Collaborative Research: Template-Free Manufacturing of Regular Microstructures by Ribbing-Enhanced Roll Coating

合作研究：通过罗纹增强辊涂无模板制造规则微结构

• 批准号: 2031558
• 负责人: Jong Ryu
• 金额: $ 61.99万
• 依托单位: North Carolina State University
• 依托单位国家: 美国
• 项目类别: Standard Grant
• 财政年份: 2020
• 资助国家: 美国
• 起止时间: 2020-09-01 至 2024-08-31
• 项目状态: 已结题
• 来源: https://www.nsf.gov/awardsearch/showAward?AWD_ID=2031558&HistoricalAwards=false
• 关键词: Collaborative; Research; Template; Free; Manufacturing

A technology that can reduce the friction or drag on ship hulls would have a substantial economic and environmental impact by improving fuel efficiency. Microstructured superhydrophobic surfaces may retain air pockets that can act as gas lubrication between the water and the ship hull. Although the superhydrophobic surfaces have been studied for nearly two decades, it is only recently that periodic linear-trench structures have been shown to be effective for marine crafts traveling in open water, which represents sea, oceans, and lakes. The manufacturing of such well-defined micro-trenches has relied on silicon-based microfabrication based on semiconductor manufacturing approaches. These silicon processes are prohibitively expensive and not scalable for large surface areas, such as ship hulls. To address these challenges, a team from North Carolina State University and University of California at Los Angeles would like to utilize roll coating methodology, which is well known for cost-effective and large-scale production, to form the periodic microstructures on large substrates. This new process is researched to develop friction-reduction coatings for ship hulls and study their physical and chemical durability. Hence, outcomes from this research will benefit a wide array of marine applications, including commercial and military ships, which play a significant role in the national and global economies and security applications. This project is investigates the spontaneous pattern generation by ribbing on polymer surfaces during roll coating in an ordered manner using a fundamentally new approach to manufacture three-dimensional micro and nano-scale structures on a large-area substrate. The objectives are to establish the scientific foundation to control the microstructures formed during the roll coating, and to fabricate and validate the drag reduction efficiency of the surfaces in realistic flow conditions of open water and Reynolds number greater than 1 million. The research team will utilize computational modeling to predict the deformation behavior of the viscoelastic polymer verified by the experimental observations. For the proof-of-concept of drag reduction in realistic flows, a microstructured film and a smooth film will be layered on the bottom of a motorboat specifically outfitted to reliably compare the fluid shear stresses on the two. This project will educate the next generation of engineers and scientists through multidisciplinary research involving manufacturing, materials science, computational modeling, and fluid mechanics. The research outcome will be also used to educate K-12, undergraduate, as well as graduate-level students through various formats such as outreach activities and innovative curricular efforts.This award reflects NSF's statutory mission and has been deemed worthy of support through evaluation using the Foundation's intellectual merit and broader impacts review criteria.

能够减少船体摩擦或阻力的技术将通过提高燃料效率产生巨大的经济和环境影响。微结构超疏水表面可以保留气穴，充当水和船体之间的气体润滑。尽管人们对超疏水表面的研究已有近二十年的历史，但直到最近，周期性线性沟槽结构才被证明对于在开阔水域（代表大海、海洋和湖泊）航行的船舶有效。这种轮廓分明的微沟槽的制造依赖于基于半导体制造方法的硅基微加工。这些硅工艺非常昂贵，并且无法扩展到大表面积，例如船体。为了应对这些挑战，来自北卡罗来纳州立大学和加州大学洛杉矶分校的团队希望利用以经济高效和大规模生产而闻名的辊涂方法，在大型基材上形成周期性微结构。研究这一新工艺的目的是开发船体减摩涂层并研究其物理和化学耐久性。因此，这项研究的成果将有利于广泛的海洋应用，包括商业和军用船舶，它们在国家和全球经济以及安全应用中发挥着重要作用。该项目研究了在辊涂过程中以有序方式通过聚合物表面上的肋条自发生成图案，使用一种全新的方法在大面积基材上制造三维微米和纳米级结构。目标是建立控制滚涂过程中形成的微观结构的科学基础，并在开放水域和雷诺数大于100万的实际流动条件下制造和验证表面的减阻效率。研究小组将利用计算模型来预测经实验观察验证的粘弹性聚合物的变形行为。为了验证实际流动中减阻的概念，微结构薄膜和光滑薄膜将分层在专门配备的摩托艇底部，以可靠地比较两者上的流体剪切应力。该项目将通过涉及制造、材料科学、计算建模和流体力学的多学科研究来教育下一代工程师和科学家。研究成果还将通过外展活动和创新课程工作等多种形式，用于教育 K-12、本科生以及研究生水平的学生。该奖项反映了 NSF 的法定使命，并通过评估认为值得支持。基金会的智力价值和更广泛的影响审查标准。

项目成果

Multiphysics FEA Simulation for Polymer Nanocomposite Laser Ultrasound Transducer

聚合物纳米复合材料激光超声换能器的多物理场有限元模拟

• DOI: 10.1109/nano54668.2022.9928742
• 发表时间: 2022-07-04
• 期刊: 2022 IEEE 22nd International Conference on Nanotechnology (NANO)
• 作者: Sipan Liu;Howuk Kim;Wei;Wenbin Huang;Xiaoning Jiang;J. Ryu
• 通讯作者: J. Ryu

Fabrication of Bioinspired Micro/Nano-Textured Surfaces Through Scalable Roll Coating Manufacturing

通过可扩展的辊涂制造制造仿生微/纳米纹理表面

• DOI: 10.1115/1.4056732
• 发表时间: 2022-06
• 期刊: Journal of Micro and Nano-Manufacturing
• 影响因子: 1
• 作者: Black, Benjamin;Chockalingam, Sekkappan;Islam, Md Didarul;Liu, Sipan;Perera, Himendra;Khan, Saad;Ryu, Jong Eun
• 通讯作者: Ryu, Jong Eun

A Scalable Microstructure Photonic Coating Fabricated by Roll-to-Roll “Defects” for Daytime Subambient Passive Radiative Cooling

通过卷对卷“缺陷”制造的可扩展微结构光子涂层，用于日间低温被动辐射冷却

• DOI: 10.1021/acs.nanolett.3c00111
• 发表时间: 2023-07
• 期刊: Nano Letters
• 影响因子: 10.8
• 作者: Liu, Sipan;Sui, Chenxi;Harbinson, Myers;Pudlo, Michael;Perera, Himendra;Zhang, Zhenzhen;Liu, Ruguan;Ku, Zahyun;Islam, Md Didarul;Liu, Yuxuan;et al
• 通讯作者: et al

Multiscale and multiphysics FEA simulation and materials optimization for laser ultrasound transducers

激光超声换能器的多尺度和多物理场有限元分析和材料优化

• DOI: 10.1016/j.mtcomm.2022.103599
• 发表时间: 2022-06
• 期刊: Materials Today Communications
• 影响因子: 3.8
• 作者: Liu, Sipan;Kim, Howuk;Huang, Wenbin;Chang, Wei;Jiang, Xiaoning;Ryu, Jong Eun
• 通讯作者: Ryu, Jong Eun

Template‐Free Scalable Fabrication of Linearly Periodic Microstructures by Controlling Ribbing Defects Phenomenon in Forward Roll Coating for Multifunctional Applications

通过控制多功能应用的正向辊涂中的罗纹缺陷现象，模板自由可扩展地制造线性周期性微结构

• DOI: 10.1002/admi.202201237
• 发表时间: 2022-08
• 期刊: Advanced Materials Interfaces
• 影响因子: 5.4
• 作者: Islam, Md Didarul;Perera, Himendra;Black, Benjamin;Phillips, Matthew;Chen, Muh‐Jang;Hodges, Greyson;Jackman, Allyce;Liu, Yuxuan;Kim, Chang‐Jin;Zikry, Mohammed;et al
• 通讯作者: et al