Discontinuous Directional Wetting Transitions in Polymeric Droplets on the Heterogeneous Microcavity Surface

The wetting transition behaviors of polymeric droplets on microcavity surfaces are familiar and play a vital role in micromanufacturing, microfluidics, and printing industries. Despite previous research indicating that microcavity surfaces can precisely control the droplet wetting state, the understanding of the complex effects of droplet spreading, surface morphology, and property of polymeric droplet on wetting transitions remains incomplete. The air-liquid interfaces (ALIs) typically arise from the entrapped air beneath the droplet on microcavity surfaces, adopting a metastable wetting state caused by either bubble escape or dissolution. Here, we discovered a previously unobserved phenomenon: the time-dependent evolution of regularly arranged ALIs with discontinuous wetting states, along with the pronounced directional wetting transitions from the Cassie-Baxter state to the Wenzel state upon deposition of polymeric droplets on heterogeneous microcavity surfaces. The durability of ALIs in microcavities was quantified, illustrating that the wetting transitions associated with droplet spreading processes obeyed power laws. By integrating the wetting theory and the viscoelastic effect of polymeric droplet, we have proposed a phenomenological coevolution model for wetting transitions that emphasizes the synergistic interaction between adjacent microcavities, resulting in the observed cluster evolution behavior of ALIs within droplets. Our study holds great significance in guiding soft manufacturing techniques utilizing internal ALIs as templates. The established mechanism opens up avenues for investigating the intricate wetting phenomena of polymeric droplets on microtextured substrates.