Polymeric nanocomposite films with embedded channels and methods for their preparation and use

1. A method of forming micro channels embedded in a polymeric nanocomposite film, the method comprising:

combining one or more monomers to form a polymer;

dispersing a plurality of carbon fibers comprising metal nanoparticles with a surfactant to form dispersed carbon fibers;

milling the dispersed carbon fibers;

mixing the milled carbon fibers prior to or concurrently with formation of the polymer from the monomers;

adding at least one hydrophobic agent and at least one plasticizer to the polymer to form the polymeric nanocomposite film; and

forming a plurality of laser-etched micro channels in a surface of the polymeric nanocomposite film.

2. The method of claim 1 , wherein the one or more monomers comprises methyl acetate, vinyl acetate, methyl acrylate, ethyl acrylate, or combinations thereof.

3. The method of claim 1 , wherein the polymer comprises polyvinyl alcohol (PVA), polyvinyl acetate (PVAc), polypropylene (PP), polyethylene (PE), polyvinylidene fluoride (PVDF), or combinations thereof.

4. The method of claim 1 , wherein the micro channels have an average length of about 5 millimeter (mm) to about 30 mm.

5. The method of claim 1 , wherein the micro channels have an average width of about 50 micrometer (μm) to about 300 μm.

6. The method of claim 1 , wherein the micro channels have an average depth of about 40 micrometer (μm) to about 150 μm.

7. The method of claim 1 , wherein the carbon fibers are added upon initiation of formation of the polymer.

8. The method of claim 1 , wherein the carbon fibers comprise carbon microfibers, carbon nanofibers (CNFs), or a combination thereof.

9. The method of claim 1 , further comprising:

casting the polymer on a substrate; and

drying the polymer to form the polymeric nanocomposite film.

10. The method of claim 1 , wherein the metal nanoparticles comprise nickel (Ni), iron (Fe), silver (Ag), copper (Cu), zinc (Zn), aluminum (Al), gold (Au), Cu—Ag (copper-silver), Zn—Ag (zinc-silver), or combinations thereof.

11. The method of claim 10 , wherein the metal nanoparticles have an average particle size of about 20 nanometer (nm) to about 180 nm.

12. The method of claim 1 , wherein the micro channels are formed in the polymeric nanocomposite film using pulsed nanosecond ultraviolet laser.

13. The method of claim 12 , wherein ultraviolet radiation applied by the ultraviolet laser has a wavelength of about 100 nanometer (nm) to about 400 nm.

14. The method of claim 12 , wherein ultraviolet radiation applied by the ultraviolet laser has a pulse energy of about 1 millijoule (mJ) to about 700 mJ.

15. The method of claim 12 , wherein ultraviolet radiation applied by the ultraviolet laser has a pulse frequency of about 1 Hertz (Hz) to about 60 Hz.

16. The method of claim 12 , wherein ultraviolet radiation applied by the ultraviolet laser has a scanning rate of about 0.1 millimeter per second (mm/s) to about 1 mm/s.

17. A method of forming micro channels embedded in a polymeric nanocomposite film, the method comprising:

initiating esterification of vinyl acetate for forming polyvinyl alcohol (PVA);

dispersing a plurality of carbon fibers comprising metal nanoparticles with a surfactant to form dispersed carbon fibers;

milling the dispersed carbon fibers;

adding the milled carbon fibers to the vinyl acetate prior to or concurrently with formation of the polyvinyl alcohol (PVA);

adding at least one hydrophobic agent and at least one plasticizer to the PVA and the milled carbon fibers to form the polymeric nanocomposite film; and

forming a plurality of micro channels in a surface of the polymeric nanocomposite film.