Homoporous Membranes with Tailored Pores by Soaking Block Copolymer/Homopolymer Blends in Selective Solvents: Dissolution versus Swelling

Assembling Vertical Block Copolymer Nanopores via Solvent Vapor Annealing on Homopolymer-Functionalized Substrates

Utilizing the self-assembly of block copolymers with large Flory-Huggins interaction parameters (χ) for nanofabrication is a formidable challenge due to the attendant large surface energy differences between the blocks. This work reports a robust protocol for the fabrication of thin films with highly ordered cylindrical nanopore arrays via the self-assembly of an asymmetric poly(styrene-block-4-vinylpyridine) (PS-b-P4VP) diblock copolymer blended with a P4VP homopolymer. The desired vertical domain orientation is achieved at the air-polymer interface by controlled solvent vapor annealing (SVA) using acetone, a solvent with weak selectivity for PS over P4VP, and at the substrate interface by functionalization using a hydroxy-terminated poly(2-vinylpyridine) (P2VP-OH) homopolymer brush. In contrast, the vertical cylinder orientation is unstable during acetone SVA on substrates functionalized using hydroxy-terminated poly(methyl methacrylate) (PMMA-OH). Although PMMA exhibits more balanced interfacial energies between PS and P4VP than P2VP in the dry state, it is also swollen more selectively by acetone. We hypothesize that the nearly balanced solvent swelling of the three polymers (P2VP, P4VP, and PS) stabilizes the vertical cylinder orientation, while unbalanced swelling (PMMA > P4VP and PS) does not. We further characterize pore formation by addition of a P4VP homopolymer and its postassembly extraction using ethanol, revealing a narrow window of pore size tunability. Notably, minimal differences in nanopore morphologies are observed for P4VP volume fractions as high as 0.1, regardless of the P4VP molar mass. However, further increasing the P4VP volume fraction results in domain reorientation or macrophase separation when its molar mass is less than or greater than the P4VP block molar mass, respectively. Using a P4VP homopolymer that is nearly equal in length to the P4VP block enables the fabrication of well-ordered arrays of vertical, through-film nanopores with high aspect ratios (>10), small periods (<23 nm), and diameters less than 10 nm.

Metal nanoparticle arrays via a water-based lift-off scheme using a block copolymer template

Metalnanoparticles(NPs) can exhibit unique electronic, magnetic, optical, and catalytic properties. Highly ordered, dense arrays of non-close-packed, surface-supported metal NPs are thus of potential use in a wide range of applications. Implementing such arrays over large surfaces can, however, be both technologically challenging and prohibitively expensive using conventional top-down nanofabrication techniques. Moreover, many existing patterning methods are too harsh for sensitive substrate surfaces and their applications. To address this, we here investigate a fabrication protocol involving a water-based lift-off scheme in which the template pattern generation is rapidly and inexpensively achieved throughblock copolymer(BCP) self-assembly. A three-layer lift-off stack consisting of, from top to bottom, a poly(styrene-block-2-vinyl pyridine) template, a SiO_xintermediate hardmask, and a water-soluble poly(vinyl alcohol) sacrificial layer is employed in this endeavor.Solvent-induced surface reconstruction(SISR) is used to generate an initial surface topography in the BCP template which is subsequently transferred to the layers beneath in a sequence of reactive ion etching steps. Through judicious selection of stack materials and dry etch chemistries, a layered, high-aspect-ratio, nanoporous mask is thus implemented. After metal deposition, the mask and excess material are simply removed in a lift-off step by dissolving the bottommost sacrificial layer in water. The incorporation of an intermediate hardmask and a water-soluble sacrificial layer obviates the need for harmful and/or corrosive lift-off solvents and decouples the BCP self-assembly process from the influence of substrate properties. We demonstrate the generation of well-ordered arrays of Au NPs capable of supporting sharp, localized surface plasmon resonances. We also investigate improvements to large-scale uniformity, as this is found sensitive to the SISR termination step in the original protocol. Extensions of the technique to other BCP morphologies and materials deposited ought to be straightforward.

Nondestructive Creation of Ordered Nanopores by Selective Swelling of Block Copolymers: Toward Homoporous Membranes

Pores regulate the entry and exit of substances based on the differences in physical sizes or chemical affinities. Pore uniformity, ordering, and the homogeneity of the surface chemistry of the pore walls are vital for maximizing the performance of a porous material because any scattering in these parameters weakens the capability of pores to discriminate foreign substances. Most strategies for the creation of homogeneous pores are destructive, and sacrificial components in the precursor materials must be selectively removed to generate porosities. The incorporation and subsequent removal of the sacrificial components frequently make the pore-making process complicated and inefficient and impose greater uncertainty in the control of the pore homogeneity. Block copolymers (BCPs) have been demonstrated to be promising precursors in the fabrication of highly ordered nanoporous structures. Unfortunately, BCP-derived porosities are also predominantly dependent on destructive pore-making processes (e.g., etching or extraction). To address this problem, we have developed a swelling-based nondestructive strategy. In this swelling process, one simply needs to immerse BCP materials in a solvent selective for the minority blocks for hours. After removing the BCPs from the solvent followed by air drying, pores are generated throughout the BCP materials in the positions where the minority blocks initially dwell. This Account discusses our recent discoveries, new insights, and emerging applications of this burgeoning pore-making method with a focus on the development of ordered porosities in bulk BCP materials. The initial morphology and orientation of the minority phases in BCPs determine the pore orientation and geometry in the produced porous materials. For nonaligned BCPs, three-dimensionally interconnected pores with sizes scattering in the 10-50 nm range are produced after swelling. There is a morphology evolution of BCP materials from the initial nonporous structure to the increasingly opened nanoporous intermediates, to interconnected networks of micellar nanofibers, and finally to isolated micellar spheres with increasing degrees of swelling. When the BCP films are aligned perpendicularly or in-plane, selective swelling results in uniform "standing" (perpendicular orientation) and "sleeping" (in-plane orientation) pores, respectively. Pore sizes can be tuned by changing molecular weights of the BCPs and swelling conditions without the loss of pore uniformity. Due to the nondestructive nature of this swelling process, nothing in the BCPs is lost during the pore-forming procedure, and consequently the formed pores can be progressively closed also by selective swelling. Such reversible pore opening/closing can be repeated many times, enabling the application of these materials in drug delivery and intelligent antireflective coatings. The monodispersed pore sizes, straight pore profile, and hydrophilic pore walls particularly favor the application of the porous BCPs in separations as homoporous membranes (HOMEs) exhibiting high selectivity, permeability, and inherent stimulus responsiveness.