Controllable growth of porous structures from co-continuous polymer blend

To enable controllable generation of porous structures, a set of new fabrication techniques utilizing the annealing kinetics of co-continuous polymer blends were proposed and investigated.;As the first step towards the creation of an organized porous material, a new technique based on regulating the thermal boundary conditions to controllably grow gradient porous structures was developed. In this technique, specially designed thermal boundaries were used to generate a well-defined temperature field inside a co-continuous polymer blend with fine phase structure. Because of the temperature dependency of zero-shear viscosity and its influence on phase coarsening rate, a graded phase size distribution was generated by this temperature field. After one component was selectively dissolved, a gradient porous structure was produced. To demonstrate the versatility of this technique, three different gradient porous structures were created.;After the effectiveness of thermal boundary condition in developing organized porous materials was verified, the possibility of utilizing kinematic and dynamic boundary conditions to obtain extra controllability was investigated. Two types of kinematic boundary conditions, no-slip wall and 1D hard wall confinement were tested separately. It was found that no-slip wall could greatly slow down the phase coarsening rate of the nearby polymer blend. When a no-slip wall and a fully slip wall were applied at each side of a molten co-continuous blend, a pore size gradient was generated in the direction perpendicular to the wall surface with smaller pores near the no-slip wall. One directional hard wall confinement formed by a pair of fully slip parallel walls led to the formation of an aligned phase structure oriented in the vertical direction to the walls. Experiments regarding the effect of dynamic boundary condition were conducted by imposing different chemical potentials at the surface of molten blend. Fully dense surface and completely open surface were generated when high energy metallic surface and low energy PTFE (polytetrafluoroethylene) were applied respectively.;In addition to the creation of polymeric porous materials, the generation of organized porous nanocomposite with high nanoparticle loading was also explored to incorporate unique properties seldom appearing in polymeric materials. The influence of blending procedure was first studied to secure the required co-continuous phase morphology for making porous nanocomposite. It was found that one had to simultaneously introduce all ingredients for mixing to minimize the change in viscosity ratio and produce the initial co-continuous structures. Because of the high nanoparticle loading, most of the formed pores were crowded with aggregates from particles originally located in the dissolved phase. To obtain the desired high permeability, a technique based on small strain oscillation was developed to facilitate rapid migration of these nanoparticles out of the sacrificial component. The effectiveness of this method was confirmed by a parametric experimental study. In addition, it was found that the migration rate of the nanoparticle could be predicted by combining the Einstein-Stokes diffusion model with the Cox-Merz rule.;To create porous material with desired geometries for different application needs, a new molding technique capable of creating precise micropatterned porous structures was developed and examined. In this new technique, hot embossing and in-mold quiescent annealing were applied successively to a co-continuous polymer blend to pattern the blend into expected geometries and in the same time produce the desired bulk microstructures. The effectiveness of this molding protocol was confirmed by experimental results in which devices with different micropatterns, average pore sizes, pore size distributions, and pore alignments were created. For cases where fully open surface is required, a criterion for choosing a proper molding condition was provided.;Other than these experimental efforts, a new numerical simulation approach was developed to obtain better control for growing complex gradient porous structures. First, rheological characterization was combined with CFD (computational fluid dynamics) to simulate the quiescent annealing process. According to experimental results from other researchers, there is a simple relation between 2D and 3D coarsening rates for a co-continuous polymer blend. If a similar relation could be obtained between 2D and 3D simulation, the computational cost could be greatly reduced. To verify the existence of the aforementioned relation, the 2D and 3D coarsening rates were calculated through simulation on a simplified 3D model. With 2D simulation, both the initiation linear growth region and the later stage plateau were predicted, and these findings agreed with experimental results from literature. Non-isothermal temperature field was also incorporated in the model to predict the phase size distribution. Finally, the experimental conditions used in the creations of 1D and 2D gradient porous structures were applied in numerical simulations. The simulation results closely matched the experimental results. (Abstract shortened by UMI.)...