Advances in Fabrication Materials of Honeycomb Structure Films by the Breath-Figure Method

A versatile route for the fabrication of micro-patterned polylactic-acid (PLA)-based membranes with tailored morphology via breath figure imprinting

Breath figure imprinting, based on surface instabilities combined with fast polymer evaporation in a humid environment, enables the creation of micro-patterned membranes with tailored pore sizes. Despite being a simple procedure, it is still challenging to fully understand the dynamics behind the formation of hierarchical structuring. In this work, we used the breath figure technique to prepare porous PLA-based (polylactic acid) membranes with two distinctive additives, polyvinylidene fluoride (PVDF) and zinc oxide nanoparticles (ZnO NPs). The selection of these additives was governed by their unique properties and the potential synergistic effects; when blended with PLA, the addition of NPs leads to more uniform structures with tunable characteristics and potential multifunctionality. This article sheds light on the multifaced interactions that intricate the interplays between PLA, PVDF, and ZnO, thus governing their assembly. Through a comprehensive investigation, we scrutinize the impact of blending PVDF and different concentrations of ZnO NPs on the morphology and chemical properties of the final self-assembled PLA membranes while presenting an advanced understanding of the potential applications of PLA-self-assembly porous membranes in various industrial sectors.

Biopolymer Honeycomb Microstructures: A Review

In this review, we present a comprehensive summary of the formation of honeycomb microstructures and their applications, which include tissue engineering, antibacterial materials, replication processes or sensors. The history of the honeycomb pattern, the first experiments, which mostly involved the breath figure procedure and the improved phase separation, the most recent approach to honeycomb pattern formation, are described in detail. Subsequent surface modifications of the pattern, which involve physical and chemical modifications and further enhancement of the surface properties, are also introduced. Different aspects influencing the polymer formation, such as the substrate influence, a particular polymer or solvent, which may significantly contribute to pattern formation, and thus influence the target structural properties, are also discussed.

The Functionalization of a Honeycomb Polystyrene Pattern by Excimer Treatment in Liquid

In this article, we present a unique combination of techniques focusing on the immobilization of noble metal nanoparticles into a honeycomb polystyrene pattern prepared with the improved phase-separation technique. The procedure consists of two main steps: the preparation of the honeycomb pattern (HCP) on a perfluoroethylenepropylene substrate (FEP), followed by an immobilization procedure realized by the honeycomb pattern's exposure to an excimer laser in a noble metal nanoparticle solution. The surface physico-chemical properties, mainly the surface morphology and chemistry, are characterized in detail in the study. The two-step procedure represents the unique architecture of the surface immobilization process, which reveals a wide range of potential applications, mainly in tissue engineering, but also as substrates for analytical use.

Ultrathin and handleable nanofibrous net as a novel biomimetic basement membrane material for endothelial barrier formation

Many strategies have been adopted to develop porous membranes to reconstitute basement membrane in vitro, which play a key role in the development of in vitro biomimetic models. However, the development of an artificial basement membrane combines cytocompatibility and nano-thickness is still challenging. Herein, a monolayer nanofibrous net patch was fabricated by combining microfabrication and electrospinning as a biomimetic basement membrane material, which was demonstrated for endothelial barrier formation. The nanofibrous net patches with different fiber densities were obtained by controlling electrospinning time. The net was with high porosity and ultrathin thickness approximate to the diameter of nanofibers, which is comparable to that of the native basement membrane. The morphology, proliferation and cell-cell/cell-substrate interactions of endothelial cells on the nanofibrous nets were studied and compared with track-etched polycarbonate membrane and traditional multilayer nanofibers membrane. In addition, the results of TEER measurement and permeability test demonstrated that the endothelial barrier formed on the nanofibrous net patch displayed stronger barrier integrity and function. Therefore, the proposed nanofibrous net patch shows great potential as a novel biomimetic basement membrane, which is promising to be applied for in vitro tissue mimetic applications.

Controlled Release Mechanism of Vancomycin from Double-Layer Poly-L-Lactic Acid-Coated Implants for Prevention of Bacterial Infection

Implantation failure due to bacterial infection incurs significant medical expenditure annually, and treatment tends to be complicated. This study proposes a method to prevent bacterial infection in implants using an antibiotic delivery system consisting of vancomycin loaded into poly-L-lactic acid (PLLA) matrices. A thin layer of this antibiotic-containing polymer was formed on stainless steel surfaces using a simple dip-coating method. SEM images of the polymeric layer revealed a honeycomb structure of the PLLA network with the entrapment of vancomycin molecules inside. In the in vitro release study, a rapid burst release was observed, followed by a sustained release of vancomycin for approximately 3 days. To extend the release time, a drug-free topcoat of PLLA was introduced to provide a diffusion resistance layer. As expected, the formulation with the drug-free topcoat exhibited a significant extension of the release time to approximately three weeks. Furthermore, the bonding strength between the double-layer polymer and the stainless steel substrate, which was an important property reflecting the quality of the coating, significantly increased compared to that of the single layer to the level that met the requirement for medical coating applications. The release profile of vancomycin from the double-layer PLLA film was best fitted with the Korsmeyer–Peppas model, indicating a combination of Fickian diffusion-controlled release and a polymer relaxation mechanism. More importantly, the double-layer vancomycin-PLLA coating exhibited antibacterial activity against S. aureus, as confirmed by the agar diffusion assay, the bacterial survival assay, and the inhibition of bacterial surface colonization without being toxic to normal cells (L929). Our results showed that the proposed antibiotic delivery system using the double-layer PLLA coating is a promising solution to prevent bacterial infection that may occur after orthopedic implantation.

Gradient monolayered porous membrane for liquid manipulation: from fabrication to application

The controlled transport of liquid on a smart material surface has important applications in the fields of microreactors, mass and heat transfer, water collection, microfluidic devices and so on. Porous membranes with special wettability have attracted extensive attention due to their unique unidirectional transport behavior, that is, liquid can easily penetrate in one direction while reverse transport is prevented, which shows great potential in functional textiles, fog collection, oil/water separation, sensors, etc. However, many porous membranes are synthesized from multilayer structural materials with poor mechanical properties and are currently prone to delamination, which limits their stability. While a monolayered porous membrane, especially for gradient structure, is an efficient, stable and durable material owing to its good durability and difficult stratification. Therefore, it is of great significance to fabricate a monolayered porous membrane for controllable liquid manipulation. In this minireview, we briefly introduce the classification and fabrication of typical monolayered porous membranes. And the applications of monolayered porous membranes in unidirectional penetration, selective separation and intelligent response are further emphasized and discussed. Finally, the controllable preparation and potential applications of porous membranes are featured and their prospects discussed on the basis of their current development.

Dimensional Stability of 3D Printed Objects Made from Plastic Waste Using FDM: Potential Construction Applications

Construction projects are often challenged by tight budgets and limited time and resources. Contractors are, therefore, looking for ways to become competitive by improving efficiency and using cost-effective materials. Using three-dimensional (3D) printing for shaping materials to produce cost-effective construction elements is becoming a feasible option to make contractors more competitive locally and globally. The process capabilities for 3D printers and related devices have been tightened in recent years with the booming of 3D printing industries and applications. Contractors are attempting to improve production skills to satisfy firm specifications and standards, while attempting to have costs within competitive ranges. The aim of this research is to investigate and test the production process capability (Cp) of 3D printers using fused deposition modeling (FDM) to manufacture 3D printed parts made from plastic waste for use in the construction of buildings with different infill structures and internal designs to reduce cost. This was accomplished by calculating the actual requirement capabilities of the 3D printers under consideration. The production capabilities and requirements of FDM printers are first examined to develop instructions and assumptions to assist in deciphering the characteristics of the 3D printers that will be used. Possible applications in construction are then presented. As an essential outcome of this study, it was noticed that the 3D printed parts made from plastic waste using FDM printers are less expensive than using traditional lightweight non-load bearing concrete hollow masonry blocks, hourdi slab hollow bocks, and concrete face bricks.

The rapid and controllable fabrication of large-scale and highly ordered micro-honeycomb arrays induced by nonsolvent phase separation

Structures that are highly ordered in nature show unique light propagation abilities. Among them, micro-honeycomb arrays are attractive owing to their advantages relating to the collection of light or enlarging the viewing angle and, also, owing to their potential applications in precision optics. Inspired by the natural phenomenon of droplet condensation on a cold surface, breath figure self-assembly has been a common approach used to fabricate such ordered micro-honeycomb arrays. However, the harsh preparation conditions and specific polymer architecture required have limited the widespread application of this approach. In this work, by using a commercial linear homopolymer and introducing its nonsolvent, we successfully fabricated uniform micro-honeycomb arrays on a large scale in just seconds and at ambient humidity. The morphology of the structures can be easily tuned via controlling the preparation conditions. Furthermore, high fill-factor convex micro-lenses were prepared based on the as-prepared concave micro-honeycomb arrays as templates through a simple replication process. They demonstrate properties such as clear multiple image presentation and light diffraction. They can also assist the strong scattering of light, which enhances the fluorescent intensity by more than 10%. This method is envisaged as a potential candidate to replace breath figure self-assembly for micro-honeycomb arrays in a low-cost and high-efficiency manner under mild conditions.

Direct-writing microporous polymer architectures - print, capture and release

In the nature-inspired breath figure method, rafts of condensed water droplets self-organise and imprint into a permanent microporous polymer structure. This could have exciting applications in drug delivery, tissue engineering and sensors but it is extremely difficult to control or functionalise the final structure. Here, we show direct-writing of droplets onto fluid surfaces by inkjet printing as a breakthrough to dial-in a required pattern, structure and function into the polymer film.

Superior photoresponse MIS Schottky barrier diodes with nanoporous:Sn–WO3 films for ultraviolet photodetector application

Nanoporous:Sn–WO₃ film based metal–insulator–semiconductor type Schottky diodes exhibit ultra-high responsivity with higher quantum efficiency and detectivity.

In Search of a Green Process: Polymeric Films with Ordered Arrays via a Water Droplet Technique

As an efficient technique for the preparation of polymeric hexagonal orderly arrays, the breath figure (BF) process has opened a modern avenue for a bottom-up fabrication method for more than two decades. Through the use of the water vapor condensation on the solution surface, the water droplets will hexagonally pack into ordered arrays, acting as a template for controlling the regular micro patterns of polymeric films. Comparing to the top-down techniques, such as lithography or chemical etching, the use of water vapor as the template provides a simple fabrication process with sustainability. However, using highly hazardous solvents such as chloroform, carbon disulfide (CS2), benzene, dichloromethane, etc., to dissolve polymers might hinder the development toward green processes based on this technique. In this review, we will touch upon the contemporary techniques of the BF process, including its up-to-date applications first. More importantly, the search of greener processes along with less hazardous solvents for the possibility of a more sustainable BF process is the focal point of this review.

Preparation of pocket shaped microfiltration membranes with binary porous structures

Highly permeable pocket-shaped microfiltration membranes with binary porous structures, which are composed of brominated poly(2,6-dimethyl-1,4-phenylene oxide) (BPPO), were prepared on needles by breath figure (BF) and colloidal crystal template (CCT) methods. In colloidal crystal templates, the membrane pore size in the bottom layer was adjusted by SiO2 microsphere diameter in the colloidal crystal template, while that in the top layer was adjusted by changing the BPPO concentration. The permeability of the binary porous membrane prepared by BF and CCT methods was higher than that of membranes only prepared by the BF method. Due to high permeability and antifouling properties, the pocket shaped binary porous membrane was connected to a syringe and used as a filter film in microfiltration and sample preparation fields.

Design Method of Lightweight Metamaterials with Arbitrary Poisson's Ratio

A heuristic approach to design lightweight metamaterials with novel configurations and arbitrary Poisson’s ratio is studied by using the functional element topology optimization (FETO) method. Mathematical model of the optimization problem is established, where the minimization of the mass is set as the objective, then a series of metamaterials with Poisson’s ratio ranging from −1.0 to +1.0 are designed by solving this model. The deformation resistance and vibration reduction performance of the novel metamaterials and conventional honeycomb are compared by numerical simulations. Specific stiffness analysis shows that the novel metamaterials are 5.6 to 21.0 times more resistant to deformation than that of the honeycomb, and frequency response shows about 60% improvement in vibration reduction performance. Finally, the lightweight effects of the novel metamaterials on deformation resistance and vibration reduction performance are analyzed, and further analysis reflects that the lightweight effects increase with the increase of the absolute value of the Poisson’s ratio.

Fabrication of ordered honeycomb porous poly(vinyl chloride) thin film doped with a Schiff base and nickel(II) chloride

A modified poly(vinyl chloride) honeycomb thin film containing a low concentration of a thiadiazole Schiff base and nickel(II) chloride was successfully fabricated using the casting process. The surface morphology of the synthesized thin film was investigated using the scanning electronic microscopy. The synthesized poly(vinyl chloride) thin film was found to have a homogeneous surface morphology with a high crystalline nature. The addition of nickel(II) chloride was discovered to be vital for the formation of the honeycomb like structure.

Designing 3D Biological Surfaces via the Breath-Figure Method

The fabrication of biointerfaces that mimic cellular physiological environments is critical to understanding cell behaviors in vitro and for the design of tissue engineering. Breath figure is a self-assemble method that uses water droplets condensed from moisture as template and ends up with a highly ordered hexagonal pore array; this approach is used to fabricate various biological substrates. This progress report provides an overview of strategies to achieve topographical modifications and chemical-patterned arrays, such as modulation of the pore size, shape and selective decoration of the honeycomb holes. Using recent results in the biological fields, potential future applications and developments of honeycomb structures are commented upon.

Honeycomb-patterned hybrid films of surfactant-encapsulated polyoxometalates by a breath figure method and its electrocatalysis for BrO3−

Surfactant-encapsulated POMs can self-assemble into ordered porous honeycomb films under a moist atmosphere. We successfully fabricated (DODA)₁₀{Cu₄(PW₉)₂} honeycomb films by using a one-step method.

Assembly of Ultrathin Gold Nanowires into Honeycomb Macroporous Pattern Films with High Transparency and Conductivity

Because of its promising properties, honeycomb macroporous pattern (HMP) film has attracted increasing attention. It has been realized in many artificial nanomaterials, but the formation of these HMPs was attributed to templates or polymer/supermolecule/surfactant assistant assembly. Pure metal HMP film has been difficult to produce using a convenient colloidal template-free method. In this report, a unique template-free approach for preparation of Au HMP film with high transparency and conductivity is presented. Ultrathin Au nanowires, considered a linear polymer analogue, are directly assembled into HMP film on various substrates using a traditional static breath figure method. Subsequent chemical cross-linking and oxygen plasma treatment greatly enhance the stability and conductivity of the HMP film. The resulting HMP film exhibits great potential as an ideal candidate for transparent flexible conductive nanodevices.

Breath Figure in Reactive Vapor: A New Route to Nanopore Array

A breath figure (BF)-inspired method for preparing ordered porous films has attracted more and more attention because of its simplicity, low cost, and easy implementation. However, it remains a challenge to use this method to fabricate nanoscale porous structures without designed polymer architecture and auxiliary. Herein, we first report a facile method to fabricate BF arrays with nanopores (nanoBFAs) in reactive vapor. Depending on the chemical reaction between the formic acid (FA) droplet template and the polyvinylpyridine (PVP) segments in copolymer, we successfully create nanoBFAs by casting a PVP-containing copolymer solution in CS₂ in FA vapor. The condensed FA droplets can be instantly fixed by the PVP composition, and thus the growth and the aggregation of adjacent droplets are effectively restricted. Eventually, nanoBFAs are achieved in wide range solution concentration. In addition, binary porous structures with both nano- and microscale topology can be formed by using a FA/water mixed vapor with a one-step BF process. The produced nanoBFA films exhibit excellent antireflection performance with 0.5% reflectance, which is well-preserved even after hydrophobic treatment. This modified BF technique not only facilitates the elucidation of BFA formation mechanism but also opens a new way of fabricating nanoporous structures, which may have potential applications in electronic and optical devices.

Effects of molecular weight distribution on the self-assembly of end-functionalized polystyrenes

The molecular weight distribution of hydroxyl-end-functionalized polystyrenes shows effects on the self-assembly of patterned porous films and the mechanical strength.

Copolymers from norbornene and norbornadiene with organized morphologies and high Tg values obtained via ROMP with a highly reactive [RuCl3(PCy3)2] complex

[RuCl₃(PCy₃)₂] presented high reactivity toward ROMP of norbornene and norbornadiene in air, in the presence of ethyl diazoacetate, resulting in copolymers with high T_g values and organized morphologies.

Data from crosslinked PS honeycomb thin film by deep UV irradiation

Thin polystyrene (PS) films with highly ordered honeycomb pattern were successfully fabricated by an improved phase separation method. The PS film was successfully crosslinked after applying a deep UV irradiation. This work presents a proof of crosslinking PS by characterizing ATR-FTIR, TGA and the wetting property of the honeycomb films, which were prepared using a solvent/non-solvent ratio of 90/10, before and after 6 h of UV irradiation.

Large-scale fabrication of commercially available, nonpolar linear polymer film with a highly ordered honeycomb pattern

Highly ordered, hexagonally patterned poly(methyl methacrylate) (PMMA) thin film is successfully fabricated using an improved phase separation method. A mixture of chloroform and methanol, which is used as a volatile solvent/nonsolvent pair, effectively controls the surface morphology and sensitively determines the ordered pattern. In particular, the methanol accumulation, which induces the formation of a gel-like protective layer and enhances the lateral capillary force, is crucial in the formation of the highly ordered hexagonal pattern even when using a nonpolar polymer such as PMMA. The convergence of cost-effective and large-scale production of highly ordered micropatterned film has wide potential for application, and it can enable new prospects for the commercialization of future high-tech devices that require specific multifunctionality.

Conductive Polymer Porous Film with Tunable Wettability and Adhesion

A conductive polymer porous film with tunable wettability and adhesion was fabricated by the chloroform solution of poly(3-hexylthiophene) (P3HT) and [6,6]-phenyl-C61-butyricacid-methyl-ester (PCBM) via the freeze drying method. The porous film could be obtained from the solution of 0.8 wt%, whose pore diameters ranged from 50 nm to 500 nm. The hydrophobic porous surface with a water contact angle (CA) of 144.7° could be transferred into a hydrophilic surface with CA of 25° by applying a voltage. The water adhesive force on the porous film increased with the increase of the external voltage. The electro-controllable wettability and adhesion of the porous film have potential application in manipulating liquid collection and transportation.

Ordered porous structure hybrid films generated by breath figures for directional water penetration

A highly ordered open-pore hybrid film was fabricated by controlling the substrate roughness and wettability. The composite with different wettability on the two side resulted in an attractive unidirectional water-penetration function (see figure).

Honeycomb-like porous gel polymer electrolyte membrane for lithium ion batteries with enhanced safety

Lithium ion batteries have shown great potential in applications as power sources for electric vehicles and large-scale energy storage. However, the direct uses of flammable organic liquid electrolyte with commercial separator induce serious safety problems including the risk of fire and explosion. Herein, we report the development of poly(vinylidene difluoride-co-hexafluoropropylene) polymer membranes with multi-sized honeycomb-like porous architectures. The as-prepared polymer electrolyte membranes contain porosity as high as 78%, which leads to the high electrolyte uptake of 86.2 wt%. The PVDF-HFP gel polymer electrolyte membranes exhibited a high ionic conductivity of 1.03 mS cm(-1) at room temperature, which is much higher than that of commercial polymer membranes. Moreover, the as-obtained gel polymer membranes are also thermally stable up to 350 °C and non-combustible in fire (fire-proof). When applied in lithium ion batteries with LiFePO4 as cathode materials, the gel polymer electrolyte demonstrated excellent electrochemical performances. This investigation indicates that PVDF-HFP gel polymer membranes could be potentially applicable for high power lithium ion batteries with the features of high safety, low cost and good performance.

Formation of breath figure arrays in methanol vapor assisted by surface active agents

Breath figure (BF) process is a promising technique for fabricating honeycomb polymer films. It is usually conducted in water vapor. While, in organic vapors only unique polymer can be used to prepare BF arrays as reported in our previous article (Breath Figure in Nonaqueous Vapor. Soft Matter, 2013, 506-514), although new structure features are induced in the film. In this paper, a universal modified BF processing is devised for preparing porous films in methanol vapor with conventional polymers, by adding a small amount of surface active agent into the casting solution, such as siloxane- and fluorine-containing block copolymers. The pores in the PS films prepared with this method are of cylindrical shape with large depth-diameter aspect ratio, and the diameter and depth of pores can be well controlled by the experiment conditions. Based on these results, the formation mechanism of honeycomb structure in methanol vapor is discussed.