Swelling of lamellar diblock copolymer by homopolymer: influences of homopolymer concentration and molecular weight

Chain Redistribution Stabilizes Coexistence Phases in Block Copolymer Blends

The nanoscale morphologies of block copolymer (BCP) thin films are determined by chain architecture. Experimental studies of thin film blends of different BCP chain types have demonstrated that blending can stabilize new motifs, such as coexistence phases. Here, we deploy coarse-grained molecular dynamics (MD) simulations in order to better understand the self-assembly behavior of BCP blend thin films. We consider blends of lamella- and cylinder-forming BCP chains, studying their morphological makeup, the chain distribution within the morphology, and the underlying polymer chain conformations. Our simulations show that there are local concentration deviations at the scale of the morphological objects that dictate the local structure, and that BCP chains redistribute within the morphology so as to stabilize the structure. Underlying these effects are measurable distortions in the BCP chain conformations. The conformational freedom afforded by BCP blending stabilizes defects and allows coexistence phases to appear, while also leading to kinetic trapping effects. These results highlight the power of blending in designing the morphology that forms.

Orbital Angular Momentum from Self-Assembled Concentric Nanoparticle Rings

Ring-shaped nanostructures can focus, filter, and manipulate electromagnetic waves, but are challenging to incorporate into devices using standard nanofabrication techniques. Directed self-assembly (DSA) of block copolymers (BCPs) on lithographically patterned templates has successfully been used to fabricate concentric rings and spirals as etching masks. However, this method is limited by BCP phase behavior and material selection. Here, a straightforward approach to generate ring-shaped nanoparticle assemblies in thin films of supramolecular nanocomposites is demonstrated. DSA is used to guide the formation of concentric rings with radii spanning 150-1150 nm and ring widths spanning 30-60 nm. When plasmonic nanoparticles are used, ring nanodevice arrays can be fabricated in one step, and the completed devices produce high-quality orbital angular momentum (OAM). Nanocomposite DSA simplifies and streamlines nanofabrication by producing metal structures without etching or deposition steps; it also introduces interparticle coupling as a new design axis. Detailed analysis of the nanoparticle ring assemblies confirms that the supramolecular system self-regulates the spatial distribution of its components, and thus exhibits a degree of flexibility absent in DSA of BCPs alone, where structures are determined by polymer-pattern incommensurability. The present studies also provide guidelines for developing self-regulating DSA as an alternative to incommensurability-driven methods.

High-throughput morphology mapping of self-assembling ternary polymer blends

Multicomponent blending is a convenient yet powerful approach to rationally control the material structure, morphology, and functional properties in solution-deposited films of block copolymers and other self-assembling nanomaterials. However, progress in understanding the structural and morphological dependencies on blend composition is hampered by the time and labor required to synthesize and characterize a large number of discrete samples. Here, we report a new method to systematically explore a wide composition space in ternary blends. Specifically, the blend composition space is divided into gradient segments deposited sequentially on a single wafer by a new gradient electrospray deposition tool, and characterized using high-throughput grazing-incidence small-angle X-ray scattering. This method is applied to the creation of a ternary morphology diagram for a cylinder-forming polystyrene-block-poly(methyl methacrylate) (PS-b-PMMA) block copolymer blended with PS and PMMA homopolymers. Using “wet brush” homopolymers of very low molecular weight (∼1 kg mol⁻¹), we identify well-demarcated composition regions comprising highly ordered cylinder, lamellae, and sphere morphologies, as well as a disordered phase at high homopolymer mass fractions. The exquisite granularity afforded by this approach also helps to uncover systematic dependencies among self-assembled morphology, topological grain size, and domain period as functions of homopolymer mass fraction and PS : PMMA ratio. These results highlight the significant advantages afforded by blending low molecular weight homopolymers for block copolymer self-assembly. Meanwhile, the high-throughput, combinatorial approach to investigating nanomaterial blends introduced here dramatically reduces the time required to explore complex process parameter spaces and is a natural complement to recent advances in autonomous X-ray characterization.

Compositionally graded electrospray deposition combined with grazing incidence small angle X-ray scattering forms a high-throughput approach for mapping phase behavior in ternary mixtures as demonstrated here using block copolymer blends.

Nanostructured Polymer Monoliths for Biomedical Delivery Applications

Drug delivery systems are designed to control the release rate and location of therapeutic agents in the body to achieve enhanced drug efficacy and to mitigate adverse side effects. In particular, drug-releasing implants provide sustained and localized release. We report nanostructured polymer monoliths synthesized by polymerization-induced microphase separation (PIMS) as potential implantable delivery devices. As a model system, free poly(ethylene oxide) homopolymers were incorporated into the nanoscopic poly(ethylene oxide) domains contained within a cross-linked polystyrene matrix. The in vitro release of these poly(ethylene oxide) molecules from monoliths was investigated as a function of poly(ethylene oxide) loading and molar mass as well as the molar mass and weight fraction of poly(ethylene oxide) macro-chain transfer agent used in the PIMS process for forming the monoliths. We also developed nanostructured microneedles targeting efficient and long-term transdermal drug delivery by combining PIMS and microfabrication techniques. Finally, given the prominence of poly(lactide) in drug delivery devices, the degradation rate of microphase-separated poly(lactide) in PIMS monoliths was evaluated and compared with bulk poly(lactide).

Emergence of a C15 Laves Phase in Diblock Polymer/Homopolymer Blends

The observation of complex, Frank-Kasper (FK) particle packings in diblock polymer melts has until recently been limited to low molecular weight, conformationally asymmetric polymers. We report temperature-dependent small-angle X-ray scattering (SAXS) studies of blends of a sphere-forming poly(styrene-block-1,4-butadiene) (SB) diblock polymer (M_n = 33.3 kg/mol, Đ = M_w/M_n = 1.08, f_B = 0.18) with two different poly(1,4-butadiene) (B) homopolymer additives. When the B additive M_n is the same as that of the diblock core-forming B segment, these blends remarkably form tetrahedrally close-packed FK σ and Laves C14 and C15 phases with increasing B content. However, binary blends in which the B additive M_n is 60% of that of the diblock B segment form only the canonical body-centered cubic (BCC) particle packing and hexagonally-packed cylinders (HEXc). The observed phase behavior is rationalized in terms of "wet" and "dry" brush blending, whereby higher B M_n drives stronger localization of the homopolymer in the particle cores while preserving the interfacial area per SB diblock chain. The consequent packing constraints in these blends destabilize the BCC packing, and FK phases emerge as optimal minimal surface solutions to filling space at constant density while maximizing local particle sphericity.

Role of Defects in Achieving Highly Asymmetric Lamellar Self-Assembly in Block Copolymer/Homopolymer Blends

Lamellar structure is a prominent state in soft condensed matter. Swelling lamellar layers to highly asymmetric structures by a second component is a facile, cost-effective strategy to impart materials with adaptive size and tunable properties. One key question that remains unsolved is how defects form and affect the asymmetric lamellar order. This study unravels the role of defects by swelling a miktoarm block copolymer with a homopolymer. Ordered lamellae first lose translational order by a significant increase in the number of dislocations and then lose orientational order by the generation of disclinations. The homopolymers are not uniformly distributed in defective lamellae and primarily segregate in the vicinity of disclination cores. The free energy of defects is mainly contributed by molecular splay and significantly alleviated by an increased radius of local curvature. This study provides direct evidence to reveal the role of defects and lamellar order in block copolymer/homopolymer blends and also sheds light on understanding analogous structural transitions in other soft systems, including lyotropic liquid crystals, phospholipid membranes, and polymer nanocomposites.

The Influence of Additives on the Interfacial Width and Line Edge Roughness in Block Copolymer Lithography

The challenges of patterning next generation integrated circuits have driven the semiconductor industry to look outside of traditional lithographic methods in order to continue cost effective size scaling. The directed self-assembly (DSA) of block copolymers (BCPs) is a nanofabrication technique used to reduce the periodicity of patterns prepared with traditional optical methods. BCPs with large interaction parameters (χ eff), provide access to smaller pitches and reduced interface widths. Larger χ eff is also expected to be correlated with reduced line edge roughness (LER), a critical performance parameter in integrated circuits. One approach to increasing χ eff is blending the BCP with a phase selective additive, such as an Ionic liquid (IL). The IL does not impact the etching rates of either phase, and this enables a direct interrogation of whether the change in interface width driven by higher χ eff translates into lower LER. The effect of the IL on the layer thickness and interface width of a BCP are examined, along with the corresponding changes in LER in a DSA patterned sample. The results demonstrate that increased χ eff through additive blending will not necessarily translate to a lower LER, clarifying an important design criterion for future material systems.

Precise control of grafting density in periodically grafted amphiphilic copolymers: an alternate strategy to fine-tune the lamellar spacing in the sub-10 nm regime

By exactly locating pendant PEG550 segments at varying intervals along a hydrocarbon-rich polyester backbone, the lamellar dimension has been precisely tuned.

Widely tunable persistent micelle templates via homopolymer swelling

The combination of precision control with wide tunability remains a challenge for the fabrication of porous nanomaterials suitable for studies of nanostructure-behavior relationships. Polymer micelle templates broadly enable porous materials, however micelle equilibration hampers independent pore and wall size control. Persistent micelle templates (PMT) have emerged as a kinetic controlled platform that uniquely decouples the control of pore and wall dimensions. Here, chain exchange is inhibited to preserve a constant template dimension (pore size) despite the shifting equilibrium while materials are added between micelles. Early PMT demonstrations were synthesis intensive with limited 1-1.3× pore size tuning for a given polymer. Here we demonstrate PMT swelling with homopolymer enables 1-3.2× (13.3-41.9 nm) pore size variation while maintaining a monomodal distribution with up to 250 wt% homopolymer, considerably higher than the ∼90 wt% limit found for equilibrating micelles. These swollen PMTs enabled nanomaterial series with constant pore size and precision varied wall-thickness. Kinetic size control here is unexpected since the homopolymer undergoes dynamic exchange between micelles. The solvent selection influenced the time window before homopolymer phase separation, highlighting the importance of considering homopolymer-solvent interactions. This is the first PMT demonstration with wide variation of both the pore and wall dimensions using a single block polymer. Lastly this approach was extended to a 72 kg mol^-1 block polymer to enable a wide 50-290 nm range of tunable macropores. Here the use of just two different block polymers and one homopolymer enabled wide ranging pore sizes spanning from 13.3-290 nm (1-22×).

Influence of Homopolymer Addition in Templated Assembly of Cylindrical Block Copolymers

Templated assembly of cylindrical block copolymers provides a promising strategy for patterning holes at the nanoscale. However, remaining challenges include the ability to achieve defect-free patterns and to generate architectures useful for device patterning. The aim of this work is to gain insight into the influence of homopolymer addition on the assembly of a cylindrical block copolymer in confined space. To do so, a concerted examination that relies on experiments and simulations is carried out for different block copolymer/homopolymer blends. It is shown that by adding a majority block homopolymer with low molecular weight (compared to the blocks that make up the block copolymer), the pattern quality is significantly improved and a larger defect-free window is obtained in terms of template dimensions for two-hole features in elliptical confinements. The redistribution of the homopolymer chains effectively enables the assembly of two cylinders, despite the geometrical mismatch between the elliptical shape of the confinement and the natural hexagonal ordering of the unguided block copolymer. Monte Carlo simulations show that the homopolymer segregates to the spaces in the template that are entropically unfavorable for the block copolymer. This work serves to highlight the importance of optimizing block copolymer formulation.

Rapid Production of Internally Structured Colloids by Flash Nanoprecipitation of Block Copolymer Blends

Colloids with internally structured geometries have shown great promise in applications ranging from biosensors to optics to drug delivery, where the internal particle structure is paramount to performance. The growing demand for such nanomaterials necessitates the development of a scalable processing platform for their production. Flash nanoprecipitation (FNP), a rapid and inherently scalable colloid precipitation technology, is used to prepare internally structured colloids from blends of block copolymers and homopolymers. As revealed by a combination of experiments and simulations, colloids prepared from different molecular weight diblock copolymers adopt either an ordered lamellar morphology consisting of concentric shells or a disordered lamellar morphology when chain dynamics are sufficiently slow to prevent defect annealing during solvent exchange. Blends of homopolymer and block copolymer in the feed stream generate more complex internally structured colloids, such as those with hierarchically structured Janus and patchy morphologies, due to additional phase separation and kinetic trapping effects. The ability of the FNP process to generate such a wide range of morphologies using a simple and scalable setup provides a pathway to manufacturing internally structured colloids on an industrial scale.

Highly functional ellipsoidal block copolymer nanoparticles: a generalized approach to nanostructured chemical ordering in phase separated colloidal particles

Spatially controlled introduction of chemical functionalities into ellipsoidal block copolymer nanoparticles is achieved through pre- and post-assembly strategies.

Rapid Ordering in "Wet Brush" Block Copolymer/Homopolymer Ternary Blends

The ubiquitous presence of thermodynamically unfavored but kinetically trapped topological defects in nanopatterns formed via self-assembly of block copolymer thin films may prevent their use for many envisioned applications. Here, we demonstrate that lamellae patterns formed by symmetric polystyrene-block-poly(methyl methacrylate) diblock copolymers self-assemble and order extremely rapidly when the diblock copolymers are blended with low molecular weight homopolymers of the constituent blocks. Being in the "wet brush" regime, the homopolymers uniformly distribute within their respective self-assembled microdomains, preventing increases in domain widths. An order-of-magnitude increase in topological grain size in blends over the neat (unblended) diblock copolymer is achieved within minutes of thermal annealing as a result of the significantly higher power law exponent for ordering kinetics in the blends. Moreover, the blends are demonstrated to be capable of rapid and robust domain alignment within micrometer-scale trenches, in contrast to the corresponding neat diblock copolymer. These results can be attributed to the lowering of energy barriers associated with domain boundaries by bringing the system closer to an order-disorder transition through low molecular weight homopolymer blending.

Domain swelling in ARB-type triblock copolymers via self-adjusting effective dispersity

We investigated the domain spacing of an ordered structure formed by polydisperse ARB-type triblock copolymers (triBCPs) with random middle R blocks consisting of A and B monomers. ARB-type triBCPs were synthesized via reversible addition-fragmentation chain transfer (RAFT) polymerization, and the dispersities of all samples were controlled as narrow as ∼1.2. From the bulk and film morphologies, it was found that the domain swelling increases as the content of middle R blocks increases, which implies that the middle R block even with a small content plays a critical role in dilating the domain spacing. Since the random middle R blocks are energetically neutral, they can be segregated into either A or B blocks. The strong stretching theory (SST) suggests that the dispersities of the resulting constituent blocks are maximized to reduce the elastic energy associated with chain stretching, thereby leading to the dilation of domain spacing.

Manipulating the ABCs of self-assembly via low-χ block polymer design

Block polymer self-assembly typically translates molecular chain connectivity into mesoscale structure by exploiting incompatible blocks with large interaction parameters (χ_ij). In this article, we demonstrate that the converse approach, encoding low-χ interactions in ABC bottlebrush triblock terpolymers (χ_AC [Formula: see text] 0), promotes organization into a unique mixed-domain lamellar morphology, which we designate LAM_P Transmission electron microscopy indicates that LAM_P exhibits ACBC domain connectivity, in contrast to conventional three-domain lamellae (LAM₃) with ABCB periods. Complementary small-angle X-ray scattering experiments reveal a strongly decreasing domain spacing with increasing total molar mass. Self-consistent field theory reinforces these observations and predicts that LAM_P is thermodynamically stable below a critical χ_AC, above which LAM₃ emerges. Both experiments and theory expose close analogies to ABA' triblock copolymer phase behavior, collectively suggesting that low-χ interactions between chemically similar or distinct blocks intimately influence self-assembly. These conclusions provide fresh opportunities for block polymer design with potential consequences spanning all self-assembling soft materials.

Fabrication of Two-Dimensional Arrays of Diameter-Tunable PS-b-P2VP Nanowires at the Air/Water Interface

Composite thin films with well-defined and parallel nanowires were fabricated from the binary blends of a diblock copolymer polystyrene-block-poly(2-vinylpyridine) (PS-b-P2VP) and several homopolystyrenes (h-PSs) at the air/liquid interface through a facile technique, which involves solution self-assembly, interface adsorption, and further self-organization processes. It was confirmed that the nanowires that appeared at the air/water interface came from the cylindrical micelles formed in solution. Interestingly, the diameters of the nanowires are uniform and can be tuned precisely from 45 to 247 nm by incorporating the h-PS molecules into the micellar core. This parallel alignment of the nanowires has potential applications in optical devices and enables the nanowires to be used as templates to prepare functional nanostructures. The extent to which h-PS molecules with different molecular weights are able to influence the diameter control of the nanowires was also systematically investigated.

Development of polycarbonate-containing block copolymers for thin film self-assembly applications

High quality block copolymers are needed for thin film self-assembly and directed self-assembly applications.

Morphology Control of Poly(styrene-block-dimethylsiloxane) by Simple Blending with Trimethylsilylated Silicate Nanoparticles

Trimethylsilylated silicate nanoparticle (termed MQ resin, combining M Me3SiO1/2 and Q SiO4/2 units)/poly(styrene-block-polydimethylsiloxane) (PS-PDMS, 31K-15K, polydispersity PD = 1.15, weight-average molecular weight Mw = 45.5K) blends behave similarly to block copolymers with different PS/PDMS ratios. MQ is localized in the PDMS phase virtually extending the volume fraction in the block copolymer. This allows for microdomain morphology control beyond what can be achieved with the starting block copolymer. Synthesizing siloxane-containing block copolymers targeted at certain equilibrium morphologies can be time-consuming and in some cases technically challenging. This work shows that MQ is a robust morphology modifier, not limited by the occurrence of surface segregation and the high diffusion rates typically associated with homopolymer modification, as confirmed by looking at the PDMS/PS-PDMS reference. The convenient and robust structure control MQ nanoparticle modification of PS-PDMS provides could overcome one of the hurdles to adoption of block copolymer lithography.

Reduction and control of domain spacing by additive inclusion: morphology and orientation effects of glycols on microphase separated PS-b-PEO

Cylindrical phase polystyrene-b-polyethylene oxide (PS-b-PEO) block copolymer (BCP) was combined with lower molecular weight poly/ethylene glycols at different concentrations and their effect on the microphase separation of BCP thin films were studied. Well-ordered microphase separated, periodic nanostructures were realized using a solvent annealing approach for solution cast thin films. By optimizing solvent exposure time, the nature and concentration of the additives etc. the morphology and orientation of the films can be controlled. The addition of the glycols to PS-b-PEO enables a simple method by which the microdomain spacing of the phase separated BCP can be controlled at dimensions below 50 nm. Most interestingly, the additives results in an expected increase in domain spacing (i.e. pitch size) but in some conditions an unexpected reduction in domain spacing. The pitch size achieved by modification is in the range of 16-31 nm compared to an unmodified BCP system which exhibits a pitch size of 25 nm. The pitch size modification achieved can be explained in terms of chemical structure, solubility parameters, crystallinity and glass transition temperature of the PEO because the additives act as PEO 'stress cracking agents' whereas the PS matrix remains chemically unaffected.

Binary Polymer Brushes of Strongly Immiscible Polymers

The phenomenon of microphase separation is an example of self-assembly in soft matter and has been observed in block copolymers (BCPs) and similar materials (i.e., supramolecular assemblies (SMAs) and homo/block copolymer blends (HBCs)). In this study, we use microphase separation to construct responsive polymer brushes that collapse to generate periodic surfaces. This is achieved by a chemical reaction between the minor block (10%, poly(4-vinylpyridine)) of the block copolymer and a substrate. The major block of polystyrene (PS) forms mosaic-like arrays of grafted patches that are 10-20 nm in size. Depending on the nature of the assembly (SMA, HBC, or neat BCP) and annealing method (exposure to vapors of different solvents or heating above the glass transition temperature), a range of "mosaic" brushes with different parameters can be obtained. Successive grafting of a secondary polymer (polyacrylamide, PAAm) results in the fabrication of binary polymer brushes (BPBs). Upon being exposed to specific selective solvents, BPBs may adopt different conformations. The surface tension and adhesion of the binary brush are governed by the polymer occupying the top stratum. The "mosaic" brush approach allows for a combination of strongly immiscible polymers in one brush. This facilitates substantial contrast in the surface properties upon switching, previously only possible for substrates composed of predetermined nanostructures. We also demonstrate a possible application of such PS/PAAm brushes in a tunable bioadhesion-bioadhesive (PS on top) or nonbioadhesive (PAAm on top) surface as revealed by Escherichia coli bacterial seeding.