Incomplete Wenzel State Induced by Dual-Critical Angles in Regular Square Pyramid Microstructures

The array of regular square pyramid microstructures with zero-spacing features is an ideal structural topology for building superhydrophobic functional surfaces due to its excellent anti-wetting performance and low surface adhesion properties. In the framework of existing studies, this microstructured array is usually considered to exist only in two typical wetting states, the stable Cassie state and the Wenzel state. In this study, a third type of wetting state, the incomplete Wenzel state, was discovered for the first time using experimental characterization, and the evolution mechanism of this new wetting state was revealed based on critical contact angle theory and numerical simulation. It is revealed that the faces and edges of the square pyramid microstructures exhibit different tilting angles, and this unique geometrical design endows them with dual critical contact angles. When the intrinsic contact angle of the microstructure is between the critical contact angles for the edges and faces, the wetting behavior of the droplet contact line in the directions parallel to the edges and faces will generate spontaneous and non-spontaneous competition effects, which lead to the formation of the incomplete Wenzel state. The dual-critical-angle theoretical model constructed in this study provides a new perspective for improving the theoretical system of wetting dynamics on pyramid arrays.