Controlling dropwise condensation is fundamental to water-harvesting systems, desalination, thermal power generation, air conditioning, distillation towers, and numerous other applications. For any of these, it is essential to design surfaces that enable droplets to grow rapidly and to be shed as quickly as possible. However, approaches based on microscale, nanoscale or molecular-scale textures suffer from intrinsic trade-offs that make it difficult to optimize both growth and transport at once. Here we present a conceptually different design approach—based on principles derived from Namib desert beetles, cacti, and pitcher plants—that synergistically combines these aspects of condensation and substantially outperforms other synthetic surfaces. Inspired by an unconventional interpretation of the role of the beetle’s bumpy surface geometry in promoting condensation, and using theoretical modelling, we show how to maximize vapour diffusion fluxat the apex of convex millimetric bumps by optimizing the radius of curvature and cross-sectional shape. Integrating this apex geometry with a widening slope, analogous to cactus spines, directly couples facilitated droplet growth with fast directional transport, by creating a free-energy profile that drives the droplet down the slope before its growth rate can decrease. This coupling is further enhanced by a slippery, pitcher-plant-inspired nanocoating that facilitates feedback between coalescence-driven growth and capillary-driven motion on the way down. Bumps that are rationally designed to integrate these mechanisms are able to grow and transport large droplets even against gravity and overcome the effect of an unfavourable temperature gradient. We further observe an unprecedented sixfold-higher exponent of growth rate, faster onset, higher steady-state turnover rate, and a greater volume of water collected compared to other surfaces. We envision that this fundamental understanding and rational design strategy can be applied to a wide range of water-harvesting and phase-change heat-transfer applications.

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Condensation on Slippery Asymmetric Bumps

Passive anti-icing or icephobic superhydrophobic surfaces have attracted great interest due to their potential multifaceted implications for the prevention and/or easy removal of undesired ice in many applications. However, a superhydrophobic surface with both excellent anti-icing and icephobic performances has rarely been reported due to difficulties in sustaining a good Cassie state stability. This is the case especially under high humidity and freezing environment conditions. In the present study, a new triple-scale micro/nanostructured superhydrophobic surface with both excellent anti-icing and icephobic properties has been designed via a hybrid method, combining ultrafast laser ablation and chemical oxidation. The novel surface structure is composed of periodical microcone arrays covered with densely grown nanograsses and dispersedly distributed microflowers. This surface exhibits an excellent Cassie state stability with its critical Laplace pressure reaching up to 1450 Pa, which is essential for good anti-icing and icephobic performances. The anti-icing feature of the prepared superhydrophobic surface is achieved by a rapid rolling-off of the impacting droplets. Moreover, an excellent resistance to the impact of high humidity has been achieved via hierarchical condensation, coalescence-induced jumping, and upward moving. A good delay of the heterogeneous nucleation at the solid-liquid interface under freezing condition has been registered as well, due to the presence of stable air pockets within the surface structures. In addition, the ice adhesion strength of the prepared superhydrophobic surface can be as low as 1.7 kPa, which is the lowest value when compared with the state-of-the-art superhydrophobic surfaces. Such a low ice adhesion strength allows the ice to be easily removed by its own weight and demonstrates an excellent icephobic performance. The repeated icing-deicing tests indicate a decent deicing robustness of the synthesized superhydrophobic surface. Thus, this triple-scale superhydrophobic surface exhibits a good anti-icing and icephobic performance with an excellent Cassie state stability, high humidity resistance, and good deicing durability. We hypothesize that the proposed fabrication strategy and associated basic findings will shed new light on the design of robust ice-resistant superhydrophobic surfaces and contribute to a better understanding of the relationship between superhydrophobicity and ice resistance.

Triple-Scale Superhydrophobic Surface with Excellent Anti-Icing and Icephobic Performance via Ultrafast Laser Hybrid Fabrication.

We investigate the spreading at variable rate of a water drop on a smooth hydrophobic substrate in an ambient oil bath driven by electrowetting. We find that a thin film of oil is entrapped under the drop. Its thickness is described by an extension of the Landau-Levich law of dip coating that includes the electrostatic pressure contribution. Once trapped, the thin film becomes unstable under the competing effects of the electrostatic pressure and surface tension and dewets into microscopic droplets, in agreement with a linear stability analysis. Our results recommend electrowetting as an efficient experimental approach to the fundamental problem of dynamic wetting in the presence of a tunable substrate-liquid interaction.

Electrowetting-induced oil film entrapment and instability

Droplet transport on, and shedding from, surfaces is ubiquitous in nature and is a key phenomenon governing applications including biofluidics, self-cleaning, anti-icing, water harvesting, and electronics thermal management. Conventional methods to achieve spontaneous droplet shedding enabled by surface-droplet interactions suffer from low droplet transport velocities and energy conversion efficiencies. Here, by spatially confining the growing droplet and enabling relaxation via rationally designed grooves, we achieve single-droplet jumping of micrometer and millimeter droplets with dimensionless jumping velocities v* approaching 0.95, significantly higher than conventional passive approaches such as coalescence-induced droplet jumping (v* ≈ 0.2-0.3). The mechanisms governing single-droplet jumping are elucidated through the study of groove geometry and local pinning, providing guidelines for optimized surface design. We show that rational design of grooves enables flexible control of droplet-jumping velocity, direction, and size via tailoring of local pinning and Laplace pressure differences. We successfully exploit this previously unobserved mechanism as a means for rapid removal of droplets during steam condensation. Our study demonstrates a passive method for fast, efficient, directional, and surface-pinning-tolerant transport and shedding of droplets having micrometer to millimeter length scales.

Laplace pressure driven single-droplet jumping on structured surfaces

Even though droplet microfluidics has been developed since the early 1980s, the number of applications that have resulted in commercial products is still relatively small. This is partly due to an ongoing maturation and integration of existing methods, but possibly also because of the emergence of new techniques, whose potential has not been fully realized. This review summarizes the currently existing techniques for manipulating droplets in two-phase flow microfluidics. Specifically, very recent developments like the use of acoustic waves, magnetic fields, surface energy wells, and electrostatic traps and rails are discussed. The physical principles are explained, and (potential) advantages and drawbacks of different methods in the sense of versatility, flexibility, tunability and durability are discussed, where possible, per technique and per droplet operation: generation, transport, sorting, coalescence and splitting.

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Droplet Manipulations in Two Phase Flow Microfluidics

We show that electrowetting (EW) with structured electrodes significantly modifies the distribution of drops condensing onto flat hydrophobic surfaces by aligning the drops and by enhancing coalescence. Numerical calculations demonstrate that drop alignment and coalescence are governed by the drop-size-dependent electrostatic energy landscape that is imposed by the electrode pattern and the applied voltage. Such EW-controlled migration and coalescence of condensate drops significantly alter the statistical characteristics of the ensemble of droplets. The evolution of the drop size distribution displays self-similar characteristics that significantly deviate from classical breath figures on homogeneous surfaces once the electrically induced coalescence cascades set in beyond a certain critical drop size. The resulting reduced surface coverage, coupled with earlier drop shedding under EW, enhances the net heat transfer.

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Breath Figures under Electrowetting: Electrically Controlled Evolution of Drop Condensation Patterns.

The equilibrium morphology of liquid drops exposed to geometric constraints can be rather complex. Even for simple geometries, analytical solutions are scarce. Here, we investigate the equilibrium shape and position of liquid drops confined in the wedge between two solid surfaces at an angle α. Using electrowetting, we control the contact angle and thereby manipulate the shape and the equilibrium position of aqueous drops in ambient oil. In the absence of contact angle hysteresis and buoyancy, we find that the equilibrium shape is given by a truncated sphere, at a position that is determined by the drop volume and the contact angle. At this position, the net normal force between drop and the surfaces vanishes. The effect of buoyancy gives rise to substantial deviations from this equilibrium configuration which we discuss here as well. We eventually show how the geometric constraint and electrowetting can be used to position droplets inside a wedge in a controlled way, without mechanical actuation.

On the shape of a droplet in a wedge: new insight from electrowetting

We show here that ac electrowetting (ac-EW) with structured electrodes can be used to control the gravity-driven shedding of drops condensing onto flat hydrophobic surfaces. Under ac-EW with straight interdigitated electrodes, the condensate drops shed with relatively small radii due to the ac-EW-induced reduction of contact angle hysteresis. The smaller shedding radius, coupled with the enhanced growth due to coalescence under EW, results in an increased shedding rate. We also show that the condensate droplet pattern under EW can be controlled, and the coalescence can be further enhanced, using interdigitated electrodes with zigzag edges. Such enhanced coalescence in conjunction with the electrically induced trapping effect due to the electrode geometry results in a larger shedding radius, but a lower shedding rate. However, the shedding characteristics can be further optimized by applying the electrical voltage intermittently. We finally provide an estimate of the condensate volume removed per unit time in order to highlight how it is enhanced using ac-EW-controlled dropwise condensation.

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Controlling shedding characteristics of condensate drops using electrowetting

Electrowetting (EW) of water drops in ambient oil has found a wide range of applications including lab-on-a-chip devices, display screens, and variable focus lenses. The efficacy of all these applications is dependent on the contact angle hysteresis (CAH), which is generally reduced in the presence of ambient oil due to thin lubrication layers. While it is well-known that AC voltage reduces the effective contact angle hysteresis (CAH) for EW in ambient air, we demonstrate here that CAH for EW in ambient oil increases with increasing AC and DC voltage. Taking into account the disjoining pressure of the fluoropolymer-oil-water system, short range chemical interactions, viscous oil entrainment, and electrostatic stresses, we find that this observation can be explained by progressive thinning of the oil layer underneath the drop with increasing voltage. This exposes the droplet to the roughness of the underlying solid and thereby increases hysteresis.

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Contact angle hysteresis and oil film lubrication in electrowetting with two immiscible liquids

The motion of confined droplets in immiscible liquid-liquid systems strongly depends on the intrinsic relative wettability of the liquids on the confining solid material and on the typical speed, which can induce the formation of a lubricating layer of the continuous phase. In electrowetting, which routinely makes use of aqueous drops in ambient non-polar fluids that wet the wall material, electric stresses enter the force balance in addition to capillary and viscous forces and confinement effects. Here, we study the mobility of droplets upon electrowetting actuation in a wedge-shaped channel, and the subsequent relaxation when the electrowetting actuation is removed. We find that the droplets display two different mobility regimes: a fast regime, corresponding to gliding on a thin film of the ambient fluid, and a slow regime, where the film is replaced by direct contact between the droplet and the channel walls. Using a combination of experiments and numerical simulations, we show that the cross-over between these regimes arises from the interplay between the small-scale dynamics of the thin film of ambient fluid and the large-scale motion of the droplet. Our results shed light on the complex dynamics of droplets in non-uniform channels driven by electric actuation, and can thus help the rational design of devices based on electrowetting-driven droplet transport.

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Davood Baratian

Papers

Breath Figures under Electrowetting: Electrically Controlled Evolution of Drop Condensation Patterns.

On the shape of a droplet in a wedge: new insight from electrowetting

Controlling shedding characteristics of condensate drops using electrowetting

Contact angle hysteresis and oil film lubrication in electrowetting with two immiscible liquids

Slippery when wet: mobility regimes of confined drops in electrowetting