Frost can spread not only along surfaces but also via suspended “ice bridges” that form above them. The discovery of this previously unknown frost-propagation pathway could lead to new ways of making surfaces that resist frost growth, thereby improving the performance of devices that operate in cold, humid environments.

Frost accumulation is a major problem in refrigerators, aeroplanes and heat pumps, to name just a few. On the microscale, it primarily spreads from one individual freezing water droplet to the next via two-dimensional bridges, or causeways, that temporarily form on the surface of an object. Although the wettability of the surface is known to affect the spreading process, the mechanism behind this effect was poorly understood.

Ice bridges can grow in two distinct spatial modes

To learn more, a team led by physicist Nenad Miljkovic at the University of Illinois Urbana-Champaign, US imaged the channel-forming process using high-speed high-resolution optical microscopy combined with a profilometry technique called focal plane shift imaging (FPSI). They found that frost can spread in two distinct ways. On hydrophilic surfaces, causeways form along the substrate, in line with current theoretical models. On superhydrophobic surfaces, however, the situation is quite different. Here, frost spreads via ice bridges that are suspended above the surface in three-dimensional space.

This suspended or “out-of-plane” growth mode represents a fundamentally different pathway for frost propagation, says team member Siyan Yang, the first author of a Nature Physics  paper about the work. Previous studies likely overlooked this mechanism, Yang adds, because of limitations in experimental observations.

Superhydrophobic coatings nearly double the frost propagation time

The researchers also studied the growth rate of the different bridge types. They found that suspended bridges grew slower than bridges on the surface due to the reduced thermal coupling between the bridges and the cold substrate.  This reduced coupling correspondingly reduces the vapour pressure difference between ice and water droplets (which depends on surface droplet geometry, itself controlled by wettability) and drives down ice growth. Indeed, the team found that the speed at which frost spreads fell more than 80% in this mode.

To test the practical relevance of their findings, the researchers applied superhydrophobic coatings to metre-sized structures such as the finned-tube aluminium heat exchangers commonly found in air conditioners, refrigerators and automotive systems. Condensation frosting on such systems poses a major efficiency challenge because frost has an inherently low thermal conductivity. When it accumulates on heat exchangers, it therefore severely impedes heat being exchanged with the surrounding air.

On uncoated commercial heat exchangers that are inherently hydrophilic, the team found that frost rapidly forms and spreads across the fins. “In the superhydrophobic counterparts, however, the onset of frost formation is delayed, and it propagates much more slowly,” Yang says. In the two kinds of commercial systems they tested, she adds, applying superhydrophobic coatings nearly doubled the frost propagation time.

The results suggest that designers of anti-frost surfaces could benefit from trying this new strategy, Yang says. “Rather than focusing solely on delaying initial ice nucleation, surfaces could be engineered to control the geometry of ice-bridge growth and interrupt frost spreading, thereby improving the performance and energy efficiency of a host of equipment operating in cold and humid environments,” she tells Physics World.

The team is now investigating how surface chemistry and surface structures influence suspended ice-bridge formation and frost propagation. “We are also exploring ways to translate the fundamental mechanism into scalable anti-frost coatings and heat-exchanger technologies,” Yang reveals. “Ultimately, our goal is to establish predictive design rules that connect microscale ice-bridge dynamics with real-world frost management performance.”

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A new contact-free way of rotating delicate samples, such as biological cells, undergoing three-dimensional (3D) optical microscopy increases the image resolution and could reveal more details about microscale structures and processes.

Current optical microscopes provide extremely good image resolution in a single plane, but since depth information is often lacking, samples are routinely rotated and imaged at multiple different angles to create a 3D picture. Because rotating via mechanical microtools such as tiny grippers, needles or pipettes can damage samples, contact-free approaches such as optical tweezers, magnetic manipulation or optothermal forces are often used instead. However, these methods rely on the sample being birefringent, magnetic, light-absorbing or specially shaped.

By contrast, the laser-based technique developed by a team led by Moritz Kreysing and Fan Nan from the Institute of Biological and Chemical Systems at the Karlsruher Institut für Technologie (KIT) in Germany can rotate and spin floating microscopic objects no matter what their shape or material properties.

Their method involves focusing a 1455 nm infrared laser beam on a small region of a highly viscous liquid – initially at 25°C – in which the sample will be suspended. This gently heats that region of the liquid by a few degrees. But rather than focusing on one spot, an acousto-optic deflector steers the beam rapidly along a carefully designed two-dimensional (2D) pattern.

“Because the viscosity of the liquid changes with temperature, this moving heat pattern generates tiny fluid flows, known as thermoviscous flows. By choosing the scan geometry and timing correctly, these flows become three-dimensional and helical, like microscopic corkscrew-shaped currents,” explain Kreysing and Nan. Once a small object is floated freely in these 3D helical flows, it can be rotated, spun, transported or stabilized solely via software-defined scan patterns, with different symmetries controlling the movement of the surrounding liquid.

The KIT technique allows stacks of high-resolution images focused at different depths to be acquired along multiple different angles by re-orienting the sample, a feature that “can help overcome the anisotropic resolution of conventional 3D microscopy”, explain the researchers. Using a high-viscosity liquid to suspend the samples not only enables kinematic stop-and-go actuation, it also suppresses Brownian motion (the jiggling around of tiny particles in fluids), which otherwise decreases image resolution and makes the study of cellular transport processes tricky.

Since previous methods of laser-driving fluid flows could only create motion in one plane, the researchers found it “particularly exciting” when they first observed their laser scanning in a 2D plane generating 3D flow fields. “Another key moment was the observation of opto-hydrodynamic focusing. The particles did not just rotate; their spiral motion converged toward a stable height and position. This was significant because it meant that the optofluid could stabilize the sample, rather than requiring mechanical confinement or complex feedback control.”

As detailed in their recent Light: Science & Applications paper, the KIT team demonstrated rotation and spinning of various samples including stained biological cells, nano-printed micro-tiles and perfectly spherical beads. “We see immediate potential in advanced optical microscopy, especially multi-view imaging of suspended cells, cell clusters, organelles, microstructures or soft materials,” Kreysing and Nan tell Physics World.

Since the basic hardware components of their system will be familiar to many optics and microscopy labs, they are hoping for early adoption by specialized research groups. But to optimize the technique for biological applications, they will now investigate the use of different liquids and operating conditions “that better preserve the viability of live mammalian cells while still providing sufficient stability for precise rotation and imaging”.

The researchers suggest that future areas of application could include microfluidics, microrobotics, colloidal assembly, materials science and 3D microfabrication. As such, they also want to develop more advanced scan patterns that can generate curved, programmable or multi-axis helical flows. “This could allow more complex 3D manipulation, such as controlled orientation of irregular objects, coordinated actuation of multiple particles, or integration with microfabrication workflows,” they explain.

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