U.S. patent application number 13/302356 was filed with the patent office on 2013-02-07 for liquid-impregnated surfaces, methods of making, and devices incorporating the same.
The applicant listed for this patent is Rajeev Dhiman, Ernesto Reza-Garduno Cabello, J. David Smith, Kripa K. Varanasi. Invention is credited to Rajeev Dhiman, Ernesto Reza-Garduno Cabello, J. David Smith, Kripa K. Varanasi.
Application Number | 20130032316 13/302356 |
Document ID | / |
Family ID | 45509633 |
Filed Date | 2013-02-07 |
United States Patent
Application |
20130032316 |
Kind Code |
A1 |
Dhiman; Rajeev ; et
al. |
February 7, 2013 |
Liquid-Impregnated Surfaces, Methods of Making, and Devices
Incorporating the Same
Abstract
The invention is directed to an article with a
liquid-impregnated surface, the surface having a matrix of features
thereupon, spaced sufficiently close to stably contain a liquid
therebetween or therewithin, and preferable also a thin film
thereupon. The surface provides the article with advantageous
non-wetting properties. Compared to previous non-wetting surfaces,
which include a gas (e.g., air) entrained within surface textures,
these liquid-impregnated surfaces are resistant to impalement and
frost formation, and are therefore more robust.
Inventors: |
Dhiman; Rajeev; (Malden,
MA) ; Smith; J. David; (Cambridge, MA) ;
Varanasi; Kripa K.; (Lexington, MA) ; Reza-Garduno
Cabello; Ernesto; (Cambridge, MA) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Dhiman; Rajeev
Smith; J. David
Varanasi; Kripa K.
Reza-Garduno Cabello; Ernesto |
Malden
Cambridge
Lexington
Cambridge |
MA
MA
MA
MA |
US
US
US
US |
|
|
Family ID: |
45509633 |
Appl. No.: |
13/302356 |
Filed: |
November 22, 2011 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
61515395 |
Aug 5, 2011 |
|
|
|
Current U.S.
Class: |
165/133 ;
138/145 |
Current CPC
Class: |
B64D 15/06 20130101;
B08B 17/065 20130101; Y10T 428/24355 20150115; Y10T 428/24372
20150115; Y02E 10/72 20130101; F28F 19/006 20130101; C09D 5/1681
20130101; Y02E 10/721 20130101 |
Class at
Publication: |
165/133 ;
138/145 |
International
Class: |
F28F 13/18 20060101
F28F013/18; F16L 9/18 20060101 F16L009/18 |
Claims
1. A liquid-impregnated surface, said surface comprising a matrix
of features spaced sufficiently close to stably contain a liquid
therebetween or therewithin.
2. The surface of claim 1, wherein said liquid has viscosity at
room temperature no greater than about 1000 cP.
3. The surface of claim 1, wherein said liquid has vapor pressure
at room temperature no greater than about 20 mm Hg.
4. The surface of claim 2, wherein said liquid has a viscosity at
room temperature no greater than about 100 cP.
5. The surface of claim 2, wherein said liquid has a viscosity at
room temperature no greater than about 50 cP.
6. The surface of claim 1, wherein the features have substantially
uniform height and wherein the liquid fills space between the
features and coats the features with a layer at least about 5 nm in
thickness over the top of the features.
7. The surface of claim 1, wherein the features define pores or
other wells and wherein the liquid fills the features.
8. The surface of claim 1, wherein the liquid has receding contact
angle of 0.degree. such that the liquid forms a stable thin film on
the top of the features.
9. The surface of claim 1, wherein the matrix has a
feature-to-feature spacing from about 1 micrometer to about 100
micrometers.
10. The surface of claim 1, wherein the matrix has a
feature-to-feature spacing from about 5 nanometers to about 1
micrometer.
11. The surface of claim 1, wherein the matrix comprises
hierarchical structures.
12. The surface of claim 11, wherein the hierarchical structures
are micro-scale features that comprise nano-scale features
thereupon.
13. The surface of claim 1, wherein the features have height no
greater than about 100 micrometers.
14. The surface of claim 1, wherein the features are posts.
15. The surface of claim 1, wherein the features comprise at least
one member selected from the group consisting of a spherical
particle, a nanoneedle, a nanograss, and a random geometry feature
that provides surface roughness.
16. The surface of claim 1, wherein the features comprise at least
one member selected from the group consisting of a pore, a cavity,
interconnected pores, and interconnected cavities.
17. The surface of claim 16, wherein the surface comprises porous
media with a plurality of pores having different sizes.
18. The surface of claim 1, wherein the liquid comprises a member
selected from the group consisting of silicone oil, a
perfluorocarbon liquid, a perfluoroFluorinated vaccum oil (such as
Krytox 1506 or Fromblin 06/6), a fluorinated coolant (e.g.,
perfluoro-tripentylamine sold as FC-70, manufactured by 3M), an
ionic liquid, a fluorinated ionic liquid that is immiscible with
water, a silicone oil comprising PDMS, a fluorinated silicone oil,
a liquid metal, an eletro-rheological fluid, a magneto-rheological
fluid, a ferrofluid, a dielectric liquid, a hydrocarbon liquid, a
fluorocarbon liquid, a refrigerant, a vacuum oil, a phase-change
material, a semi-liquid, grease, synovial fluid, bodily fluid.
19.-29. (canceled)
Description
CROSS-REFERENCE TO RELATED APPLICATION
[0001] This application claims priority to and the benefit of, and
incorporates herein by reference in its entirety, U.S. Provisional
Patent Application No. 61/515,395, which was filed on Aug. 5,
2011.
TECHNICAL FIELD
[0002] This invention relates generally to non-wetting and low
adhesion surfaces. More particularly, in certain embodiments, the
invention relates to non-wetting surfaces that resist liquid
impalement, ice formation, scale formation, hydrate formation,
and/or have antifouling properties.
BACKGROUND
[0003] The advent of micro/nano-engineered surfaces in the last
decade has opened up new techniques for enhancing a wide variety of
physical phenomena in thermofluids sciences. For example, the use
of micro/nano surface textures has provided nonwetting surfaces
capable of achieving less viscous drag, reduced adhesion to ice and
other materials, self-cleaning, and water repellency. These
improvements result generally from diminished contact (i.e., less
wetting) between the solid surfaces and adjacent liquids.
[0004] One type of non-wetting surface of interest is a
superhydrophobic surface. In general, a superhydrophobic surface
includes micro/nano-scale roughness on an intrinsically hydrophobic
surface, such as a hydrophobic coating. Superhydrophobic surfaces
resist contact with water by virtue of an air-water interface
within the micro/nano surface textures.
[0005] One of the drawbacks of existing non-wetting surfaces (e.g.,
superhydrophobic, superoleophobic, and supermetallophobic surfaces)
is that they are susceptible to impalement, which destroys the
non-wetting capabilities of the surface. Impalement occurs when an
impinging liquid (e.g., a liquid droplet or liquid stream)
displaces the air entrained within the surface textures. Previous
efforts to prevent impalement have focused on reducing surface
texture dimensions from micro-scale to nano-scale.
[0006] Another drawback with existing non-wetting surfaces is that
they are susceptible to ice formation and adhesion. For example,
when frost forms on existing superhydrophobic surfaces, the
surfaces become hydrophilic. Under freezing conditions, water
droplets can stick to the surface, and ice may accumulate. Removal
of the ice can be difficult because the ice may interlock with the
textures of the surface. Similarly, when these surfaces are exposed
to solutions saturated with salts, for example as in desalination
or oil and gas applications, scale builds on surfaces and results
in loss of functionality. Similar limitations of existing
non-wetting surfaces include problems with hydrate formation, and
formation of other organic or inorganic deposits on the
surfaces.
[0007] There is a need for non-wetting surfaces (e.g.,
superhydrophobic surfaces, superoleophobic surfaces, and
supermetallophobic surfaces) that are more robust. In particular,
there is a need for non-wetting surfaces that resist impalement and
ice formation.
SUMMARY OF THE INVENTION
[0008] Described herein are non-wetting surfaces that include a
liquid impregnated within a matrix of micro/nano-engineered
features on the surface, or a liquid filling pores or other tiny
wells on the surface. Compared to previous non-wetting surfaces,
which include a gas (e.g., air) entrained within the surface
textures, these liquid-impregnated surfaces are resistant to
impalement and frost formation, and are therefore more robust. The
invention is fundamental in nature and can be used in any
application that benefits from non-wetting surfaces. For example,
the methods described herein may be used to reduce viscous drag in
oil and gas pipelines, prevent ice formation on aircraft and/or
powerlines, and minimize the accumulation of impinging liquids.
[0009] The methods and apparatus described herein have several
advantages over existing non-wetting surfaces, referred to herein
as gas-impregnated surfaces. For example, compared to
gas-impregnated surfaces, liquid-impregnated surfaces have a much
higher resistance to impalement. This enables a liquid-impregnated
surface to withstand higher pressures (e.g., higher droplet
velocities) during liquid impingement. In certain embodiments, a
liquid-impregnated surface resists impalement through the use of
micro-scale surface textures, rather than nano-scale textures, as
utilized in previous gas-impregnated surface approaches. The use of
micro-scale textures, rather than nano-scale textures is extremely
advantageous at least because micro-scale features are less
expensive and much easier to fabricate.
[0010] Through proper selection of the impregnating liquid, the
liquid-impregnated surfaces described herein are easily
customizable to suit a wide variety of applications. For example,
water drag reduction on a solid surface may be achieved with the
use of oil as the impregnating liquid, because water slips readily
on oils. The use of oil as the impregnating liquid is also suitable
for the prevention of frost and ice formation. In this application,
the frost and ice may form only on the peaks of the surface
textures, thereby greatly reducing ice formation rates and adhesion
strengths.
[0011] In one aspect, the invention is directed to an article
comprising a liquid-impregnated surface, said surface comprising a
matrix of features spaced sufficiently close to stably contain a
liquid therebetween or therewithin. In certain embodiments, the
liquid has viscosity at room temperature no greater than about 1000
cP (or cSt), no greater than about 100 cP (or cSt), or no greater
than about 50 cP (or cSt). In certain embodiments, the liquid has
vapor pressure at room temperature no greater than about 20 mm Hg,
no greater than about 1 mm Hg, or no greater than about 0.1
mmHg.
[0012] In certain embodiments, the features have substantially
uniform height and wherein the liquid fills space between the
features and coats the features with a layer at least about 5 nm in
thickness over the top of the features. In certain embodiments, the
features define pores or other wells and the liquid fills the
features.
[0013] In certain embodiments, the liquid has receding contact
angle of 0.degree. such that the liquid forms a stable thin film on
the top of the features.
[0014] In certain embodiments, the matrix has a feature-to-feature
spacing from about 1 micrometer to about 100 micrometers. In
certain embodiments, the matrix has a feature-to-feature spacing
from about 5 nanometers to about 1 micrometer. In certain
embodiments, the matrix comprises hierarchical structures. For
example, the hierarchical structures may be micro-scale features
that comprise nano-scale features thereupon.
[0015] In certain embodiments, the features have height no greater
than about 100 micrometers. In certain embodiments, the features
are posts. In certain embodiments, the features include one or more
spherical particles, nanoneedles, nanograss, and/or random geometry
features that provides surface roughness. In certain embodiments,
the feature comprises one or more pores, cavities, interconnected
pores, and/or interconnected cavities. In certain embodiments, the
surface comprises porous media with a plurality of pores having
different sizes.
[0016] In certain embodiments, the liquid comprises a
perfluorocarbon liquid, a perfluoroFluorinated vacuum oil (such as
Krytox 1506 or Fromblin 06/6), a fluorinated coolant (e.g.,
perfluoro-tripentylamine sold as FC-70, manufactured by 3M), an
ionic liquid, a fluorinated ionic liquid that is immiscible with
water, a silicone oil comprising PDMS, a fluorinated silicone oil,
a liquid metal, an eletro-rheological fluid, a magneto-rheological
fluid, a ferrofluid, a dielectric liquid, a hydrocarbon liquid, a
fluorocarbon liquid, a refrigerant, a vacuum oil, a phase-change
material, a semi-liquid, grease, synovial fluid, and/or a bodily
fluid.
[0017] In certain embodiments, the article is a steam turbine part,
a gas turbine part, an aircraft part, or a wind turbine part, and
the liquid-impregnated surface is configured to repel impinging
liquid. In certain embodiments, the article is eyeglasses, goggles,
a ski mask, a helmet, a helmet face shield, or a mirror, and the
liquid-impregnated surface is configured to inhibit fogging
thereupon. In certain embodiments, the article is an aircraft part,
a wind turbine part, a power transmission line, or a windshield,
and the liquid-impregnated surface is configured to inhibit
formation of ice thereupon. In certain embodiments, the article is
a pipeline (or a part or coating thereof), and the
liquid-impregnated surface is configured to inhibit the formation
of hydrate thereupon and/or enhance the slippage (reduce drag) of
fluid flowing thereupon (or therethrough). In certain embodiments,
the article is a heat exchanger part or an oil or gas pipeline (or
a part or coating thereof), and the liquid-impregnated surface is
configured to inhibit the formation and/or adhesion of salt
thereupon. In certain embodiments, the liquid-impregnated surface
is configured to inhibit corrosion.
[0018] In certain embodiments, the article is an artificial joint
and the liquid-impregnated surface is configured to reduce friction
between mating surfaces and/or provide long-lasting lubrication of
the joint. In certain embodiments, the article is an engine part
(e.g., piston or cylinder), and the liquid-impregnated surface is
configured to provide long-lasting lubrication of the part. In
certain embodiments, the liquid-impregnated surface is configured
to release liquid from the surface over time, thereby providing
lubrication over time.
[0019] In certain embodiments, the liquid-impregnated surface is an
anti-fouling surface configured to resist adsorption of debris
thereupon. In certain embodiments, the article is a heat exchanger
part, and the liquid-impregnated surface is configured to
facilitate shedding of condensate thereupon, thereby enhancing
condensation heat transfer.
BRIEF DESCRIPTION OF THE DRAWINGS
[0020] The objects and features of the invention can be better
understood with reference to the drawing described below, and the
claims.
[0021] FIG. 1a is a schematic cross-sectional view of a liquid
contacting a non-wetting surface, in accordance with certain
embodiments of the invention.
[0022] FIG. 1b is a schematic cross-sectional view of a liquid that
has impaled a non-wetting surface, in accordance with certain
embodiments of the invention.
[0023] FIG. 1c is a schematic cross-sectional view of a liquid in
contact with a liquid-impregnated surface, in accordance with
certain embodiments of the invention.
[0024] FIG. 2a is a schematic cross-sectional view of a droplet
resting on a liquid-impregnated surface, in accordance with certain
embodiments of the invention.
[0025] FIG. 2b is an SEM image of a non-wetting surface that
includes posts, in accordance with certain embodiments of the
invention.
[0026] FIG. 2c is a schematic perspective view of a non-wetting
surface that includes posts, in accordance with certain embodiments
of the invention.
[0027] FIG. 2d is a schematic top, cross-sectional view of a
non-wetting surface that includes posts, in accordance with certain
embodiments of the invention.
[0028] FIG. 3 includes a photograph of a microtextured surface, in
accordance with certain embodiments of the invention.
[0029] FIGS. 4a and 4b include a sequence of high speed video
images depicting the impingement of a water droplet on a
gas-impregnated surface and a liquid-impregnated surface,
respectively, in accordance with certain embodiments of the
invention.
[0030] FIG. 5 includes a sequence of high speed video images
showing a droplet impacting a liquid-impregnated surface tilted at
25.degree. with respect horizontal, in accordance with certain
embodiments of the invention.
[0031] FIGS. 6a-6d include a sequence of ESEM images showing the
formation of frost on a gas-impregnated non-wetting surface, in
accordance with certain embodiments of the invention.
[0032] FIG. 7a-7c include images from droplet impact testing on dry
and frosted superhydrophobic surfaces, in accordance with certain
embodiments of the invention.
[0033] FIG. 8 is a plot of measured normalized ice adhesion
strength versus normalized surface area, in accordance with certain
embodiments of the invention.
[0034] FIG. 9 is a plot of roll-off angle versus surface solid
fraction, in accordance with certain embodiments of the
invention.
[0035] FIGS. 10, 11, and 12 are plots of droplet rolling velocity
on a tilted liquid-impregnated surface, in accordance with certain
embodiments of the invention.
[0036] FIGS. 13 and 14 include Environmental SEM (ESEM) images of
frost nucleation on micropost surfaces impregnated with silicone
oil, in accordance with certain embodiments of the invention.
[0037] FIG. 15 is an image of a droplet of water on a surface
having a matrix of post features and impregnated with silicone oil,
contrasting an impaled state with a nonwetted state, in accordance
with certain embodiments of the invention.
[0038] FIG. 16 is a schematic describing six liquid-impregnated
surface wetting states, in accordance with certain embodiments of
the invention.
[0039] FIG. 17 is a schematic showing conditions for the six
liquid-impregnated surface wetting states shown in FIG. 16, in
accordance with certain embodiments of the invention.
DESCRIPTION
[0040] It is contemplated that compositions, mixtures, systems,
devices, methods, and processes of the claimed invention encompass
variations and adaptations developed using information from the
embodiments described herein. Adaptation and/or modification of the
compositions, mixtures, systems, devices, methods, and processes
described herein may be performed by those of ordinary skill in the
relevant art.
[0041] Throughout the description, where articles, devices and
systems are described as having, including, or comprising specific
components, or where processes and methods are described as having,
including, or comprising specific steps, it is contemplated that,
additionally, there are articles, devices, and systems of the
present invention that consist essentially of, or consist of, the
recited components, and that there are processes and methods
according to the present invention that consist essentially of, or
consist of, the recited processing steps.
[0042] Similarly, where articles, devices, mixtures, and
compositions are described as having, including, or comprising
specific compounds and/or materials, it is contemplated that,
additionally, there are articles, devices, mixtures, and
compositions of the present invention that consist essentially of,
or consist of, the recited compounds and/or materials.
[0043] It should be understood that the order of steps or order for
performing certain actions is immaterial so long as the invention
remains operable. Moreover, two or more steps or actions may be
conducted simultaneously.
[0044] The mention herein of any publication, for example, in the
Background section, is not an admission that the publication serves
as prior art with respect to any of the claims presented herein.
The Background section is presented for purposes of clarity and is
not meant as a description of prior art with respect to any
claim.
[0045] In certain embodiments, a static contact angle .theta.
between a liquid and solid is defined as the angle formed by a
liquid drop on a solid surface as measured between a tangent at the
contact line, where the three phases--solid, liquid, and
vapor--meet, and the horizontal. The term "contact angle" usually
implies the static contact angle .theta. since the liquid is merely
resting on the solid without any movement.
[0046] As used herein, dynamic contact angle, .theta..sub.d , is a
contact angle made by a moving liquid on a solid surface. In the
context of droplet impingement, .theta..sub.d may exist during
either advancing or receding movement.
[0047] As used herein, a surface is "non-wetting" if it has a
dynamic contact angle with a liquid of at least 90 degrees.
Examples of non-wetting surfaces include, for example,
superhydrophobic surfaces, superoleophobic surfaces, and
supermetallophobic surfaces.
[0048] As used herein, contact angle hysteresis (CAH) is
CAH=.theta..sub.a-.theta..sub.r, where .theta..sub.a and
.theta..sub.r are advancing and receding contact angles,
respectively, formed by a liquid on a solid surface. The advancing
contact angle .theta..sub.a is the contact angle formed at the
instant when a contact line is about to advance, whereas the
receding contact angle .theta..sub.r is the contact angle formed
when a contact line is about to recede.
[0049] FIG. 1a is a schematic cross-sectional view of a contacting
liquid 102 in contact with a traditional or previous non-wetting
surface 104 (i.e., a gas impregnating surface), in accordance with
one embodiment of the invention. The surface 104 includes a solid
106 having a surface texture defined by posts 108. The regions
between the posts 108 are occupied by a gas 110, such as air. As
depicted, while the contacting liquid 102 is able to contact the
tops of the posts 108, a gas-liquid interface 112 prevents the
liquid 102 from wetting the entire surface 104.
[0050] Referring to FIG. 1b, in certain instances, the contacting
liquid 102 may displace the impregnating gas and become impaled
within the posts 108 of the solid 106. Impalement may occur, for
example, when a liquid droplet impinges the surface 104 at high
velocity. When impalement occurs, the gas occupying the regions
between the posts 108 is replaced with the contacting liquid 102,
either partially or completely, and the surface 104 may lose its
non-wetting capabilities.
[0051] Referring to FIG. 1c, in certain embodiments, a non-wetting,
liquid-impregnated surface 120 is provided that includes a solid
122 having textures (e.g., posts 124) that are impregnated with an
impregnating liquid 126, rather than a gas. In the depicted
embodiment, a contacting liquid 128 in contact with the surface,
rests on the posts 124 (or other texture) of the surface 120. In
the regions between the posts 124, the contacting liquid 128 is
supported by the impregnating liquid 126. In certain embodiments,
the contacting liquid 128 is immiscible with the impregnating
liquid 126. For example, the contacting liquid 128 may be water and
the impregnating liquid 126 may be oil.
[0052] The solid 122 may include any intrinsically hydrophobic,
oleophobic, and/or metallophobic material or coating. For example,
the solid 122 may include: hydrocarbons, such as alkanes, and
fluoropolymers, such as teflon,
trichloro(1H,1H,2H,2H-perfluorooctyl)silane (TCS),
octadecyltrichlorosilane (OTS),
heptadecafluoro-1,1,2,2-tetrahydrodecyltrichlorosilane, fluoroPOSS,
and/or other fluoropolymers. Additional possible materials or
coatings for the solid 122 include: ceramics, polymeric materials,
fluorinated materials, intermetallic compounds, and composite
materials. Polymeric materials may include, for example,
polytetrafluoroethylene, fluoroacrylate, fluoroeurathane,
fluorosilicone, fluorosilane, modified carbonate, chlorosilanes,
silicone, polydimethylsiloxane (PDMS), and/or combinations thereof.
Ceramics may include, for example, titanium carbide, titanium
nitride, chromium nitride, boron nitride, chromium carbide,
molybdenum carbide, titanium carbonitride, electroless nickel,
zirconium nitride, fluorinated silicon dioxide, titanium dioxide,
tantalum oxide, tantalum nitride, diamond-like carbon, fluorinated
diamond-like carbon, and/or combinations thereof. Intermetallic
compounds may include, for example, nickel aluminide, titanium
aluminide, and/or combinations thereof.
[0053] The textures within the liquid-impregnated surface 120 are
physical textures or surface roughness. The textures may be random,
including fractal, or patterned. In certain embodiments, the
textures are micro-scale or nano-scale features. For example, the
textures may have a length scale L (e.g., an average pore diameter,
or an average protrusion height) that is less than about 100
microns, less than about 10 microns, less than about 1 micron, less
than about 0.1 microns, or less than about 0.01 microns. In certain
embodiments, the texture includes posts 124 or other protrusions,
such as spherical or hemispherical protrusions. Rounded protrusions
may be preferable to avoid sharp solid edges and minimize pinning
of liquid edges. The texture may be introduced to the surface using
any conventional method, including mechanical and/or chemical
methods such as lithography, self-assembly, and deposition, for
example.
[0054] The impregnating liquid 126 may be any type of liquid that
is capable of providing the desired non-wetting properties. For
example, the impregnating liquid 126 may be oil-based or
water-based (i.e., aqueous). In certain embodiments, the
impregnating liquid 126 is an ionic liquid (e.g., BMI-IM). Other
examples of possible impregnating liquids include hexadecane,
vacuum pump oils (e.g., FOMBLIN.RTM. 06/6, KRYTOX.RTM. 1506)
silicon oils (e.g., 10 cSt or 1000 cSt), fluorocarbons (e.g.,
perfluoro-tripentylamine, FC-70), shear-thinning fluids,
shear-thickening fluids, liquid polymers, dissolved polymers,
viscoelastic fluids, and/or liquid fluoroPOSS. In certain
embodiments, the impregnating liquid is (or comprises) a liquid
metal, a dielectric fluid, a ferro fluid, a magneto-rheological
(MR) fluid, an electro-rheological (ER) fluid, an ionic fluid, a
hydrocarbon liquid, and/or a fluorocarbon liquid. In one
embodiment, the impregnating liquid 126 is made shear thickening
with the introduction of nano particles. A shear-thickening
impregnating liquid 126 may be desirable for preventing impalement
and resisting impact from impinging liquids, for example.
[0055] To minimize evaporation of the impregnating liquid 126 from
the surface 120, it is generally desirable to use impregnating
liquids 126 that have low vapor pressures (e.g., less than 0.1
mmHg, less than 0.001 mmHg, less than 0.00001 mmHg, or less than
0.000001 mmHg). In certain embodiments, the impregnating liquid 126
has a freezing point of less than -20.degree. C., less than
-40.degree. C., or about -60.degree. C. In certain embodiments, the
surface tension of the impregnating liquid 126 is about 15 mN/m,
about 20 mN/m, or about 40 mN/m. In certain embodiments, the
viscosity of the impregnating liquid 126 is from about 10 cSt to
about 1000 cSt).
[0056] The impregnating liquid 126 may be introduced to the surface
120 using any conventional technique for applying a liquid to a
solid. In certain embodiments, a coating process, such as a dip
coating, blade coating, or roller coating, is used to apply the
impregnating liquid 126. Alternatively, the impregnating liquid 126
may be introduced and/or replenished by liquid materials flowing
past the surface 120 (e.g., in a pipeline). After the impregnating
liquid 126 has been applied, capillary forces hold the liquid in
place. Capillary forces scale roughly with the inverse of
feature-to-feature distance or pore radius, and the features may be
designed such that the liquid is held in place despite movement of
the surface and despite movement of air or other fluids over the
surface (e.g., where the surface 120 is on the outer surface of an
aircraft with air rushing over, or in a pipeline with oil and/or
other fluids flowing therethrough). In certain embodiments,
nano-scale features are used (e.g., 1 nanometer to 1 micrometer)
where high dynamic forces, body forces, gravitational forces,
and/or shearing forces could pose a threat to remove the liquid
film, e.g., for surfaces used in fast flowing pipelines, on
airplanes, on wind turbine blades, etc. Small features may also be
useful to provide robustness and resistance to impact.
[0057] Compared to gas-impregnated surfaces, the liquid-impregnated
surfaces described herein offer several advantages. For example,
because liquids are incompressible over a large range of pressures,
liquid-impregnated surfaces are generally more resistant to
impalement. In certain embodiments, while nano-scale (e.g., less
than one micron) textures may be necessary to avoid impalement with
gas-impregnated surfaces, micro-scale (e.g., from 1 micron to about
100 microns) textures are sufficient for avoiding impalement with
liquid-impregnated surface. As mentioned, micro-scale textures are
much easier to manufacture and more practical than nano-scale
textures.
[0058] Liquid-impregnated surfaces are also useful for reducing
viscous drag between a solid surface and a flowing liquid. In
general, the viscous drag or shear stress exerted by a liquid
flowing over a solid surface is proportional to the viscosity of
the liquid and the shear rate adjacent to the surface. A
traditional assumption is that liquid molecules in contact with the
solid surface stick to the surface, in a so-called "no-slip"
boundary condition. While some slippage may occur between the
liquid and the surface, the no-slip boundary condition is a useful
assumption for most applications.
[0059] In certain embodiments, non-wetting surfaces, such as
liquid-impregnated surfaces, are desirable as they induce a large
amount of slip at the solid surface. For example, referring again
to FIGS. 1a and 1c, when a contacting liquid 102, 128 is supported
by an impregnating liquid 126 or a gas, the liquid-liquid or
liquid-gas interface is free to flow or slip with respect to the
underlying solid material. Drag reductions of as much as 40% may be
achieved due to this slippage. As mentioned, however,
gas-impregnated surfaces are susceptible to impalement. When
impalement occurs with a gas-impregnated surface, the benefits of
reduced drag reduction may be lost.
[0060] Another advantage of the liquid-impregnated surfaces
described herein is that they are useful for minimizing the
formation and adhesion of frost or ice. In theory, previous (i.e.,
gas-impregnated) superhydrophobic surfaces, reduce ice formation
and adhesion by forcing the ice to rest atop low surface energy,
micro-and/or nanoscale surface textures, so that the ice contacts
mostly air. In practice, however, these gas-impregnated surfaces
can actually result in increased formation and adhesion of ice. For
example, when the temperature of the gas-impregnated surface is
brought below freezing, the gas-impregnated surface may begin to
accumulate frost, which converts the surface from superhydrophobic
to hydrophilic. When water contacts the now hydrophilic surface,
the water may infiltrate the hydrophilic textures and freeze. The
adhesive bond between the gas-impregnated surface and the ice may
be strengthened by interlocking between the ice and the surface
textures. Similarly, the liquid-impregnated surfaces described
herein are useful in situations where nucleation on the surface
poses a problem, for example, to reduce scaling, hydrate-formation,
plaque build-up on surgical implants, and the like.
[0061] According to classical nucleation theory, clusters of water
molecules gathered together under random thermal motion must reach
a critical size in order to sustain growth. The free energy
barrier, .DELTA.G*, to the heterogeneous nucleation of an embryo of
critical size on a flat surface, and the corresponding nucleation
rate are expressed as
.DELTA. G * = .pi. .sigma. IV r c 2 3 ( 2 - 3 m + m 3 ) ( 1 )
##EQU00001##
and
J=J.sub.0 exp(.DELTA.G*/kT).
The parameter m is the ratio of the interfacial energies given
by
m = ( .sigma. SV - .sigma. SI ) .sigma. IV , ( 3 ) ##EQU00002##
where .sigma..sub.SV, .sigma..sub.SI, and .sigma..sub.IV are the
interfacial energies for the substrate-vapor, substrate-ice, and
ice-vapor interfaces, respectively. In defining the free energy in
terms of a critical radius r.sub.c, the substrate and the ice are
assumed to be isotropic, and the nucleating particles are assumed
to be spherical. The critical radius r.sub.c can then be defined by
the Kelvin equation:
ln(p/p.sub.o)=2.sigma..sub.IV/n.sub.lkTr.sub.c. (4)
[0062] Nucleation experiments on solids demonstrate much lower
energy barriers to nucleation than the free energy barrier
predicted by Equation 1. This is likely due to nanoscale
heterogeneity and roughness, as high surface energy patches of a
surface and nanoscale concavities may act as nucleation sites.
Liquids, however, are commonly very smooth and homogeneous, and
nucleation of water on liquids has been shown experimentally to
agree well with classical theory. Consequently, the energy barrier
to frost nucleation or condensation is generally much higher for
hydrophobic liquids than it is for solids. In certain embodiments,
impregnating a liquid within the textures of a liquid-impregnated
surface prevents nucleation in these regions and forces
preferential nucleation on the peaks of the surfaces textures
(e.g., the tops of posts). With respect to ice formation, use of a
liquid-impregnated surface overcomes or reduces the ice formation
and adhesion challenges encountered with gas-impregnated,
superhydrophobic surfaces.
[0063] In certain embodiments, the liquid-impregnated surfaces
described herein have advantageous droplet roll-off properties that
minimize the accumulation of liquid or ice layers on the surfaces.
To prevent ice formation, for example, it is important for a
surface to be able to shed super-cooled droplets (e.g., freezing
rain) before the droplets freeze. Otherwise, droplets with
sufficiently high velocity (such as a rain droplet) may penetrate
the textures of a surface and remain pinned until ice is formed.
Advantageously, in certain embodiments, the liquid-impregnated
surfaces described herein have low roll-off angles (i.e., the angle
or slope of a surface at which a droplet in contact with the
surface will begin to roll or slide off the surface). The low
roll-off angles associated with liquid-impregnated surfaces allow
droplets in contact with the surface to easily roll off the surface
before the liquid can freeze and ice can accumulate. As described
in more detail below, the roll-off angle for water one surface
(i.e., an octadecyltrichlorosilane-treated silicone post surface
impregnated with hexadecane) was measured to be
1.7.degree..+-.0.1.degree.. In certain embodiments, the roll-off
angle for a liquid-impregnated surface is less than about
2.degree., or less than about 1.degree..
[0064] FIG. 2 is a schematic cross-sectional view of a liquid
droplet 202 resting on a liquid-impregnated surface 204, in
accordance with certain embodiments of the invention. In one
embodiment, the morphology of the droplet edge, which governs its
mobility, is affected by the properties of the impregnating liquid
126. For example, as depicted, the droplet may "pick up" the
impregnating liquid 126 locally near the droplet edges. The pooling
of impregnating liquid 126 at the edges of the droplet gives rise
to pinning forces. During droplet roll-off, the pinning forces and
viscous forces resist droplet movement due to gravity. For a
surface tilted at an angle .alpha., the force balance equation for
droplet roll-off is given by
V.SIGMA.g sin .alpha.=.pi.r.sup.2(1-.phi.).mu.v.sub.o/h+2r {square
root over (.phi.)}.gamma..sub.w(cos .theta..sub.r-cos
.theta..sub.a), (5)
where V.rho.g sin .alpha. is the gravity force on the droplet,
.pi.r.sup.2(1-.phi.).mu.v.sub.o/h is the viscous force, and 2r
{square root over (.phi.)}.gamma..sub.w(cos .theta..sub.r-cos
.theta..sub.a) is the pinning force. In this equation, V is droplet
volume, .rho. is the density of the non-wetted liquid, .phi. is
surface solid fraction (area fraction of the substrate in direct
contact with the non-wetted phase), .mu. is dynamic viscosity of
the impregnated liquid, v.sub.o is droplet sliding velocity
(characteristic drop velocity), h is a characteristic length scale
over whish shearing of the impregnated liquid occurs (e.g., a
height of surface posts or other surface texture height), a is the
angle the substrate makes with respect to the horizontal, g is the
acceleration of gravity, r is the contact radius of the non-wetted
droplet, .theta..sub.a and .theta..sub.r are the advancing and
receding contact angles of the non-wetted droplet, and
.gamma..sub.w is the surface energy of the non-wetted liquid in
equilibrium with vapor.
[0065] FIGS. 2b through 2d depict a non-wetting surface 250 that
includes a base portion 252 and an array of substantially square
posts 254, which have post tops 256. As shown, the posts 254 have a
height h, a side length a, and a post spacing b (i.e., a distance
between adjacent post surfaces). The base portion 252 includes base
regions 258 between the posts 260. The surface solid fraction .phi.
for the surface 250 is given by .phi.=a.sup.2/(a+b).sup.2.
[0066] In certain embodiments, the choice of impregnating liquid
influences the speed with which droplet roll-off occurs. For
example, if the liquid has a high viscosity, roll-off may occur
very slowly.
[0067] The liquid-impregnated surfaces described herein have a wide
variety of applications across many different industries. For
example, in certain embodiments, the liquid-impregnated surfaces
are used to repel liquids. There are many physical processes that
involve impingement of liquids on solid surfaces. Examples include
water droplets impinging steam turbine blades, oil droplets
impinging gas turbine blades, and rain droplets impinging aircraft
and wind turbine surfaces. For steam and gas turbines, water
droplets entrained in steam impinge on and stick to turbine blades,
thereby reducing turbine power output. By applying a
liquid-impregnated surface to the turbine blades, however, droplets
can be shed off the blades and turbine power output can be
significantly improved. In one embodiment, liquid-impregnated
surfaces present a large energy barrier to condensation and are
suitable as anti-fogging coatings for surfaces such as windows,
glasses, and/or mirrors.
[0068] In certain embodiments, liquid-impregnated surfaces are used
to provide ice-phobicity, thereby preventing or minimizing the
formation of ice. Ice may form on surfaces in many situations, such
as aircraft, wind turbines, power transmission lines, and
windshields. Ice formed on liquid-impregnated surfaces exhibits
much lower adhesion compared to ordinary surfaces and therefore can
easily be removed resulting into significant energy savings.
Liquid-impregnated surfaces are also ice-repellent in the sense
that their atomically smooth and low energy surface results in a
large energy barrier to desublimation (frost formation). In certain
embodiments, liquid-impregnated surfaces inhibit macroscopic ice
formation from freezing rain. For aircraft, since the
liquid-impregnating surfaces result in diminished ice and frost
adhesion, the energy and environmentally harmful chemicals required
to deice aircraft can be significantly reduced. When
liquid-impregnated surfaces are used on power transmission lines,
ice is less likely to form and can be more easily removed.
Liquid-impregnated surfaces can also significantly reduce ice
formation on wind turbines, thereby increasing turbine
efficiency.
[0069] In certain embodiments, liquid-impregnated surfaces are used
to provide hydrate-phobicity, thereby preventing or minimizing the
formation of hydrates. Hydrates form in oil and gas pipelines
during deep-sea drilling and/or extraction. Hydrates can plug
pipelines and cause a catastrophic rise in liquid pressures. By
choosing a suitable impregnating liquid, a liquid-impregnated
surface presents a high energy barrier to nucleation of hydrates
and thus resists hydrate formation. Furthermore, hydrates formed on
liquid-impregnated surfaces show much lower adhesion strength
compared to ordinary surfaces and hence can be easily removed. In
certain embodiments, the impregnating liquid is a permanent liquid
supplied with an original coating. Alternatively, the impregnating
liquid may be continuously supplied by oil present in the
pipeline.
[0070] In certain embodiments, liquid-impregnated surfaces are used
to provide salt-phobicity, thereby preventing or minimizing the
formation of salts or mineral scale. Salts may form on solid
surfaces in water-based or steam-based industrial facilities, such
as heat exchangers in power and desalination plants. Salts may also
form on the surfaces of oil and gas pipelines. Formation of salts
reduces the thermal performance of heat exchangers and also
requires expensive maintenance and/or shutdowns. Liquid-impregnated
surfaces exhibit a high energy barrier to salt nucleation that
resists salt formation and leads to much lower adhesion strength
compared to ordinary surfaces, thus facilitating easy removal. The
impregnating liquid may be a permanent liquid supplied with an
original coating, and/or it may be continuously supplied or
replenished by an adjacent liquid phase (e.g., oil present in an
oil or gas pipeline).
[0071] In certain embodiments, the liquid-impregnated surfaces are
used to reduce viscous drag between a solid surface and a flowing
liquid. Many engineering applications, such as the transportation
of crude oil in pipelines, require transport of liquids through
pipes over long distances. Due to drag forces between the liquids
and adjacent surfaces, the energy consumption associated with the
transport of these liquids is often significant. Use of
liquid-impregnated surfaces may greatly reduce the energy
consumption in these applications. By suitably choosing the
impregnated liquid, liquid-impregnated surfaces can exhibit
enhanced slippage of the contacting liquid and hence lead to a
drastic reduction in liquid-solid drag. In certain embodiments,
liquid-impregnated surfaces may be effective for use in artificial
arteries and/or veins.
[0072] In certain embodiments, liquid-impregnated surfaces are
useful for inhibiting corrosion. By using a corrosion-resistant
impregnating liquid, the underlying solid material may be protected
from a corrosive environment. Additionally, the ability of
liquid-impregnated surfaces to shed liquid droplets reduces
corrosion as moisture is more easily removed from the surface.
[0073] Liquid-impregnated surfaces may also be used in stents,
artificial arteries, and/or other surgical implants to prevent or
reduce deposit build-up thereupon.
[0074] In certain embodiments, a liquid-impregnated surface is used
to provide self-lubricating bone joints. For example, a
liquid-impregnated surface may be used as a material for artificial
joints implanted during knee and/or hip replacement surgeries. The
liquid-impregnated surface provides significantly reduced friction
between mating surfaces and also provides long-lasting lubrication.
The impregnating liquid may be a permanent liquid incorporated
before implantation, or it may be continuously supplied by
lubricating fluids present within the body (e.g., synovial
fluid).
[0075] There are many other applications in which
liquid-impregnated surfaces may be used to provide lubrication. For
example, liquid-impregnated surfaces may be used in bearings, on
piston/cylinder surfaces, and/or in any other automotive or
mechanical devices or equipment where a reduction in friction
between adjacent moving surfaces is beneficial. In one embodiment,
the impregnating liquid within the surface provides a long-lasting
supply of lubricant and hence reduces the time and energy spent in
applying lubricant to necessary locations.
[0076] Liquid-impregnated surfaces may also be used to provide
anti-fouling and/or self-cleaning. For example, liquid-impregnated
surfaces may be used for anti-fouling by resisting the adsorption
of debris by virtue of their low surface energy. In certain
embodiments, particles and chemicals on the liquid-impregnated
surface are absorbed and carried away by droplets that are shed
from the surface. This self-cleaning property is important for many
applications, such as self-cleaning glass (e.g., for windows,
glasses, and/or mirrors) and industrial coatings.
[0077] Liquid-impregnated surfaces may also be used to promote the
condensation of moisture. For example, liquid-impregnated surfaces
may be used to shed condensate easily and thereby enhance
condensation heat transfer (e.g., drop-wise condensation). In
certain embodiments, liquid-impregnated surfaces are applied to
heat exchangers, ranging from steam condensers, to HVAC condensers,
to natural gas condensers used in liquefying natural gas.
[0078] In certain embodiments, the liquid-impregnated surfaces
described herein are useful for coatings on sports equipment such
as ski glasses/goggles (e.g., antifogging), skis, snowboards, ice
skates, swimsuits, and the like.
[0079] FIG. 15 is an image of a droplet of water on a surface
having a matrix of post features and impregnated with silicone oil,
contrasting an impaled state with a nonwetted state. In the example
showing an impaled state--which may be disfavored for certain
embodiments in which an extremely non-wetting surface is
desired--the droplet is water, the impregnated liquid is silicone
oil, and the surface is untreated silicon with 10 micrometer square
posts having 10 micrometer spacing. In the impaled state, liquid
does not roll off of the surface. In the example showing a
non-wetted state--which is favored for certain embodiments in which
non-wetting is desired--the conditions are the same except that the
surface is treated with OTS (octadecyltrichlorosilane). Other
coatings could be used.
[0080] FIG. 16 is a schematic describing six liquid-impregnated
surface wetting states, in accordance with certain embodiments of
the invention. The six surface wetting states (state 1 through
state 6) depends on the four wetting conditions shown at the bottom
of FIG. 16 (conditions 1 to 4). In most embodiments, the non-wetted
states are preferred (states 1 to 4). Additionally, where a thin
film stably forms on the tops of the posts (or other features on
the surface), as in non-wetted states 1 and 3, even more preferable
non-wetting properties (and other related properties described
herein) may be observed.
[0081] In order to achieve non-wetted states, it is preferable to
have low solid surface energy and low surface energy of the
impregnated liquid compared to the nonwetted liquid. For example,
surface energies below about 25 mJ/m.sup.2 are preferred. Low
surface energy liquids include certain hydrocarbon and
fluorocarbon-based liquids, for example, silicone oil,
perfluorocarbon liquids, perfluorinated vaccum oils (e.g., Krytox
1506 or Fromblin 06/6), fluorinated coolants such as
perfluoro-tripentylamine (e.g., FC-70, sold by 3M, or FC-43),
fluorinated ionic liquids that are immiscible with water, silicone
oils comprising PDMS, and fluorinated silicone oils.
[0082] Examples of low surface energy solids include the following:
silanes terminating in a hydrocarbon chain (such as
octadecyltrichlorosilane), silanes terminating in a fluorocarbon
chain (e.g. fluorosilane), thiols terminating in a hydrocarbon
chain (such butanethiol), and thiols terminating in a fluorocarbon
chain (e.g. perfluorodecane thiol). In certain embodiments, the
surface comprises a low surface energy solid such as a
fluoropolymer, for example, a silsesquioxane such as fluorodecyl
polyhedral oligomeric silsesquioxane. In certain embodiments, the
fluoropolymer is (or comprises) tetrafluoroethylene (ETFE),
fluorinated ethylenepropylene copolymer (FEP), polyvinylidene
fluoride (PVDF), perfluoroalkoxytetrafluoroethylene copolymer
(PFA), polytetrafluoroethylene (PTFE), tetrafluoroethylene,
perfluoromethylvinylether copolymer (MFA),
ethylenechlorotrifluoroethylene copolymer (ECTFE),
ethylene-tetrafluoroethylene copolymer (ETFE), perfluoropolyether,
or Tecnoflon.
[0083] In FIG. 16, Gamma_wv is the surface energy of the non-wetted
phase in equilibrium with vapor; Gamma_ow is the interfacial energy
between the non-wetted phase and the impregnated liquid; Gamma_ov
is the surface energy of the impregnated liquid phase in
equilibrium with vapor; Gamma_sv is the surface energy of the solid
in equilibrium with vapor; Gamma_so is the interfacial energy
between the impregnated phase and the solid; Gamma_sw is the
interfacial energy between the solid and the non-wetted phase;
r=total surface area divided by projected surface area; Theta_c1,
Theta_c2, theta_c3, theta_c4, theta_w1, theta_w2, are the
macroscopic contact angles made by the non-wetted phase in each
wetting state; Theta*_os(v) is the macroscopic contact angle of oil
on the textured substrate when the phase surrounding the textured
substrate is vapor; Theta_os(v) is the contact angle of oil on a
smooth solid substrate of the same chemistry when the phase
surrounding the oil droplet is vapor; Theta*_os(w) is the
macroscopic contact angle of oil on the textured substrate when the
phase surrounding the oil droplet is water; and theta_os(w) is the
contact angle of oil on a smooth substrate of the same chemistry as
the textured surface when the phase surrounding the oil droplet is
water.
[0084] FIG. 17 is a schematic showing conditions for the six
liquid-impregnated surface wetting states shown in FIG. 16, in
accordance with certain embodiments of the invention.
EXPERIMENTAL EXAMPLES
[0085] FIG. 3 includes a photograph of a microtextured surface 302,
in accordance with certain embodiments of the invention. The
surface 302 was made of silicon and includes a square pattern of 10
.mu.m pillars spaced 25 .mu.m apart. As depicted, a bottom portion
304 of the surface 302 was impregnated with hexadecane (an
impregnating liquid), while a top portion 306 was impregnated with
air (i.e., no impregnating liquid). An edge 308 of the hexadecane
defines a boundary between the top portion 306 and the bottom
portion 304. Impregnation with hexadecane was achieved by (i)
dipping the bottom portion 304 of surface 302 in a bath of
hexadecane and (ii) withdrawing the bottom portion 304 from the
hexadecane at a slow rate (10 mm/min), with the help of a dip
coater. The impregnation was robust as the hexadecane remained in
place while being sprayed with water jets having an impact velocity
of approximately 5 m/s. Contact angle hysteresis and roll-off angle
for a 7 .mu.L water droplet were measured on the bottom portion 304
of the surface 302 (i.e., the liquid-impregnated portion of surface
302). Contact angle hysteresis (CAH) and roll-off angle were both
were extremely low: CAH was less than 1.degree. whereas the
roll-off angle was only 1.7.+-.0.1.degree..
[0086] FIGS. 4a and 4b depict a sequence of high speed video images
depicting the impingement of a water droplet 402 on a
gas-impregnated surface 404 and a liquid-impregnated surface 406,
respectively. As discussed above, when a liquid droplet impinges a
surface, it can exert large pressures on the surface. This is true
even for millimetric sized drops impacting the surface at a
velocity less than about 5 m/s. As a result of these pressures,
droplets may become impaled on a gas-impregnated surface, thereby
causing the gas-impregnated surface to lose its enhanced drop
shedding qualities. Droplet impalement is depicted in FIG. 4a in
which the droplet is shown to stick to the gas-impregnated surface
404, rather than bounce off of the surface. To prevent sticking,
previous approaches with gas-impregnated surfaces emphasize the
introduction of texturing at nano-scale. However, with a
liquid-impregnated surface approach, even microtextures, on the
order of 10 .mu.m, can successfully shed impinging droplets. This
is shown in FIG. 4b in which the same microtexture that impaled the
water drop when air was present completely repelled the droplet
when it was impregnated with hexadecane. The scale bar 408 in these
figures is 3 mm.
[0087] FIG. 5 includes a sequence of high speed video images
showing a droplet 502 impacting a liquid-impregnated surface 504
tilted at 25.degree. with respect horizontal. The water droplet 502
in this instance slipped and eventually bounced off the surface
504, demonstrating that the liquid-impregnated surface 504 could
shed the impinging droplet successfully, and was robust against
impalement. The water droplet in this case was 2.5 mm in diameter.
The liquid-impregnated surface 504 was a microtextured surface
containing an impregnating liquid of hexadecane in an array of 10
.mu.m square posts of silicon, spaced 25 .mu.m apart.
[0088] FIGS. 6a-6d include a sequence of ESEM images showing the
formation of frost on a gas-impregnated, superhydrophobic surface
602, in accordance with certain embodiments of the invention. The
superhydrophobic surface 602 included an array of hydrophobic
square posts 604 with width, edge-to edge spacing, and aspect ratio
of 15 .mu.m, 30 .mu.m, and 7, respectively. FIG. 6a depicts a dry
surface (i.e., no frost), while FIGS. 6b-6d depict the formation of
frost 606 on the surface. The intrinsic water contact angle of the
hydrophobic coating on the posts was 110.degree.. The surface was
maintained at a temperature of -13.degree. C. by means of a cold
stage accessory of the ESEM. At the beginning of the experiment,
the chamber pressure was maintained at .about.100 Pa, well below
the saturation pressure to ensure a dry surface. The vapor pressure
in the chamber was then slowly increased until frost nucleation was
observed. Frost nucleation and growth occurred without any
particular spatial preference on all of the available area,
including post tops, sidewalls, and valleys, due to the uniform
intrinsic wettability of the surface.
[0089] FIG. 7a-7c depict images from droplet impact testing on dry
and frosted superhydrophobic surfaces, in accordance with certain
embodiments of the invention. The testing was conducted using water
droplets having a radius of 1 mm and impacting the surface at a
velocity of 0.7 m/s. FIG. 7a is a top view SEM image of the
representative Si post array surface 702 having a width,
edge-to-edge spacing, and aspect ratio of 10 .mu.m, 20 .mu.m, and
1, respectively. FIG. 7b includes a sequence of high-speed video
images of droplet impact on a dry surface 704. As depicted, the
droplet recoils from the surface 704, as the anti-wetting capillary
pressure is greater than the dynamic wetting pressures. FIG. 7c
includes a sequence of high-speed video images of droplet impact on
a surface covered with frost 706. The results show that frost 706
alters the wetting properties of the surface, making the surface
hydrophilic, and causing Cassie-to-Wenzel wetting transition of the
impacting drop, subsequent pinning, and formation of "Wenzel" ice
on the surface.
[0090] FIG. 8 is a plot of measured normalized ice adhesion
strength versus normalized surface area, in accordance with certain
embodiments of the invention. Normalized ice adhesion strength is
the ice adhesion strength as measured with textured surfaces
divided by the ice adhesion strength as measured with a smooth
surface. Normalized surface area is the total surface area
normalized by the projected area. As the figure indicates, the
normalized ice adhesion strength was found to increase with
normalized surface area and shows a strong linear trend. The best
linear fit to the data (solid line, correlation coefficient
R2=0.96) has a slope of one and passes through the origin
(extrapolated using a dashed line), indicating that ice is
contacting all available surface area, including the sides of the
posts. The interlocking of the ice with the textured surface
results in increased adhesion strength. Insets (a)-(d) in this
figure are top view optical images of representative replicated
PDMS post arrays from sparse to dense spacing (a=15 .mu.m, h=10
.mu.m, b=45, 30, 15, and 5 .mu.m, respectively, where a, h, and b
are dimensions shown in FIGS. 2C and 2D) showing the excellent
quality of replication.
[0091] Roll-off experiments were conducted using a Rame-hart
Goniometer with a tilting stage to measure the drop-shedding
properties of an octadecyltrichlorosilane-treated silicone post
surface (with 25 .mu.m post spacing) impregnated with hexadecane. A
roll-off angle of 1.7.degree..+-.0.1.degree. was measured for a 7
.mu.l drop. Advancing and receding contact angles were
98.degree..+-.1.degree. and 97.degree..+-.1.degree., respectively.
This very low roll-off angle allows the liquid-impregnated surface
to shed liquid droplets quickly (e.g., before they freeze in
freezing rain applications).
[0092] FIGS. 9 and 10 show experimental measurements of water
droplet mobility on liquid impregnating surfaces. FIG. 9 is a plot
of roll-off angle .alpha. (or the tilt angle) as a function of
surface solid fraction .phi., for four different fluids impregnated
in the surface (feature dimensions a and b are as shown in FIG.
2D). Note that the "Air" case represents a conventional
superhydrophobic surface (i.e., a gas-impregnated surface). The
plot shows that roll-off angle .alpha. was very small (less than
5.degree.) for silicone oils and was not significantly affected by
solid fraction .phi.. For an ionic liquid (i.e., BMI-IM), which
does not wet the impregnating surface completely, the roll-off
angle .alpha. was relatively higher, almost equal to the air case,
and increased with solid fraction .phi. due to increased pinning of
the droplet on microposts. This is likely because an increase of
solid fraction .phi. means more microposts in a unit area. FIG. 10
is a plot of water droplet sliding velocity v.sub.o, for a test in
which the surface was tilted at 30.degree., as a function of solid
fraction .phi. for 1000 cSt silicone oil. The plot shows that
sliding velocity v.sub.o decreased when the solid fraction .phi.
increased, due to increased pinning
[0093] FIGS. 11 and 12 show additional experimental measurements of
water droplet sliding velocity v.sub.o for different impregnating
fluids having different viscosities, when the surface was tilted to
30.degree.. The figures show that sliding velocity v.sub.o with air
is higher than with silicone oils, but sliding velocity v.sub.o has
the same decreasing trend with solid fraction .phi. due to
increased pinning FIG. 12 is a plot of sliding velocity v.sub.o as
a function of solid fraction .phi. for 10 cSt silicone oil. The
plot shows that the magnitude of sliding velocity v.sub.o is higher
than with 1000 cSt but less than with air. The trend with solid
fraction .phi. remains the same. The measurements in FIGS. 10 and
12 show that droplet mobility (e.g., sliding velocity v.sub.o)
increases as the viscosity of the impregnating liquid decreases.
This suggests that the greatest mobility is likely achieved low
viscosity impregnating fluids, such as air.
[0094] In one experiment, the viscosity of the impregnating liquid
was varied to determine the influence of viscosity on droplet
impingement. The surface used for the test included silicon
microposts (10.times.10.times.10 .mu.m) with a post spacing of 10
.mu.m. When the viscosity of the impregnating liquid was 10 cSt,
the impinging water droplet was able to bounce-off the
liquid-impregnated surface. By contrast, when the viscosity of the
impregnating liquid was 1000 cSt, the impinging water droplet
remained on the surface (i.e., it did not bounce off the surface).
Unlike a similar impingement experiment conducted with a
gas-impregnated surface, however, the droplet was able to
subsequently roll-off the surface, although the sliding velocity
was low.
[0095] FIGS. 13 and 14 include Environmental SEM (ESEM) images of
frost nucleation on micropost surfaces impregnated with silicone
oil. FIG. 13 shows a surface 1402 before nucleation was triggered.
FIG. 14 shows a surface 1404 during nucleation and indicates that
frost 1306 had the tendency to nucleate on the micropost tops.
Equivalents
[0096] While the invention has been particularly shown and
described with reference to specific preferred embodiments, it
should be understood by those skilled in the art that various
changes in form and detail may be made therein without departing
from the spirit and scope of the invention as defined by the
appended claims
* * * * *