Boosting water evaporation via continuous formation of a 3D thin film through triple-level super-wicking routes

Abstract

Capillary-fed thin-film evaporation via micro/nanoscale structures has attracted increasing attention for its high evaporation flux and pumpless liquid replenishment. However, maximizing thin-film evaporation has been hindered by the intrinsic trade-off between the heat flux and liquid transport. Here, we designed and fabricated nanostructured micro-steam volcanoes on copper surfaces featuring triple-level super-wicking routes to overcome this trade-off and boost water evaporation. The triple-level super-wicking routes enable the continuous formation of a 3D thin film for highly efficient evaporation by continuous self-driven liquid replenishment and extending the thin-film region. The micro-steam volcanoes increased the surface area by 225%, improving the evaporation rate by 141%, with a rapid self-pumping water transport speed up to 80 mm s⁻¹. A remarkable solar-driven water evaporation rate of 3.33 kg m⁻² h⁻¹ under one sun vertical incidence was achieved, which is among the highest reported values for metal-based evaporators. When attached to electric-heating plates, the evaporator realized an electrothermal evaporation rate of 12.13 kg m⁻² h⁻¹. Moreover, it can also be used for evaporative cooling with enhanced convective heat transfer, reaching a 36.2 °C temperature reduction on a heat source with a heat flux of 6 W cm⁻². This study promises a general strategy for designing thin-film evaporators with high efficiencies, low costs, and multi-functional compatibilities.