Replication of micro-sized pillars in polypropylene using the extrusion coating process

Okulova, Nastasia; Johansen, Per Michael; Christensen, Lars Rune; Taboryski, Rafael J.

doi:10.1016/j.mee.2017.01.027

Cited by 15 publications

(14 citation statements)

References 15 publications

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“…Extrusion coating has a capacity for the manufacturing of up to 2 m wide packaging foils at the production speed up to 1000 m/min. Production of micro- and nano-patterns using R2R EC is a relatively new method that has shown promising results for scaling up the production of biomimetic surfaces [ 37 , 38 , 39 ].…”

Section: Introductionmentioning

confidence: 99%

Effect of Structure Hierarchy for Superhydrophobic Polymer Surfaces Studied by Droplet Evaporation

Okulova

Johansen²,

Christensen³

et al. 2018

Nanomaterials

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Super-hydrophobic natural surfaces usually have multiple levels of structure hierarchy. Here, we report on the effect of surface structure hierarchy for droplet evaporation. The two-level hierarchical structures studied comprise micro-pillars superimposed with nanograss. The surface design is fully scalable as structures used in this study are replicated in polypropylene by a fast roll-to-roll extrusion coating method, which allows effective thermoforming of the surface structures on flexible substrates. As one of the main results, we show that the hierarchical structures can withstand pinning of sessile droplets and remain super-hydrophobic for a longer time than their non-hierarchical counterparts. The effect is documented by recording the water contact angles of sessile droplets during their evaporation from the surfaces. The surface morphology is mapped by atomic force microscopy (AFM) and used together with the theory of Miwa et al. to estimate the degree of water impregnation into the surface structures. Finally, the different behavior during the droplet evaporation is discussed in the light of the obtained water impregnation levels.

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Section: Introductionmentioning

confidence: 99%

Effect of Structure Hierarchy for Superhydrophobic Polymer Surfaces Studied by Droplet Evaporation

Okulova

Johansen²,

Christensen³

et al. 2018

Nanomaterials

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“…The polymer surface is modified on the onset of fabrication using injection molding, extrusion, and lamination template techniques 26a. While it cannot change the inherent chemical nature of the polymer, modifying the polymer surface by physical methods alters its wettability by inducing roughness in micro‐ and nanoscale.…”

Section: Polymer Surface Modification By Physical Routesmentioning

confidence: 99%

“…Chen and Huang have demonstrated a fast and flexible method for fabricating T‐shaped micropillars on polypropylene (PP) surfaces with robust Cassie‐Baxter states where they applied microinjection compression molding (µ‐ICM) technique for replicating the templates. Chen and Huang have used roll‐to‐roll extrusion coating (R2R‐EC) process to replicate microsized pillars in PP (Figure c) while also studying the replication fidelity of the pillars with different process parameters. Among the line‐speed of the rolls, the extruder output, the cooling roll temperature, and the pressure, the temperature of the cooling roll was reported to affect the replication process to a large extent.…”

Section: Polymer Surface Modification By Physical Routesmentioning

confidence: 99%

Surface Modification of Polymers: Methods and Applications

Nemani

Annavarapu

Mohammadian

et al. 2018

Adv Materials Inter

274

161

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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.

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“…The high yield of the pattern transfer is important in order to achieve the consistent quality of the foils and provide a stable performance. The yield of the pattern transfer has been investigated for both micro-and nano-structures [57,58] where good results for structures of the sizes between 100 μm down to 50 nm have been presented.…”

Section: Fabrication Of Superhydrophobic Surfaces In Thermoplastic Foilsmentioning

confidence: 99%

Aerodynamic effect of icing/rain impacts on super-hydrophobic surfaces

Okulova

Taboryski

Sørensen

et al. 2018

AIP Conference Proceedings

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The rain impact and ice accretion on different aerodynamic constructions represent a large problem to their safety and operation. Most current de-icing systems include either physical or chemical removal of ice, which is resource-and energy-intensive as well as environmentally polluting. A more desirable approach to prevent initial ice formation from water droplets on a surface is to employ highly ordered super-hydrophobic materials, which mimic lotus leaves and other natural dirt-and water-repelling surfaces and reproduced in many laboratory tests. The ability to fend off water droplets could lead to prevention of icing as an inherent material property, which further would prevent ice formations, rather than fighting its build-up. Our objective is to draw attention to problems of an extension of this effect to technical applications. The main idea of the icing or rain protection of the different aerodynamic constructions may be the use of superhydrophobic thermoplastic polymers with the water-repellent properties to prevent corrosion, improve aerodynamics or add self-cleaning properties to the material. The purpose of the present study is to explore the possibility of using a fast and cheap technology of R2R-EC to enable the fabrication of nanostructures on polymer foils of sizes ranging from 50 nanometers and up to 100 micrometers with the aim of improving the ice-cleaning and water-repellent properties of the coating. This high-speed and low-cost lithography method is developed at DTU and Danapak Flexibles A/S. These superhydrophobic surfaces with water-repelling structures provide rebound actions on the impacting droplets with the large contact angle θ. For the foils with the different micro-and nanostructures, the wetting properties are measured and impact with single droplet is presented. These coatings can be used for different engineering tasks, which need to establish and test new anti-icing/rain solutions for complex aerodynamic flows. We will start the present investigation from the initial point to include main aspects of the previous water-repellent investigations and test a single droplet impacts on the surface with the thermoplastic foil for the coating.

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Replication of micro-sized pillars in polypropylene using the extrusion coating process

Cited by 15 publications

References 15 publications

Effect of Structure Hierarchy for Superhydrophobic Polymer Surfaces Studied by Droplet Evaporation

Effect of Structure Hierarchy for Superhydrophobic Polymer Surfaces Studied by Droplet Evaporation

Surface Modification of Polymers: Methods and Applications

Aerodynamic effect of icing/rain impacts on super-hydrophobic surfaces

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