bonding the two components. Non-uniform residue stress is generated along weft wires, with larger stress on weft wire top location than elsewhere. Oxidation of the sintered package forms micro pits with few nanograsses on weft wire top location, due to the stress corrosion mechanism. Nanograsses grow elsewhere to show hydrophobic behavior. Thus, surface-energy-gradient weft wires are formed. Cooling the structure in a wet air environment nucleates water droplets on weft wire top location, which is more "hydrophilic" than elsewhere. Droplet size is well controlled by substrate temperature, air humidity and cooling time. Because warp wires do not contact copper substrate and there is a larger conductive thermal resistance between warp wire and weft wire, warp wires contribute less to condensation but function as supporting structure. The surface energy analysis of drops along weft wires explains why droplet array can be generated on the mesh screen piece. Because the commercial material is used, the droplet system is cost effective and can be used for large scale utilization.

Droplet migration on hydrophobic–hydrophilic hybrid surfaces: a lattice Boltzmann study

Droplet migration on textured hydrophobic–hydrophilic surfaces.

On Localized Vapor Pressure Gradients Governing Condensation and Frost Phenomena

Interdroplet vapor pressure gradients are the driving mechanism for several phase-change phenomena such as condensation dry zones, interdroplet ice bridging, dry zones around ice, and frost halos. Despite the fundamental nature of the underlying pressure gradients, the majority of studies on these emerging phenomena have been primarily empirical. Using classical nucleation theory and Becker-Döring embryo formation kinetics, here we calculate the pressure field for all possible modes of condensation and desublimation in order to gain fundamental insight into how pressure gradients govern the behavior of dry zones, condensation frosting, and frost halos. Our findings reveal that in a variety of phase-change systems the thermodynamically favorable mode of nucleation can switch between condensation and desublimation depending upon the temperature and wettability of the surface. The calculated pressure field is used to model the length of a dry zone around liquid or ice droplets over a broad parameter space. The long-standing question of whether the vapor pressure at the interface of growing frost is saturated or supersaturated is resolved by considering the kinetics of interdroplet ice bridging. Finally, on the basis of theoretical calculations, we propose that there exists a new mode of frost halo that is yet to be experimentally observed; a bimodal phase map is developed, demonstrating its dependence on the temperature and wettability of the underlying substrate. We hope that the model and predictions contained herein will assist future efforts to exploit localized vapor pressure gradients for the design of spatially controlled or antifrosting phase-change systems.

An ultrahigh-accuracy Miniature Dew Point Sensor based on an Integrated Photonics Platform

The dew point is the temperature at which vapour begins to condense out of the gaseous phase. The deterministic relationship between the dew point and humidity is the basis for the industry-standard "chilled-mirror" dew point hygrometers used for highly accurate humidity measurements, which are essential for a broad range of industrial and metrological applications. However, these instruments have several limitations, such as high cost, large size and slow response. In this report, we demonstrate a compact, integrated photonic dew point sensor (DPS) that features high accuracy, a small footprint, and fast response. The fundamental component of this DPS is a partially exposed photonic micro-ring resonator, which serves two functions simultaneously: 1) sensing the condensed water droplets via evanescent fields and 2) functioning as a highly accurate, in situ temperature sensor based on the thermo-optic effect (TOE). This device virtually eliminates most of the temperature-related errors that affect conventional "chilled-mirror" hygrometers. Moreover, this DPS outperforms conventional "chilled-mirror" hygrometers with respect to size, cost and response time, paving the way for on-chip dew point detection and extension to applications for which the conventional technology is unsuitable because of size, cost, and other constraints.

Zwitterionic polymer brush coatings with excellent anti-fog and anti-frost properties

The anti-fog and anti-frost properties of superhydrophilic pSBMA and pSBVI polymer brushes compared to bare substrates.