The manufacturing of thin films with structured surfaces by large‐scale rolling has distinct advantages over other techniques, such as lithography, due to scalability. However, it is not well understood or quantified how processing conditions can affect the microstructure at different physical scales. Hence, the objective of this investigation is to develop a validated computational model of the symmetric forward‐roll coating process to understand, predict, and control the morphology of carbon nanotube (CNT)
Periodic micro/nanoscale structures from nature have inspired the scientific community to adopt surface design for various applications, including superhydrophobic drag reduction. One primary concern of practical applications of such periodic microstructures remains the scalability of conventional microfabrication technologies. This study demonstrates a simple template‐free scalable manufacturing technique to fabricate periodic microstructures by controlling the ribbing defects in the forward roll coating. Viscoelastic composite coating materials are designed for roll‐coating using carbon nanotubes (CNT) and polydimethylsiloxane (PDMS), which helps achieve a controllable ribbing with a periodicity of 114–700 µm. Depending on the process parameters, the patterned microstructures transition from the linear alignment to a random structure. The periodic microstructure enables hydrophobicity as the water contact angles of the samples ranged from 128° to 158°. When towed in a static water pool, a model boat coated with the microstructure film shows 7%–8% faster speed than the boat with a flat PDMS film. The CNT addition shows both mechanical and electrical properties improvement. In a mechanical scratch test, the cohesive failure of the CNT‐PDMS film occurs in ≈90% higher force than bare PDMS. Moreover, the nonconductive bare PDMS shows sheet resistance of 747.84–22.66 Ω □−1with 0.5 to 2.5 wt% CNT inclusion.
more » « less- NSF-PAR ID:
- 10372764
- Publisher / Repository:
- Wiley Blackwell (John Wiley & Sons)
- Date Published:
- Journal Name:
- Advanced Materials Interfaces
- Volume:
- 9
- Issue:
- 27
- ISSN:
- 2196-7350
- Format(s):
- Medium: X
- Sponsoring Org:
- National Science Foundation
More Like this
-
more » « less
– polydimethylsiloxane (PDMS) pastes. The effects of the thin‐film rheological properties and the roller gap on the ribbing behavior are investigated and a ribbing instability prediction model is formulated from experimental measurements and computational predictions. The CNT–PDMS thin‐film system is modeled by a nonlinear implicit dynamic finite‐element method that accounts for ribbing instabilities, large displacements, rolling contact, and material viscoelasticity. Dynamic mechanical analysis is used to obtain the viscoelastic properties of the CNT–PDMS paste for various CNT weight distributions. Furthermore, a Morris sensitivity analysis is conducted to obtain insights on the dominant predicted characteristics pertaining to the ribbing microstructure. Based on the sensitivity analysis, a critical ribbing aspect ratio is identified for the CNT–PDMS system corresponding to a critical roller gap. -
more » « less
Summary We combined optical and atomic force microscopy to observe morphology and kinetics of microstructures (typically referred to as bees) that formed at free surfaces of unmodified Performance Graded (PG) 64‐22 asphalt binders upon cooling from 150°C to room temperature (RT) at 5°C min–1, and changes in these microstructures when the surface was terminated with a transparent solid (glass) or liquid (glycerol) overlayer. The main findings are: (1) at free binder surfaces, wrinkled microstructures started to form near the crystallization temperature (∼45°C) of saturates such as wax observed by differential scanning calorimetry, then grew to ∼5 µm diameter, ∼25 nm wrinkle amplitude and 10–30% surface area coverage upon cooling to RT, where they persisted indefinitely without observable change in shape or density. (2) Glycerol coverage of the binder surface during cooling reduced wrinkled area and wrinkle amplitude three‐fold compared to free binder surfaces upon initial cooling to RT; continued glycerol coverage at RT eliminated most surface microstructures within ∼4 h. (3) No surface microstructures were observed to form at binder surfaces covered with glass. (4) Submicron bulk microstructures were observed by near‐infrared microscopy beneath the surfaces of all binder samples, with size, shape and density independent of surface coverage. No tendency of such structures to float to the top or sink to the bottom of mm‐thick samples was observed. (5) We attribute the dependence of surface wrinkling on surface coverage to variation in interface tension, based on a thin‐film continuum mechanics model.
Lay Description Asphalt binder, or bitumen, is the glue that holds aggregate particles together to form a road surface. It is derived from the heavy residue that remains after distilling gasoline, diesel and other lighter products out of crude oil. Nevertheless, bitumen varies widely in composition and mechanical properties. To avoid expensive road failures, bitumen must be processed after distillation so that its mechanical properties satisfy diverse climate and load requirements. International standards now guide these mechanical properties, but yield varying long‐term performance as local source composition and preparation methods vary.
In situ diagnostic methods that can predict bitumen performance independently of processing history are therefore needed. The present work focuses on one promising diagnostic candidate: microscopic observation of internal bitumen structure. Past bitumen microscopy has revealed microstructures of widely varying composition, size, shape and density. A challenge is distinguishing bulk microstructures, which directly influence a binder's mechanical properties, from surface microstructures, which often dominate optical microscopy because of bitumen's opacity and scanning‐probe microscopy because of its inherent surface specificity. In previously published work, we used infrared microscopy to enhance visibility of bulk microstructure. Here, as a foil to this work, we use visible‐wavelength microscopy together with atomic‐force microscopy (AFM) specifically to isolatesurface microstructure, to understand its distinct origin and morphology, and to demonstrate its unique sensitivity to surface alterations. To this end, optical microscopy complements AFM by enabling us to observe surface microstructures form at temperatures (50°C–70°C) at which bitumen's fluidity prevents AFM, and to observe surface microstructure beneath transparent, but chemically inert, liquid (glycerol) and solid (glass) overlayers, which alter surface tension compared to free surfaces. From this study, we learned, first, that, as bitumen cools, distinctly wrinkled surface microstructures form at the same temperature at which independent calorimetric studies showed crystallization in bitumen, causing it to release latent heat of crystallization. This shows that surface microstructures are likely precipitates of the crystallizable component(s). Second, a glycerol overlayer on the cooling bitumen results in smaller, less wrinkled, sparser microstructures, whereas a glass overlayer suppresses them altogether. In contrast, underlying smaller bulk microstructures are unaffected. This shows that surface tension is the driving force behind formation and wrinkling of surface precipitates. Taken together, the work advances our ability to diagnose bitumen samples noninvasively by clearly distinguishing surface from bulk microstructure. -
Abstract Bio-inspired, micro/nanotextured surfaces have a variety of applications including superhydrophobicity, self-cleaning, anti-icing, antibiofouling, and drag reduction. In this paper, a template-free and scalable roll coating process is studied for fabrication of micro/nanoscale topographies surfaces. These micro/nanoscale structures are generated with viscoelastic polymer nanocomposites and derived by controlling ribbing instabilities in forward roll coating. The relationship between process conditions and surface topography is studied in terms of shear rate, capillary number, and surface roughness parameters (e.g., Wenzel factor and the density of peaks). For a given shear rate, the sample roughness increased with a higher capillary number until a threshold point. Similarly, for a given capillary number, the roughness increased up to a threshold range associated with shear rate. A peak density coefficient (PDC) model is proposed to relate capillary number and shear rate to surface roughness. The optimum range of the shear rate and the capillary number was found to be 40–60 s−1 and 4.5 × 105–6 × 105, respectively. This resulted in a maximum Wenzel roughness factor of 1.91, a peak density of 3.94 × 104 (1/mm2), and a water contact angle (WCA) of 128 deg.more » « less
-
more » « less
Abstract Many natural surfaces such as butterfly wings, beetles' backs, and rice leaves exhibit anisotropic liquid adhesion; this is of fundamental interest and is important to applications including self‐cleaning surfaces, microfluidics, and phase change energy conversion. Researchers have sought to mimic the anisotropic adhesion of butterfly wings using rigid surface textures, though natural butterfly scales are sufficiently compliant to be deflected by capillary forces exerted by drops. Here, inspired by the flexible scales of the
Morpho aega butterfly wing, synthetic surfaces coated with flexible carbon nanotube (CNT) microscales with anisotropic drop adhesion properties are fabricated. The curved CNT scales are fabricated by a strain‐engineered chemical vapor deposition technique, giving ≈5000 scales of ≈10 µm thickness in a 1 cm2area. Using various designed CNT scale arrays, it is demonstrated that the anisotropy of drop roll‐off angle is influenced by the geometry, compliance, and hydrophobicity of the scales; and a maximum roll‐off anisotropy of 6.2° is achieved. These findings are supported by a model that relates the adhesion anisotropy to the scale geometry, compliance, and wettability. The electrical conductivity and mechanical robustness of the CNTs, and the ability to fabricate complex multidirectional patterns, suggest further opportunities to create engineered synthetic scale surfaces. -
more » « less
Abstract Flexible electronics have received considerable attention in the past decades due to their promising application in rollable display screens, wearable devices, implantable devices, and other electronic applications. In particular, conjugated polymers are favored for flexible electronics due to their mechanical flexibility and potential for solution‐processed fabrication techniques, such as blade‐coating, roll‐to‐roll printing, and high‐throughput printing allowing for high‐performance transistor devices. Thiophene is the prevailing conjugated unit to construct these conjugated polymers due to its favorable electronic properties. On the other hand, furans are among the few conjugated moieties that are easily derived from bio renewable resources. To promote sustainability, we selectively introduced furan into the conjugated backbone of a high‐mobility polymer scaffold and systematically studied the effect on the microstructure and charge transport. We show that partially and selectively replacing thiophene units with furan can yield nearly comparable performance compared to the all‐thiophene polymer. This strategy offers an improvement in the sustainability of the polymer by incorporating bio‐sourced furan without sacrificing the high‐performance characteristics. Meanwhile, polymers with incorrect or complete furan incorporation show reduced mobilities. This work serves to develop coherent structure–morphology–performance relationships; such knowledge will establish guidelines for the future development of sustainable, furan‐based conjugated materials.
