Polymeric Composites Having Oriented Nanopores and Methods of Making the Same

Abstract

The present invention relates to the development and fabrication of thin-film polymer composite materials containing vertically aligned nanopores. The present invention provides methods of aligning nanopores in a polymeric film. The present invention also provides composite materials and methods of fabricating composite materials containing vertically aligned nanopores.

1 . A method of aligning nanopores in a polymeric film, comprising the steps of:
 depositing a solution of at least one monomer in a solvent onto a surface of a first substrate to form a mesophase comprised of nanopores;   applying a second substrate onto a surface of the mesophase, such that the mesophase is in contact with both the first substrate and the second substrate, and wherein the nanopores at least partially align in response to the second substrate; and   polymerizing the mesophase to form a polymeric film containing the at least partially aligned nanopores.   
     
     
         2 . The method of  claim 1 , wherein the monomer is sodium 3,4,5-tris(11′-acryloyloxyundecyloxy)benzoate (Na-GA3C11). 
     
     
         3 . The method of  claim 1 , wherein the solvent further comprises a photoinitiator. 
     
     
         4 . The method of  claim 3 , wherein the photoinitiator is 2,4,6-trimethylbenzoyl-diphenylphosphine oxide. 
     
     
         5 . The method of  claim 3 , wherein the monomer is polymerized by exposing the mesophase to UV light. 
     
     
         6 . The method of  claim 1 , wherein the solvent is removed prior to applying the second substrate. 
     
     
         7 . The method of  claim 1 , wherein the first substrate is a polydimethylsiloxane (PDMS) substrate. 
     
     
         8 . The method of  claim 1 , wherein the first substrate is a glass substrate. 
     
     
         9 . The method of  claim 1 , wherein the second substrate is a PDMS substrate. 
     
     
         10 . The method of  claim 1 , wherein the second substrate is a glass substrate. 
     
     
         11 . The method of  claim 1 , further comprising the steps of:
 raising the temperature of the mesophase such that the mesophase is in a disordered state; and   controlling the rate of cooling of the mesophase as it returns to an ordered state.   
     
     
         12 . The method of  claim 1 , wherein the polymeric film has a pore diameter of about 1 nm. 
     
     
         13 . The method of  claim 1 , wherein the polymeric film has a thickness ranging from about 200 nm to 40 μm. 
     
     
         14 . The method of  claim 1 , wherein the amount of photoinitiator is about 0.5%. 
     
     
         15 . The method of  claim 1 , wherein the polymeric film has a pore arrangement which is hexagonal. 
     
     
         16 . The method of  claim 1 , wherein the nanopores are vertically aligned. 
     
     
         17 . A polymeric film formed by the method of  claim 1 . 
     
     
         18 . A composite material, comprising:
 a first substrate;   a second substrate; and   a layer between the first and second substrate, the layer comprising at least one monomer, at least one photoinitiator and a plurality of nanopores;   wherein the plurality of nanopores are at least partially aligned in the layer.   
     
     
         19 . The composite material of  claim 18 , wherein the at least one monomer is sodium 3,4,5-tris(11′-acryloyloxyundecyloxy)benzoate (Na-GA3C11). 
     
     
         20 . A method of fabricating a polymeric film, comprising the steps of:
 depositing a solution of at least one monomer in a solvent onto a surface of a first substrate to form a mesophase comprised of nanopores;   removing the solvent;   applying a second substrate onto a surface of the mesophase, wherein the mesophase is in contact with both the first substrate and the second substrate, and wherein the nanopores at least partially align in response to the second substrate; and   raising the temperature of the mesophase such that the mesophase is in a disordered state;   controlling the rate of cooling of the mesophase as it returns to an ordered state; and   polymerizing the mesophase to form a polymeric film containing the at least partially aligned nanopores.   
     
     
         21 . The method of  claim 20 , wherein the first substrate is a polydimethylsiloxane (PDMS) substrate. 
     
     
         22 . The method of  claim 20 , wherein the first substrate is a glass substrate. 
     
     
         23 . The method of  claim 20 , wherein the second substrate is a PDMS substrate. 
     
     
         24 . The method of  claim 20 , wherein the second substrate is a glass substrate. 
     
     
         25 . The method of  claim 20 , wherein the photoinitiator is 2,4,6-trimethylbenzoyl-diphenylphosphine oxide. 
     
     
         26 . The method of  claim 20 , wherein the at least one monomer is sodium 3,4,5-tris(11′-acryloyloxyundecyloxy)benzoate (Na-GA3C11). 
     
     
         27 . The method of  claim 20 , wherein the method further comprises removing at least one of the substrates from the composite material after the polymerizing step. 
     
     
         28 . A method of fabricating a polymeric film of aligned nanopores, comprising the steps of:
 depositing a mixture of at least one monomer and at least one template compound onto a surface of a first substrate to form a mesophase;   polymerizing the mesophase to form a polymeric film;   rinsing the polymeric film with NaOH in DMSO to remove the template compound; and   wetting the polymeric film with water to form aligned nanopores.   
     
     
         29 . The method of  claim 28 , further comprising the step of applying a second substrate prior to polymerization. 
     
     
         30 . The method of  claim 29 , wherein the first substrate and second substrate are glass substrates. 
     
     
         31 . The method of  claim 29 , wherein the first and second substrate are coated with poly(sodium styrene sulfonate). 
     
     
         32 . The method of  claim 29 , wherein the first substrate and second substrate are coated with octadecyltrimethoxysilane. 
     
     
         33 . The method of  claim 28 , wherein the mixture further comprises at least one crosslinker and at least one photoinitiator. 
     
     
         34 . The method of  claim 33 , wherein the photoinitiator is benzoin methyl ether. 
     
     
         35 . The method of  claim 33 , wherein the crosslinker is selected from the group containing divinylbenzene, butyl acrylate, and 1,6-hexanediol diacrylate. 
     
     
         36 . The method of  claim 28 , wherein the monomer is an unsaturated fatty acid. 
     
     
         37 . The method of  claim 28 , wherein the monomer is an epoxidized fatty acid. 
     
     
         38 . The method of  claim 28 , wherein the template compound is 1,3,5-tris(1H-benzo[d]imidazol-2-yl)benzene. 
     
     
         39 . The method of  claim 28 , wherein the monomer and template compound are in the mixture in a ratio of about 3:1. 
     
     
         40 . The method of  claim 28 , wherein the template compound can be recycled for later use. 
     
     
         41 . The method of  claim 28 , further comprising the steps of:
 applying a magnetic field to the mesophase;   rotating the mesophase about the normal of the first substrate;   heating the mesophase; and   gradually cooling the mesophase to room temperature.   
     
     
         42 . A polymeric film formed by the method of  claim 28 .