Study of oriented block copolymers films obtained by roll-casting

The stress deformation response influenced by the chain rigidity for mesostructures in diblock copolymers

A self-consistent field theory formalism based on the wormlike chain model is developed to investigate the stress-strain relation for mesostructures in diblock copolymers under the influence of chain rigidity, involving the adjustable simulation cell in the non-orthogonal coordinates by means of optimization of free energy. We elucidate the effect of the chain persistency broadly spanning from the Gaussian chain to the rigid rodlike chain on the elastic response of mesophases that deviate from the initial equilibrium structures. We analytically and numerically demonstrate that our current approach in the long chain limit recovers to the Gaussian-chain-based theory. Being ascribed to the distinct conformational behaviors for flexible chains and rigid rodlike chains, the tensile and compressive stresses applied to lamellae exhibit asymmetric deformation behaviors and the shear stress applied to the initial equilibrium hexagonal cylinders results in noticeable deviations in the shape and spatial arrangement of cylindroids for various chain rigidity values. For the zero stress, in addition, our approach can be straightforwardly utilized to explore the optimal size and shape of the simulation cell in order to achieve a stress free configuration of systems.

The Influence of Annealing Atmosphere, Blending Ratio, and Molecular Weight on the Phase Behavior of Blend Materials

In the study of block copolymers, many parameters need to be adjusted to obtain good phase separation results. Based on block copolymer polystyrene-b-polycarbonate and homopolymer polystyrene, the effects of the annealing atmosphere, blending ratio, and molecular weight on phase separation were studied. The results show that annealing in air can inhibit the occurrence of phase separation. In addition, snowflake patterns are formed during phase separation. The blending ratio affects the quality of the pattern. The molecular weight affects the size of the pattern, and the size increases as the molecular weight increases. In this article, the influence of process conditions and materials on phase separation was discussed, which has laid a solid foundation for the development of block copolymer self-assembly in the future.

Rapid Fabrication by Lyotropic Self-Assembly of Thin Nanofiltration Membranes with Uniform 1 Nanometer Pores

Nanostructured materials with precisely defined and water-bicontinuous 1-nm-scale pores are highly sought after as advanced materials for next-generation nanofiltration membranes. While several self-assembled systems appear to satisfy this need, straightforward fabrication of such materials as submicron films with high-fidelity retention of their ordered nanostructure represents a nontrivial challenge. We report the development of a lyotropic liquid crystal mesophase that addresses the aforementioned issue. Films as thin as ∼200 nm are prepared on conventional support membranes using solution-based methods. Within these films, the system is composed of a hexagonally ordered array of ∼3 nm diameter cylinders of cross-linked polymer, embedded in an aqueous medium. The cylinders are uniformly oriented in the plane of the film, providing a transport-limiting dimension of ∼1 nm, associated with the space between the outer surfaces of nearest-neighbor cylinders. These membranes exhibit molecular weight cutoffs of ∼300 Da for organic solutes and are effective in rejecting dissolved salts, and in particular, divalent species, while exhibiting water permeabilities that rival or exceed current state-of-the-art commercial nanofiltration membranes. These materials have the ability to address a broad range of nanofiltration applications, while structure-property considerations suggest several avenues for potential performance improvements.

Alignment of Copolymer Morphology by Planar Step Elongation during Spinodal Self-Assembly

Using simulation and numerical self-consistent field theory of an unentangled diblock copolymer melt, we study the interplay between relaxation of molecular conformations from a highly stretched, nonequilibrium state and structure formation of the local, conserved density during self-assembly from a disordered state. We observe that the planar elongation of molecular conformations in the initial, disordered state results in an alignment of lamella normals perpendicular to the stretch direction during the subsequent self-assembly. Although thermodynamically the parallel orientation is favored, the alignment of the lamella normal perpendicular to the stretch direction is characterized by the larger growth rate of composition fluctuations during the spinodal ordering process.

Structural changes of block copolymers with bi-modal orientation under fast cyclical stretching as observed by synchrotron SAXS

Load-bearing tissues are composite materials that depend strongly on anisotropic fibre arrangement to maximise performance. One such tissue is the heart valve, with orthogonally arranged fibrosa and ventricularis layers. Their function is to maintain mechanical stress while being resilient. It is postulated that while one layer bears the applied stress, the orthogonal layer helps to regenerate the microstructure when the load is released. The present paper describes changes in the microstructure of a block copolymer with cylindrical morphology, having a bio-inspired microstructure of anisotropic orthogonally oriented layers, under uniaxial strain. To allow structural observations during fast deformation, equivalent to the real heart valve operation, we used a synchrotron X-ray source and recorded 2D SAXS patterns in only 1 ms per frame. The deformation behaviour of the composite microstructure has been reported for two arrangements of the cylinders in skin and core layers. The behaviour is very different to that observed either for uniaxially oriented or isotropic samples. Deformation is far from being affine. Cylinders aligned in the direction of stretch show fragmentation, but complete recovery of the spacing between cylinders on removal of the load. Those oriented perpendicular to the direction of stretch incline at an angle of approximately 25° to their original direction during load.

In situ study of the annealing process of a polyethylene cast film with a row-nucleated crystalline structure by SAXS

The secondary crystallization has more effect on polyethylene crystal thickening than melt recrystallization during the annealing process.

Hard templating of symmetric and asymmetric carbon thin films with three-dimensionally ordered mesoporosity

Sacrificial colloidal crystal templating of porous carbon films of tunable thickness is demonstrated using a facile thin-film assembly and hard-template-based nanoreplication process. Convectively assembled, colloidal crystal films composed of size-tunable silica nanoparticles (ca. 10-50 nm) serve as scalable sacrificial scaffolds for the formation of thickness-tunable, structurally robust, and flexible porous carbon films. Both precursor vapor infiltration (PVI) and precursor immersion/spin-off (PIS) techniques, suitable for replication by various carbon sources (e.g., furfural/oxalic acid, phenol-formaldehyde, resorcinol-formaldehyde, sucrose), result in continuous, crack-free porous replica films. Systematic PVI-based underfilling of the template film or PIS-based complete spin-off of excess carbon replica precursor results in porous carbon films endowed with a symmetric three-dimensionally ordered mesopore (3DOm) topology uniformly distributed across the film thickness. Alternatively, by tuning the nanoparticle crystal film thickness and the degree of overfilling (PVI) or rate of spin-off of the carbon replica precursor (PIS), films bearing an asymmetric structure composed of 3DOm-supported ultrathin carbon layers can be realized. The stability of the silica templates under polymerization and carbonization conditions helps bolster mesopore robustness within the replica films, eliminating uniaxial pore shrinkage upon template sacrifice. The decoupling of the template assembly and its replication enables film formation from a wide range of carbon sources and possibly a further expanded materials palette. Realization of porous carbon films on various substrates without degradation of the mesostructure is enabled by robustness of the coating/replication process to characteristic surface roughness at scales several-fold larger than the template particle size as well as to polymer-mediated film transfer. Among various possible applications, we demonstrate how properties of the symmetric 3DOm films in particular (e.g., high surface area, large pore volume) enable their exploitation as potential low-cost alternatives to costly Pt-based electrodes for dye-sensitized solar cell (DSSC) technologies.

Self-Organization Schemes towards Thermodynamic Stable Bulk Heterojunction Morphologies: A Perspective on Future Fabrication Strategies of Polymer Photovoltaic Architectures

Research efforts to improve our understanding of electronic polymers are developing fast because of their promising advantages over silicon in photovoltaic solar cells. A major challenge in the development of polymer photovoltaic devices is the viable fabrication strategies of stable bulk heterojunction architecture that will retain functionality during the expected lifetime of the device. Block copolymer self-assembly strategies have attracted particular attention as a scalable means toward thermodynamically stable microstructures that combine the ideal geometrical characteristics of a bulk heterojunction with the fortuitous combination of properties of the constituent blocks. Two primary routes that have been proposed in the literature involve the coassembly of block copolymers in which one domain is a hole conductor with the electron-conducting filler (such as fullerene derivatives) or the self-assembly of block copolymers in which the respective blocks function as hole and electron conductor. Either way has proven difficult because of the combination of synthetic challenges as well as the missing understanding of the complex governing parameters that control structure formation in semiconducting block copolymer blends. This paper summarizes important findings relating to structure formation of block copolymer and block copolymer/nanoparticle blend assembly that should provide a foundation for the future design of block copolymer-based photovoltaic systems.

Toward anisotropic materials via forced assembly coextrusion

Multilayer coextrusion offers a diverse platform to examine layer dependent confinement effects on self-assembling nanomaterials via conventional extrusion technology. A triblock copolymer (BCP) with a cylindrical microstructure was processed via "forced assembly" to elucidate the effect of microdomain orientation on the mechanical behavior of multilayer films. The mechanical response was investigated in both the extrusion (ED) and transverse directions (TD) of the multilayer systems, revealing an influence of both cylinder-orientation and the interface on the mechanical response with decreasing layer thickness. The stress-strain curves for samples with the stress field along the cylinder axis revealed a sharp yielding phenomenon, while curves for specimens with the stress field applied perpendicular to the axis exhibited weak yielding behavior. The extensibility of the multilayer films stressed in the ED increases with decreasing layer thickness, but remains constant when deformed along the TD. Coextrusion technology allows for tunable mechanical toughness in industrial grade polymers via a continuous process. By altering the layer thickness of the two polymeric materials, we can tune the mechanics from strong, brittle behavior to a tough, ductile response by manipulation of the hierarchical structure. The enabling technology provides a unique platform to couple the inherent mechanical response of dissimilar polymers and allows for the design of composite materials with tailored mechanics.

Unidirectionally aligned line patterns driven by entropic effects on faceted surfaces

A simple, versatile approach to the directed self-assembly of block copolymers into a macroscopic array of unidirectionally aligned cylindrical microdomains on reconstructed faceted single crystal surfaces or on flexible, inexpensive polymeric replicas was discovered. High fidelity transfer of the line pattern generated from the microdomains to a master mold is also shown. A single-grained line patterns over arbitrarily large surface areas without the use of top-down techniques is demonstrated, which has an order parameter typically in excess of 0.97 and a slope error of 1.1 deg. This degree of perfection, produced in a short time period, has yet to be achieved by any other methods. The exceptional alignment arises from entropic penalties of chain packing in the facets coupled with the bending modulus of the cylindrical microdomains. This is shown, theoretically, to be the lowest energy state. The atomic crystalline ordering of the substrate is transferred, over multiple length scales, to the block copolymer microdomains, opening avenues to large-scale roll-to-roll type and nanoimprint processing of perfectly patterned surfaces and as templates and scaffolds for magnetic storage media, polarizing devices, and nanowire arrays.

A simple route to highly oriented and ordered nanoporous block copolymer templates

Controlling the orientation and lateral ordering of the block copolymer microdomains is essential to their use as templates and scaffolds for the fabrication of nanostructured materials. In addition, a process must be robust, simple to implement, and rapid, and should not introduce disruptive processing steps that would impede their use. Here, we describe thin films of poly(styrene-b-4-vinylpyridine) (PS-b-P4VP) diblock copolymers, spin-coated from mixed solvents that show highly oriented, cylindrical microdomains with a high degree of order on a wide range of substrates, including silicon oxide, polystyrene, germanium, polyimide, and poly(butylene terephthalate). In addition, the preferential solvation of the P4VP block with an alcohol caused a surface reconstruction that resulted in the formation of a nanoporous film upon drying. The evaporation of gold onto the reconstructed films produced thermally stable and reactive ion etching resistant films.

Formation of ordered microphase-separated pattern during spin coating of ABC triblock copolymer

In this paper, the authors have systematically studied the microphase separation and crystallization during spin coating of an ABC triblock copolymer, polystyrene-b-poly(2-vinylpyridine)-b-poly(ethylene oxide) (PS-b-P2VP-b-PEO). The microphase separation of PS-b-P2VP-b-PEO and the crystallization of PEO blocks can be modulated by the types of the solvent and the substrate, the spinning speed, and the copolymer concentration. Ordered microphase-separated pattern, where PEO and P2VP blocks adsorbed to the substrate and PS blocks protrusions formed hexagonal dots above the P2VP domains, can only be obtained when PS-b-P2VP-b-PEO is dissolved in N,N-dimethylformamide and the films are spin coated onto the polar substrate, silicon wafers or mica. The mechanism of the formation of regular pattern by microphase separation is found to be mainly related to the inducement of the substrate (middle block P2VP wetting the polar substrate), the quick vanishment of the solvent during the early stage of the spin coating, and the slow evaporation of the remaining solvent during the subsequent stage. On the other hand, the probability of the crystallization of PEO blocks during spin coating decreases with the reduced film thickness. When the film thickness reaches a certain value (3.0 nm), the extensive crystallization of PEO is effectively prohibited and ordered microphase-separated pattern over large areas can be routinely prepared. When the film thickness exceeds another definite value (12.0 nm), the crystallization of PEO dominates the surface morphology. For films with thickness between these two values, microphase separation and crystallization can simultaneously occur.