Superhydrophobic polyolefin surfaces: controlled micro- and nanostructures

Superhydrophobic polyolefin surfaces were prepared by simultaneous micro- and nanostructuring. Electropolished aluminum foil was microstructured with a micro working robot and then anodized in polyprotic acid. The surface microstructure can be tailored by adjusting the settings of the micro working robot and the nanostructure by adjusting the parameters of the anodization procedure. Surface structuring was done by injection molding where a microstructured anodized aluminum oxide mold insert was used to pattern the surfaces. Structuring had a marked effect on the contact angle between the injection-molded polyolefins and water. When the optimized microstructure was covered with nanostructure, the static contact angle between polypropylene and water obtained a value of about 165 degrees and the sliding angle decreased to about 2.5 degrees. The superhydrophobic state was achieved.     

Self-assembly of amino-functionalized monolayers on silicon surfaces and preparation of superhydrophobic surfaces based on alkanoic acid dual layers and surface roughening

Reproducibly smooth amino-functionalized surfaces were obtained by deposition of aminopropyltrimethoxysilane (APTMS) at the vapor/solid interface. Characteristics of these amino-functionalized surfaces were evaluated based on atomic force microscopy, water contact angle measurement and X-ray photoelectron spectroscopy. The results showed that APTMS modified surfaces are very homogeneous and the chemical reactivity of modified surfaces can be ensured with high free amino content. Furthermore, for the purpose of tailoring the wettability of silicon surface, dual self-assembled films were achieved by performing reaction between amino-functionalized surface and n-alkanoic acids with different chain length. The wettability of the self-assembled films can be adjusted with altering the hydrocarbon chain length of alkanoic acids. Moreover, cooperation of dual self-assembled films with surface roughening, superhydrophobic surfaces with CA larger than 153 degrees were obtained. Thus, the wettability of modified surfaces can be altered greatly with changing hydrocarbon chain length of self-assembled films.     

Electrowetting-based control of droplet transition and morphology on artificially microstructured surfaces

Electrowetting (EW) has recently been demonstrated as a powerful tool for controlling droplet morphology on smooth and artificially structured surfaces. The present work involves a systematic experimental investigation of the influence of electrowetting in determining and altering the state of a static droplet resting on an artificially microstructured surface. Extensive experimentation is carried out to benchmark a previously developed energy-minimization-based model that analyzed the influence of interfacial energies, surface roughness parameters, and electric fields in determining the apparent contact angle of a droplet in the Cassie and Wenzel states under the influence of an EW voltage. The EW voltage required to trigger a transition from the Cassie state to the Wenzel state is experimentally determined for surfaces having a wide range of surface parameters (surface roughness and fraction of surface area covered with pillars). The reversibility of the Cassie-Wenzel transition upon the removal of the EW voltage is also quantified and analyzed. The experimental results from the present work form the basis for the design of surfaces that enable dynamic control of droplet morphology. A significant finding from the present work is that nonconservative dissipative forces have a significant influence in opposing fluid flow inside the microstructured surface that inhibits reversibility of the Cassie-Wenzel transition. The artificially structured surfaces considered in this work have microscale roughness feature sizes that permits direct visual observation of EW-induced Cassie-Wenzel droplet transition; this is the first reported visual confirmation of EW-induced droplet state transition.     

Superhydrophobic surfaces prepared by microstructuring of silicon using a femtosecond laser

We present a simple method for fabricating superhydrophobic silicon surfaces. The method consists of irradiating silicon wafers with femtosecond laser pulses and then coating the surfaces with a layer of fluoroalkylsilane molecules. The laser irradiation creates a surface morphology that exhibits structure on the micro- and nanoscale. By varying the laser fluence, we can tune the surface morphology and the wetting properties. We measured the static and dynamic contact angles for water and hexadecane on these surfaces. For water, the microstructured silicon surfaces yield contact angles higher than 160 degrees and negligible hysteresis. For hexadecane, the microstructuring leads to a transition from nonwetting to wetting.     

Enhanced hydrophobicity of rough polymer surfaces

Molecular dynamics simulations were used to study the effect of periodic roughness of PE and PVC polymer surfaces on the hydrophobicity. Pillars of different lateral dimensions and heights were derived from flat crystalline surfaces, and the results of nanoscale simulations on the structured surfaces were compared with theoretical predictions of the Wenzel and Cassie equations. Hydrophobicity increased on all rough surfaces, but the increase was greater on the structured PE surfaces because of the larger water contact angle on the flat PE surface than the corresponding PVC surface. Equally sized pillar structures on the two polymers resulted in different equilibrium wetting geometries. Composite contacts were observed on rough PE surfaces, and the contact angle increased with decreasing contact area between the solid and the liquid. Opposite results were obtained for rough PVC surfaces; the contact angle increased with the solid-liquid contact area, in agreement with Wenzel's equation. However, the composite contact was observed if the energies of the wetted and composite contacts were almost equal. Good agreement was obtained between the simulated contact angles and equilibrium droplet shapes and the theories but there were also some limitations of the nanoscale simulations.     

Contact angle hysteresis on regular pillar-like hydrophobic surfaces

A series of pillar-like patterned silicon wafers with different pillar sizes and spacing are fabricated by photolithography and further modified by a self-assembled fluorosilanated monolayer. The dynamic contact angles of water on these surfaces are carefully measured and found to be consistent with the theoretical predictions of the Cassie model and the Wenzel model. When a water drop is at the Wenzel state, its contact angle hysteresis increases along with an increase in the surface roughness. While the surface roughness is further raised beyond its transition roughness (from the Wenzel state to the Cassie state), the contact angle hysteresis (or receding contact angle) discontinuously drops (or jumps) to a lower (or higher) value. When a water drop is at the Cassie state, its contact angle hysteresis strongly depends on the solid fraction and has nothing to do with the surface roughness. Even for a superhydrophobic surface, the contact angle hysteresis may still exhibit a value as high as 41 degrees for the solid fraction of 0.563.     

Wetting phenomena on micro-grooved aluminum surfaces and modeling of the critical droplet size

The behavior of water droplets on aluminum surfaces with parallel grooves tens of microns in width and depth is considered, and a mechanistic model is developed for predicting the critical droplet size-droplets at incipient sliding due to gravity. The critical droplet size is nearly 50% smaller on micro-grooved surfaces than on the same surface without micro-grooves. The application of existing models fails to predict this behavior, and a new model based on empiricism is developed. The new model provides reasonable predictions of the critical droplet size for a given inclination angle, advancing contact angle, and maximum contact angle. When the grooves are aligned parallel to gravity, the maximum apparent contact angle does not occur at the advancing front but rather along the side of the droplet because of contact-line pinning. Droplets on these surfaces are elongated and possess a parallel-sided base contour shape. Novel data are provided for droplets in a Wenzel state, a Cassie-Baxter state, and combined state on micro-grooved surfaces, and the ability of the empirical model to handle these variations is explored. These findings may be important to a broad range of engineering applications.     

Contact-angle hysteresis on super-hydrophobic surfaces

The relationship between perturbations to contact angles on a rough or textured surface and the super-hydrophobic enhancement of the equilibrium contact angle is discussed theoretically. Two models are considered. In the first (Wenzel) case, the super-hydrophobic surface has a very high contact angle and the droplet completely contacts the surface upon which it rests. In the second (Cassie-Baxter) case, the super-hydrophobic surface has a very high contact angle, but the droplet bridges across surface protrusions. The theoretical treatment emphasizes the concept of contact-angle amplification or attenuation and distinguishes between the increases in contact angles due to roughening or texturing surfaces and perturbations to the resulting contact angles. The theory is applied to predicting contact-angle hysteresis on rough surfaces from the hysteresis observable on smooth surfaces and is therefore relevant to predicting roll-off angles for droplets on tilted surfaces. The theory quantitatively predicts a "sticky" surface for Wenzel-type surfaces and a "slippy" surface for Cassie-Baxter-type surfaces.     

Advancing and receding motion of droplets on ultrahydrophobic post surfaces

We have fabricated a range of silicon post surfaces where post width and spacing have been systematically varied. As one subset, we have generated surfaces where the post spacings in x and y assume different values. On these surfaces, the dynamic contact angles become anisotropic. A fluoropolymer monolayer is photochemically attached to the microstructured silicon, leading to the appearance of ultrahydrophobic properties. On one side, the advancing contact angles on these surfaces are not affected by variations in the geometric parameters. This furthers the conclusion that, during the advancing motion, a true contact angle of 180 degrees is reached. On the other side, the receding angles are strongly influenced by the post size and spacing. We quantitatively analyze this dependence and relate variations in the receding angle to the shape and movement of the three-phase contact line. It is suggested that during the receding motion the meniscus successively dewets from one post at a time, with a step function running along the contact line until it has receded from a row of posts over its entire length.     

Effect of three-phase contact line topology on dynamic contact angles on heterogeneous surfaces

Cassie-Baxter theory has traditionally been used to study liquid drops in contact with microstructured surfaces. The Cassie-Baxter theory arises from a minimization of the global Gibbs free energy of the system but does not account for the topology of the three-phase contact line. We experimentally compare two situations differing only in the microstructure of the roughness, which causes differences in contact line topology. We report that the contact angle is independent of area void fraction for surfaces with microcavities, which correspond to situations when the advancing contact line is continuous. This result is in contrast with Cassie-Baxter theory, which uses area void fraction as the determining parameter, regardless of the type of roughness.     

Bioinspired preparation of regular dual‐level micropillars on polypropylene surfaces with robust hydrophobicity inspired by green bristlegrass leaves

The fine microstructure on the natural green bristlegrass leaf of Setaria viridis (L.) Beauv, which exhibits a contact angle (CA) of 155°±2° and a rolling angle (RA) of 79°±2°, is carefully observed. Based on the understanding of the underlying mechanisms for superhydrophobicity and moderate surface adhesion, an efficient replica molding strategy is proposed for mimicking the microstructures on green bristlegrass leaf surface to polypropylene (PP) surfaces. The bioinspired PP replica with dual‐level micropillars are molded by using the unitized template of steel Meshes A and B. Interestingly, the PP replica inherits both hydrophobicity and adhesion of the natural leaf. Furthermore, the PP replica can stabilize its hydrophobic state under a 980 Pa external pressure, which is attributed to the composite Cassie‐Wenzel mixed wetting state on the microstructured interface. The CA comparatively goes down and RA increases, resulting in superhydrophobic surface with moderate adhesion on the bioinspired surface. Hence, the microstructures and hydrophobicity are successfully replicated to the PP surface by only using the low cost, available and reliable steel meshes in the bioinspired replica molding process.     

Wetting of nanogrooved polymer surfaces

Molecular dynamics simulations were used to study the wetting of nanogrooved PE and PVC polymer surfaces. The contact angles, equilibrium states, and equilibrium shapes of two nanosized water droplets were analyzed on surfaces with 1D-arranged periodic roughness of various dimensions. The composite solid-liquid contact, which is preferred in practical applications and in which a droplet rests on top of the surface asperities, was observed on the roughest PE surfaces, whereas water filled the similar but slightly deeper grooves on PVC surfaces. The transition from the wetted to composite contact regime occurred when the contact angle with a flat surface reached the value at which the apparent Wenzel and Cassie contact angles are equal. Droplets on grooved PE surfaces with the composite contact exhibited contact angles in agreement with Cassie's equation, but the increase in hydrophobicity on smoother surfaces with the wetted contact was less than expected from Wenzel's equation. The difference between the simulated and theoretical values decreased as the dimensions of the surface grooves increased. Only a slight increase or even a slight decrease in the contact angles was observed on the grooved PVC surfaces, owing to the less hydrophobic nature of the flat PVC surface. On both polymers, the nanodroplet assumed a spherical shape in the composite contact. Only minor anisotropy was observed in the wetted contact on PE surfaces, whereas even a highly anisotropic shape was seen on the grooved PVC surfaces. The contact angle in the direction of the grooves was smaller than that in the perpendicular direction, and the difference between the two angles decreased with the increasing size of the water droplet.     

Patterned nonadhesive surfaces: superhydrophobicity and wetting regime transitions

Nonadhesive and water-repellent surfaces are required for many tribological applications. We study mechanisms of wetting of patterned superhydrophobic Si surfaces, including the transition between various wetting regimes during microdroplet evaporation in environmental scanning electron microscopy (ESEM) and for contact angle and contact angle hysteresis measurements. Wetting involves interactions at different scale levels: macroscale (water droplet size), microscale (surface texture size), and nanoscale (molecular size). We propose a generalized formulation of the Wenzel and Cassie equations that is consistent with the broad range of experimental data. We show that the contact angle hysteresis involves two different mechanisms and how the transition from the metastable partially wetted (Cassie) state to the homogeneously wetted (Wenzel) state depends upon droplet size and surface pattern parameters.     

Formation of superhydrophobic surfaces by biomimetic silicification and fluorination

The amazing water repellency of many biological surfaces, exemplified by lotus leaves, has recently received a great deal of interest. These surfaces, called superhydrophobic surfaces, exhibit water contact angles larger than 150 degrees and a low contact angle hysteresis because of both their low surface energy and heterogeneously rough structures. In this paper, we suggest a biomimetic method, "biosilicification", for generating heterogeneously rough structures and fabricating superhydrophobic surfaces. The superhydrophobic surface was prepared by a combination of the formation of heterogeneously rough, nanosphere-like silica structures through biosilicification and the formation of self-assembled monolayers of fluorosilane on the surface. The resulting surface exhibited the water contact angle of 160.1 degrees and the very low water contact angle hysteresis of only 2.3 degrees, which are definite characteristics of superhydrophobic surfaces. The superhydrophobic property of our system probably resulted from the air trapped in the rough surface. The wetting behavior on the surface was in the heterogeneous regime, which was totally supported by Cassie-Baxter equation.     

Directing droplets using microstructured surfaces

Systematic variation of microscale structures has been employed to create a rough superhydrophobic surface with a contact angle gradient. Droplets are propelled down these gradients, overcoming contact angle hysteresis using energy supplied by mechanical vibration. The rough hydrophobic surfaces have been designed to maintain air traps beneath the droplet by stabilizing its Fakir state. Dimensions and spacing of the microfabricated pillars in silicon control the solid-liquid contact area and are varied to create a gradient in the apparent contact angle. This work introduces the solid-liquid contact area fraction as a new control variable in any scheme of manipulating droplets, presenting theory, fabricated structures, and experimental results that validate the approach.     

Wettability of zinc oxide surfaces with controllable structures

Zinc oxide (ZnO) surfaces with controllable structures (i.e, microstructure, nanostructure, and micronanobinary structure) have been created by controlling pH at < 4 or > 10.5 in the Zn(gray) + H2O2 reaction. The resulting surface shows superhydrophobicity. It is found that the water contact angle (CA) of the surface with micronanobinary structure is greater than that of nanostructure and that of nanostructure is greater than that of the microstructure. Theoretical analysis is completely in agreement with the experimental results.     

Stability of silanols and grafted alkylsilane monolayers on plasma-activated mica surfaces

We investigated the effect of physical and chemical modifications of mica surfaces induced by water vapor-based plasma treatments on the stability of silanols and grafted alkylsilane monolayers. The plasma-activated substrates were characterized using XPS, TOF-SIMS, and contact angle measurements. They revealed a large surface coverage of silanol groups (Si-OH) and a loss of aluminum atoms compared to freshly cleaved mica surfaces. The stability of plasma-induced silanol groups was investigated by contact angle measurements using ethylene glycol as a probe liquid. The Si-OH surface coverage decreased rapidly under vacuum or thermal treatment to give rise to hydrophobic dehydrated surfaces. The stability of end-grafted monofunctionalized n-alkylsilanes was investigated in different solvents and at different pH using water contact angle measurements. The degrafting of alkylsilanes from the activated mica was promoted in acidic aqueous solutions. This detachment was associated with the hydrolysis of covalent bonds between the alkylsilanes and the mica surface. The monolayer stability was enhanced by increasing the length of the alkyl chains that probably act as a hydrophobic protective layer against hydrolysis reactions. Stable alkylsilane monolayers in water with pH greater than 5.5 were obtained on mica surfaces activated at low plasma pressure. We attributed this stability to the loss of surface Al atoms induced by the plasma treatment.     

Control over wettability of polyethylene glycol surfaces using capillary lithography

We demonstrate that wettability of poly(ethylene glycol) (PEG) surfaces can be controlled using nanostructures with various geometrical features. Capillary lithography was used to fabricate PEG nanostructures using a new ultraviolet (UV) curable mold consisting of functionalized polyurethane with acrylate group (MINS101m, Minuta Tech.). Two distinct wetting states were observed depending of the height of nanostructures. At relatively lower heights (< 300 nm for 150 nm pillars with 500 nm spacing), the initial contact angle of water was less than 80 degrees and the water droplet easily invaded into the surface grooves, leading to a reduced contact angle at equilibrium (Wenzel state). At relatively higher heights (> 400 nm for 150 nm pillars with 500 nm spacing), on the other hand, the nanostructured PEG surface showed hydrophobic nature and no significant change in contact angle was observed with time (Cassie state). The presence of two wetting states was also confirmed by dynamic wetting properties and contact-angle hysteresis. The wetting transition from hydrophilic (bare PEG surface) to hydrophobic (PEG nanostructures) was described by the Cassie-Baxter equation assuming that enhanced hydrophobicity is due to the heterogeneous wetting mediated by an air pocket on the surface. The measured contact angles in the Cassie state were increased with increasing air fraction, in agreement with the theoretical prediction.     

Effects of contact angle hysteresis on ice adhesion and growth on superhydrophobic surfaces under dynamic flow conditions

In this paper, the icephobic properties of superhydrophobic surfaces are investigated under dynamic flow conditions using a closed-loop low-temperature wind tunnel. Superhydrophobic surfaces were prepared by coating aluminum and steel substrate plates with nano-structured hydrophobic particles. The superhydrophobic plates, along with uncoated controls, were exposed to a wind tunnel air flow of 12 m/s and ?7 °C with deviations of ±1 m/s and ±2.5 °C, respectively, containing micrometer-sized (～50 μm in diameter) water droplets. The ice formation and accretion were observed by CCD cameras. Results show that the superhydrophobic coatings significantly delay ice formation and accretion even under the dynamic flow condition of highly energetic impingement of accelerated supercooled water droplets. It is found that there is a time scale for this phenomenon (delay in ice formation) which has a clear correlation with contact angle hysteresis and the length scale of the surface roughness of the superhydrophobic surface samples, being the highest for the plate with the lowest contact angle hysteresis and finest surface roughness. The results suggest that the key for designing icephobic surfaces under the hydrodynamic pressure of impinging droplets is to retain a non-wetting superhydrophobic state with low contact angle hysteresis, rather than to only have a high apparent contact angle (conventionally referred to as a “static” contact angle).     

Wettability of clean metal surfaces

Experimental and theoretical investigations bearing on the question of the wettability, by water, of clean oxygen-free metal surfaces are reviewed. Results on gold, silver, and copper are discussed in terms of surface cleanliness, surface structure, and extent of dispersion (London) force interaction. It is concluded that clean solid metal surfaces are hydrophilic. They will yield a zero degree contact angle when prepared in the amorphous state and possibly in the perfect crystalline state as well. These results do not necessarily preclude the possibility that physical interaction at the metal-water interface consists solely of dispersion forces.