Electrodeposited Thin-Film Micro-Thermoelectric Coolers with Extreme Heat Flux Handling and Microsecond Time Response.

Thin-film thermoelectric coolers are emerging as a viable option for the on-chip temperature management of electronic and photonic integrated circuits. In this work, we demonstrate the record heat flux handling capability of electrodeposited Bi2Te3 films of 720(±60) W cm-2 at room temperature, achieved by careful control of the contact interfaces to reduce contact resistance. The characteristic parameters of a single leg thin-film devices were measured in situ, giving a Seebeck coefficient of S = -121(±6) µV K-1, thermal conductivity of κ = 0.85(±0.08) W m-1 K-1, electrical conductivity of σ = 5.2(±0.32) × 104 S m-1, and electrical contact resistivity of ∼10-11 Ω m2. These thermoelectric parameters lead to a material ZT = 0.26(±0.04), which, for our device structure, allowed a net cooling of ΔTmax = 4.4(±0.12) K. A response time of τ = 20 µs was measured experimentally. This work shows that with the correct treatment of contact interfaces, electrodeposited thin-film thermoelectrics can compete with more complicated and expensive technologies such as metal organic chemical vapor deposition (MOCVD) multilayers.

Molecular physics of jumping nanodroplets.

Next-generation processor-chip cooling devices and self-cleaning surfaces can be enhanced by a passive process that requires little to no electrical input, through coalescence-induced nanodroplet jumping. Here, we describe the crucial impact thermal capillary waves and ambient gas rarefaction have on enhancing/limiting the jumping speeds of nanodroplets on low adhesion surfaces. By using high-fidelity non-equilibrium molecular dynamics simulations in conjunction with well-resolved volume-of-fluid continuum calculations, we are able to quantify the different dissipation mechanisms that govern nanodroplet jumping at length scales that are currently difficult to access experimentally. We find that interfacial thermal capillary waves contribute to a large statistical spread of nanodroplet jumping speeds that range from 0-30 m s-1, where the typical jumping speeds of micro/millimeter sized droplets are only up to a few m s-1. As the gas surrounding these liquid droplets is no longer in thermodynamic equilibrium, we also show how the reduced external drag leads to increased jumping speeds. This work demonstrates that, in the viscous-dominated regime, the Ohnesorge number and viscosity ratio between the two phases alone are not sufficient, but that the thermal fluctuation number (Th) and the Knudsen number (Kn) are both needed to recover the relevant molecular physics at nanoscales. Our results and analysis suggest that these dimensionless parameters would be relevant for many other free-surface flow processes and applications that operate at the nanoscale.

Synthesis of centimeter-size free-standing perovskite nanosheets from single-crystal lead bromide for optoelectronic devices.

Considerable attention has been drawn to the lead halide perovskites (LHPs) because of their outstanding optoelectronic characteristics. LHP nanosheets (NSs) grown from single crystalline lead halide possess advantages in device applications as they provide the possibility for control over morphology, composition, and crystallinity. Here, free-standing lead bromide (PbBr2) single-crystalline NSs with sizes up to one centimeter are synthesized from solution. These NSs can be converted to LHP while maintaining the NS morphology. We demonstrate that these perovskite NSs can be processed directly for fabrication of photodetector and laser arrays on a large scale. This strategy will allow high-yield synthesis of large-size perovskite NSs for functional devices in an integrated photonics platform.

Exploring the Role of Adsorption and Surface State on the Hydrophobicity of Rare Earth Oxides.

Rare earth oxides (REOs) are attracting attention for use as cost-effective, high-performance dropwise condensers because of their favorable thermal properties and robust nature. However, to engineer a suitable surface for industrial applications, the mechanism governing wetting must be first fully elucidated. Recent studies exploring the water-wetting state of REOs have suggested that these oxides are intrinsically hydrophobic owing to the unique electronic structure of the lanthanide series. These claims have been countered with evidence that they are inherently hydrophilic and that adsorption of contaminants from the environment is responsible for the apparent hydrophobic nature of these surfaces. Here, using X-ray photoelectron spectroscopy and dynamic water contact angle measurements, we provide further evidence to show that REOs are intrinsically hydrophilic, with ceria demonstrating advancing water contact angles of ≈6° in a clean surface state and similar surface energies to two transition metal oxides (≳72 mJ/m2). Using two model volatile species, it is shown that an adsorption mechanism is responsible for the apparent hydrophobic property observed in REOs as well as in transition metal oxides and silica. This is correlated with the screening of the polar surface energy contribution of the underlying oxide with apparent surface energies reduced to <40 mJ/m2 for the case of nonane adsorption. Moreover, we show that the degree of surface hydroxylation plays an important role in the observed contact angle hysteresis with the receding contact angle of ceria increasing from ∼10° to 45° following thermal annealing in an inert atmosphere. Our findings suggest that high atomic number metal oxides capable of strongly adsorbing volatile species may represent a viable paradigm toward realizing robust surface coating for industrial condensers if certain challenges can be overcome.

Controlled solvent vapor annealing of a high χ block copolymer thin film.

Molecular self-assembling block copolymers (BCPs) have shown promise as a next generation bottom-up lithography technology. However, a critical step in advancing this approach is the elimination of polymer dewetting due to bulk solvent nucleation and thermodynamically driven film rupture that can occur during the solvent vapor annealing process. We report on the pattern formation via phase segregation of spin coated diblock copolymer films through the investigation of annealing parameters in the limit of high solvent vapor saturation conditions that results in wafer-scale patterning without observing polymer dewetting defects. Specifically, the work addresses polymer dewetting in diblock copolymer nanodot templates through the use of a "neutral" functionalization layer and the development of a custom-built solvent vapor annealing chamber to precisely control saturation conditions. Furthermore, the long anneal times (4 h) using a standard static solvent vapor annealing procedure were reduced to ∼15-30 minutes with our dynamic solvent vapor annealing system for the high χ, cylindrical forming poly(styrene)-block-poly(4-vinyl-pyridine) [PS-b-P4VP] diblock copolymer system. We discuss the kinetic mechanism governing the phase segregation process that highlights the small processing window bounded by long phase segregation timescales (≳1 min) on one side and the initiation of polymer film dewetting on the other. These results demonstrate a key step towards realizing a high fidelity, low cost BCP patterning technique for large-scale "bottom-up" feature definition at nanometer length scales.

High-resolution liquid patterns via three-dimensional droplet shape control.

Understanding liquid dynamics on surfaces can provide insight into nature's design and enable fine manipulation capability in biological, manufacturing, microfluidic and thermal management applications. Of particular interest is the ability to control the shape of the droplet contact area on the surface, which is typically circular on a smooth homogeneous surface. Here, we show the ability to tailor various droplet contact area shapes ranging from squares, rectangles, hexagons, octagons, to dodecagons via the design of the structure or chemical heterogeneity on the surface. We simultaneously obtain the necessary physical insights to develop a universal model for the three-dimensional droplet shape by characterizing the droplet side and top profiles. Furthermore, arrays of droplets with controlled shapes and high spatial resolution can be achieved using this approach. This liquid-based patterning strategy promises low-cost fabrication of integrated circuits, conductive patterns and bio-microarrays for high-density information storage and miniaturized biochips and biosensors, among others.

How coalescing droplets jump.

Surface engineering at the nanoscale is a rapidly developing field that promises to impact a range of applications including energy production, water desalination, self-cleaning and anti-icing surfaces, thermal management of electronics, microfluidic platforms, and environmental pollution control. As the area advances, more detailed insights of dynamic wetting interactions on these surfaces are needed. In particular, the coalescence of two or more droplets on ultra-low adhesion surfaces leads to droplet jumping. Here we show, through detailed measurements of jumping droplets during water condensation coupled with numerical simulations of binary droplet coalescence, that this process is fundamentally inefficient with only a small fraction of the available excess surface energy (≲ 6%) convertible into translational kinetic energy. These findings clarify the role of internal fluid dynamics during the jumping droplet coalescence process and underpin the development of systems that can harness jumping droplets for a wide range of applications.

Electric-field-enhanced condensation on superhydrophobic nanostructured surfaces.

When condensed droplets coalesce on a superhydrophobic nanostructured surface, the resulting droplet can jump due to the conversion of excess surface energy into kinetic energy. This phenomenon has been shown to enhance condensation heat transfer by up to 30% compared to state-of-the-art dropwise condensing surfaces. However, after the droplets jump away from the surface, the existence of the vapor flow toward the condensing surface increases the drag on the jumping droplets, which can lead to complete droplet reversal and return to the surface. This effect limits the possible heat transfer enhancement because larger droplets form upon droplet return to the surface, which impedes heat transfer until they can be either removed by jumping again or finally shedding via gravity. By characterizing individual droplet trajectories during condensation on superhydrophobic nanostructured copper oxide (CuO) surfaces, we show that this vapor flow entrainment dominates droplet motion for droplets smaller than R ≈ 30 µm at moderate heat fluxes (q″ > 2 W/cm(2)). Subsequently, we demonstrate electric-field-enhanced condensation, whereby an externally applied electric field prevents jumping droplet return. This concept leverages our recent insight that these droplets gain a net positive charge due to charge separation of the electric double layer at the hydrophobic coating. As a result, with scalable superhydrophobic CuO surfaces, we experimentally demonstrated a 50% higher overall condensation heat transfer coefficient compared to that on a jumping-droplet surface with no applied field for low supersaturations (<1.12). This work not only shows significant condensation heat transfer enhancement but also offers avenues for improving the performance of self-cleaning and anti-icing surfaces as well as thermal diodes.

Non-wetting droplets on hot superhydrophilic surfaces.

Controlling wettability by varying surface chemistry and roughness or by applying external stimuli is of interest for a wide range of applications including microfluidics, drag reduction, self-cleaning, water harvesting, anti-corrosion, anti-fogging, anti-icing and thermal management. It has been well known that droplets on textured hydrophilic, that is superhydrophilic, surfaces form thin films with near-zero contact angles. Here we report an unexpected behaviour where non-wetting droplets are formed by slightly heating superhydrophilic microstructured surfaces beyond the saturation temperature (>5 °C). Although such behaviour is generally not expected on superhydrophilic surfaces, an evaporation-induced pressure in the structured region prevents wetting. In particular, the increased thermal conductivity and decreased vapour permeability of the structured region allows this behaviour to be observed at such low temperatures. This phenomenon is distinct from the widely researched Leidenfrost and offers an expanded parametric space for fabricating surfaces with desired temperature-dependent wettability.

Electrostatic charging of jumping droplets.

With the broad interest in and development of superhydrophobic surfaces for self-cleaning, condensation heat transfer enhancement and anti-icing applications, more detailed insights on droplet interactions on these surfaces have emerged. Specifically, when two droplets coalesce, they can spontaneously jump away from a superhydrophobic surface due to the release of excess surface energy. Here we show that jumping droplets gain a net positive charge that causes them to repel each other mid-flight. We used electric fields to quantify the charge on the droplets and identified the mechanism for the charge accumulation, which is associated with the formation of the electric double layer at the droplet-surface interface. The observation of droplet charge accumulation provides insight into jumping droplet physics as well as processes involving charged liquid droplets. Furthermore, this work is a starting point for more advanced approaches for enhancing jumping droplet surface performance by using external electric fields to control droplet jumping.

Immersion condensation on oil-infused heterogeneous surfaces for enhanced heat transfer.

Enhancing condensation heat transfer is important for broad applications from power generation to water harvesting systems. Significant efforts have focused on easy removal of the condensate, yet the other desired properties of low contact angles and high nucleation densities for high heat transfer performance have been typically neglected. In this work, we demonstrate immersion condensation on oil-infused micro and nanostructured surfaces with heterogeneous coatings, where water droplets nucleate immersed within the oil. The combination of surface energy heterogeneity, reduced oil-water interfacial energy, and surface structuring enabled drastically increased nucleation densities while maintaining easy condensate removal and low contact angles. Accordingly, on oil-infused heterogeneous nanostructured copper oxide surfaces, we demonstrated approximately 100% increase in heat transfer coefficient compared to state-of-the-art dropwise condensation surfaces in the presence of non-condensable gases. This work offers a distinct approach utilizing surface chemistry and structuring together with liquid-infusion for enhanced condensation heat transfer.

Jumping-droplet-enhanced condensation on scalable superhydrophobic nanostructured surfaces.

When droplets coalesce on a superhydrophobic nanostructured surface, the resulting droplet can jump from the surface due to the release of excess surface energy. If designed properly, these superhydrophobic nanostructured surfaces can not only allow for easy droplet removal at micrometric length scales during condensation but also promise to enhance heat transfer performance. However, the rationale for the design of an ideal nanostructured surface as well as heat transfer experiments demonstrating the advantage of this jumping behavior are lacking. Here, we show that silanized copper oxide surfaces created via a simple fabrication method can achieve highly efficient jumping-droplet condensation heat transfer. We experimentally demonstrated a 25% higher overall heat flux and 30% higher condensation heat transfer coefficient compared to state-of-the-art hydrophobic condensing surfaces at low supersaturations (<1.12). This work not only shows significant condensation heat transfer enhancement but also promises a low cost and scalable approach to increase efficiency for applications such as atmospheric water harvesting and dehumidification. Furthermore, the results offer insights and an avenue to achieve high flux superhydrophobic condensation.

Unified model for contact angle hysteresis on heterogeneous and superhydrophobic surfaces.

Understanding the complexities associated with contact line dynamics on chemically heterogeneous and superhydrophobic surfaces is important for a wide variety of engineering problems. Despite significant efforts to capture the behavior of a droplet on these surfaces over the past few decades, modeling of the complex dynamics at the three-phase contact line is needed. In this work, we demonstrate that contact line distortion on heterogeneous and superhydrophobic surfaces is the key aspect that needs to be accounted for in the dynamic droplet models. Contact line distortions were visualized and modeled using a thermodynamic approach to develop a unified model for contact angle hysteresis on chemically heterogeneous and superhydrophobic surfaces. On a surface comprised of discrete wetting defects on an interconnected less wetting area, the advancing contact angle was determined to be independent of the defects, while the relative fraction of the distorted contact line with respect to the baseline surface was shown to govern the receding contact angle. This behavior reversed when the relative wettability of the discrete defects and interconnected area was inverted. The developed model showed good agreement with the experimental advancing and receding contact angles, both at low and high solid fractions. The thermodynamic model was further extended to demonstrate its capability to capture droplet shape evolution during liquid addition and removal in our experiments and those in literature. This study offers new insight extending the fundamental understanding of solid-liquid interactions required for design of advanced functional coatings for microfluidics, biological, manufacturing, and heat transfer applications.

Condensation on superhydrophobic surfaces: the role of local energy barriers and structure length scale.

Water condensation on surfaces is a ubiquitous phase-change process that plays a crucial role in nature and across a range of industrial applications, including energy production, desalination, and environmental control. Nanotechnology has created opportunities to manipulate this process through the precise control of surface structure and chemistry, thus enabling the biomimicry of natural surfaces, such as the leaves of certain plant species, to realize superhydrophobic condensation. However, this "bottom-up" wetting process is inadequately described using typical global thermodynamic analyses and remains poorly understood. In this work, we elucidate, through imaging experiments on surfaces with structure length scales ranging from 100 nm to 10 µm and wetting physics, how local energy barriers are essential to understand non-equilibrium condensed droplet morphologies and demonstrate that overcoming these barriers via nucleation-mediated droplet-droplet interactions leads to the emergence of wetting states not predicted by scale-invariant global thermodynamic analysis. This mechanistic understanding offers insight into the role of surface-structure length scale, provides a quantitative basis for designing surfaces optimized for condensation in engineered systems, and promises insight into ice formation on surfaces that initiates with the condensation of subcooled water.

Effect of droplet morphology on growth dynamics and heat transfer during condensation on superhydrophobic nanostructured surfaces.

Condensation on superhydrophobic nanostructured surfaces offers new opportunities for enhanced energy conversion, efficient water harvesting, and high performance thermal management. These surfaces are designed to be Cassie stable and favor the formation of suspended droplets on top of the nanostructures as compared to partially wetting droplets which locally wet the base of the nanostructures. These suspended droplets promise minimal contact line pinning and promote passive droplet shedding at sizes smaller than the characteristic capillary length. However, the gas films underneath such droplets may significantly hinder the overall heat and mass transfer performance. We investigated droplet growth dynamics on superhydrophobic nanostructured surfaces to elucidate the importance of droplet morphology on heat and mass transfer. By taking advantage of well-controlled functionalized silicon nanopillars, we observed the growth and shedding behavior of suspended and partially wetting droplets on the same surface during condensation. Environmental scanning electron microscopy was used to demonstrate that initial droplet growth rates of partially wetting droplets were 6× larger than that of suspended droplets. We subsequently developed a droplet growth model to explain the experimental results and showed that partially wetting droplets had 4-6× higher heat transfer rates than that of suspended droplets. On the basis of these findings, the overall performance enhancement created by surface nanostructuring was examined in comparison to a flat hydrophobic surface. We showed these nanostructured surfaces had 56% heat flux enhancement for partially wetting droplet morphologies and 71% heat flux degradation for suspended morphologies in comparison to flat hydrophobic surfaces. This study provides insights into the previously unidentified role of droplet wetting morphology on growth rate, as well as the need to design Cassie stable nanostructured surfaces with tailored droplet morphologies to achieve enhanced heat and mass transfer during dropwise condensation.

Prediction and optimization of liquid propagation in micropillar arrays.

Prediction and optimization of liquid propagation rates in micropillar arrays are important for various lab-on-a-chip, biomedical, and thermal management applications. In this work, a semianalytical model based on the balance between capillary pressure and viscous resistance was developed to predict liquid propagation rates in micropillar arrays with height-to-period ratios greater than 1 and diameter-to-period ratios less than 0.57. These geometries represent the most useful regimes for practical applications requiring large propagation rates. The capillary pressure was obtained using an energy approach where the meniscus shape was predicted using Surface Evolver simulations and experimentally verified by interference microscopy. The combined viscous resistance of the pillars and the substrate was determined using Brinkman's equation with a numerically obtained permeability and corroborated with finite element simulations. The model shows excellent agreement with one-dimensional propagation experiments of deionized water in silicon micropillar arrays, highlighting the importance of accurately capturing the details of the meniscus shape and the viscous losses. Furthermore, an effective propagation coefficient was obtained through dimensionless analysis that is functionally dependent only on the micropillar geometry. The work offers design guidelines to obtain optimal liquid propagation rates on micropillar surfaces.