Capillary Transfer of Self-Assembled Colloidal Crystals.

Colloidal self-assembly has attracted significant interest in numerous applications including optics, electrochemistry, thermofluidics, and biomolecule templating. To meet the requirements of these applications, numerous fabrication methods have been developed. However, these are limited to narrow ranges of feature sizes, are incompatible with many substrates, and/or have low scalability, significantly limiting the use of colloidal self-assembly. In this work, we study the capillary transfer of colloidal crystals and demonstrate that this approach overcomes these limitations. Enabled by capillary transfer, we fabricate 2D colloidal crystals with nano-to-micro feature sizes spanning 2 orders of magnitude and on typically challenging substrates including those that are hydrophobic, rough, curved, or structured with microchannels. We developed and systemically validated a capillary peeling model, elucidating the underlying transfer physics. Due to its high versatility, good quality, and simplicity, this approach can expand the possibilities of colloidal self-assembly and enhance the performance of applications using colloidal crystals.

Bottom-Up Synthesized All-Thermal-Catalyst Aerogels for Heat-Regenerative Air Filtration.

Airborne particular matter (PM) pollution is an increasing global issue and alternative sources of filter fibers are now an area of significant focus. Compared with relatively mature hazardous gas treatments, state of the art high-efficiency PM filters still lack thermal decomposition ability for organic PM pollutants, such as soot from coal-fired power plants and waste-combustion incinerators, resulting in frequent replacement, high cost, and second-hand pollution. In this manuscript, we propose a bottom-up synthesis method to make the first all-thermal-catalyst air filter (ATCAF). Self-assembled from ∼50 nm diameter TiO2 fibers, ATCAF could not only capture the combustion-generated PM pollutants with >99.999% efficiency but also catalyze the complete decomposition of the as-captured hydrocarbon pollutants at high temperature. It has the potential of in situ eliminating the PM pollutants from burning of hydrocarbon materials leveraging the burning heat.

Rational Fabrication of Nano-to-Microsphere Polycrystalline Opals Using Slope Self-Assembly.

Self-assembly of artificial opals has garnered significant interest as a facile nanofabrication technique capable of producing highly ordered structures for optical, electrochemical, biomolecular, and thermal applications. In these applications, the optimum opal particle diameter can vary by several orders of magnitude because the properties of the resultant structures depend strongly on the feature size. However, current opal fabrication techniques only produce high-quality structures over a limited range of sphere sizes or require complex processes and equipment. In this work, the rational and simple fabrication of polycrystalline opals with diameters between 500 nm and 10 µm was demonstrated using slope self-assembly of colloids suspended in ethanol-water. The role of the various process parameters was elucidated through a scaling-based model that accurately captures the variations of opal substrate coverage for spheres of size 2 µm or smaller. For spheres of 10 µm and larger, capillary forces were shown to play a key role in the process dynamics. Based on these insights, millimeter-scale monolayered opals were successfully fabricated, while centimeter-scale opals were possible with sparse sphere stacking or small uncovered areas. These insights provide a guide for the simple and fast fabrication of opals that can be used as optical coatings, templates for high power density electrodes, molecule templates, and high-performance thermo-fluidic devices.

Microtube Surfaces for the Simultaneous Enhancement of Efficiency and Critical Heat Flux during Pool Boiling.

Boiling is an essential process in numerous applications including power plants, thermal management, water purification, and steam generation. Previous studies have shown that surfaces with microcavities or biphilic wettability can enhance the efficiency of boiling heat transfer, that is, the heat transfer coefficient (HTC). Surfaces with permeable structures such as micropillar arrays, in contrast, have shown significant enhancement of the critical heat flux (CHF). In this work, we investigated microtube structures, where a cavity is defined at the center of a pillar, as structural building blocks to enhance HTC and CHF simultaneously in a controllable manner. We demonstrated simultaneous CHF and HTC enhancements of up to 62 and 244%, respectively, compared to those of a smooth surface. The experimental data along with high-speed images elucidate the mechanism for simultaneous enhancement where bubble nucleation occurs in the microtube cavities for increased HTC and microlayer evaporation occurs around microtube sidewalls for increased CHF. Furthermore, we combined micropillars and microtubes to create surfaces that further increased CHF by achieving a path to separate nucleating bubbles and rewetting liquids. This work provides guidelines for the systematic surface design for boiling heat transfer enhancement and has important implications for understanding boiling heat transfer mechanisms.

A unified relationship for evaporation kinetics at low Mach numbers.

We experimentally realized and elucidated kinetically limited evaporation where the molecular gas dynamics close to the liquid-vapour interface dominates the overall transport. This process fundamentally dictates the performance of various evaporative systems and has received significant theoretical interest. However, experimental studies have been limited due to the difficulty of isolating the interfacial thermal resistance. Here, we overcome this challenge using an ultrathin nanoporous membrane in a pure vapour ambient. We demonstrate a fundamental relationship between the evaporation flux and driving potential in a dimensionless form, which unifies kinetically limited evaporation under different working conditions. We model the nonequilibrium gas kinetics and show good agreement between experiments and theory. Our work provides a general figure of merit for evaporative heat transfer as well as design guidelines for achieving efficient evaporation in applications such as water purification, steam generation, and thermal management.