Abstract
Many surfaces in nature such as the lotus leaf, cicada wings, water spider legs and gecko feet have attracted attention due to their inherent superhydrophobicity and self-cleaning properties. These surfaces are characterized by water contact angles greater than 150° and contact angle hysteresis < 10°. In this work, a continuous fabrication methodology for production of such superhydrophobic surfaces consisting of well-ordered micro-pillar structures (aspect ratio greater than 1 (1.3)) on a large area polyamide film using roll-to-roll hot embossing process was demonstrated. It was found that the temperature played a significant role in replication. Incomplete replication was observed in regime 1 (150 to 155 °C) and the height of replication was influenced by nip pressure and roll speed due to viscosity variations. In contrast, complete replication was seen in regime 2 (190 to 195 °C) and the height of replication was insensitive to nip pressure and roll speed due to a fairly constant viscosity value. The embossed polyamide surface, once coated with a low surface energy 1H, 1H, 2H, 2H-perfluorooctyltrichlorosilane (PFTS) monolayer, showed super-repellant characteristics with respect to water and demonstrated a successful manufacturing approach to fabricate superhydrophobic surfaces.
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