Control of Morphology in Polymer Blends through Light Self-Trapping: An in Situ Study of Structure Evolution, Reaction Kinetics, and Phase Separation

Interplay of Luminophores and Photoinitiators during Synthesis of Bulk and Patterned Luminescent Photopolymer Blends

Four-dimensional printing with embedded photoluminescence is emerging as an exciting area in additive manufacturing. Slim polymer films patterned with three-dimensional lattices of multimode cylindrical waveguides (waveguide-encoded lattices, WELs) with enhanced fields of view can be fabricated by localizing light as self-trapped beams within a photopolymerizable formulation. Luminescent WELs have potential applications as solar cell coatings and smart planar optical components. However, as luminophore-photoinitiator interactions are expected to change the photopolymerization kinetics, the design of robust luminescent photopolymer sols is nontrivial. Here, we use model photopolymer systems based on methacrylate-siloxane and epoxide homopolymers and their blends to investigate the influence of the luminophore Lumogen Violet (LV) on the photolysis kinetics of the Omnirad 784 photoinitiator through UV-vis absorbance spectroscopy. Initial rate analysis with different bulk polymers reveals differences in the pseudo-first-order rate constants in the absence and presence of LV, with a notable increase (∼40%) in the photolysis rate for the 1:1 blend. Fluorescence quenching studies, coupled with density functional theory calculations, establish that these differences arise due to electron transfer from the photoexcited LV to the ground-state photoinitiator molecules. We also demonstrate an in situ UV-vis absorbance technique that enables real-time monitoring of both waveguide formation and photoinitiator consumption during the fabrication of WELs. The in situ photolysis kinetics confirm that LV-photoinitiator interactions also influence the photopolymerization process during WEL formation. Our findings show that luminophores play a noninnocent role in photopolymerization and highlight the necessity for both careful consideration of the photopolymer formulation and a real-time monitoring approach to enable the fabrication of high-quality micropatterned luminescent polymeric films.

Fluorescent Waveguide Lattices for Enhanced Light Harvesting and Solar Cell Performance

We present the properties and performance of fluorescent waveguide lattices as coatings for solar cells, designed to address the significant mismatch between the solar cell's spectral response range and the solar spectrum. Using arrays of microscale visible light optical beams transmitted through photoreactive polymer resins comprising acrylate and silicone monomers and fluorescein o,o'-dimethacrylate comonomer, we photopolymerize well-structured films with single and multiple waveguide lattices. The materials exhibited bright green-yellow fluorescence emission through down-conversion of blue-UV excitation and light redirection from the dye emission and waveguide lattice structure. This enables the films to collect a broader spectrum of light, spanning UV-vis-NIR over an exceptionally wide angular range of ±70°. When employed as encapsulant coatings on commercial silicon solar cells, the polymer waveguide lattices exhibited significant enhancements in solar cell current density. Below 400 nm, the primary mode of enhancement is through down-conversion and light redirection from the dye emission and collection by the waveguides. Above 400 nm, the primary modes of enhancement were a combination of down-conversion, wide-angle light collection, and light redirection from the dye emission and collection by the waveguides. Waveguide lattices with higher dye concentrations produced more well-defined structures better suited for current generation in encapsulated solar cells. Under standard AM 1.5 G irradiation, we observed nominal average current density increases of 0.7 and 1.87 mA/cm² for single waveguide lattices and two intersecting lattices, respectively, across the full ±70° range and reveal optimal dye concentrations and suitable lattice structures for solar cell performance. Our findings demonstrate the significant potential of incorporating down-converting fluorescent dyes in polymer waveguide lattices for improving the current spectral and angular response of solar cell technologies toward increasing clean energy in the energy grid.

Multidirectional Polymer Waveguide Lattices for Enhanced Ultrawide-Angle Light Capture in Silicon Solar Cells

We report the synthesis and characterization of a polymer thin-film structure consisting of two intersecting broadband optical waveguide lattices, and its performance in wide-angle optical energy collection and conversion in silicon solar cells. The structures are synthetically organized via the concurrent irradiation of photoreactive polymer blends by two arrays of intersecting, microscale optical beams transmitted through the medium. Through optical beam-induced photopolymerization and photopolymerization-induced phase separation, well-organized lattices are produced comprising of cylindrical core-cladding waveguide architectures that intersect one another. The optical waveguide properties of the lattices transform the transmission characteristics of the polymer film so that incident optical energy is collected and transmitted along the waveguide axes, rather than their natural directions dictated by refraction, thereby creating efficient light-collecting capability. The embedded structures collectively impart their wide-angle acceptance ranges to enable the film to efficiently collect and interact with light over a large angular range (±70°). When employed as the encapsulant material for a commercial silicon solar cell, the novel light collection and transmission properties result in greater wide-angle conversion efficiency and electrical current density, compared to a single vertically aligned waveguide array. The sustained and greater conversion of light afforded by the encapsulating optical material promises to increase solar cell performance by enabling ultrawide-angle solar energy conversion.

Simulations of Structure and Morphology in Photoreactive Polymer Blends under Multibeam Irradiation

We present a theoretical study of the organization of photoreactive polymer blends under irradiation by multiple arrays of intersecting optical beams. In a simulated medium possessing an integrated intensity-dependent refractive index, optical beams undergo self-focusing and reduced divergence. A corresponding intensity-dependent increase in molecular weight induces polymer blend instability and consequent phase separation, whereby the medium can evolve into an intersecting waveguide lattice structure, comprising high refractive index cylindrical cores and a surrounding low refractive index medium (cladding). We conduct simulations for two propagation angles and a range of thermodynamic, kinetic, and polymer blend parameters to establish correlations to structure and morphology. We show that spatially correlated structures, namely, those that have a similar intersecting three-dimensional (3D) pattern as the arrays of intersecting optical beams, are achieved via a balance between the competitive processes of photopolymerization rate and phase separation dynamics. A greater intersection angle of the optical beams leads to higher correlations between structures and the optical beam pattern and a wider parameter space that achieves correlated structures. This work demonstrates the potential to employ complex propagating light patterns to create 3D organized structures in multicomponent photoreactive soft systems.

Two-Photon Polymerization of Albumin Hydrogel Nanowires Strengthened with Graphene Oxide

Multifunctional biomaterials can pave a way to novel types of micro- and nanoelectromechanical systems providing benefits in mimicking of biological functions in implantable, wearable structures. The production of biocomposites that hold both superior electrical and mechanical properties is still a challenging task. In this study, we aim to fabricate 3D printed hydrogel from a biocomposite of bovine serum albumin with graphene oxide (BSA@GO) using femtosecond laser processing. We have developed the method for functional BSA@GO composite nanostructuring based on both two-photon polymerization of nanofilaments and direct laser writing. The atomic-force microscopy was used to probe local electrical and mechanical properties of hydrogel BSA@GO nanowires. The improved local mechanical properties demonstrate synergistic effect in interaction of femtosecond laser pulses and novel composite structure.

Superhydrophobic Polymer Composite Surfaces Developed via Photopolymerization

Fabrication of superhydrophobic materials using incumbent techniques involves several processing steps and is therefore either quite complex, not scalable, or often both. Here, the development of superhydrophobic surface-patterned polymer-TiO₂ composite materials using a simple, single-step photopolymerization-based approach is reported. The synergistic combination of concurrent, periodic bump-like pattern formation created using irradiation through a photomask and photopolymerization-induced nanoparticle (NP) phase separation enables the development of surface textures with dual-scale roughness (micrometer-sized bumps and NPs) that demonstrate high water contact angles, low roll-off angles, and desirable postprocessability such as flexibility, peel-and-stick capability, and self-cleaning capability. The effect of nanoparticle concentration on surface porosity and consequently nonwetting properties is discussed. Large-area fabrication over an area of 20 cm², which is important for practical applications, is also demonstrated. This work demonstrates the capability of polymerizable systems to aid in the organization of functional polymer-nanoparticle surface structures.

Gel Polymer Electrolytes Based on Cross-Linked Poly(ethylene glycol) Diacrylate for Calcium-Ion Conduction

Calcium batteries are promising alternatives to lithium batteries owing to their high energy density, comparable reduction potential, and mineral abundance. However, to meet practical demands in high-performance applications, suitable electrolytes must be developed. Here, we report the synthesis and characterization of polymer gel electrolytes for calcium-ion conduction prepared by the photo-cross-linking of poly(ethylene glycol) diacrylate (PEGDA) in the presence of solutions of calcium salts in a mixture of ethylene carbonate (EC) and propylene carbonate (PC) solvents. The results show room-temperature conductivity between 10^-5 and 10^-4 S/cm, electrochemical stability windows of ∼3.8 V, full dissociation of the salt, and minimal coordination with the PEGDA backbone. Cycling in symmetric Ca metal cells proceeds but with increasing overpotentials, which can be attributed to interfacial impedance between the electrolyte and calcium surface, which inhibits charge transfer. Calcium may still be plated and stripped yielding high-purity deposits and no indication of significant electrolyte breakdown, indicating that high overpotentials are associated with an electrically insulating, yet ion-permeable solid electrolyte interface (SEI). This work provides a contribution to the study and understanding of polymer gel materials toward their improvement and application as electrolytes for calcium batteries.

Stimuli-Responsive Electrospun Piezoelectric Mats of Ethylene-co-vinyl Acetate-Millable Polyurethane-Nanohydroxyapatite Composites

Piezoelectric materials have gained interest among materials scientists as body motion sensors and energy harvesters on account of their fast responsiveness and substantial output signals. In this work, piezoelectric polymer mats have been fabricated from ethylene-co-vinyl acetate-millable polyurethane/nanohydroxyapatite (EVA-MPU/nHA) composite systems by employing the electrospinning technique. The ferro-piezoelectric features of the samples were confirmed from the butterfly loops of electrostatic force microscopy (EFM) amplitude signals as well as through the hysteresis curves of the EFM phase recorded with the assistance of dynamic-contact EFM. Piezoelectric responses of the samples to random finger tapping were evaluated after fabricating a simple device prototype connected to an oscilloscope. The efficacy of the mats to generate a voltage in response to activities such as mechanical bending, movement of throat muscles while drinking, movement of elbow joints, air blowing, and so forth has also been investigated. The results suggest the promising possibility of fabricating user-friendly piezoelectric mats out of the EVA-MPU/nHA system for physiological motion-sensing applications.

Capture of Iodine from Nuclear-Fuel-Reprocessing Off-Gas: Influence of Aging on a Reduced Silver Mordenite Adsorbent after Exposure to NO/NO2

Iodine radioisotopes released during nuclear fuel reprocessing must be removed from the off-gas stream before discharge. One promising material for iodine capture is reduced silver mordenite (Ag⁰Z). Nevertheless, the adsorbent's capacity will degrade, or age, over time when the material is exposed to other off-gas constituents. Though the overall impact of aging is known, the underlying physical and chemical processes are not. To examine these processes, Ag⁰Z samples were prepared and aged in 2% NO₂ in dry air and in 1% NO in N₂ gas streams at 150 °C for up to six months. Aged samples were then characterized using scanning electron microscopy, X-ray diffraction, Raman spectroscopy, and X-ray absorption spectroscopy. These techniques show that aging involves two overarching processes: (i) oxidation of the silver nanoparticles present in Ag⁰Z and (ii) migration of oxidized silver into the mordenite's inner network. Silver on the nanoparticle's surface is oxidized through adsorption of O₂, NO, and NO₂. Raman spectroscopy and X-ray absorption spectroscopy indicate that nitrates are the primary products of this adsorption. Most of these nitrates migrate into the interior of the mordenite and exchange at framework binding sites, returning silver to its unreduced state (AgZ). The remaining nitrates exist at a persistent concentration without aggregating into bulk-phase AgNO₃. X-ray absorption spectroscopy results further indicate that iodine adsorption occurs on not just Ag⁰Z but also on AgZ and a portion of the nitrates in the system. AgZ adsorbs a sizable quantity of iodine early in the aging process, but its capacity drops rapidly over time. For well-aged samples, nitrates are responsible for up to 95% of mordenite's iodine capacity. These results have enhanced our understanding of the aging process in silver mordenite and are expected to guide the development of superior adsorbents for the capture of radioactive iodine from reprocessing off-gas.

Observation of intensity dependent phase-separation in photoreactive monomer-nanoparticle formulations under non-uniform visible light irradiation

We report observations of photopolymerization driven phase-separation in a mixture of a photo-reactive monomer and inorganic nanoparticles. The mixture is irradiated with visible light possessing a periodic intensity profile that elicits photopolymerization along the depth of the mixture, establishing a competition between photo-crosslinking and thermodynamically favorable phase-separating behavior inherent to the system. In situ Raman spectroscopy was used to monitor the polymerization reaction and morphology evolution, and reveals a key correlation between irradiation intensity and composite morphology extending the entire depth of the mixture, i.e. unhindered phase-separation at low irradiation intensity and arrested phase-separation at high irradiation intensity. 3D Raman volume mapping and energy dispersive X-ray mapping confirm that the intensity-dependent irradiation process dictates the extent of phase separation, enabling single-parameter control over phase evolution and subsequent composite morphology. These observations can potentially enable a single-step route to develop polymer-inorganic composite materials with tunable morphologies.

Mechanochromic Fluorescent Polymers Enabled by AIE Processes

Polymeric materials are susceptible to the chain re-conformation, reorientation, slippage, and bond cleavage upon mechanical stimuli, which are likely to further grow into macro-damages and eventually lead to the compromise or loss of materials performance. Therefore, it is of great academic importance and practical significance to sensitively detect the local mechanical states in polymers and monitor the dynamic variations in polymer structures and properties under external forces. Mechanochromic fluorescent polymers (MFP) are a class of smart materials by utilizing sensitive fluorescent motifs to detect polymer chain events upon mechanical stimuli. Taking advantage of the unique aggregation-induced emission (AIE) effect, a variety of MFP systems that can self-report their mechanical states and mechano-induced structural and property changes through fluorescence signals have been developed. In this feature article, an overview of the recent progress on MFP systems enabled by AIE process is presented. The main design principles, including physically doping dispersed or microencapsulated AIE luminogens (AIEgens) into polymer matrix, chemically linking AIEgens in polymer backbones, and utilizing the clusterization-triggered emission of polymers containing nonconventional luminogens, are discussed with representative examples. Perspectives on the existing challenges and problems in this field are also discussed to guide future development.

Self-Organized Lattices of Nonlinear Optochemical Waves in Photopolymerizable Fluids: The Spontaneous Emergence of 3-D Order in a Weakly Correlated System

Many of the extraordinary three-dimensional architectures that pattern our physical world emerge from complex nonlinear systems or dynamic populations whose individual constituents are only weakly correlated to each other. Shoals of fish, murmuration behaviors in birds, congestion patterns in traffic, and even networks of social conventions are examples of spontaneous pattern formation, which cannot be predicted from the properties of individual elements alone. Pattern formation at a different scale has been observed or predicted in weakly correlated systems including superconductors, atomic gases near Bose Einstein condensation, and incoherent optical fields. Understanding pattern formation in nonlinear weakly correlated systems, which are often unified through mathematical expression, could pave intelligent self-organizing pathways to functional materials, architectures, and computing technologies. However, it is experimentally difficult to directly visualize the nonlinear dynamics of pattern formation in most populations-especially in three dimensions. Here, we describe the collective behavior of large populations of nonlinear optochemical waves, which are poorly correlated in both space and time. The optochemical waves-microscopic filaments of white light entrapped within polymer channels-originate from the modulation instability of incandescent light traveling in photopolymerizable fluids. By tracing the three-dimensional distribution of optical intensity in the nascent polymerizing system, we find that populations of randomly distributed, optochemical waves synergistically and collectively shift in space to form highly ordered lattices of specific symmetries. These, to our knowledge, are the first three-dimensionally periodic structures to emerge from a system of weakly correlated waves. Their spontaneous formation in an incoherent and effectively chaotic field is counterintuitive, but the apparent contradiction of known behaviors of light including the laws of optical interference can be explained through the soliton-like interactions of optochemical waves with nearest neighbors. Critically, this work casts fundamentally new insight into the collective behaviors of poorly correlated nonlinear waves in higher dimensions and provides a rare, accessible platform for further experimental studies of these previously unexplored behaviors. Furthermore, it defines a self-organization paradigm that, unlike conventional counterparts, could generate polymer microstructures with symmetries spanning all the Bravais lattices.

Polymer Encapsulants Incorporating Light-Guiding Architectures to Increase Optical Energy Conversion in Solar Cells

The fabrication of a new type of solar cell encapsulation architecture comprising a periodic array of step-index waveguides is reported. The materials are fabricated through patterning with light in a photoreactive binary blend of crosslinking acrylate and urethane, wherein phase separation induces the spontaneous, directed formation of broadband, cylindrical waveguides. This microstructured material efficiently collects and transmits optical energy over a wide range of entry angles. Silicon solar cells comprising this encapsulation architecture show greater total external quantum efficiencies and enhanced wide-angle light capture and conversion. This is a rapid, straightforward, and scalable approach to process light-collecting structures, whereby significant increases in cell performance may be achieved.

Superhydrophobic Microporous Substrates via Photocuring: Coupling Optical Pattern Formation to Phase Separation for Process-Tunable Pore Architectures

We present a new approach to synthesize microporous surfaces through the combination of photopolymerization-induced phase separation and light pattern formation in photopolymer-solvent mixtures. The mixtures are irradiated with a wide-area light pattern consisting of high and low intensity regions. This light pattern undergoes self-focusing and filamentation, thereby preserving its spatial profile through the mixture. Over the course of irradiation, the mixture undergoes phase separation, with the polymer and solvent located in the bright and dark regions of the light profile, respectively, to produce a binary phase morphology with a congruent arrangement as the optical pattern. A congruently arranged microporous structure is attained upon solvent removal. The microporous surface structure can be varied by changing the irradiating light profile via photomask design. The porous architecture can be further tuned through the relative weight fractions of photopolymer and solvent in the mixture, resulting in porosities ranging from those with discrete and uniform pore sizes to hierarchical pore distributions. All surfaces become superhydrophobic (water contact angles >150°) when spray-coated with a thin layer of polytetrafluoroethylene nanoparticles. The water contact angles can be enhanced by changing the surface porosity via the processing conditions. This is a scalable and tunable approach to precisely control microporous surface structure in thin films to create functional surfaces and antiwetting coatings.

Coupling nonlinear optical waves to photoreactive and phase-separating soft matter: Current status and perspectives

Nonlinear optics and polymer systems are distinct fields that have been studied for decades. These two fields intersect with the observation of nonlinear wave propagation in photoreactive polymer systems. This has led to studies on the nonlinear dynamics of transmitted light in polymer media, particularly for optical self-trapping and optical modulation instability. The irreversibility of polymerization leads to permanent capture of nonlinear optical patterns in the polymer structure, which is a new synthetic route to complex structured soft materials. Over time more intricate polymer systems are employed, whereby nonlinear optical dynamics can couple to nonlinear chemical dynamics, opening opportunities for self-organization. This paper discusses the work to date on nonlinear optical pattern formation processes in polymers. A brief overview of nonlinear optical phenomenon is provided to set the stage for understanding their effects. We review the accomplishments of the field on studying nonlinear waveform propagation in photopolymerizable systems, then discuss our most recent progress in coupling nonlinear optical pattern formation to polymer blends and phase separation. To this end, perspectives on future directions and areas of sustained inquiry are provided. This review highlights the significant opportunity in exploiting nonlinear optical pattern formation in soft matter for the discovery of new light-directed and light-stimulated materials phenomenon, and in turn, soft matter provides a platform by which new nonlinear optical phenomenon may be discovered.