Scalable manufacturing of superhydrophobic structures in plastics

Patent metadata

Field	Value
Publication number	US-2016158969-A1
Application number	US-201514964295-A
Country	US
Kind code	A1
Filing date	Dec 9, 2015
Priority date	Dec 9, 2014
Publication date	Jun 9, 2016
Grant date	—

Abstract

Disclosed are methods of manufacturing a SH surface including: creating a master with SH features by: depositing a rigid material onto a first surface, wherein the first surface is a shrinkable platform; shrinking the first surface by heating to create a SH surface, wherein the SH surface has micro- and nano-scale structural features that trap air pockets and prevent water from wetting the surface; forming the master by molding an epoxy with the shrunken first surface having a SH surface, wherein the master acquires the SH features of the first surface; and imprinting the SH features of the master onto a second surface to impart the SH features of the master onto the second surface. Some embodiments relate to a superhydrophobic (SH) surface, an article including a SH surface as disclosed, such as a microfluidic device or a food container.

First claim

What is claimed is:

1 . A method of manufacturing a SH surface comprising:
creating a master with SH features by:
depositing a rigid material onto a first surface, wherein the first surface is a shrinkable platform;
shrinking the first surface by heating to create a SH surface, wherein the SH features comprise micro- and nano-scale structures that trap air pockets and prevent water from wetting the surface;
forming the master by contacting a master material with the shrunken first surface having a SH surface and hardening the master material while in contact with the shrunken first surface, wherein master material solidifies and acquires the SH features of the first surface; and
imprinting the SH features of the master onto a second surface to impart the SH features of the master onto the second surface.

2 . The method of claim 1 , wherein said rigid material comprises a metal.

3 . The method of claim 2 , wherein said metal is gold or silver.

4 . The method of claim 1 , wherein said rigid material comprises calcium.

5 . The method of claim 1 , wherein said rigid material comprises a combination of silver and calcium.

6 . The method of claim 1 , wherein said rigid material is vapor-deposited onto the first surface.

7 . The method of claim 1 , wherein the master material is selected from the group consisting of nickel, polydimethylsiloxane (PDMS), ormocer and spurr.

8 . The method of claim 1 , wherein the master is formed by electroplating nickel onto the SH surface.

9 . The method of claim 1 , wherein said imprinting is done by hot embossing of the second surface with the master.

10 . The method of claim 1 , wherein the first surface is a polyolefin (PO).

11 . The method of claim 1 , wherein the second surface is a hard plastic.

12 . The method of claim 1 , wherein a master is repetitively imprinted onto the second surface at adjacent positions to seamlessly transfer the SH features of the master to the second surface.

13 . The method of claim 1 , wherein the SH features of a master are imprinted onto the second surface by roll-to-roll processing.

14 . A superhydrophobic (SH) surface, wherein the SH surface has micro- and nano-scale features configured to reduce water wetting of the surface and wherein the micro- and nano-scale features of the SH surface are complementary to micro- and nano-scale structural features of a corresponding cylindrical master mold configured to create the micro- and nano-scale structural features of the SH surface.

15 . The SH surface according to claim 14 , wherein the SH surface is formed on a surface of a hard plastic.

16 . The SH surface according to claim 14 , wherein the SH surface comprises polypropylene.

17 . The SH surface according to claim 14 , wherein the surface is not chemically modified to achieve the micro- and nano-scale features.

18 . The SH surface according to claim 14 , wherein the SH surface has a surface area of from 0.5 mm 2 -1 m 2 .

19 . An article comprising the SH surface according to claim 14 .

20 . A microfluidic device comprising the SH surface of claim 14 .

21 . An article of manufacture, comprising:
a layer of flexible material having a first end and a second end; and an exposed surface having a surface texture comprising an expanse of hydrophobicity inducing features, the features having micro- and/or nano-scale dimensions, wherein the expanse provides a contact angle of at least 150 degrees and/or a sliding angle of less than 10 degrees.

22 . The article of claim 21 , wherein the hydrophobicity inducing features comprise wrinkles.

23 . The article of claim 21 , wherein the hydrophobicity inducing features comprise invaginations.

24 . The article of claim 21 , wherein a length of the layer from the first end to the second end exceeds 1 meter.

25 . A microfluidic device, comprising the article of manufacture of claim 21 .

26 . A food container comprising a volume defined by at least one wall comprising the article of manufacture of claim 21 .

Assignees

• Technical Res Ct Of Finland Ltd
• Univ California

Inventors

• Mclane Jolie
• Khine Michelle
• Liedert Ralph

Classifications

• B82Y30/00

  Nanotechnology for materials or surface science, e.g. nanocomposites · CPC title

• B29L2031/7532

  Artificial members, protheses · CPC title

• C25D1/10

  Moulds; Masks; Masterforms · CPC title

• B29K2905/00

  Use of metals, their alloys or their compounds, as mould material · CPC title

• B29C2059/023

  Microembossing · CPC title