Self-Sustained Cascading Coalescence in Surface Condensation

Sustained dropwise condensation of water requires rapid shedding of condensed droplets from the surface. Here, we elucidate a microfluidic mechanism that spontaneously sweeps condensed microscale droplets without the need for the traditional droplet removal pathways such as use of superhydrophobicity for droplet rolling and jumping and utilization of wettability gradients for directional droplet transport among others. The mechanism involves self-generated, directional, cascading coalescence sequences of condensed microscale droplets along standard hydrophobic microgrooves. Each sequence appears like a spontaneous zipping process, can sweep droplets along the microgroove at speeds of up to ∼1 m/s, and can extend for lengths more than 100 times the microgroove width. We investigate this phenomenon through high-speed in situ microscale condensation observations and demonstrate that it is enabled by rapid oscillations of a condensate meniscus formed locally in a filled microgroove and pinned on its edges. Such oscillations are in turn spontaneously initiated by coalescence of an individual droplet growing on the ridge with the microgroove meniscus. We quantify the coalescence cascades by characterizing the size distribution of the swept droplets and propose a simple analytical model to explain the results. We also demonstrate that, as condensation proceeds on the hydrophobic microgrooved surface, the coalescence cascades recur spontaneously through repetitive dewetting of the microgrooves. Lastly, we identify surface design rules for consistent realization of the cascades. The hydrophobic microgrooved textures required for the activation of this mechanism can be realized through conventional, scalable surface fabrication methods on a broad range of materials (we demonstrate with aluminum and silicon), thus promising direct application in a host of phase-change processes.