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Procedure for the Transfer of Polymer Films Onto Porous Substrates with Minimized Defects

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Holes in Sheets: Double-Threshold Rupture of Draining Liquid Films.

Ayush K Dixit¹, Chunheng Zhao², Stéphane Zaleski^3,4

¹University of Twente, Physics of Fluids Department, Max Planck Center Twente for Complex Fluid Dynamics, and J. M. Burgers Center for Fluid Dynamics, P.O. Box 217, 7500AE Enschede, Netherlands.

Physical Review Letters

|March 13, 2026

Summary

Liquid film rupture occurs when outward driving forces and cavity distortion reach a double threshold. Below this, surface tension reseals the film, explaining micrometer-thick film perforation and enabling control over spray formation and respiratory films.

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Area of Science:

Fluid dynamics
Surface physics
Material science

Background:

Classical rupture theories focus on molecular forces at nanometric scales.
The mechanism for perforation of micron-thick liquid films remains unclear.
Understanding film rupture is crucial for processes like spray formation and respiratory therapies.

Purpose of the Study:

To elucidate the mechanism governing the rupture of micron-thick liquid films.
To identify the critical conditions that determine film opening versus healing.
To provide insights for controlling liquid film breakup.

Main Methods:

Direct numerical simulations of a draining liquid sheet.
Modeling of an entrained air bubble (cavity) within the sheet.
Analysis of the interplay between driving forces, cavity distortion, surface tension, inertia, and viscosity.

Main Results:

Irreversible rupture occurs only when a double threshold is met: sufficient outward driving force and significant cavity distortion.
If either threshold is not met, surface tension drives cavity healing and reseals the film.
The rupture timescale depends on the balance between inertia and viscosity.

Conclusions:

A double-threshold mechanism explains micron-thick liquid film perforation.
Controlling driving strength and defect geometry can predict and manage film breakup.
Findings have implications for spray formation, wave breaking, and respiratory film technologies.