Anti‐Frosting and Defrosting Fins with Hierarchical Interlocking Structure for Enhancing Energy Utilization Efficiency of Heat Exchanger

Abstract Air conditioners, being an indispensable component of contemporary living, consume a significant amount of electricity every year. The accumulation of frost, dust, and water on the fins surface hinders the efficiency of the heat exchange process, thereby reducing the effectiveness of the air conditioning system. To address these limitations, this paper proposes a large‐scale and cost‐effective method combining compression molding, chemical etching, and spray coating to fabricate aluminum fins (HMNA) with hierarchical interlocking structures. The HMNA exhibits outstanding durability, passive and active anti‐icing, anti‐frosting and defrosting, and self‐cleaning capabilities associated with the robust super‐hydrophobicity. The hierarchical interlocking structure effectively enhances the physical and environmental durability of the HMNA. Most significantly, the frost time of the HMNA fins assembled heat exchanger is significantly delayed by ≈700% compared to the traditional Al fins heat exchanger, while the frost layer thickness is reduced by ≈75%. This greatly reduces the frequency with which the defrosting cycle is started, thus effectively improving the efficiency of the air conditioning system. The proposed method for economical and mass production of the HMNA fins can be an excellent candidate for the development of low energy consumption air conditioning system.