Correlating Nanostructure, Optical and Electronic Properties of Nanogranular Silver Layers during Polymer-Template-Assisted Sputter Deposition

Long-Range Uniform Deposition of Ag Nanoseed on Cu Current Collector for High-Performance Lithium Metal Batteries

Uniform lithium deposition is essential to hinder dendritic growth. Achieving this demands even seed material distribution across the electrode, posing challenges in correlating the electrode's surface structure with the uniformity of seed material distribution. In this study, the effect of periodic surface and facet orientation on seed distribution is investigated using a model system consisting of a wrinkled copper (Cu)/graphene structure with a [100] facet orientation. A new methodology is developed for uniformly distributed silver (Ag) nanoparticles over a large area by controlling the surface features of Cu substrates. The regularly arranged Ag nanoparticles, with a diameter of 26.4 nm, are fabricated by controlling the Cu surface condition as [100]-oriented wrinkled Cu. The wrinkled Cu guides a deposition site for spherical Ag nanoparticles, the [100] facet determines the Ag morphology, and the presence of graphene leads to spacings of Ag seeds. This patterned surface and high lithiophilicity, with homogeneously distributed Ag nanoparticles, lead to uniform Li+ flux and reduced nucleation energy barrier, resulting in excellent battery performance. The electrochemical measurements exhibit improved cyclic stability over 260 cycles at 0.5 mA cm-2 and 100 cycles at 1.0 mA cm-2 and enhanced kinetics even under a high current density of 5.0 mA cm-2.

Diblock copolymer pattern protection by silver cluster reinforcement

Pattern fabrication by self-assembly of diblock copolymers is of significant interest due to the simplicity in fabricating complex structures. In particular, polystyrene-block-poly-4-vinylpyridine (PS-b-P4VP) is a fascinating base material as it forms an ordered micellar structure on silicon surfaces. In this work, silver (Ag) is applied using direct current magnetron sputter deposition and high-power impulse magnetron sputter deposition on an ordered micellar PS-b-P4VP layer. The fabricated hybrid materials are structurally analyzed by field emission scanning electron microscopy, atomic force microscopy, and grazing incidence small angle X-ray scattering. When applying simple aqueous posttreatment, the pattern is stable and reinforced by Ag clusters, making micellar PS-b-P4VP ordered layers ideal candidates for lithography.

Lithography-Free, Large-Area Spatially Segmented Disordered Structure for Light Harvesting in Photovoltaic Modules

Optical losses in photovoltaic (PV) systems cause nonradiative recombination or incomplete absorption of incident light, hindering the attainment of high energy conversion efficiency. The surface of the PV cells is encapsulated to not only protect the cell but also control the transmission properties of the incident light to promote maximum conversion. Despite many advances in elaborately designed photonic structures for light harvesting, the complicated process and sophisticated patterning highly diminish the cost-effectiveness and further limit the mass production on a large scale. Here, we propose a robust/comprehensive strategy based on the hybrid disordered photonic structure, implementing multifaceted light harvesting with an affordable/scalable fabrication method. The spatially segmented structures include (i) nanostructures in the active area for antireflection and (ii) microstructures in the inactive edge area for redirecting the incident light into the active area. A lithography-free hybrid disordered structure fabricated by the thermal dewetting method is a facile approach to create a large-area photonic structure with hyperuniformity over the entire area. Based on the experimentally realized nano-/microstructures, we designed a computational model and performed an analytical calculation to confirm the light behavior and performance enhancement. Particularly, the suggested structure is manufactured by the elastomeric stamps method, which is affordable and profitable for mass production. The produced hybrid structure integrated with the multijunction solar cell presented an improved efficiency from 28.0 to 29.6% by 1.06 times.

Dynamic Color Display with Viewing-Angle Tolerance Based on the Responsive Asymmetric Fabry-Perot Cavity

At present, it remains challenging and desirable to prepare dynamic color-changing materials with wide viewing angles for practical applications. Herein, we proposed a responsive asymmetric metal-insulator-metal (MIM) Fabry-Perot resonance cavity to achieve dynamic color display with high viewing-angle tolerance. The responsive asymmetric MIM cavity is constructed with thermal-responsive poly(N-isopropyl acrylamide) (PNIPAm) brush as the mid-insulator layer sandwiched by two different metallic layers (Sn and Ag). The as-prepared MIM cavity shows both improved viewing-angle tolerance owing to the asymmetric architecture of the cavity and a wide tunable color gamut because of the thermal responsiveness of the mid PNIPAm layer. Remarkably, the as-prepared asymmetric MIM resonance cavity also possesses a relatively fast response rate and good repeatability. Together, with all these advantages, the proposed responsive asymmetric MIM cavity may open a new pathway to prepare high-performance color display material for future practical optical applications.

Correlating Optical Reflectance with the Topology of Aluminum Nanocluster Layers Growing on Partially Conjugated Diblock Copolymer Templates

Large-scale fabrication of metal cluster layers for usage in sensor applications and photovoltaics is a huge challenge. Physical vapor deposition offers large-scale fabrication of metal cluster layers on templates and polymer surfaces. In the case of aluminum (Al), only little is known about the formation and interaction of Al clusters during sputter deposition. Complex polymer surface morphologies can tailor the deposited Al cluster layer. Here, a poly(methyl methacrylate)-block-poly(3-hexylthiophen-2,5-diyl) (PMMA-b-P3HT) diblock copolymer template is used to investigate the nanostructure formation of Al cluster layers on the different polymer domains and to compare it with the respective homopolymers PMMA and P3HT. The optical properties relevant for sensor applications are monitored with ultraviolet-visible (UV-vis) measurements during the sputter deposition. The formation of Al clusters is followed in situ with grazing-incidence small-angle X-ray scattering (GISAXS), and the chemical interaction is revealed by X-ray photoelectron spectroscopy (XPS). Furthermore, atomic force microscopy (AFM) and field emission scanning electron microscopy (FESEM) yield topographical information about selective wetting of Al on the P3HT domains and embedding in the PMMA domains in the early stages, followed by four distinct growth stages describing the Al nanostructure formation.

Selective Deposition of Copper on Self-Assembled Block Copolymer Surfaces via Physical Vapor Deposition

Block copolymer (BCP) self-assembly produces chemically and topographically patterned surfaces which are used to guide the formation of Cu nanostructures by exploiting differences in the mobility of vapor-deposited species on each microdomain. Cu metal films a few nm thick were deposited on three different BCP surfaces self-assembled from poly(styrene-b-methyl methacrylate) (PS-b-PMMA) and polystyrene-b-poly(2-vinylpyridine) (PS-b-P2VP). For PS-b-PMMA, the effects of chemical heterogeneity dominate over the effects of the 2 nm peak-to-valley topography, and sputtered Cu preferentially wets the PS block. PS-b-P2VP has greater chemical and topographical contrast and shows a wider process window for selective deposition. Cu grown by evaporation has less surface mobility, and shadowing effects are believed to dominate pattern formation. The hierarchical self-assembly process of thin metal films on BCP surfaces provides a route to fabricating heterogeneous metallic nanostructures.

Solution-processable electrode-material embedding in dynamically inscribed nanopatterns (SPEEDIN) for continuous fabrication of durable flexible devices

A facile and scalable lithography-free fabrication technique, named solution-processable electrode-material embedding in dynamically inscribed nanopatterns (SPEEDIN), is developed to produce highly durable electronics. SPEEDIN uniquely utilizes a single continuous flow-line manufacturing process comprised of dynamic nanoinscribing and metal nanoparticle solution coating with selective embedding. Nano- and/or micro-trenches are inscribed into arbitrary polymers, and then an Ag nanoparticle solution is dispersed, soft-baked, doctor-bladed, and hard-baked to embed Ag micro- and nanowire structures into the trenches. Compared to lithographically embossed metal structures, the embedded SPEEDIN architectures can achieve higher durability with comparable optical and electrical properties and are robust and power-efficient even under extreme stresses such as scratching and bending. As one tangible application of SPEEDIN, we demonstrate a flexible metal electrode that can operate at 5 V at temperatures up to 300 °C even under the influence of harsh external stimuli. SPEEDIN can be applied to the scalable fabrication of diverse flexible devices that are reliable for heavy-duty operation in harsh environments involving high temperatures, mechanical deformations, and chemical hazards.

Surface plasmonic resonance tunable nanocomposite thin films applicable to color filters, heat mirrors, semi-transparent electrodes, and electromagnetic-shields

This study proposes a plasmonic resonance-tunable nanocomposite thin film, which applies to a color filter, heat mirror, semi-transparent color electrode, and electromagnetic shield, given that the size and structure of nanoclusters can be controlled by a sputtering power density. The structural and functional properties of silver/plasma-polymer-fluorocarbon (Ag/PPFC) nanocomposite thin films, which were sputtered by ternary composite targets, were investigated with various compositions and sputtering power densities. The growth of Ag nanoclusters of the thin film was suppressed as the sputtering power density increased due to the rich functional group of -CF_x- fluorine. As a result, a continuous color change from blue to yellow could be expressed on films given the precise control of the surface plasmonic resonance phenomenon. Grazing-incidence small-angle scattering (GISAXS) analysis indicated that the sputtering power density had a significant effect on the size, distribution, and orientation of the Ag nanoclusters in the thin film. For low sputtering power densities, Ag nanoclusters were forming aggregations along the out-of-plane direction, but as the sputtering power density increased, the nanoclusters showed random distribution instead of large aggregates. We also demonstrated applications of Ag/PPFC nanocomposite thin films to a color filter, heat mirror, semi-transparent electrode, and electromagnetic shield. In addition, the fabrication of a large-area film (400 × 700 mm²) showed that the approach applies highly to industries.

Revealing the growth of copper on polystyrene-block-poly(ethylene oxide) diblock copolymer thin films with in situ GISAXS

Copper (Cu) as an excellent electrical conductor and the amphiphilic diblock copolymer polystyrene-block-poly(ethylene oxide) (PS-b-PEO) as a polymer electrolyte and ionic conductor can be combined with an active material in composite electrodes for polymer lithium-ion batteries (LIBs). As interfaces are a key issue in LIBs, sputter deposition of Cu contacts on PS-b-PEO thin films with high PEO fraction is investigated with in situ grazing-incidence small-angle X-ray scattering (GISAXS) to follow the formation of the Cu layer in real-time. We observe a hierarchical morphology of Cu clusters building larger Cu agglomerates. Two characteristic distances corresponding to the PS-b-PEO microphase separation and the Cu clusters are determined. A selective agglomeration of Cu clusters on the PS domains explains the origin of the persisting hierarchical morphology of the Cu layer even after a complete surface coverage is reached. The spheroidal shape of the Cu clusters growing within the first few nanometers of sputter deposition causes a highly porous Cu-polymer interface. Four growth stages are distinguished corresponding to different kinetics of the cluster growth of Cu on PS-b-PEO thin films: (I) nucleation, (II) diffusion-driven growth, (III) adsorption-driven growth, and (IV) grain growth of Cu clusters. Percolation is reached at an effective Cu layer thickness of 5.75 nm.

Tailoring the Optical Properties of Sputter-Deposited Gold Nanostructures on Nanostructured Titanium Dioxide Templates Based on In Situ Grazing-Incidence Small-Angle X-ray Scattering Determined Growth Laws

Gold/titanium dioxide (Au/TiO₂) nanohybrid materials have been widely applied in various fields because of their outstanding optical and photocatalytic performance. By state-of-the-art polymer templating, it is possible to make uniform nanostructured TiO₂ layers with potentially large-scale processing methods. We use customized polymer templating to achieve TiO₂ nanostructures with different morphologies. Au/TiO₂ hybrid thin films are fabricated by sputter deposition. An in-depth understanding of the Au morphology on the TiO₂ templates is achieved with in situ grazing-incidence small-angle X-ray scattering (GISAXS) during the sputter deposition. The resulting Au nanostructure is largely influenced by the TiO₂ template morphology. Based on the detailed understanding of the Au growth process, characteristic distances can be selected to achieve tailored Au nanostructures at different Au loadings. For selected sputter-deposited Au/TiO₂ hybrid thin films, the optical response with a tailored localized surface plasmon resonance is demonstrated.

Real-time insight into nanostructure evolution during the rapid formation of ultra-thin gold layers on polymers

Ultra-thin metal layers on polymer thin films attract tremendous research interest for advanced flexible optoelectronic applications, including organic photovoltaics, light emitting diodes and sensors. To realize the large-scale production of such metal-polymer hybrid materials, high rate sputter deposition is of particular interest. Here, we witness the birth of a metal-polymer hybrid material by quantifying in situ with unprecedented time-resolution of 0.5 ms the temporal evolution of interfacial morphology during the rapid formation of ultra-thin gold layers on thin polystyrene films. We monitor average non-equilibrium cluster geometries, transient interface morphologies and the effective near-surface gold diffusion. At 1 s sputter deposition, the polymer matrix has already been enriched with 1% gold and an intermixing layer has formed with a depth of over 3.5 nm. Furthermore, we experimentally observe unexpected changes in aspect ratios of ultra-small gold clusters growing in the vicinity of polymer chains. For the first time, this approach enables four-dimensional insights at atomic scales during the gold growth under non-equilibrium conditions.

Time-Resolved Morphology and Kinetic Studies of Pulsed Laser Deposition-Grown Pt Layers on Sapphire at Different Growth Temperatures by in Situ Grazing Incidence Small-Angle X-ray Scattering

Optimizing and monitoring the growth conditions of Pt films, often used as bottom electrodes in multiferroic material systems, represents a highly relevant issue that is of importance for controlling the crystalline quality and performance of ferroelectric oxides such as, e.g. LuFeO₃. We performed a time-resolved monitoring of the growth and morphology of Pt films during pulsed laser deposition (PLD) in dependence on the grown film effective thickness and on the growth temperature Tg using in situ grazing incidence small-angle X-ray scattering (GISAXS). Through real-time analysis and modeling of GISAXS patterns, we could fully characterize the influence of Tg on the morphology and on the growth kinetics of the Pt layers. Consequently, critical and characteristic effective thicknesses for the transitions nucleation phase (I)/coalescence phase (II) and coalescence phase (II)/coarsening phase (III) could be determined. In combination with complementary microscopic imaging and chemical mapping via combined SEM/EDXS, we demonstrate the occurrence of a morphological progression in the Pt PLD-grown Pt films, changing from grains at room temperature to a 3D-island morphology at 300 °C, further to a hole-free structure at 500 °C, and finally to a channel structure for 700 and 900 °C. The film topography, as characterized by atomic force microscopy (AFM), favors the PLD growth of Pt layers at temperatures beyond 700 °C where the film is homogeneous, continuous, and hole-free with a flat and smooth surface. The double dependency of the percolation transition on the film effective thickness and on the growth temperature has been established by measuring the electrical conductivity.

Chemical Interactions at the Al/Poly-Epoxy Interface Rationalized by DFT Calculations and a Comparative XPS Analysis

A metal-polymer interface is pertinent to numerous technological applications, especially in spatial sectors. The focus of this work is to elaborate on the metallization process of the poly-epoxy surface with aluminum thin films, using atomistic details. To this end, X-ray photoelectron spectroscopy (XPS) under ultrahigh vacuum and density functional theory calculations are employed. The interfacial bonding between Al atoms and the poly-epoxide surface, represented by a dimer model, is studied by determining adsorption energies and by simulating XPS spectra. The latter simulations are mainly performed using the ΔKS method, taking into account the initial and the final state effects. Simulated atom-by-atom metal deposition on model epoxy systems is attempted to further elucidate energetics of metallization and preferential arrangement of metal atoms at the interface. A fair agreement obtained between XPS experiments and computations rationalizes the interaction mechanism at the atomic scale explaining the formation of the Al/poly-epoxy interface. Electronic structure properties highlight the charge transfer from the Al atom(s) to dehydrogenated model epoxy system.

In situ Grazing-Incidence Small-Angle X-ray Scattering Observation of Gold Sputter Deposition on a PbS Quantum Dot Solid

For PbS quantum dot (QD)-based optoelectronic devices, gold is the most frequently used electrode material. In most device architectures, gold is in direct contact with the QD solid. To better understand the formation of the interface between gold and a close-packed QD layer at an early stage, in situ grazing-incidence small-angle X-ray scattering is used to observe the gold sputter deposition on a 1,2-ethanedithiol (EDT)-treated PbS QD solid. In the kinetics of gold layer growth, the forming and merging of small gold clusters (radius less than 1.6 nm) are observed at the early stages. The thereby formed medium gold clusters (radius between 1.9-2.4 nm) are influenced by the QDs' templating effect. Furthermore, simulations suggest that the medium gold clusters grow preferably along the QDs' boundaries rather than as a top coating of the QDs. When the thickness of the sputtered gold layer reaches 6.25 nm, larger gold clusters with a radius of 5.3 nm form. Simultaneously, a percolation layer with a thickness of 2.5 nm is established underneath the gold clusters. This fundamental understanding of the QD-gold interface formation will help to control the implementation of sputtered gold electrodes on close-packed QD solids in device manufacturing processes.

Ultrafast Photoinduced Interconnection of Metal-Polymer Composites for Fabrication of Transparent and Stretchable Electronic Skins

The high interest sparked by the foldable smartphones recently released on the market is gradually shifting to the next generation of flexible electronic devices, such as electronic skins in the form of stretchable thin films. To develop such devices, good mechanical flexibility of all components (including the substrate, electrode, and encapsulant) is critical. Various technologies have been developed to enhance the flexibility of these components; however, progress in developing interconnection methods for flexible and stretchable devices has been limited. Here, we developed an ultrafast photoinduced interconnection method that does not require any adhesive or surface treatment. This method is based on heating metal nanostructures using intense pulsed light (IPL) and the reversible cross-linking of polymers. First, we synthesized a stretchable, transparent, and free-standing polymer substrate that can be reversibly cross-linked, and then Ag nanowire (AgNW) networks were formed on its surface. This electrode was irradiated with IPL, which locally heated the AgNWs, followed by decomposition of the polymer via the retro-Diels-Alder reaction and recross-linking. Independently fabricated AgNW/polymer films were layered and irradiated three times with IPL to form a bonded sample with excellent joint quality and no increase in electrical resistance compared to a single electrode. Furthermore, the interconnected electrodes were stretchable and optically transparent. Even when more than 200% strain was applied in a peel test, no breakage at the joint was observed. This allowed us to successfully produce a stretchable, transparent, and bending-insensitive pressure sensor for various applications such as motion detectors or pressure sensor arrays.

A novel dry-blending method to reduce the coefficient of thermal expansion of polymer templates for OTFT electrodes

Among the patterning technologies for organic thin-film transistors (OTFTs), the fabrication of OTFT electrodes using polymer templates has attracted much attention. However, deviations in the electrode alignment occur because the coefficient of thermal expansion (CTE) of the polymer template is much higher than the CTE of the dielectric layer. Here, a novel dry-blending method is described in which SiO₂ nanoparticles are filled into a grooved silicon template, followed by permeation of polydimethylsiloxane (PDMS) into the SiO₂ nanoparticle gaps. The SiO₂ nanoparticles in the groove are extracted by curing and peeling off PDMS to prepare a PDMS/SiO₂ composite template with a nanoparticle content of 83.8 wt %. The composite template has a CTE of 96 ppm/°C, which is a reduction by 69.23% compared with the original PDMS template. Finally, we achieved the alignment of OTFT electrodes using the composite template.

Hydrochromic Smart Windows to Remove Harmful Substances by Mimicking Medieval European Stained Glasses

Medieval European stained glass windows are known to display various splendid colors and remove harmful airborne substances. At present, the functions of medieval stained glass windows are imperative, from the environment, health, and energy perspectives, to develop multi-functional windows that report/control environmental conditions and remove harmful substances by utilizing visible-near-infrared light sources. Here, we suggest a strategy to mimic medieval European stained glasses for devising plasmonic-based multi-functional smart stained glass windows. The stained glass windows are prepared from the deposition of gold nanoparticles on a glass that is preliminarily coated with a responsive colloidal nanosheet. The temperature responsiveness of the nanosheet enables the effective control the gold nanoparticle density of the stained glasses. Therefore, the windows can display blue, violet, and cranberry colors. The colors become iridescent by introducing a photonic crystal monolayer. The stained glass windows are hydrochromic: they switch the colors (blue ↔ cranberry) and modulate light transmittance depending on humidity conditions. Moreover, they can remove formaldehyde under the illumination of a low-power indoor light. These functions provide a new platform for the futuristic smart windows that clean indoor air for the human health and save energy.

Following in Situ the Deposition of Gold Electrodes on Low Band Gap Polymer Films

Metal top electrodes such as gold are widely used in organic solar cells. The active layer can be optimized by modifications of the polymer band gap via side-chain engineering, and low band gap polymers based on benzodithiophene units such as PTB7 and PTB7-Th are successfully used. The growth of gold contacts on PTB7 and PTB7-Th films is investigated with in situ grazing incidence small-angle X-ray scattering (GISAXS) and grazing incidence wide-angle X-ray scattering (GIWAXS) during the sputter deposition of gold. From GIWAXS, the crystal structure of the gold film is determined. Independent of the type of side chain, gold crystals form in the very early stages and improve in quality during the sputter deposition until the late stages. From GISAXS, the nanoscale structure is determined. Differences in terms of gold cluster size and growth phase limits for the two polymers are caused by the side-chain modification and result in a different surface coverage in the early phases. The changes in the diffusion and coalescence behavior of the forming gold nanoparticles cause differences in the morphology of the gold contact in the fully percolated regime, which is attributed to the different amount of thiophene rings of the side chains acting as nucleation sites.

Dynamic Tunable Color Display Based on Metal-Insulator-Metal Resonator with Polymer Brush Insulator Layer as Signal Transducer

Dynamic color-changing nanomaterials have been widely investigated for applications in fields like optical sensors, wearable activity monitors, smart electronic devices, and anticounterfeiting materials due to the excellent ability to change their optical properties with external variation. Here, a simple metal-insulator-metal (MIM) trilayer Fabry-Perot resonance cavity with a poly(N-isopropylacrylamide) (PNIPAm) brush layer as a responsive element is reported as a thermal-induced colorimetric response platform. The dynamic changes of conformation and physical properties of PNIPAm brush layer in response to external signals give rise to a significant color change of the MIM Fabry-Perot resonance cavity. This MIM Fabry-Perot resonance cavity shows the advantages of dynamic color change, rapid response, good repeatability, and simple construction. Additionally, the as-prepared MIM cavity shows great potential in various applications such as color printing, multicolor indicator, and information anticounterfeiting.