Ultra-thin and strong formvar-based membranes with controlled porosity for micro- and nano-scale systems.

We present a methodology for developing ultra-thin and strong formvar-based membranes with controlled morphologies. Formvar is a thin hydrophilic and oleophilic polymer inert to most chemicals and resistant to radiation. The formvar-based membranes are viable materials as support structures in micro- and macro-scale systems depending on thinness and porosity control. Tunable sub-micron thick porous membranes with 20%-65% porosity were synthesized by controlling the ratios of formvar, glycerol, and chloroform. This synthesis process does not require complex separation or handling methods and allows for the production of strong, thin, and porous formvar-based membranes. An expansive array of these membrane characterizations including chemical compatibility, mechanical responses, wettability, as well as the mathematical simulations as a function of porosity has been presented. The wide range of chemical compatibility allows for membrane applications in various environments, where other polymers would not be suitable. Our formvar-based membranes were found to have an elastic modulus of 7.8 GPa, a surface free energy of 50 mN m-1 and an average thickness of 125 nm. Stochastic model simulations indicate that formvar with the porosity of ∼50% is the optimal membrane formulation, allowing the most material transfer across the membrane while also withstanding the highest simulated pressure loadings before tearing. Development of novel, resilient and versatile membranes with controlled porosity offers a wide range of exciting applications in the fields of nanoscience, microfluidics, and MEMS.

Micromachining of Polyurethane Membranes for Tissue Engineering Applications.

Engineered tissue barrier models offer in vitro alternatives in toxicology and disease research. To mimic barrier-tissue microenvironment, a porous membrane that can approach the stiffness of physiological basement membranes is required. While several biocompatible membranes with micrometer range thickness (10 µm) and a stiffness less than polystyrene (3 GPa) or polyethylene (PET, 2 GPa), have been developed, there has been little effort to optimize the process to enable rapid and reproducible pore production in these membranes. Here, we investigate the use of laser irradiation with femtosecond (fs) pulses because the combination of high-precision and cold-ablation causes minimal damage to polymeric membranes. This process enables automated, high-throughput and reproducible fabrication of thin, microporous membranes that can be utilized to culture cells at air-liquid interface (ALI), a unique culture technique that simulates the tissue-barrier microenvironment. We show the optimization of laser parameters on a thin polyurethane membrane and patterned pores with an average diameter of 5 µm. Tissue was cultured at ALI for 28 days to demonstrate the membrane's utility in constructing a tissue barrier model. These results confirm the utilization of fs laser machining as a viable method for creating a porous barrier substrate in tissue engineering platforms.

Geo-material microfluidics at reservoir conditions for subsurface energy resource applications.

Microfluidic investigations of flow and transport in porous and fractured media have the potential to play a significant role in the development of future subsurface energy resource technologies. However, the majority of experimental systems to date are limited in applicability due to operating conditions and/or the use of engineered material micromodels. We have developed a high pressure and temperature microfluidic experimental system that allows for direct observations of flow and transport within geo-material micromodels (e.g. rock, cement) at reservoir conditions. In this manuscript, we describe the experimental system, including our novel micromodel fabrication method that works in both geo- and engineered materials and utilizes 3-D tomography images of real fractures as micromodel templates to better represent the pore space and fracture geometries expected in subsurface formations. We present experimental results that highlight the advantages of using real-rock micromodels and discuss potential areas of research that could benefit from geo-material microfluidic investigations. The experiments include fracture-matrix interaction in which water imbibes into the shale rock matrix from etched fractures, supercritical CO2 (scCO2) displacing brine in idealized and realistic fracture patterns, and three-phase flow involving scCO2-brine-oil.