A solvent-shrinkage method for producing polymeric microsieves with sub-micron size pores

Float-Cast Microsieves with Elliptical Pores

Polymeric microsieves bearing elliptical pores were successfully prepared via float-casting: a dispersion comprising nonvolatile acrylate monomers and ellipsoidal polystyrene particles was spread onto a water surface. The resulting self-organized monolayer was laterally compressed, and the monomer was photopolymerized, giving rise to a membrane comprising ellipsoidal particles laterally embedded in a 0.5 μm thin polymer membrane. The particles were dissolved, leaving behind elliptical pores. These pores had an average length of the major axis of 0.87 ± 0.1 μm and of the minor axis of 0.42 ± 0.07 μm and an aspect ratio of approximately 2. The microsieve bearing these submicrometric elliptical pores was transferred to a hierarchical structure made out of microsieves bearing circular pores of 6 μm diameter on top of a microsieve with 70 μm diameter pores. The resulting hierarchically structured microsieve had a porosity of 0.13. At a pressure difference of typically 103 Pa (Reynolds number aprox. 0.002), the volumetric permeance for water was Pe = V ˙ /A/Δp = 0.5·10-6 m/s/Pa, the product viscosity·permeance is η·V ˙ /A/Δp = 0.5·10-9 m. This value is lower than the corresponding values of microsieves with circular pores of similar diameter produced by the same technique. The beneficial effects of higher permeance per pore caused by the elliptical shape are countered by lower porosity caused by less efficient packing of the ellipsoidal particles.

Advances in Micro/Nanoporous Membranes for Biomedical Engineering

Porous membrane materials at the micro/nanoscale have exhibited practical and potential value for extensive biological and medical applications associated with filtration and isolation, cell separation and sorting, micro-arrangement, in-vitro tissue reconstruction, high-throughput manipulation and analysis, and real-time sensing. Herein, an overview of technological development of micro/nanoporous membranes (M/N-PMs) is provided. Various membrane types and the progress documented in membrane fabrication techniques, including the electrochemical-etching, laser-based technology, microcontact printing, electron beam lithography, imprinting, capillary force lithography, spin coating, and microfluidic molding are described. Their key features, achievements, and limitations associated with micro/nanoporous membrane (M/N-PM) preparation are discussed. The recently popularized applications of M/N-PMs in biomedical engineering involving the separation of cells and biomolecules, bioparticle operations, biomimicking, micropatterning, bioassay, and biosensing are explored too. Finally, the challenges that need to be overcome for M/N-PM fabrication and future applications are highlighted.

Hierarchically Structured Microsieves Produced via Float-Casting

This article shows a new way to produce hierarchical microsieves by layering three types of float-cast microsieves, differing from each other in their pore diameters (approximately 68 μm, 7 μm, and 0.24 μm) on top of each other. The unsupported microsieves with 7 and 0.24 μm pore sizes are mechanically fragile. The complete hierarchical sieve composed of all three layers, however, can be handled manually without special precaution. This article further investigates the flow through the hierarchical sieve and filtration via experiment, theory (Hagen-Poiseuille's and Sampson-Roscoe's law), and simulation (numerically solving the Navier-Stokes equations for a predefined set of discrete volumetric elements). The experimental, theoretical, and simulated permeances of the microsieves and the hierarchical sieves are in reasonable agreement with each other and are significantly higher than the permeances of conventional filtration media. In filtration experiments, the hierarchical sieves show the expected sharp size cut-off, retaining particles of diameters exceeding the pore diameter.

Printing Reinforcing Structures onto Microsieves That Are Floating on a Water Surface

This article describes the preparation of hierarchically structured microsieves via a suitable combination of float-casting and inkjet-printing: A mixture of hydrophobized silica particles of 600 nm ± 20 nm diameter, a suitable non-water-soluble nonvolatile acrylic monomer, a nonvolatile photoinitiator, and volatile organic solvents is applied to a water surface. This mixture spontaneously spreads on the water surface; the volatile solvents evaporate and leave behind a layer of the monomer/initiator mixture comprising a monolayer of particles, each particle protruding out of the monomer layer at the top and bottom surface. Photopolymerization of the monomer converts this mixed layer into a solid composite membrane floating on the water surface. Onto this membrane, while still floating on the water surface, a hierarchical reinforcing structure based on a photocurable ink is inkjet-printed and solidified. In contrast to the nonreinforced membrane, the reinforced membrane can easily be lifted off the water surface without suffering damage. Subsequently, the silica particles are removed, and thus, the reinforced composite membrane is converted into a reinforced microsieve of 350 nm ± 50 nm thickness bearing uniform through pores of 465 nm ± 50 nm diameter. This reinforced microsieve is mounted into a filtration unit and used to filter model dispersions: its permeance for water at low Reynolds numbers is in accordance with established theories on the permeance of microsieves and significantly above the permeance of conventional filtration media; it retains particles exceeding the pore size, while letting particles smaller than the pore size pass.

Fabrication of large-area polymer microfilter membranes and their application for particle and cell enrichment

A vacuum assisted UV micro-molding (VAUM) process is proposed for the fabrication of freestanding and defect-free polymer membranes based on a UV-curable methacrylate polymer (MD 700). VAUM is a highly flexible and powerful method for fabricating low cost, robust, large-area membranes over 9 × 9 cm² with pore sizes from 8 to 20 μm in diameter, 20 to 100 μm in thickness, high aspect ratio (the thickness of the polymer over the diameter of the hole is up to 15 : 1), high porosity, and a wide variety of geometrical characteristics. The fabricated freestanding membranes are flexible while mechanically robust enough for post manipulation and handling, which allows them to be cut and integrated as a plastic cartridge onto thermoplastic 3D microfluidic devices with single or double filtration stages. Very high particle capture efficiencies (≈98%) have been demonstrated in the microfluidic devices integrated with polymer membranes, even when the size of the beads is very close to the size of the pores of the microfilter. About 85% of the capture efficiency has been achieved in cancer cell trapping experiments, in which a breast cancer cell line (MDA-MB-231) spiked with phosphate-buffered saline buffer when the pore size of the filter is 8 μm and the device is operated at a flow rate of 0.1 mL min^-1.

Hierarchical Porous Polybenzimidazole Microsieves: An Efficient Architecture for Anhydrous Proton Transport via Polyionic Liquids

Liquid-induced phase-separation micromolding (LIPSμM) has been successfully used for manufacturing hierarchical porous polybenzimidazole (HPBI) microsieves (42-46% porosity, 30-40 μm thick) with a specific pore architecture (pattern of macropores: ∼9 μm in size, perforated, dispersed in a porous matrix with a 50-100 nm pore size). Using these microsieves, proton-exchange membranes were fabricated by the infiltration of a 1H-3-vinylimidazolium bis(trifluoromethanesulfonyl)imide liquid and divinylbenzene (as a cross-linker), followed by in situ UV polymerization. Our approach relies on the separation of the ion conducting function from the structural support function. Thus, the polymeric ionic liquid (PIL) moiety plays the role of a proton conductor, whereas the HPBI microsieve ensures the mechanical resistance of the system. The influence of the porous support architecture on both proton transport performance and mechanical strength has been specifically investigated by means of comparison with straight macroporous (36% porosity) and randomly nanoporous (68% porosity) PBI counterparts. The most attractive results were obtained with the poly[1-(3H-imidazolium)ethylene]bis(trifluoromethanesulfonyl)imide PIL cross-linked with 1% divinylbenzene supported on HPBI membranes with a 21-μm-thick skin layer, achieving conductivity values up to 85 mS cm^-1 at 200 °C under anhydrous conditions and in the absence of mineral acids.

A Novel Polyvinylidene Fluoride Tree-Like Nanofiber Membrane for Microfiltration

A novel polyvinylidene fluoride (PVDF) tree-like nanofiber membrane (PVDF-TLNM) was fabricated by adding tetrabutylammonium chloride (TBAC) into a PVDF spinning solution via one-step electrospinning. The structure of the prepared membranes was characterized by field emission scanning electron microscopy (FE-SEM), Fourier transform infrared spectroscopy (FT-IR) and pore size analysis, and the hydrophilic property and microfiltration performance were also evaluated. The results showed that the tree-like nanofiber was composed of trunk fibers and branch fibers with diameters of 100-500 nm and 5-100 nm, respectively. The pore size of PVDF-TLNM (0.36 μm) was smaller than that of a common nanofiber membrane (3.52 μm), and the hydrophilic properties of the membranes were improved significantly. The PVDF-TLNM with a thickness of 30 ± 2 μm showed a satisfactory retention ratio of 99.9% against 0.3 μm polystyrene (PS) particles and a high pure water flux of 2.88 × 10⁴ L·m-2·h-1 under the pressure of 25 psi. This study highlights the potential benefits of this novel PVDF tree-like nanofiber membrane in the membrane field, which can achieve high flux rates at low pressure.