Geometric model describing the banded morphology of particle films formed by convective assembly.

Nanoparticle films coated on smooth substrates by convective assembly from dilute suspensions in dip-coating configuration are known to have discrete film morphologies. Specifically, the film morphology is characterized by alternating bands of densely packed particles and bands of bare substrate. Convective assembly is a frontal film-growth process that occurs at the three-phase contact line formed by the substrate, the suspension in which it is submersed, and the surrounding air. The bands are parallel to this contact line and can be either monolayered or multilayered. Monolayered bands result whenever the substrate is withdrawn from the suspension at a rate too high for particles to assemble into a continuous film. We report a new insight to the mechanism behind this banding phenomenon, namely, that inter-band spacing is strongly influenced by the constituent particle size. We therefore propose a geometric model relating the inter-band spacing to the particle size. By making banded films with systematically varied particle sizes (silica/zeolite, 20 to 500 nm), we are able to quantitatively validate our model. Furthermore, the model correctly predicts that multilayered banded films have higher inter-band spacings than monolayered banded films comprising the same particles.

Ferroin-collodion membranes: dynamic concentration patterns in planar membranes.

Patterns and waves of the Belousov-Zhabotinskii reaction are produced in membranes in which one reactant is immobilized. Convection is eliminated, the generation and deformation of wave forms are studied, and patterns are permnanently fixed. Wave shape, frequency, length, and phase velocity are explained theoretically by the interactions of diffusion with reaction.

Cryo-SEM studies of latex/ceramic nanoparticle coating microstructure development.

Cryogenic scanning electron microscopy (cryo-SEM) was used to investigate microstructure development of composite coatings prepared from dispersions of antimony-doped tin oxide (ATO) nanoparticles (approximately 30 nm) or indium tin oxide (ITO) nanoparticles (approximately 40 nm) and latex particles (polydisperse, D(v): approximately 300 nm). Cryo-SEM images of ATO/latex dispersions as-frozen show small clusters of ATO and individual latex particles homogeneously distribute in a frozen water matrix. In contrast, cryo-SEM images of ITO/latex dispersions as-frozen show ITO particles adsorb onto latex particle surfaces. Electrostatic repulsion between negatively charged ATO and negatively charged latex particles stabilizes the ATO/latex dispersion, whereas in ITO/latex dispersion, positively charged ITO particles are attracted onto surfaces of negatively charged latex particles. These results are consistent with calculations of interaction potentials from past research. Cryo-SEM images of frozen and fractured coatings reveal that both ceramic nanoparticles and latex become more concentrated as drying proceeds; larger latex particles consolidate with ceramic nanoparticles in the interstitial spaces. With more drying, compaction flattens the latex-latex particle contacts and shrinks the voids between them. Thus, ceramic nanoparticles are forced to pack closely in the interstitial spaces, forming an interconnected network. Finally, latex particles partially coalesce at their flattened contacts, thereby yielding a coherent coating. The research reveals how nanoparticles segregate and interconnect among latex particles during drying.

Imaging vesicular dispersions with cold-stage electron microscopy.

A fast-freeze, cold-stage transmission electron microscopy technique which can incorporate in situ freeze-drying of the sample is described. Its use in elucidating structure in unstained and stained, hydrated and freeze-dried, aqueous vesicular dispersions of biological and chemical interest is demonstrated with vesicles of L-alpha-phosphatidylcholine (bovine phosphatidylcholine) and of the synthetic surfactant sodium 4-(1'-heptylnonyl)benzenesulfonate (SHBS). The contrast features observed in transmission electron microscope images of frozen, hydrated samples are identified and explained with the dynamical theory of electron diffraction. Radiolysis by the electron beam is shown to increase contrast in vesicle images and to change their structure and size. Micrographs illustrate the freeze-drying of a dispersion in the microscope; the process causes vesicles to shrink and collapse.

Engineering the microstructure and permeability of thin multilayer latex biocatalytic coatings containing E. coli.

The microstructure and permeability of rehydrated 20-100 microm thick partially coalesced (vinyl-actetate acrylic copolymer) SF091 latex coatings and a 118 microm thick model trilayer biocatalytic coating consisting of two sealant SF091 layers containing a middle layer of viable E. coli HB101 + latex were studied as delaminated films in a diffusion apparatus with KNO(3) as the diffussant. The permeability of the hydrated coatings is due to diffusive transport through the pore space between the partially coalesced SF091 latex particles. Coating microstructure was visualized by fast freeze cryogenic scanning electron microscopy (cryo-SEM). The effective diffusion coefficient of SF091 latex coatings (diffusive permeability/film thickness) was determined as the ratio of the effective diffusivity of KNO(3) to its diffusivity in water (D(eff)/D). Polymer particle coalescence was arrested by two methods to increase coating permeability. The first used glycerol with coating drying at 4 degrees C, near the glass transition temperature (T(g)). The second method used sucrose or trehalose as a filler to arrest coalescence; the filler was then dissolved away. D(eff)/D was measured as a function of film thickness; content of glycerol, sucrose, and trehalose; drying time; and rehydration time. D(eff)/D varied from 3 x 10(-4) for unmodified SF091 coatings to 6.8 x 10(-2) for coatings containing sucrose. D(eff)/D was reduced by the flattening of latex particles against the surface of the solid substrate, as well as by the presence of the colloid stabilizer hydroxyethylcellulose (HEC). When corrected for the flattened particle layer, D(eff)/D of HEC-free coatings was as high as 0.20, which agreed with the value predicted from analysis of cryo-SEM images of the coat surface. D(eff)/D decreased by one-half in approximately 5 days in rehydrated SF091 coatings, indicating that significant wet coalescence occurs after glycerol, sucrose, or trehalose are leached from the films. D(eff)/D of SF091 latex trilayer coatings containing viable E. coli HB101 cells decreased as cell loading was increased from 2.2 x 10(-2) for 64 g dry cell weight per liter of coat volume to 5 x 10(-3) for 151 g DCW/L of coat volume. The reduction in coating permeability with increasing cell loading is predicted by Maxwell's equation for D(eff)/D in periodic composites.

Paramagnetic tracer concentration evolution by NMR relaxation time mapping: application to Aris-Taylor dispersion.

A procedure to study tracer dispersion was proposed and tested for the case of tracer spreading in tube flow. Concentration maps of paramagnetic tracers Gd3+ were measured in time through direct measurements of spin lattice relaxation time T1 obtained by using a two-point stimulated echo pulse sequence. The procedure was used to test the linear dependence of Peclet number on inverse velocity in the range of flow rates 0.3-1.2 cc/min.

Dispersion of paramagnetic tracers in bead packs by T1 mapping: experiments and simulations.

NMR imaging was used to study dispersion in 6 mm bead pack. T1 maps were employed to measure the rate of axial spreading of paramagnetic tracers (GdCl3) inside the bead pack in the range of flow rate from 0.015 mL/s to 0.175 mL/s. From the T1 maps, tracer concentration profiles were obtained, which yielded dimensionless axial dispersion coefficient and mean transit time. Spatial variations in the dispersion coefficient were observed at flow rates above 0.08 mL/s. We hypothesized that the observed spatial oscillations in the dispersion coefficient arise from the spatial variations of the velocity distribution. To validate this mechanism we showed by simulation that similar dispersion coefficient variation occur in a layered network.

Cold-stage microscopy system for fast-frozen liquids.

The least artifact-laden fixation technique for examining colloidal suspensions, microemulsions, and other microstructured liquids in the electron microscope appears to be thermal fixation, i.e., ultrafast freezing of the liquid specimen. For rapid-enough cooling and for observation in TEM/STEM a thin sample is needed. The need is met by trapping a thin layer ( approximately 100 nm) of liquid between two polyimide films ( approximately 40 nm thickness) mounted on copper grids and immersing the resulting sandwich in liquid nitrogen at its melting point. For liquids containing water, polyimides films are used since this polymer is far less susceptible to the electron beam damage observed for the commonly used polymer films such as Formvar and collodion in contact with ice. Transfer of the frozen sample into the microscope column without deleterious frost deposition and warming is accomplished with a new transfer module for the cooling stage of the JEOL JEM-100CX microscope, which makes a true cold stage out of a device originally intended for cooling specimens inside the column. Sample results obtained with the new fast-freeze, cold-stage microscopy system are given.

New controlled environment vitrification system for preparing wet samples for cryo-SEM.

A new controlled environment vitrification system (CEVS) has been designed and constructed to facilitate examination by cryogenic scanning electron microscopy (Cryo-SEM) of initial suspension state and of microstructure development in latex, latex-composite and other coatings while they still contain solvent. The new system has a main chamber with provisions for coating as well as drying, and for well-controlled plunging into cryogen. An added subsidiary chamber holds samples for drying or annealing over minutes to days before they are returned to the main chamber and plunged from it. In the main chamber, samples are blade-coated on 5 x 7 mm pieces of silicon wafer and held at selected temperature and humidity for successively longer times, either there or after transfer along a rail into the subsidiary chamber. They are then placed in the sample holder mounted on the plunge rod, so as to permit adjustment of the sample's attitude when it plunges, at controlled speed, into liquid ethane at its freezing point, to a chosen depth, in order to solidify the sample without significant shear or freezing artifacts. The entries of plunging samples and related sample holders into liquid ethane were recorded with a high-speed, high-resolution Photron digital camera. The data were interpreted with a new hypothesis about the width of the band of extremely rapid cooling by deeply subcooled nucleate boiling below the line of entry. Complementary cryo-SEM images revealed that the freezing rate and surface shearing of a sample need to be balanced by adjusting the plunging attitude.

Ceramic nanoparticle/monodisperse latex coatings.

Ceramic nanoparticle/monodisperse latex coatings with a nanoparticle-rich surface and a latex-rich body were created by depositing aqueous dispersions of monodisperse latex, approximately 550 nm in diameter, and nanosized ceramic particles onto substrates and drying. On the top surface of the dried coating, the latex particles are closely packed with nanoparticles uniformly occupying the interstitial spaces, and along the cross section, nanoparticles fill the spaces between the latex particles in the near surface region; a compacted latex structure, nearly devoid of nanoparticles, lies beneath. Cryogenic scanning electron microscopy images of partially dried coatings at successive drying stages reveal two important steps in forming this structure: top-down consolidation of latex particles and accumulation of nanoparticles in interstitial spaces among latex particles near the surface. A systematic study of the effect of processing conditions, including nanoparticle concentration, nanoparticle size, latex glass transition temperature, and drying conditions, on the final microstructure was carried out. The unique microstructure described above forms when the monodisperse latex is large enough to create pore channels for the transport of nanosized particles and the drying conditions favor "top-down" as opposed to "edge-in" drying.

Mechanistic principles of colloidal crystal growth by evaporation-induced convective steering.

We simulate evaporation-driven self-assembly of colloidal crystals using an equivalent network model. Relationships between a regular hexagonally close-packed array of hard, monodisperse spheres, the associated pore space, and selectivity mechanisms for face-centered cubic microstructure propagation are described. By accounting for contact line rearrangement and evaporation at a series of exposed menisci, the equivalent network model describes creeping flow of solvent into and through a rigid colloidal crystal. Observations concerning colloidal crystal growth are interpreted in terms of the convective steering hypothesis, which posits that solvent flow into and through the pore space of the crystal may play a major role in colloidal self-assembly. Aspects of the convective steering and deposition of high-Peclet-number rigid spherical particles at a crystal boundary are inferred from spatially resolved solvent flow into the crystal. Gradients in local flow through boundary channels were predicted due to the channels' spatial distribution relative to a pinned free surface contact line. On the basis of a uniform solvent and particle flux as the criterion for stability of a particular growth plane, these network simulations suggest the stability of a declining {311} crystal interface, a symmetry plane which exclusively propagates fcc microstructure. Network simulations of alternate crystal planes suggest preferential growth front evolution to the declining {311} interface, in consistent agreement with the proposed stability mechanism for preferential fcc microstructure propagation in convective assembly.

Silica nanoparticle crystals and ordered coatings using lys-sil and a novel coating device.

Silica nanoparticles with a narrow particle size distribution and controlled diameters of 10-20 nm are synthesized via hydrolysis and hydrothermal aging of tetraethylorthosilicate in an aqueous L-lysine solution. Cryo-transmission electron microscopy (cryo-TEM) reveals that the silica nanoparticles assemble to form close-packed nanoparticle crystals over short length scales on carbon-coated grids. Evaporative drying of the same sols results in nanoparticle stability and remarkable long-range facile ordering of the silica nanoparticles over scales greater than 10 microm. Whereas small-angle X-ray scattering (SAXS) and small-angle neutron scattering (SANS) discount the possibility of a core (silica)-shell (lysine) structure, the possibility remains for lysine occlusion within the silica nanoparticles and concomitant hydrogen bonding effects driving self-assembly. Facile ordering of the silica nanoparticles into multilayer and monolayer coatings over square-centimeter areas by evaporation-induced self-assembly is demonstrated using a novel dip-coating device.

Painting and printing living bacteria: engineering nanoporous biocatalytic coatings to preserve microbial viability and intensify reactivity.

Latex biocatalytic coatings containing approximately 50% by volume of microorganisms stabilize, concentrate and preserve cell viability on surfaces at ambient temperature. Coatings can be formed on a variety of surfaces, delaminated to generate stand-alone membranes or formulated as reactive inks for piezoelectric deposition of viable microbes. As the latex emulsion dries, cell preservation by partial desiccation occurs simultaneously with the formation of pores and adhesion to the substrate. The result is living cells permanently entrapped, surrounded by nanopores generated by partially coalesced polymer particles. Nanoporosity is essential for preserving microbial viability and coating reactivity. Cryo-SEM methods have been developed to visualize hydrated coating microstructure, confocal microscopy and dispersible coating methods have been developed to quantify the activity of the entrapped cells, and FTIR methods are being developed to determine the structure of vitrified biomolecules within and surrounding the cells in dry coatings. Coating microstructure, stability and reactivity are investigated using small patch or strip coatings where bacteria are concentrated 102- to 103-fold in 5-75 microm thick layers with pores formed by carbohydrate porogens. The carbohydrate porogens also function as osmoprotectants and are postulated to preserve microbial viability by formation of glasses inside the microbes during coat drying; however, the molecular mechanism of cell preservation by latex coatings is not known. Emerging applications include coatings for multistep oxidations, photoreactive coatings, stabilization of hyperthermophiles, environmental biosensors, microbial fuel cells, as reaction zones in microfluidic devices, or as very high intensity (>100 g.L-1 coating volume.h-1) industrial or environmental biocatalysts. We anticipate expanded use of nanoporous adhesive coatings for prokaryotic and eukaryotic cell preservation at ambient temperature and the design of highly reactive "living" paints and inks.

Hydrogen production by photoreactive nanoporous latex coatings of nongrowing Rhodopseudomonas palustris CGA009.

Nonuniform light distribution is a fundamental limitation to biological hydrogen production by phototrophic bacteria. Numerous light distribution designs and culture conditions have been developed to reduce self-shading and nonuniform reactivity within bioreactors. In this study, highly concentrated (2.0 x 108 CFU/muL formulation) nongrowing Rhodopseudomonas palustris CGA009 were immobilized in thin, nanoporous, latex coatings. The coatings were used to study hydrogen production in an argon atmosphere as a function of coating composition, thickness, and light intensity. These coatings can be generated aerobically or anaerobically and are more reactive than an equivalent number of suspended or settled cells. Rhodopseudomonas palustris latex coatings remained active after hydrated storage for greater than 3 months in the dark and over 1 year when stored at -80 degrees C. The initial hydrogen production rate of the microphotobioreactors containing 6.25 cm2, 58.4 mum thick Rps. palustris latex coatings illuminated by 34.1 PAR mumol photons m-2 s-1 was 6.3 mmol H2 m-2 h-1 and had a final yield of 0.55 mol H2 m-2 in 120 h. A dispersible latex blend has been developed for direct comparison of the specific activity of settled, suspended, and immobilized Rps. palustris.

Disordered network state in hydrated block-copolymer surfactants.

Hydration of poly(butadiene-b-ethylene oxide) diblock copolymers leads to various ordered and disordered phases, analogous to the aqueous phase behavior of surfactants and lipids. Small-angle x-ray scattering measurements corroborated by cryogenic scanning electron microscopy imaging reveal a random network (N) morphology at polymer compositions and water content intermediate to those associated with ordered cylinders (H1) and lamellae (L). This sequence of self-assembled structures is strikingly similar to the phase behavior of certain water-oil-surfactant microemulsions.

Stress generation by solvent absorption and wrinkling of a cross-linked coating atop a viscous or elastic base.

An in-plane constrained cross-linked gel layer absorbs an equilibrium amount of solvent and experiences in-plane compressive stress. A stability analysis of such an elastic gel layer that is attached to either a viscous or an elastic bottom layer atop a rigid substrate is considered. The effects of the top and bottom layer moduli (E(t) and E(b)), the bottom-to-top layer thickness ratio (H/h), and the polymer solvent interaction parameter (chi) on the critical condition of wrinkling, wrinkle wavelength, and amplitude are examined. When the bottom layer is viscous, the compressed top layer is always unstable, and wrinkling is rate-controlled. The viscous flow of the bottom layer governs the rate and determines the fastest growing wavelength. As E(t) rises, the bending stiffness of the elastic layer does as well, and so the fastest growing wavelength (lambda(m)) rises and the equilibrium amplitude (A(e)) falls. As H/h rises, the constraint of the rigid substrate diminishes, and so lambda(m) and A(e) rise. As chi falls or as the solvent has higher affinity for the polymeric gel, lambda(m) falls and A(e) rises because better solvents create higher compressive strain that promote low-wavelength, high-amplitude wrinkles. When the bottom layer is elastic, a critical compressive stress exists. If the generated compressive stress by solvent absorption is greater than the critical stress, the top layer wrinkles. It was found that wrinkling is most likely at intermediate E(t), low E(b), high H/h, and low chi. Further, lower chi, higher H/h, and lower E(b) were found to promote higher equilibrium amplitude and higher wavelength wrinkles.

Colloidal crystal layers of hexagonal nanoplates by convective assembly.

Particles of the zeolite ZSM-2 prepared as nearly hexagonal nanoplatelets were coated onto flat substrates by a convective assembly technique. On the submillimeter scale, coatings ranged in patterns from striped to continuous. Particles were preferentially oriented out-of-plane, as supported by X-ray diffractometry. The novel observation is that where the particle coating was only a monolayer thick, particles were locally close-packed and uniformly oriented both in and out of plane in a hexagonal colloidal crystalline arrangement that may be described as being tiled (observations by scanning electron microscopy). This is the first documented demonstration of convective assembly applied to anisometric nanoparticles that resulted in particulate coatings with locally ordered microstructure, i.e., colloidal crystallinity.

The role of thickness transitions in convective assembly.

Here we examine the microscopic details of convective assembly, a process in which thin colloidal crystals are deposited on a substrate from suspensions of nearly monodisperse spheres. Previously, such crystals have been shown to exhibit a strong tendency toward the face-centered cubic structure, which is difficult to explain on thermodynamic grounds. Using real-time microscopic visualization, electron microscopy, and scanning confocal microscopy, we obtain clues about the crystallization mechanism. Our results indicate that the regions at which a growing crystal transitions from n to n + 1 layers can play an important and previously unrecognized role in the crystallization. For thin crystals, we show both from experiment and through simple modeling that these transition regions can generate specific crystal structures. In thicker crystals, the crystallization is more complicated, but the transition regions must still be considered before a complete understanding of convective assembly can be obtained.

A model system for increasing the intensity of whole-cell biocatalysis: investigation of the rate of oxidation of D-sorbitol to L-sorbose by thin bi-layer latex coatings of non-growing Gluconobacter oxydans.

We developed a novel <50-microm thick nano-porous bi-layer latex coating for preserving Gluconobacter oxydans, a strict aerobe, as a whole cell biocatalyst. G. oxydans was entrapped in an acrylate/vinyl acetate co-polymer matrix (T (g) approximately 10 degrees C) and cast into 12.7-mm diameter patch coatings (cellcoat) containing approximately 10(9) CFU covered by a nano-porous topcoat. The oxidation of D-sorbitol to L-sorbose was used to investigate the coating catalytic properties. Intrinsic kinetics was studied in microbioreactors using a pH 6.0 D-sorbitol, phosphate, pyruvate (SPP) non-growth medium at 30 degrees C, and the Michaelis-Menten constants determined. By using a diffusion cell, cellcoat and topcoat diffusivities, optimized by arresting polymer particle coalescence by glycerol and/or sucrose addition, were determined. Cryo-FESEM images revealed a two-layer structure with G. oxydans surrounded by <40-nm pores. Viable cell density, cell leakage, and oxidation kinetics in SPP medium for >150 h were investigated. Even though the coatings were optimized for permeability, approximately 50% of G. oxydans viability was lost during cellcoat drying and further reduction was observed as the topcoat was added. High reaction rates per unit volume of coating (80-100 g/L x h) were observed which agreed with predictions of a diffusion-reaction model using parameters estimated by independent experiments. Cellcoat effectiveness factors of 0.22-0.49 were observed which are 20-fold greater than any previously reported for this G. oxydans oxidation. These nano-structured coatings and the possibility of improving their ability to preserve G. oxydans viability may be useful for engineering highly reactive adhesive coatings for multi-phase micro-channel and membrane bioreactors to dramatically increase the intensity of whole-cell oxidations.

Permeability and reactivity of Thermotoga maritima in latex bimodal blend coatings at 80 degrees C: a model high temperature biocatalytic coating.

Thermostable polymers cast as thin, porous coatings or membranes may be useful for concentrating and stabilizing hyperthermophilic microorganisms as biocatalysts. Hydrogel matrices can be unstable above 65 degrees C. Therefore a 55-microm thick, two layer (cell coat + polymer top coat) bimodal, adhesive latex coating of partially coalesced polystyrene particles was investigated at 80 degrees C using Thermotoga maritima as a model hyperthermophile. Coating permeability (pore structure) was critical for maintaining T. maritima viability. The permeability of bimodal coatings generated from 0.8 v/v of a suspension of non-film-forming 800 nm polystyrene particles with high glass transition temperature (T(g) = 94 degrees C, 26.9% total solids) blended with 0.2 v/v of a suspension of film-forming 158 nm polyacrylate/styrene particles (T(g) approximately -5 degrees C, 40.9% total solids) with 0.3 g sucrose/g latex was measured in a KNO3 diffusion cell. Diffusivity ratio remained above 0.04 (D(eff)/D) when incubated at 80 degrees C in artificial seawater (ASW) for 5 days. KNO3 permeability was corroborated by cryogenic-SEM images of the pore structure. In contrast, the permeability of a mono-dispersed acrylate/vinyl acetate latex Rovace SF091 (T(g) approximately 10 degrees C) rapidly decreased and became impermeable after 2 days incubation in ASW at 80 degrees C. Thermotoga maritima were entrapped in these coatings at a cell density of 49 g cell wet weight/liter of coating volume, 25-fold higher than the density in liquid culture. Viable T. maritima were released from single-layer coatings at 80 degrees C but accurate measurement of the percentage of viable entrapped cells by plate counting was not successful. Metabolic activity could be measured in bilayer coatings by utilization of glucose and maltose, which was identical for latex-entrapped and suspended cells. Starch was hydrolyzed for 200 h by latex-entrapped cells due to the slow diffusion of starch through the polymer top coat compared to only 24 h by suspended T. maritima. The observed reactivity and stability of these coatings was surprising since cryo-SEM images suggested that the smaller low T(g) polyacrylate/styrene particles preferentially bound to the T. maritima toga-sheath during coat formation. This model system may be useful for concentrating, entrapment and stabilization of metabolically active hyperthermophiles at 80 degrees C.