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Capillary Coatings: Flow and Drying Dynamics in Open Microchannels.

Robert K Lade1, Krystopher S Jochem1, Christopher W Macosko1

  • 1Department of Chemical Engineering and Materials Science , University of Minnesota-Twin Cities , 421 Washington Avenue SE , Minneapolis , Minnesota 55455 , United States.

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Drying polymer solutions in microchannels causes pinning, limiting flow distance. Optimal conditions for longer flow and uniform films involve lower drying rates and specific channel widths, crucial for printed electronics inks.

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Area of Science:

  • Fluid dynamics
  • Materials science
  • Surface science

Background:

  • Capillary flow and drying of polymer solutions are critical in microscale fabrication.
  • Understanding contact line dynamics during drying is essential for controlling thin film formation.

Purpose of the Study:

  • To investigate capillary flow and drying dynamics of polymer solutions in open microchannels.
  • To identify and characterize pinning events and their impact on flow distance and time.
  • To explore the influence of channel width and drying rate on capillary coating processes.

Main Methods:

  • Experimental observation of capillary filling and drying over seven orders of magnitude in time.
  • Identification and characterization of three distinct types of microscale pinning events.
  • Analysis of polymer solution behavior in PEDOT:PSS and graphene inks.

Main Results:

  • Drying-induced viscosity increases lead to microscale pinning, eventually arresting contact line motion.
  • Flow distance and time are strongly dependent on channel width and drying rate; lower drying rates and intermediate widths favor longer flows.
  • Internal flows persist after initial pinning, driven by evaporation, leading to solids accumulation.
  • Functional inks like PEDOT:PSS and graphene show unique pinning resistance attributed to chemistry, particle size, and rheology.

Conclusions:

  • Drying dynamics significantly influence capillary coating processes in microchannels.
  • Optimizing channel width and drying rate is key to controlling flow and achieving uniform films.
  • Functional inks exhibit complex pinning behaviors requiring tailored design for advanced applications in printed electronics.