Low cost, controlled crystallinity, chemical, and mechanical stability enable application of polymers in energy, water, electronics, and biomedical industries. Recent studies have shown that tailoring surface properties of polymers impacts their durability and functionality in these applications. However, the functionality and performance of polymer‐based devices and systems are greatly affected by the modification method and the process parameters, highlighting the need for understanding these methods and their mechanisms of operation in detail. The selection of the modification method invariably decides the properties enhanced in the polymer. In this review, various polymer surface modification treatments are discussed. These methods are categorized into physical, chemical, thermal, and optical ways, while illustrating their advantages and disadvantages. This review also explores the surface modification of polymers by patterning which encompasses one or more surface treatment methods. An application‐oriented study is presented discussing the relative importance of a method pertaining to a specific field of end‐application.

Ice formation and accumulation on surfaces can result in severe problems for solar photovoltaic installations, offshore oil platforms, wind turbines and aircrafts. In addition, blockage of pipelines by formation and accumulation of clathrate hydrates of natural gases has safety and economical concerns in oil and gas operations, particularly at high pressures and low temperatures such as those found in subsea or arctic environments. Practical adoption of icephobic/hydrate-phobic surfaces requires mechanical robustness and stability under harsh environments. Here, we develop durable and mechanically robust bilayer poly-divinylbenzene (pDVB)/poly-perfluorodecylacrylate (pPFDA) coatings using initiated chemical vapor deposition (iCVD) to reduce the adhesion strength of ice/hydrates to underlying substrates (silicon and steel). Utilizing a highly-cross-linked polymer (pDVB) underneath a very thin veneer of fluorine-rich polymer (pPFDA) we have designed inherently rough bilayer polymer films that can be deposited on rough steel substrates resulting in surfaces which exhibit a receding water contact angle (WCA) higher than 150° and WCA hysteresis as low as 4°. Optical profilometer measurements were performed on the films and root mean square (RMS) roughness values of Rq = 178.0 ± 17.5 nm and Rq = 312.7 ± 23.5 nm were obtained on silicon and steel substrates, respectively. When steel surfaces are coated with these smooth hard iCVD bilayer polymer films, the strength of ice adhesion is reduced from 1010 ± 95 kPa to 180 ± 85 kPa. The adhesion strength of the cyclopentane (CyC5) hydrate is also reduced from 220 ± 45 kPa on rough steel substrates to 34 ± 12 kPa on the polymer-coated steel substrates. The durability of these bilayer polymer coated icephobic and hydrate-phobic substrates is confirmed by sand erosion tests and examination of multiple ice/hydrate adhesion/de-adhesion cycles.

The ability of hydrophobic surfaces to repel impinging liquid droplets is important in applications ranging from self-cleaning of solar panels to avoiding ice formation in freezing rain environments. In quest of maximizing water repellency, modification of droplet dynamics and subsequent reduction of contact time have been achieved by incorporating macrotexture on the superhydrophobic surfaces. However, the dynamics of low temperature water, and other viscous liquid droplets impacting anti-wetting surfaces with macrotextures is not well explored. Here, we investigate the effect of viscosity on the bouncing dynamics of liquid droplets impacting macrotextured superamphiphobic surfaces using various glycerol-water mixtures as model liquids at different impacting conditions. We demonstrate that the changes of reduction in contact times by macrotextures due to the increasing viscosity are in opposite trends at low and at high impact velocities. Since macrotexture executes substantial contact time reduction for the droplets which exhibit splitting after the impact, a preliminary model for predicting the minimum impact velocity to observe droplet splitting by macrotexture is proposed considering the important parameters of an impinging droplet along with the surface characteristics and the macrotexture size. This work aims to provide an insight on several possible outcomes of viscous droplets impacting on the macrotextured surfaces and a model that will help to design the desired superamphiphobic surfaces capable of exhibiting reduced contact time and enhanced repellency of low-temperature water droplets (such as freezing rain) and other viscous liquids (such as oils) under different impacting conditions.

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