Fabrication of Suspended Functional Polymer Membranes Based on the Combination of Planar Technology and Advanced Manufacturing Techniques

Simple SummaryContent extracted from patent full text and abstract with AI.

This patent describes a novel method for fabricating suspended functional polymer membranes supported by 3D-printed polymer frames. The technology combines planar manufacturing techniques like spin-coating and embossing with advanced additive manufacturing (3D printing) to create thin, free-standing polymer membranes with tunable holes and surface properties, optimized for use as sample supports or for filtration and separation processes. The membranes can be engineered for transparency, pore size, and other functionalities to suit specific scientific and industrial needs.

Use CasesContent extracted from patent full text and abstract with AI.

• Supporting protein crystallography samples for analysis at synchrotron X-ray or X-ray Free Electron Laser (XFEL) facilities.
• Cell culture applications, including stem cell research and differentiation studies, as permeable barriers or scaffolds.
• Membrane filters for microfiltration, ultrafiltration, gas separation, water purification, and wastewater treatment.
• Industrial separation processes in pharmaceutical manufacturing, food and beverage processing, blood purification, and electropaint recovery.
• Integration into microfluidic devices or lab-on-a-chip platforms for biomedical and analytical applications.

BenefitsContent extracted from patent full text and abstract with AI.

• Enhanced flexibility in membrane design (customizable pore sizes, shapes, membrane thickness, and functionalization).
• Improved sample support for protein crystallography, enabling high-resolution imaging and data collection with minimal background interference.
• Potentially lower cost and simpler fabrication using widely available polymers and additive manufacturing.
• Scalability and adaptability for a wide range of industrial and scientific filtration and separation needs.
• Ability to integrate additional features such as microfluidic channels or electrodes within the same fabrication process.
• Reduced risk of detector damage due to the use of polymer, compared to traditional silicon-based supports.
• Adaptability for both room temperature and cryogenic applications.

Technical Classifications (CPCs)

Inventors & Applicants

Patent Abstract

The present invention relates to suspended polymer membranes comprising:a) at least one polymer membrane with a specific functionality, andb) at least one polymer-based supporting frame prepared by additive manufacturing such that the polymer-based supporting frame adheres to the polymer membrane thereby generating freestanding suspended sections of the polymer membrane.Further, the present invention relates to a method for manufacturing suspended polymer membranes, comprising the steps of:a) spin-coating of a soluble polymer layer onto a silicon wafer or another flat substrate being similar in terms of physical and chemical behavior;b) spin-coating of a layer of a polymer with low solubility on top of the soluble polymer layer;c) hot embossing of this two-layer setup with a master with structural features of height equal to or larger than the thickness of the two-layer setup;d) optionally reactive ion etching to the holes generated by the hot embossing;e) additive manufacturing of a support frame on top of the hot embossed two-layer setup;f) dissolving of the soluble polymer underlayer resulting in a freestanding suspended-polymer membrane being supported by the support frame; andg) optional treating the surface of the polymer membrane in order to modify the chemical and/or physical properties of the polymer membrane, such as the surface energy of the polymer membrane.