Sprayable superhydrophobic nano-chains coating with continuous self-jumping of dew and melting frost

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.

Atmospheric Corrosion Protection Performance and Mechanism of Superhydrophobic Surface Based on Coalescence-Induced Droplet Self-Jumping Behavior

The coalescence-induced droplet self-jumping behavior on the superhydrophobic surface (SHS) provides a new way to achieve atmospheric corrosion protection. This work controls the droplet self-jumping behavior by regulating the SHS's surface energy and analyzes the relevant mechanism from the energy perspective, revealing the key pathway by which the surface energy impacts the droplet self-jumping behavior. On this basis, the electrochemical impedance spectroscopy testing technique is used to evaluate the effect of the droplet self-jumping behavior on the SHS corrosion protection performance, and the SHS atmospheric corrosion protection mechanism based on the coalescence-induced droplet self-jumping behavior is revealed. This study provides theoretical guidance for the development of SHS-based anticorrosion protection.

A Review of Fabrication Methods, Properties and Applications of Superhydrophobic Metals

Hydrophobicity and superhydrophobicity with self-cleaning properties are well-known characteristics of several natural surfaces, such as the leaves of the sacred lotus plant (Nelumbo nucifera). To achieve a superhydrophobic state, micro- and nanometer scale topography should be realized on a low surface energy material, or a low surface energy coating should be deposited on top of the micro-nano topography if the material is inherently hydrophilic. Tailoring the surface chemistry and topography to control the wetting properties between extreme wetting states enables a palette of functionalities, such as self-cleaning, antifogging, anti-biofouling etc. A variety of surface topographies have been realized in polymers, ceramics, and metals. Metallic surfaces are particularly important in several engineering applications (e.g., naval, aircrafts, buildings, automobile) and their transformation to superhydrophobic can provide additional functionalities, such as corrosion protection, drag reduction, and anti-icing properties. This review paper focuses on the recent advances on superhydrophobic metals and alloys which can be applicable in real life applications and aims to provide an overview of the most promising methods to achieve sustainable superhydrophobicity.

Large-Scale Fabrication of Wettability-Controllable Coatings for Optimizing Condensate Transfer Ability

Systematic regulation of hydrophilic regions plays a key role in optimizing the heterogeneous hydrophilic-hydrophobic surface for promoting condensate transfer ability (CTA) under subcooling or high-humidity conditions. In this work, we develop an operable method to fabricate wettability-controllable coatings by regulating the mass ratio of superamphiphobic and superamphiphilic powder (MRP). By investigating the synergic relationship between CTA and MRP, we display an interesting competition between condensation and detachment of condensates. The initial dewing rate associated with reflecting phase change heat transfer capacity could be continuously strengthened by promoting MRP, while the detachment capacity with respect to improving the long-term condensing rate can be limited by the excessive superamphiphilic microregions. Based on this, we have optimized the threshold of MRP for promoting the condensation heat transfer ability and the water harvesting efficiency with the values of 10:0-8:2 and 10:0-4:6, respectively. This work provides important guidance in designing and optimizing heterogeneous hydrophilic-hydrophobic surfaces for multiple industrial applications including heat management, water harvesting, and desalination.

Spray-On Nanocomposite Coatings: Wettability and Conductivity

Nanocomposite coatings, i.e., a combination of nanocompounds, and a polymer matrix together with suitable additives and solvents is a very versatile method for producing multifunctional coatings. Some of the most desired coating properties have a high repellency to liquids (e.g., superhydrophobic and/or superoleophobic) and electrical and thermal conductivities. From a practical perspective, coatings that can be sprayed are very suitable for large-scale production, conformity, and reduced time and cost. Carbon-based, metallic, and ceramic are the three groups of nanocompounds commonly used to formulate spray-on nanocomposite coatings. In this invited feature article, we discuss the applications, advantages, and challenges of using such nanocompounds to produce coatings with good water repellency or/and elevated electrical or/and thermal conductivities. We also discuss the role of additives and solvents briefly in relation to the properties of the coatings. Important spraying parameters, such as stand-off distance and its influence on the final coating properties, will also be examined. Our overall aim is to provide a guideline for the production of practical multifunctional nanocomposites utilizing carbon-based, metallic, or ceramic nanoparticles or nanofibers that covers both aspects of in-air wettability and conductivity under one umbrella.

Dropwise Condensation on a Hierarchical Nanopillar Structured Surface

Nanopillar structure processing has been performed on condensation surfaces to control wettability and achieve a high heat transfer coefficient via dropwise condensation and jumping droplets. Modified dry etching was performed using gold (Au) nanoparticles generated by annealing Au as a mask. High-aspect-ratio nanopillar processing was also performed to produce uniform pillar surfaces and novel hierarchical pillar surfaces. A uniform nanopillar surface with pillars having diameters of 20-850 nm and a hierarchical pillar surface with thick pillars having diameters ranging from 100 to 860 nm and thin pillars with diameters ranging from 20 to 40 nm were mixed and fabricated. Condensation experiments were performed using the noncoated nanopillar surfaces, and the condensation behaviors on the silicon (Si) surfaces were observed from above using a microscope and from the side using a high-speed camera. On the uniform surface US-3 and the hierarchical surfaces HS-1 and HS-2, droplet jumps were observed frequently in the droplet size range of 20-50 μm. In contrast, as the droplet size increased to 50 μm or more, the number of jumps observed decreased as the droplet size increased. The frequency of droplet jumps on the hierarchical surfaces from the start of condensation to approximately 2 min was higher than that on the uniform surfaces, although the density of droplet formation on the hierarchical surfaces was not relatively large. On the basis of the observation of droplet behavior from the side surface, we identified that the primary jump was due to the coalescence of droplets adhering to the surface and that the subsequent jump was caused by the droplet coalescence when the jump droplets were reattached. The primary jump occurrence rate was high on all pillar surfaces.

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.

Coexistence of Antiadhesion Performance, Intrinsic Stretchability, and Transparency

Antiadhesion performance, stretchability, and transparency are highly desirable properties for materials and devices in numerous applications. However, the existing strategies for imparting materials with antiadhesion performance generally induce rigidity and opacity, and principle is yet to be provided for designing materials that combine these important parameters. Here, we show that four factors including a low surface energy, appropriate cross-linking, availability of a homogeneous and amorphous composite, and a smooth material surface can be used to design an intrinsically stretchable and transparent polymer film with antiadhesion performance against various liquids including water, diiodomethane, hexadecane, cooking oil, and pump oil. The film can be obtained via simply molding a waterborne polymer network at ambient temperature. Furthermore, the film can retain its antiadhesion performance and outstanding transparency even when it is subjected to large mechanical deformations reaching up to 1800%, and its maximal fracture strain exceeds 3000%. These design concepts offer a general platform for achieving multiple material functionalities, and may open new avenues for the surface functionalization of stretchable materials and devices.

Fabrication and Frosting Properties Study of Surface-Active Agents Coating Based on Nanoporous Aluminum Substrate

In order to solve the frosting and blockage problem of an air conditioning evaporator’s fin in winter, the nanoporous aluminum plates with low surface energy has been proposed in this paper, which are fabricated by an anodizing method and then modified by lauric acid. The nanoporous aluminum plates with different nanoporous diameters ranging from 15 nm to 400 nm are obtained by changing the magnitude of the oxidation current. The surface contact angle of the nanoporous aluminum plates is an important factor influencing its surface frost and condensation. The test results show that the surface contact angle is decreased with the increasing of nanoporous diameter. When the nanoporous aluminum plates are modified by lauric acid, the contact angle is proportional to the nanoporous diameter, and the maximum contact angle can reach about 171°. A set of experimental instruments has been set up to simulate the typical winter climate in northern China, and the frosting properties of the nanoporous aluminum plate’s fin is analyzed by experiment. The results show that increasing the contact angle of aluminum plates can effectively improve its anti-frosting properties. The average frosting rate of the aluminum plate with the contact angle of 60° is about 0.33 [g/(min∙m2)], which is 1.74 times that of the aluminum plate with the contact angle of 171°, whose frosting rate is about 0.19 [g/(min∙m2)]. After taking the expanded aperture processing to the aluminum plate, the diameter with 30 nm, 100 nm, 200 nm, 300 nm, and 400 nm nanoporous aluminum plates are obtained and the polished aluminum plates are also prepared for comparing. Through the test results, the nanoporous aluminum plates are shown to have anti-frosting properties, and the nanoporous aluminum plates with diameter of 300 nm are shown to have the best anti-frosting properties. The calculation mode of frosting growth is derived on the base of experimental results. This research will be helpful in indicating the potential research area of the low-carbon-emission and energy-saving technology for the researchers all over the world.

Meltwater Evolution during Defrosting on Superhydrophobic Surfaces

Defrosting is essential for removing frost from engineering surfaces, but some fundamental issues are still unclear, especially for defrosting on superhydrophobic surfaces. Here, defrosting experiments on prepared superhydrophobic surfaces were conducted along with the investigation on meltwater evolution characteristics. According to the experiments, the typical meltwater evolution process on superhydrophobic surfaces can be divided into two stages: dewetting by edge curling and dewetting by shrinkage. The edge curling of a meltwater film is a distinct phenomenon and has been first reported in this work. Profiting from the ultralow adhesion of the superhydrophobic surface, edge curling is mainly attributed to two unbalanced forces (one at the interface between the ice slurry layer and pure water layer and the other in the triple phase line area) acting on the layered meltwater film. During the multi-meltwater evolution process, the nonbreaking of chained droplets on superhydrophobic surfaces is also an interesting phenomenon, which is controlled by the interaction between the surface tension and the retentive force because of contact angle hysteresis. An approximate criterion was then developed to explain and determine the status of chained droplets, and experimental data from various surfaces have validated the effectiveness of this criterion. This work may deepen the understanding of defrosting on superhydrophobic surfaces and promote antifrosting/icing applications in engineering.

Recent Progress in Bionic Condensate Microdrop Self-Propelling Surfaces

Bionic condensate microdrop self-propelling (CMDSP) surfaces are attracting increased attention as novel, low-adhesivity superhydrophobic surfaces due to their value in fundamental research and technological innovation, e.g., for enhancing heat transfer, energy-effective antifreezing, and electrostatic energy harvesting. Here, the focus is on recent progress in bionic CMDSP surfaces. Metal-based CMDSP surfaces, which are the most promising in their respective fields, are highlighted for use in future applications. The selected topics are divided into four sections: biological prototypes, mechanism and construction rules, fabrication, and applications of metal-based CMDSP surfaces. Finally, the challenges and future development trends in bionic CMDSP surfaces are envisioned, especially the utilization of potential bionic inspiration in the design of more advanced CMDSP surfaces.

Self-jumping Mechanism of Melting Frost on Superhydrophobic Surfaces

Frost accretion on surfaces may cause severe problems and the high-efficiency defrosting methods are still urgently needed in many application fields like heat transfer, optical and electric power system, etc. In this study, a nano-needle superhydrophobic surface is prepared and the frosting/defrosting experiments are conducted on it. Three steps are found in the defrosting process: melting frost shrinking and splitting, instantaneous self-triggered deforming followed by deformation-induced movements (namely, in-situ shaking, rotating, rolling, and self-jumping). The self-jumping performance of the melting frost is extremely fascinating and worth studying due to its capability of evidently shortening the defrosting process and reducing (even avoiding) residual droplets after defrosting. The study on the melting frost self-jumping phenomena demonstrates that the kinetic energy transformed from instantaneous superficial area change in self-triggered deforming step is the intrinsic reason for various melting frost self-propelled movements, and when the transformed energy reaches a certain amount, the self-jumping phenomena occur. And some facilitating conditions for melting frost self-jumping phenomena are also discussed. This work will provide an efficient way for defrosting or an inspiration for further research on defrosting.

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.

Dynamic Melting of Freezing Droplets on Ultraslippery Superhydrophobic Surfaces

Condensed droplet freezing and freezing droplet melting phenomena on the prepared ultraslippery superhydrophobic surface were observed and discussed in this study. Although the freezing delay performance of the surface is common, the melting of the freezing droplets on the surface is quite interesting. Three self-propelled movements of the melting droplets (ice- water mixture) were found including the droplet rotating, the droplet jumping, and the droplet sliding. The melting droplet rotating, which means that the melting droplet rotates spontaneously on the superhydrophobic surface like a spinning top, is first reported in this study and may have some potential applications in various engineering fields. The melting droplet jumping and sliding are similar to those occurring during condensation but have larger size scale and motion scale, as the melting droplets have extra-large specific surface area with much more surface energy available. These self-propelled movements make all the melting droplets on the superhydrophobic surface dynamic, easily removed, which may be promising for the anti-icing/frosting applications.

Condensed dewdrops self-ejecting on sprayable superhydrophobic CNT/SiO2 composite coating

We report a type of novel condensed dewdrops self-ejecting coating from sprayable paint, which was prepared by a self-assembly process of SiO₂ nano-particles on hydroxylated carbon nano-tubes with subsequent chemical modification.