Continuous Liquid-Liquid Extraction and in-Situ Membrane Separation of Miscible Liquid Mixtures.

Separation operations are critical across a wide variety of manufacturing industries and account for about one-quarter of all in-plant energy consumption in the United States. Conventional liquid-liquid separation operations require either thermal or chemical treatment, both of which have a large environmental impact and carbon footprint. Consequently, there is a great need to develop sustainable, clean methodologies for separation of miscible liquid mixtures. The greatest opportunities to achieve this lie in replacing high-energy separation operations (e.g., distillation) with low-energy alternatives such as liquid-liquid extraction. One of the primary design challenges in liquid-liquid extraction is to maximize the interfacial area between two immiscible (e.g., polar and nonpolar) liquids for efficient mass transfer. However, this often involves energy-intensive methods including ultrasonication, pumping the feed and the extractant through packed columns with high tortuosity, or using a supercritical fluid as an extractant. Emulsifying the feed and the extractant, especially with a surfactant, offers a large interfacial area, but subsequent separation of emulsions can be energy-intensive and expensive. Thus, emulsions are typically avoided in conventional extraction operations. Herein, we discuss a novel, easily scalable, platform separation methodology termed CLEANS (continuous liquid-liquid extraction and in-situ membrane separation). CLEANS integrates emulsion-enhanced extraction with continuous, gravity-driven, membrane-based separation of emulsions into a single unit operation. Our results demonstrate that the addition of a surfactant and emulsification significantly enhance extraction (by >250% in certain cases), even for systems where the best extractants for miscible liquid mixtures are known. Utilizing the CLEANS methodology, we demonstrate continuous separation of a wide range of miscible liquid mixtures, including soluble organic molecules from oils, alcohols from esters, and even azeotropes.

Superomniphobic surfaces for effective chemical shielding.

Superomniphobic surfaces display contact angles >150° and low contact angle hysteresis with essentially all contacting liquids. In this work, we report surfaces that display superomniphobicity with a range of different non-Newtonian liquids, in addition to superomniphobicity with a wide range of Newtonian liquids. Our surfaces possess hierarchical scales of re-entrant texture that significantly reduce the solid-liquid contact area. Virtually all liquids including concentrated organic and inorganic acids, bases, and solvents, as well as viscoelastic polymer solutions, can easily roll off and bounce on our surfaces. Consequently, they serve as effective chemical shields against virtually all liquids--organic or inorganic, polar or nonpolar, Newtonian or non-Newtonian.

Utilizing dynamic tensiometry to quantify contact angle hysteresis and wetting state transitions on nonwetting surfaces.

Goniometric techniques traditionally quantify two parameters, the advancing and receding contact angles, that are useful for characterizing the wetting properties of a solid surface; however, dynamic tensiometry, which measures changes in the net force on a surface during the repeated immersion and emersion of a solid into a probe liquid, can provide further insight into the wetting properties of a surface. We detail a framework for analyzing tensiometric results that allows for the determination of wetting hysteresis, wetting state transitions, and characteristic topographical length scales on textured, nonwetting surfaces, in addition to the more traditional measurement of apparent advancing and receding contact angles. Fluorodecyl POSS, a low-surface-energy material, was blended with commercially available poly(methyl methacrylate) (PMMA) and then dip- or spray-coated onto glass substrates. These surfaces were probed with a variety of liquids to illustrate the effects of probe liquid surface tension, solid surface chemistry, and surface texture on the apparent contact angles and wetting hysteresis of nonwetting surfaces. Woven meshes were then used as model structured substrates to add a second, larger length scale for the surface texture. When immersed into a probe liquid, these spray-coated mesh surfaces can form a metastable, solid-liquid-air interface on the largest length scale of surface texture. The increasing hydrostatic pressure associated with progressively greater immersion depths disrupts this metastable, composite interface and forces penetration of the probe liquid into the mesh structure. This transition is marked by a sudden change in the wetting hysteresis, which can be systematically probed using spray-coated, woven meshes of varying wire radius and spacing. We also show that dynamic tensiometry can accurately and quantitatively characterize topographical length scales that are present on microtextured surfaces.

Synthesis, characterization, and cure chemistry of renewable bis(cyanate) esters derived from 2-methoxy-4-methylphenol.

A series of renewable bis(cyanate) esters have been prepared from bisphenols synthesized by condensation of 2-methoxy-4-methylphenol (creosol) with formaldehyde, acetaldehyde, and propionaldehyde. The cyanate esters have been fully characterized by infrared spectroscopy, (1)H and (13)C NMR spectroscopy, and single crystal X-ray diffraction. These compounds melt from 88 to 143 °C, while cured resins have glass transition temperatures from 219 to 248 °C, water uptake (96 h, 85 °C immersion) in the range of 2.05-3.21%, and wet glass transition temperatures from 174 to 193 °C. These properties suggest that creosol-derived cyanate esters may be useful for a wide variety of military and commercial applications. The cure chemistry of the cyanate esters has been studied with FTIR spectroscopy and differential scanning calorimetry. The results show that cyanate esters with more sterically demanding bridging groups cure more slowly, but also more completely than those with a bridging methylene group. In addition to the structural differences, the purity of the cyanate esters has a significant effect on both the cure chemistry and final Tg of the materials. In some cases, post-cure of the resins at 350 °C resulted in significant decomposition and off-gassing, but cure protocols that terminated at 250-300 °C generated void-free resin pucks without degradation. Thermogravimetric analysis revealed that cured resins were stable up to 400 °C and then rapidly degraded. TGA/FTIR and mass spectrometry results showed that the resins decomposed to phenols, isocyanic acid, and secondary decomposition products, including CO2. Char yields of cured resins under N2 ranged from 27 to 35%, while char yields in air ranged from 8 to 11%. These data suggest that resins of this type may potentially be recycled to parent phenols, creosol, and other alkylated creosols by pyrolysis in the presence of excess water vapor. The ability to synthesize these high temperature resins from a phenol (creosol) that can be derived from lignin, coupled with the potential to recycle the composites, provides a possible route to the production of sustainable, high-performance, thermosetting resins with reduced environmental impact.

Transparent, flexible, superomniphobic surfaces with ultra-low contact angle hysteresis.

See-through surfaces: High transparency is required to use superomniphobic surfaces, which can be self-cleaning, stain-proof, anti-bio-fouling, drag-reducing, or anti-fogging, for smartphone screens, eye glasses, windshields, or flat panel displays. A spray-based method has now been developed that can fabricate transparent, flexible, and highly superomniphobic surfaces. HD=hexadecane.

Superoleophobic surfaces through control of sprayed-on stochastic topography.

The liquid repellency and surface topography characteristics of coatings comprising a sprayed-on mixture of fluoroalkyl-functional precipitated silica and a fluoropolymer binder were examined using contact and sliding angle analysis, electron microscopy, and image analysis for determination of fractal dimensionality. The coatings proved to be an especially useful class of liquid repellent materials due to their combination of simple and scalable deposition process, low surface energy, and the roughness characteristics of the aggregates. These characteristics interact in a unique way to prevent the buildup of binder in interstitial regions, preserving re-entrant curvature across multiple length scales, thereby enabling a wide range of liquid repellency, including superoleophobicity. In addition, rather than accumulating in the interstices, the binder becomes widely distributed across the surface of the aggregates, enabling a mechanism in which a simple shortage or excess of binder controls the extent of coating roughness at very small length scales, thereby controlling the extent of liquid repellence.

Incompletely condensed fluoroalkyl silsesquioxanes and derivatives: precursors for low surface energy materials.

A novel synthetic method was developed for the controlled functionalization of fluorinated polyhedral oligomeric silsesquioxanes (F-POSS), which are useful as low surface energy materials for superhydrophobic and superoleophobic materials. Utilizing triflic acid, open-cage compounds were created and then reacted with a variety of dichlorosilanes to produce functional F-POSS structures possessing alkyl-, aryl-, and acrylate-based moieties. The crystal structure for an endo,endo-disilanol F-POSS compound was determined by single-crystal X-ray diffraction. The chemical structures were confirmed using multinuclear NMR spectroscopy ((1)H, (13)C, (19)F, and (29)Si), FT-IR, and combustion analysis. Dynamic contact angle measurements of these compounds were taken with water and hexadecane. These novel structures were found to possess excellent wetting-resistant behavior, similar to that of the parent F-POSS compound. They are the first well-defined fluorinated nano-building blocks with a controlled level of reactive functionality for the development of new superhydrophobic and superoleophobic materials.

Fluoroalkyl-functionalized silica particles: synthesis, characterization, and wetting characteristics.

Fluoroalkyl-functionalized silica particles for use in nonwetting surfaces were prepared by treatment of silica particles with fluoroalkyl-functional chlorosilanes. Both fumed and precipitated silica were studied, as well as the efficiency of surface coverage using mono-, di-, and trifunctional chlorosilanes. The most effective surface treatment was accomplished via the surface grafting of monofunctional chlorosilanes in the presence of preadsorbed dimethylamine under anhydrous conditions at room temperature. Confirmation of covalent attachment was accomplished via Fourier transform infrared (FT-IR) spectroscopy, while elemental analysis, thermogravimetric analysis, and nitrogen adsorption isotherms were used to determine grafting densities and additional key geometric characteristics of the grafted layer. The effect of residual silanol content on the moisture uptake properties of the modified silica particles was determined by measuring the water uptake of unbound particles, while liquid wetting properties were determined by dynamic contact angle analysis of elastomeric composites. Although residual silanol content was shown to effect wetting properties, results suggest that surface geometry dominates the performance of liquid-repellent surfaces. The potential use of fluoroalkyl-functionalized silica particles for hydrophobic and oleophobic applications is discussed.

Robust omniphobic surfaces.

Superhydrophobic surfaces display water contact angles greater than 150 degrees in conjunction with low contact angle hysteresis. Microscopic pockets of air trapped beneath the water droplets placed on these surfaces lead to a composite solid-liquid-air interface in thermodynamic equilibrium. Previous experimental and theoretical studies suggest that it may not be possible to form similar fully-equilibrated, composite interfaces with drops of liquids, such as alkanes or alcohols, that possess significantly lower surface tension than water (gamma(lv) = 72.1 mN/m). In this work we develop surfaces possessing re-entrant texture that can support strongly metastable composite solid-liquid-air interfaces, even with very low surface tension liquids such as pentane (gamma(lv) = 15.7 mN/m). Furthermore, we propose four design parameters that predict the measured contact angles for a liquid droplet on a textured surface, as well as the robustness of the composite interface, based on the properties of the solid surface and the contacting liquid. These design parameters allow us to produce two different families of re-entrant surfaces- randomly-deposited electrospun fiber mats and precisely fabricated microhoodoo surfaces-that can each support a robust composite interface with essentially any liquid. These omniphobic surfaces display contact angles greater than 150 degrees and low contact angle hysteresis with both polar and nonpolar liquids possessing a wide range of surface tensions.

Scale dependence of omniphobic mesh surfaces.

We provide a simple design chart framework to predict the apparent contact angle on a textured surface in terms of the equilibrium contact angle on a chemically identical smooth surface and details of the surface topography. For low surface tension liquids such as methanol (gamma(lv) = 22.7 mN/m) and octane (gamma(lv) = 21.6 mN/m), a solid-liquid-air composite interface on a textured surface is inherently metastable. Thus, on application of a sufficient pressure difference (e.g., an externally applied pressure or a sufficiently large Laplace pressure at small droplet size) the metastable composite interface transitions to a fully wetted interface. A dimensionless robustness factor is used to quantify the breakthrough pressure difference necessary to disrupt a metastable composite interface and to predict a priori the existence of a robust composite interface. The impact of the length scale (radius of the cylindrical features R varying from 18 to 114 microm) and the feature spacing ratio (D(*) = (R + D)/R varying from 2.2 to 5.1, where 2D is the spacing between the cylindrical features) on the robustness is illustrated by performing contact angle measurements on a set of dip-coated wire-mesh surfaces, which provide systematically quantifiable cylindrical texture. The design chart for a given feature size R shows how the two independent design parameters--surface chemistry as revealed in the equilibrium contact angle and texture spacing embodied in the dimensionless spacing ratio (D(*))--can be used to develop surfaces with desirably large values of the apparent contact angle and robustness of the metastable composite interface. Most revealing is the scaling of the robustness with the dimensionless parameter l(cap)/R (where l(cap = (gamma(lv)/rho g)(1/2) is the capillary length), which indicates clearly why, in the consideration of self-similar surfaces, smaller is better for producing omniphobic surfaces that resist wetting by liquids with low surface tension.

Thermal annealing treatment to achieve switchable and reversible oleophobicity on fabrics.

Surfaces that are strongly nonwetting to oil and other low surface tension liquids can be realized by trapping microscopic pockets of air within the asperities of a re-entrant texture and generating a solid-liquid-vapor composite interface. For low surface tension liquids such as hexadecane (gamma(lv) = 27.5 mN/m), this composite interface is metastable as a result of the low value of the equilibrium contact angle. Consequently, pressure perturbations can result in an irreversible transition of the metastable composite interface to the fully wetted interface. In this work, we use a simple dip-coating and thermal annealing procedure to tune the liquid wettability of commercially available polyester fabrics. A mixture of 10% 1H,1H,2H,2H-heptadecafluorodecyl polyhedral oligomeric silsesquioxane (fluorodecyl POSS) and 90% polyethyl methacrylate (PEMA) is used to uniformly coat the fabric surface topography. Contact angle measurements show that a robust metastable composite interface with high apparent contact angles can be supported for hexadecane (gamma(lv) = 27.5 mN/m) and dodecane (gamma(lv) = 25.3 mN/m). To tune the solid surface energy of the coated surface, we also developed a reversible treatment using thermal annealing of the surface in contact with either dry air or water. The tunability of the solid surface energy along with the inherent re-entrant texture of the polyester fabric result in reversibly switchable oleophobicity between a highly nonwetting state and a fully wetted state for low surface tension liquids such as hexadecane and dodecane. This tunability can be explained within a design parameter framework, which provides a quantitative criterion for the transition between the two states, as well as accurate predictions of the measured values of the apparent contact angle (theta*) for the dip-coated polyester fabrics.

Smooth, All-Solid, Low-Hysteresis, Omniphobic Surfaces with Enhanced Mechanical Durability.

The utility of omniphobic surfaces stems from their ability to repel a multitude of liquids, possessing a broad range of surface tensions and polarities, by causing them to bead up and either roll or slide off. These surfaces may be self-cleaning, corrosion-resistant, heat-transfer enhancing, stain-resistant or resistant to mineral- or biofouling. The majority of reported omniphobic surfaces use texture, lubricants, and/or grafted monolayers to engender these repellent properties. Unfortunately, these approaches often produce surfaces with deficiencies in long-term stability, durability, scalability, or applicability to a wide range of substrates. To overcome these limitations, we have fabricated an all-solid, substrate-independent, smooth, omniphobic coating composed of a fluorinated polyurethane and fluorodecyl polyhedral oligomeric silsesquioxane. Liquids of varying surface tension, including water, hexadecane, ethanol, and silicone oil, exhibit low-contact-angle hysteresis (<15°) on these surfaces, allowing liquid droplets to slide off, leaving no residue. Moreover, we demonstrate that these robust surfaces retained their repellent properties more effectively than textured or lubricated omniphobic surfaces after being subjected to mechanical abrasion.

Coalescence-induced jumping of droplets on superomniphobic surfaces with macrotexture.

When two liquid droplets coalesce on a superrepellent surface, the excess surface energy is partly converted to upward kinetic energy, and the coalesced droplet jumps away from the surface. However, the efficiency of this energy conversion is very low. In this work, we used a simple and passive technique consisting of superomniphobic surfaces with a macrotexture (comparable to the droplet size) to experimentally demonstrate coalescence-induced jumping with an energy conversion efficiency of 18.8% (i.e., about 570% increase compared to superomniphobic surfaces without a macrotexture). The higher energy conversion efficiency arises primarily from the effective redirection of in-plane velocity vectors to out-of-plane velocity vectors by the macrotexture. Using this higher energy conversion efficiency, we demonstrated coalescence-induced jumping of droplets with low surface tension (26.6 mN m-1) and very high viscosity (220 mPa·s). These results constitute the first-ever demonstration of coalescence-induced jumping of droplets at Ohnesorge number >1.

Facile synthesis of hydrophobic fluoroalkyl functionalized silsesquioxane nanostructures.

New fluorinated polyhedral oligomeric silsesquioxane (F-POSS) structures possessing a high degree of hydrophobicity have been prepared via a facile corner-capping methodology.

Designing Self-Healing Superhydrophobic Surfaces with Exceptional Mechanical Durability.

The past decade saw a drastic increase in the understanding and applications of superhydrophobic surfaces (SHSs). Water beads up and effortlessly rolls off a SHS due to its combination of low surface energy and texture. Whether being used for drag reduction, stain repellency, self-cleaning, fog harvesting, or heat transfer applications (to name a few), the durability of a SHS is critically important. Although a handful of purportedly durable SHSs have been reported, there are still no criteria available for systematically designing a durable SHS. In the first part of this work, we discuss two new design parameters that can be used to develop mechanically durable SHSs via the spray coating of different binders and fillers. These parameters aid in the rational selection of material components and allow one to predict the capillary resistance to wetting of any SHS from a simple topographical analysis. We show that not all combinations of sprayable components generate SHSs, and mechanically durable components do not necessarily generate mechanically durable SHSs. Moreover, even the most durable SHSs can eventually become damaged. In the second part, utilizing our new parameters, we design and fabricate physically and chemically self-healing SHSs. The most promising surface is fabricated from a fluorinated polyurethane elastomer (FPU) and the extremely hydrophobic small molecule 1H,1H,2H,2H-heptadecafluorodecyl polyhedral oligomeric silsesquioxane (F-POSS). A sprayed FPU/F-POSS surface can recover its superhydrophobicity even after being abraded, scratched, burned, plasma-cleaned, flattened, sonicated, and chemically attacked.

Coalescence-Induced Self-Propulsion of Droplets on Superomniphobic Surfaces.

We utilized superomniphobic surfaces to systematically investigate the different regimes of coalescence-induced self-propulsion of liquid droplets with a wide range of droplet radii, viscosities, and surface tensions. Our results indicate that the nondimensional jumping velocity Vj* is nearly constant (Vj* ≈ 0.2) in the inertial-capillary regime and decreases in the visco-capillary regime as the Ohnesorge number Oh increases, in agreement with prior work. Within the visco-capillary regime, decreasing the droplet radius R0 results in a more rapid decrease in the nondimensional jumping velocity Vj* compared to increasing the viscosity µ. This is because decreasing the droplet radius R0 increases the inertial-capillary velocity Vic in addition to increasing the Ohnesorge number Oh.

Designing durable icephobic surfaces.

Ice accretion has a negative impact on critical infrastructure, as well as a range of commercial and residential activities. Icephobic surfaces are defined by an ice adhesion strength τice < 100 kPa. However, the passive removal of ice requires much lower values of τice, such as on airplane wings or power lines (τice < 20 kPa). Such low τice values are scarcely reported, and robust coatings that maintain these low values have not been reported previously. We show that, irrespective of material chemistry, by tailoring the cross-link density of different elastomeric coatings and by enabling interfacial slippage, it is possible to systematically design coatings with extremely low ice adhesion (τice < 0.2 kPa). These newfound mechanisms allow for the rational design of icephobic coatings with virtually any desired ice adhesion strength. By using these mechanisms, we fabricate extremely durable coatings that maintain τice < 10 kPa after severe mechanical abrasion, acid/base exposure, 100 icing/deicing cycles, thermal cycling, accelerated corrosion, and exposure to Michigan wintery conditions over several months.

A high-performance renewable thermosetting resin derived from eugenol.

A renewable bisphenol, 4,4'-(butane-1,4-diyl)bis(2-methoxyphenol), was synthesized on a preparative scale by a solvent-free, Ru-catalyzed olefin metathesis coupling reaction of eugenol followed by hydrogenation. After purification, the bisphenol was converted to a new bis(cyanate) ester by standard techniques. The bisphenol and cyanate ester were characterized rigorously by NMR spectroscopy and single-crystal X-ray diffraction studies. After complete cure, the cyanate ester exhibited thermal stability in excess of 350 °C and a glass transition temperature (Tg ) of 186 °C. As a result of the four-carbon chain between the aromatic rings, the thermoset displayed a water uptake of only 1.8% after a four day immersion in 85 °C water. The wet Tg of the material (167 °C) was only 19 °C lower than the dry Tg , and the material showed no significant degradation as a result of the water treatment. These results suggest that this resin is well suited for maritime environments and provide further evidence that full-performance resins can be generated from sustainable feedstocks.

Di(cyanate Ester) Networks Based on Alternative Fluorinated Bisphenols with Extremely Low Water Uptake.

A new polycyanurate network exhibiting extremely low moisture uptake has been produced via the treatment of perfluorocyclobutane-containing Bisphenol T with cyanogen bromide and subsequent thermal cyclotrimerization. The water uptake, at 0.56 ± 0.10% after immersion in water at 85 °C for 96 h, represents some of the most promising moisture resistance observed to date in polycyanurate networks. This excellent performance derives from a near optimal value of the glass transition at 190 °C at full cure. Superior dielectric loss characteristics compared to commercial polycyanurate networks based on Bisphenol E were also observed. Polycyanurate networks derived from this new monomer appear particularly well-suited for applications such as radomes and spacecrafts where polycyanurates are already widely recognized as providing outstanding properties.