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The Leidenfrost effect allows droplets to be transported on a virtually frictionless layer of vapor above a superheated substrate. The substrates are normally topographically structured using subtractive techniques to produce saw-tooth, herringbone, and other patterns and bulk heated, leading to significant challenges in energy consumption and controlled operation. Here, we propose a planar lithographic approach to levitate and propel droplets using temperature profiles, which can be spatially patterned and controlled in time. We show that micro-patterned electrodes can be heated and provide control of the pressure profile and the vapor flow. Using these almost featureless planar substrates, we achieve self-directed motion of droplets, with velocities of approximately 30 mms−1, without topographically structuring the substrate or introducing physical walls. Our approach has the potential to be integrated into applications, such as digital microfluidics, where frictionless and contactless droplet transport may be advantageous. [ABSTRACT FROM AUTHOR]

Stimuli responsive elastic instabilities provide opportunities for controlling the structures and properties of polymer surfaces, offering a range of potential applications. Here, a surface actuator based on a temperature and electrically responsive poly( N-isopropyl acrylamide-co-sodium acrylate) hydrogel that undergoes a two-step delamination and buckling instability triggered using micropatterned electrodes is described. The electrically actuated structures entail large out-of-plane displacements that take place on time-scales of less than 1 s, in response to modest triggering voltages (−3-6 V). Alongside these experimental observations, finite element simulations are conducted to better understand the two-step nature of the instability. In the first step, hydrogel films undergo delamination and formation of blisters, facilitated by electrochemical reduction of the thiol groups anchoring the film to the electrodes. Subsequently, at larger reducing potentials, the electrolytic current is sufficient to nucleate a gas bubble between the electrode and the gel, causing the delaminated region to adopt a straight-sided blister shape. Finally, thermally induced deswelling of the gel allows the film to be returned to its flat state and readhered to the electrode, thereby allowing for repeated actuation. [ABSTRACT FROM AUTHOR]

Much of the inspiration for the creation of superhydrophobic surfaces has come from nature, from plants such as the sacred lotus (Nelumbo nucifera), where the micro-scale papillae epidermal cells on the surfaces of the leaves are covered with nano-scale epicuticular wax crystalloids. The combination of the surface roughness and the hydrophobic wax coating produces a superhydrophobic wetting state on the leaves, allowing them to self-clean and easily shed water. Here, a simple scaled-up carbon nanoparticle spray coating is presented that mimics the surface of sacred lotus leaves and can be applied to a wide variety of materials, complex structures, and flexible substrates, rendering them superhydrophobic, with contact angles above 160°. The sprayable mixture is produced by combining toluene, polydimethylsiloxane, and inherently hydrophobic rapeseed soot. The ability to spray the superhydrophobic coating allows for the hydrophobisation of complex structures such as metallic meshes, which allows for the production of flexible porous superhydrophobic materials that, when formed into U-shaped channels, can be used to direct flows. The porous meshes, whilst being superhydrophobic, are also oleophilic. Being both superhydrophobic and oleophilic allows oil to pass through the mesh, whilst water remains on the surface. The meshes were tested for their ability to separate mixtures of oil and water in flow conditions. When silicone oil/water mixtures were passed over the meshes, all meshes tested were capable of separating more than 93% of the oil from the mixture.

An energy saving Leidenfrost levitation method is introduced to transport microdroplets with virtually frictionless contact between the liquid and solid substrate. Through microengineering of the heating units, selective areas of the whole substrate can be electrothermally activated. A droplet can be levitated as a result of the Leidenfrost effect and further transported when the substrate is tilted slightly. Selective electroheating produces a uniform temperature distribution on the heating units within 1 s in response to a triggering voltage. Alongside these experimental observations, finite element simulations were conducted to understand the role of substrate thermal conductivity on the temperature profile of the selectively heated substrate. We also generated phase diagrams to verify the Leidenfrost regime for different substrate materials. Finally, we demonstrated the possibility of controlling low friction high speed droplet transportation (∼65 mm/s) when the substrate is tilted (∼7°) by structurally designing the substrate. This work establishes the basis for an entirely new approach to droplet microfluidics.