Self-Assembly in Block Copolymer Thin Films upon Solvent Evaporation: A Simulation Study

On-Demand Selection of the Latent Domain Orientation in Spray-Deposited Block Copolymer Thin Films

With their ability to self-assemble spontaneously into well-defined nanoscale morphologies, block copolymer (BCP) thin films are a versatile platform to fabricate functional nanomaterials. An important challenge to wider deployment of BCPs in nanofabrication is combining precise control over the nanoscale domain orientation in BCP assemblies with scalable deposition techniques that are applicable to large-area, curved, and flexible substrates. Here, we show that spray-deposited smooth films of a nominally disordered BCP exhibit latent orientations, which can be prescriptively selected by controlling solvent evaporation during spray casting. Subsequent solvent vapor annealing triggers assembly toward highly ordered cylindrical morphologies along the pathway determined by solvent evaporation in the prior spray deposition stage. Faster evaporation promotes assembly of vertically oriented cylinders spanning the entire film thickness (100-300 nm). In comparison, slow solvent evaporation permits intermicellar aggregation and incipient cylinder formation in solution, which induces horizontal cylinder assembly upon annealing. The evaporatively controlled latent orientation mechanism presented herein elucidates how nonequilibrium phenomena during casting govern successive self-assembly pathways and facilitates a versatile method to dictate the domain orientation of BCP thin films on demand on flexible and highly curved substrates or in distinct pattern areas on the same substrate.

Phase behavior of symmetric diblock copolymers under 3D soft confinement

The phase behavior of symmetric diblock copolymers under three-dimensional (3D) soft confinement is investigated using self-consistent field theory. Soft confinement is realized in binary blends composed of AB diblock copolymers and C homopolymers, where the copolymers self-assemble to form a droplet embedded in a homopolymer matrix. The phase behavior of the confined block copolymers is regulated by the degree of confinement and the selectivity of the homopolymers, resulting in a rich variety of novel structures. When the C homopolymers are neutral to the A- and B-blocks, stacked lamellae (SL) are formed where the number of layers increases with the droplet volume, resulting in a morphological transition sequence from Janus particles to square SL. When the C homopolymers are strongly selective for the B-blocks, a series of non-lamellar morphologies, including onion-, hamburger-, cross-, ring-, and cookie-like structures, are observed. A detailed free energy analysis reveals a first-order reversible transformation between SL and onion-like (OL) structures when the selectivity of the homopolymers is changed. Our results provide a comprehensive understanding of how various factors, such as the copolymer concentration, homopolymer chain length, degree of confinement, and homopolymer selectivity, affect the self-assembled structures of diblock copolymers under soft 3D confinement.

Suppression of bubbles in unstable active liquids via fast evaporation

A common intuition in thermodynamics is that bubbles can spontaneously grow in unstable liquids, which will be detrimental to a variety of physical and chemical processes, such as evaporation-induced self-assembly and electrocatalysis. Here, we show that this common intuition can be significantly reversed by demonstrating a suppression of bubbles in unstable active liquids induced by fast evaporation, which is in contrast to the bubble growth in passive liquids. Such anomalous bubble suppression can be attributed to an activity-induced inversion of pressure difference between bubbles and their surrounding liquid. Moreover, this pressure flip depends on the activity as well as the thermodynamics of passive liquids, and it can generate different kinetic pathways that allow controlling the bubble dynamics in unstable liquids. Our results establish a foundation for promoting applications of unstable active liquids in various physical and chemical processes.

Investigating microstructure evolution in block copolymer membranes

Block copolymer self-assembly in conjunction with nonsolvent-induced phase separation (SNIPS) has been increasingly leveraged to fabricate integral-asymmetric membranes. The large number of formulation and processing parameters associated with SNIPS, however, has prevented the reliable construction of high performance membranes. In this study, we apply dynamical self-consistent field theory to model the SNIPS process and investigate the effect of various parameters on the membrane morphology: solvent selectivity, nonsolvent selectivity, initial film composition, and glass transition composition. We examine how solvent selectivity and concentration of polymers in the film impact the structure of micelles that connect to form the membrane matrix. In particular, we find that preserving the order in the surface layer and forming a connection between the supporting and surface layer are nontrivial and sensitive to each parameter studied. The effect of each parameter is discussed, and suggestions are made for successfully fabricating viable block copolymer membranes.

Simulation of Membrane Fabrication via Solvent Evaporation and Nonsolvent-Induced Phase Separation

Block copolymer membranes offer a bottom-up approach to form isoporous membranes that are useful for ultrafiltration of functional macromolecules, colloids, and water purification. The fabrication of isoporous block copolymer membranes from a mixed film of an asymmetric block copolymer and two solvents involves two stages: First, the volatile solvent evaporates, creating a polymer skin, in which the block copolymer self-assembles into a top layer, comprised of perpendicularly oriented cylinders, via evaporation-induced self-assembly (EISA). This top layer imparts selectivity onto the membrane. Subsequently, the film is brought into contact with a nonsolvent, and the exchange between the remaining nonvolatile solvent and nonsolvent through the self-assembled top layer results in nonsolvent-induced phase separation (NIPS). Thereby, a macroporous support for the functional top layer that imparts mechanical stability onto the system without significantly affecting permeability is fabricated. We use a single, particle-based simulation technique to investigate the sequence of both processes, EISA and NIPS. The simulations identify a process window, which allows for the successful in silico fabrication of integral-asymmetric, isoporous diblock copolymer membranes, and provide direct insights into the spatiotemporal structure formation and arrest. The role of the different thermodynamic (e.g., solvent selectivity for the block copolymer components) and kinetic (e.g., plasticizing effect of the solvent) characteristics is discussed.

Horizontal to perpendicular transition of lamellar and cylinder phases in block copolymer films induced by interface segregation of single-chain nanoparticles during solvent evaporation

How to fabricate perpendicularly oriented domains (PODs) of lamellar and cylinder phases in block copolymer thin films remains a major challenge. In this work, via a coarse-grained molecular dynamics simulation study, we report a solvent evaporation strategy starting from a mixed solution of A-b-B-type diblock copolymers (DBCs) and single-chain nanoparticles (SCNPs) with the same composition, which is capable of spontaneously generating PODs in drying DBC films induced by the interface segregation of SCNPs. The latter occurs at both the free surface and substrate and, consequently, neutralizes the interface selectivity of distinct blocks in DBCs, leading to spontaneous formation of PODs at both interfaces. The interface segregation of SCNPs is related to the weak solvophilicity of the internal cross-linker units. A mean-field theory calculation demonstrates that the increase in the chemical potential of SCNPs in the bulk region drives their interface segregation along with solvent evaporation. We believe that such a strategy can be useful in regulating the PODs of DBC films in practical applications.

Self-Assembly of Block Copolymers in Thin Films Swollen-Rich in Solvent Vapors

In this study we have employed a polymer processing method based on solvent vapor annealing in order to condense relatively large amounts of solvent vapors onto thin films of block copolymers and thus to promote their self-assembly into ordered nanostructures. As revealed by the atomic force microscopy, a periodic lamellar morphology of poly(2-vinylpyridine)-b-polybutadiene and an ordered morphology comprised of hexagonally-packed structures made of poly(2-vinylpyridine)-b-poly(cyclohexyl methacrylate) were both successfully generated on solid substrates for the first time.

Modeling the Phase Equilibria of Associating Polymers in Porous Media with Respect to Chromatographic Applications

Associating copolymers self-assemble during their passage through a liquid chromatography (LC) column, and the elution differs from that of common non-associating polymers. This computational study aims at elucidating the mechanism of their unique and intricate chromatographic behavior. We focused on amphiphilic diblock copolymers in selective solvents, performed the Monte Carlo (MC) simulations of their partitioning between a bulk solvent (mobile phase) and a cylindrical pore (stationary phase), and investigated the concentration dependences of the partition coefficient and of other functions describing the phase behavior. The observed abruptly changing concentration dependences of the effective partition coefficient demonstrate the significant impact of the association of copolymers with their partitioning between the two phases. The performed simulations reveal the intricate interplay of the entropy-driven and the enthalpy-driven processes, elucidate at the molecular level how the self-assembly affects the chromatographic behavior, and provide useful hints for the analysis of experimental elution curves of associating polymers.

Nonequilibrium Processes in Polymer Membrane Formation: Theory and Experiment

Porous polymer and copolymer membranes are useful for ultrafiltration of functional macromolecules, colloids, and water purification. In particular, block copolymer membranes offer a bottom-up approach to form isoporous membranes. To optimize permeability, selectivity, longevity, and cost, and to rationally design fabrication processes, direct insights into the spatiotemporal structure evolution are necessary. Because of a multitude of nonequilibrium processes in polymer membrane formation, theoretical predictions via continuum models and particle simulations remain a challenge. We compiled experimental observations and theoretical approaches for homo- and block copolymer membranes prepared by nonsolvent-induced phase separation and highlight the interplay of multiple nonequilibrium processes─evaporation, solvent-nonsolvent exchange, diffusion, hydrodynamic flow, viscoelasticity, macro- and microphase separation, and dynamic arrest─that dictates the complex structure of the membrane on different scales.

A simulation study of the self-assembly of ABC star terpolymers confined between two parallel surfaces

The phase behavior of ABC star terpolymers confined between two identical parallel surfaces is systematically studied using a simulated annealing method. Several phase diagrams are constructed for systems with different bulk phases or with different interfacial interaction strength ratios in the space of surface distance (D) and surface preference for different arms, or in the space of D and the arm-length ratio x. Phases, including tiling patterns [6.6.6], [8.8.4], [8.6.6; 8.6.4], [8.6.6; 8.6.4; 10.6.6; 10.6.4] and hierarchical lamellar structures of lamella + cylinders and lamella + rods, are identified both in the bulk and in the films. Our results suggest that the self-assembled structure of a phase is largely controlled by x, while an increase of the interfacial interaction strength ratio shifts the x-window for each phase to the smaller x side. The orientation of a confined phase depends on the "effective surface preference" which is a combined effect of the interfacial interaction strength ratio, the surface preference, and the entropic preference. In the case of neutral or weak "effective surface preference", phases with a perpendicular orientation are usually observed, while in the case of strong "effective surface preference" phases with a perpendicular orientation or also with outermost wetting-layers can be frequently observed under some circumstances.

Evaporation-Induced Liquid Expansion and Bubble Formation in Binary Mixtures

We observe an anomalous liquid expansion after quenching a binary mixture at coexistence to low pressures in the vapor phase by numerical calculations. This evaporation-induced expansion can be attributed to the pressure imbalance near the liquid-vapor interface, which originates from the interplay between the complex thermodynamics of binary mixtures both in the vapor and liquid phases, as well as their dynamical asymmetries. In addition, careful modulation of the pressure quench in the vapor phase can result in spinodal bubble formation inside liquid phase. The results indicate that the thermodynamics-kinetics interplay could foster our fundamental understanding of the evaporation process and promote its practical applications.

Feature size control using surface reconstruction temperature in block copolymer lithography for InAs nanowire growth

Here we present a method to control the size of the openings in hexagonally organized BCP thin films of poly(styrene)-block-poly(4-vinylpyridine) (PS-b-P4VP) by using surface reconstruction. The surface reconstruction is based on selective swelling of the P4VP block in ethanol, and its extraction to the surface of the film, resulting in pores upon drying. We found that the BCP pore diameter increases with ethanol immersion temperature. In our case, the temperature range 18 to 60 °C allowed fine-tuning of the pore size between 14 and 22 nm. A conclusion is that even though the molecular weight of the respective polymer blocks is fixed, the PS-b-P4VP pore diameter can be tuned by controlling temperature during surface reconstruction. These results can be used for BCP-based nanofabrication in general, and for vertical nanowire growth in particular, where high pattern density and diameter control are of importance. Finally, we demonstrate successful growth of indium arsenide InAs vertical nanowires by selective-area metal-organic vapor phase epitaxy (MOVPE), using a silicon nitride mask patterned by the proposed PS-b-P4VP surface reconstruction lithography method.

Facilitated Structure Formation in Isoporous Block Copolymer Membranes upon Controlled Evaporation by Gas Flow

The conventional fabrication of isoporous membranes via the evaporation-induced self-assembly of block copolymers in combination with non-solvent induced phase separation (SNIPS) is achieved under certain environmental conditions. In this study, we report a modification in the conventional fabrication process of (isoporous) flat sheet membranes in which the self-assembly of block copolymers is achieved by providing controlled evaporation conditions using gas flow and the process is introduced as gSNIPS. This fabrication approach can not only trigger and control the microphase separation but also provides isoporous structure formation in a much broader range of solution concentrations and casting parameters, as compared to fabrication under ambient, uncontrolled conditions. We systematically investigated the structure formation of the fabrication of integral asymmetric isoporous membranes by gSNIPS. A quantitative correlation between the evaporation conditions (causing solvent evaporation and temperature drop) and the self-assembly of block copolymers beginning from the top layer up to a certain depth, orientation of pores in the top layer and the substructure morphology has been discussed empirically.

Nanomaterial Patterning in 3D Printing

The synergistic integration of nanomaterials with 3D printing technologies can enable the creation of architecture and devices with an unprecedented level of functional integration. In particular, a multiscale 3D printing approach can seamlessly interweave nanomaterials with diverse classes of materials to impart, program, or modulate a wide range of functional properties in an otherwise passive 3D printed object. However, achieving such multiscale integration is challenging as it requires the ability to pattern, organize, or assemble nanomaterials in a 3D printing process. This review highlights the latest advances in the integration of nanomaterials with 3D printing, achieved by leveraging mechanical, electrical, magnetic, optical, or thermal phenomena. Ultimately, it is envisioned that such approaches can enable the creation of multifunctional constructs and devices that cannot be fabricated with conventional manufacturing approaches.

Anomalous Ostwald Ripening Enables 2D Polymer Crystals via Fast Evaporation

We demonstrate by molecular simulations that the Ostwald ripening of crystalline polymer nuclei within the fast-evaporation-induced 2D skin layer is retarded at suitable temperatures and evaporation rates. Such an anomalous ripening can be attributed to the interplay between the thermodynamically driven diffusion of noncrystalline fragments toward the growing nuclei and the diffusive current away from the free surface caused by the densification in the nonequilibrium skin layer. The growth orientation of the nuclei inside the skin plane can be adjusted during this anomalous ripening process, which is beneficial for fabricating 2D polymer crystals.

Formation Mechanisms of Porous Particles from Self-Assembly of Amphiphilic Diblock Copolymers inside an Oil-in-Water Emulsion Droplet upon Solvent Evaporation

The formation mechanisms of porous particles from self-assembly of amphiphilic diblock copolymers inside an oil-in-water emulsion droplet upon evaporation of the organic solvent are investigated based on Monte Carlo simulations for the first time. A morphological diagram of particles is constructed as a function of the surfactant concentration (φ) and the copolymer composition characterized by the volume fraction of the hydrophilic B block ( f_B). Particles with various morphologies are predicted. Morphological sequences from non-porosity to closed-porosity to capsules and finally to open-porosity particles are usually observed with increasing φ when f_B ≤ 1/2, with the only exception that capsules do not occur when f_B = 1/6. Furthermore, the critical φ value for a given morphological transition usually decreases with increasing f_B. Micelles are always observed at higher φ regions when f_B > 1/2. It is found that the specific surface area falls on almost the same regime for particles with the same kind of morphology, indicating that the morphology of a particle largely determines its specific surface area. The chain stretching varies with the particle morphology. It is the presence of the surfactant that makes the formation of porous particles possible, while when φ > 0, multiple morphological transitions can be induced by changing f_B. In the process of organic solvent removal, the value of f_B may affect the shape of pores inside the droplet and hence leads to the f_B dependence of the morphological sequences. When the solvent evaporation is not too fast, the resulting morphological sequence does not depend on the evaporation rate. Our results are compared with related experiments.