Orientational Order in Sphere-Forming Block Copolymer Thin Films Aligned under Shear

Deposition patterns formed by the evaporation of linear diblock copolymer solution nanodroplets on solid surfaces

The evaporation-induced deposition pattern of the linear diblock copolymer solution has attracted attention in recent years. Given its critical applications, we study deposition patterns of the linear diblock copolymer solution nanodroplet on a solid surface (the wall) by molecular dynamics simulations. This study focuses on the influence of the nonbonded interaction strength, including the interaction between the wall and polymer blocks (ɛAW and ɛBW), the interaction between the solvent and the wall (ɛSW), and the interaction between polymer blocks (ɛAB). Conditions leading to diverse deposition patterns are explored, including the coffee-ring and the volcano-like structures. The formation of the coffee-ring structure is attributed to receding interfaces, the heterogeneity inside the droplet, and the self-assembly of polymer chains. This study contributes to the establishment of guidelines for designing deposition patterns of the linear diblock copolymer solution nanodroplet, which facilitates practical applications such as inkjet printing.

Stability and Elasticity of Ultrathin Sphere-Patterned Block Copolymer Films

Sphere-patterned ultrathin block copolymer films are potentially interesting for a variety of applications in nanotechnology. We use self-consistent field theory to investigate the elastic response of sphere monolayer films with respect to in-plane shear, in-plane extension, compression deformations, and bending. The relations between the in-plane elastic moduli are roughly compatible with the expectations for two-dimensional elastic systems with hexagonal symmetry, with one notable exception: The pure shear and the simple shear moduli differ from each other by roughly 20%. Even more importantly, the bending constants are found to be negative, indicating that free-standing block copolymer membranes made of only a sphere monolayer are inherently unstable above the glass transition. Our results are discussed in view of the experimental findings.

Pendant Group Modifications Provide Graft Copolymer Silicones with Exceptionally Broad Thermomechanical Properties

Graft copolymers offer a versatile platform for the design of self-assembling materials; however, simple strategies for precisely and independently controlling the thermomechanical and morphological properties of graft copolymers remain elusive. Here, using a library of 92 polynorbornene-graft-polydimethylsiloxane (PDMS) copolymers, we discover a versatile backbone-pendant sequence-control strategy that addresses this challenge. Small structural variations of pendant groups, e.g., cyclohexyl versus n-hexyl, of small-molecule comonomers have dramatic impacts on order-to-disorder transitions, glass transitions, mechanical properties, and morphologies of statistical and block silicone-based graft copolymers, providing an exceptionally broad palette of designable materials properties. For example, statistical graft copolymers with high PDMS volume fractions yielded unbridged body-centered cubic morphologies that behaved as soft plastic crystals. By contrast, lamellae-forming graft copolymers provided robust, yet reprocessable silicone thermoplastics (TPs) with transition temperatures spanning over 160 °C and elastic moduli as high as 150 MPa despite being both unentangled and un-cross-linked. Altogether, this study reveals a new pendant-group-mediated self-assembly strategy that simplifies graft copolymer synthesis and enables access to a diverse family of silicone-based materials, setting the stage for the broader development of self-assembling materials with tailored performance specifications.

A Single Crystal 2D Hexagonal Array in a Centimeter Scale with a Self-Directed Assembly of Diblock Copolymer Spheres

The creation of a single-grain two-dimensional (2D) nanoarray over a large area (∼1 cm²) has been only realized with expensive lithographic fabrication involving a complicated multichemical process. In this work, we report the production of a highly aligned single-grain 2D crystalline nanoarray over a centimeter-scale large area with a concept of self-directed assembly (SDA) in block copolymer (BCP) thin films. No lithographic guiding pattern is employed in SDA. A sphere-forming BCP is first transformed to transient-cylinders and aligned with shear. The aligned cylinders act as a guiding pattern to restore the sphere-morphology producing a single-grain 2D crystalline array with the following solvent vapor annealing. The SDA process has two governing parameters: orientational order of guiding patterns in the first step and the lattice matching between the transient guiding cylinders and the restored spheres. The successful application of SDA yields a single-grain of 2D crystalline hexagonal nanoarray with an exceptional long-range order, which is confirmed by employing image treating algorithms and grazing incidence small-angle X-ray scattering (GISAXS) measurements. The suggested SDA strategy is found to be effective for large-scale nanopatterning with no lithographic tools.

Understanding nanodomain morphology formation in dip-coated PS-b-PEO thin films

Block copolymer (BCP) thin films prepared by dip-coating are increasingly investigated, owing to the many promising application areas, the facility, and the industrial scalability of this technique. Yet, the effect of different dip-coating parameters on BCP nanostructure formation is still underdeveloped and the results of previous literature are limited to a few block copolymers. Here, we study the effect of the withdrawal rate and solvent selectivity on the morphology evolution of dip-coated polystyrene-b-poly(ethylene oxide) thin films by applying a wide range of dip-coating speeds and altering the volume ratio of the tetrahydrofuran-water solvent system. The dip-coated films were characterized using atomic force microscopy and ellipsometry. The nanodomain morphology, its feature sizes, its spanning, and the degree of ordering were investigated with regard to different dip-coating parameters. Notably, we have obtained a hexagonally packed BCP pattern with long-range order without the need for post-annealing processes. Overall, a solid understanding of the parameters affecting the formed surface patterns and their interplay was attained and explained, extending the knowledge of this field to more materials.

Regular ordering of spherical microdomains in dewetted monolayer islands induced by thermal annealing of spin-coated ultrathin films of a triblock copolymer

We report here spontaneous dewetting of a spin-coated, ultra-thin film of a sphere-forming block copolymer (BCP) upon thermal annealing, and that the dewetting resulted in the formation of plateau-shaped islands with a constant thickness consistent with the thickness of a monolayer, in which the spherical microdomains are regularly ordered two-dimensionally in a deformed hexagonal lattice. Thus, the spontaneous dewetting was ascribed to a mismatch between the initial spin-coated film thickness with respect to the monolayer thickness. Such dewetting of sphere-forming BCPs is considered to be deterministic compared to the cases of lamella- and cylinder-forming BCPs, as incommensuration in thickness is avoided by attaining perpendicular orientation without dewetting. We further quantitatively examined the ordering regularity of spherical microdomains in the dewetted monolayer islands to clarify the effect of confinement on sphere ordering. The degree of deformation of the hexagonal lattice was found to have an increasing tendency as a function of the degree of the deformation of the dewetted islands (the island shape), irrespective of the size of the island. Namely, islands with almost round shapes exhibit a well-ordered arrangement of the spherical microdomains in a perfect hexagonal lattice. Another notable finding is that the regular ordering of the spherical microdomains was found to be spoiled in the vicinity of the edge of the island. In other words, the spherical microdomains were well-ordered in a hexagonal lattice far from the edge of the island, while they were not regularly ordered in the vicinity of the edge, which may be due to mismatch between the curvature of the island's perimeter and the polygonal shape of ordered sphere grains.

Developing Anisotropy in Self-Assembled Block Copolymers: Methods, Properties, and Applications

Block copolymers (BCPs) self-assembly has continually attracted interest as a means to provide bottom-up control over nanostructures. While various methods have been demonstrated for efficiently ordering BCP nanodomains, most of them do not generically afford control of nanostructural orientation. For many applications of BCPs, such as energy storage, microelectronics, and separation membranes, alignment of nanodomains is a key requirement for enabling their practical use or enhancing materials performance. This review focuses on summarizing research progress on the development of anisotropy in BCP systems, covering a variety of topics from established aligning techniques, resultant material properties, and the associated applications. Specifically, the significance of aligning nanostructures and the anisotropic properties of BCPs is discussed and highlighted by demonstrating a few promising applications. Finally, the challenges and outlook are presented to further implement aligned BCPs into practical nanotechnological applications, where exciting opportunities exist.

Fabrication and 3D tomographic characterization of nanowire arrays and meshes with tunable dimensions from shear-aligned block copolymers

We demonstrate a scalable method to create metallic nanowire arrays and meshes over square-centimeter-areas with tunable sub-100 nm dimensions and geometries using the shear alignment of block copolymers. We use the block copolymer poly(styrene)-b-poly(2-vinyl pyridine) (PS-P2VP) since the P2VP block complexes with metal salts like Na2PtCl4, thereby enabling us to directly pattern nanoscale platinum features. We investigate what shear alignment processing parameters are necessary to attain high quality and well-ordered nanowire arrays and quantify how the block copolymer's molecular weight affects the resulting Pt nanowires' dimensions and defect densities. Through systematic studies of processing parameters and scanning transmission electron microscopy (STEM) tomography, we determine that the equivalent of 2-3 monolayers of PS-P2VP are required to produce a single layer of well-aligned nanowires. The resulting nanowires' widths and heights can be tuned between 11-27 nm and 9-50 nm, respectively, and have periodicites varying between 37 and 63 nm, depending on the choice of block copolymer molecular weight. We observe that the height-to-width ratio of the nanowires also increases with molecular weight, reaching a value of almost 2 with the largest dimensions fabricated. Furthermore, we demonstrate that an additional layer of Pt nanowires can be orthogonally aligned on top of and without disturbing an underlying layer, thereby enabling the fabrication of Pt nanowire meshes with tunable sub-100 nm dimensions and geometries over a cm2-area.

Shear-induced parallel and transverse alignments of cylinders in thin films of diblock copolymers

Coarse-grained Langevin dynamics simulations were performed to investigate the alignment behavior of monolayer films of cylinder-forming diblock copolymers under steady shear, a structure of significant importance for many technical applications such as nanopatterning. The influences of shear conditions, the interactions involved in the films, and the initial morphology of the cylinder-forming phase were examined. Our results showed that above a critical shear rate, the cylinders can align either along the shearing direction or transverse (log-rolling) to the shearing direction depending on the relative strength between the interchain attraction in the cylinders (εAA) and the surface attraction of the confining walls with the film (εBW). To understand the underlying mechanism, the microscopic properties of the films under shear were systematically investigated. It was found that at low εAA/εBW, the majority blocks of the diblock polymer that are adsorbed on the confining walls prefer to move synchronously with the walls, inducing the cylinder-forming blocks to align along the flow direction. When εAA/εBW is above a threshold value, a strong attraction between the cylinder-forming blocks restrains their movement during shear, leading to the log-rolling motions of the cylinders. To predict the threshold εAA/εBW, we developed an approach based on equilibrium thermodynamics data and found good agreement with our shear simulations.

Ordering block copolymers with structured electrodes

We study the kinetics of alignment and registration of block copolymers in an inhomogeneous electric field by computer simulations of a soft, coarse-grained model. The two blocks of the symmetric diblock copolymers are characterized by different dielectric constants. First, we demonstrate that a combination of graphoepitaxy and a homogeneous electric field extends the maximal distance between the topographical guiding patterns that result in defect-free ordering compared to graphoepitaxy alone. In a second study, the electric field in the thin block copolymer film is fabricated by spatially structured electrodes on an isolating substrate arranged in a one-dimensional periodic array; no additional topographical guiding patterns are applied. The dielectrophoretic effect induces long-range orientational order of the lamellae and, additionally, registers the lamellar structure with the electrodes due to the field inhomogeneities at the edges of the structured electrodes. Thus, orientational and translational order is established by the inhomogeneous electric field. The simulations identify a process protocol of time-dependent electric potentials that suppresses defect formation by initially forming a sandwich-like structure and subsequently reorienting these lying into standing lamellae that are registered with the structure of the electrodes. This process-directed self-assembly results in large defect-free arrays of aligned and registered lamellae using electrodes with a saw-tooth period of 4 lamellar periodicities, L₀, and a spacing of 10L₀.

Micropore extrusion-induced alignment transition from perpendicular to parallel of cylindrical domains in block copolymers

The orientation transition from perpendicular to parallel alignment of PEO cylindrical domains of PEO-b-PMA(Az) films has been demonstrated by extruding the block copolymer (BCP) solutions through a micropore of a plastic gastight syringe. The parallelized orientation of PEO domains induced by this micropore extrusion can be recovered to perpendicular alignment via ultrasonication of the extruded BCP solutions and subsequent annealing. A plausible mechanism is proposed in this study. The BCP films can be used as templates to prepare nanowire arrays with controlled layers, which has enormous potential application in the field of integrated circuits.

Defects in the Self-Assembly of Block Copolymers and Their Relevance for Directed Self-Assembly

Block copolymer self-assembly provides a platform for fabricating dense, ordered nanostructures by encoding information in the chemical architecture of multicomponent macromolecules. Depending on the volume fraction of the components and chain topology, these macromolecules form a variety of spatially periodic microphases in thermodynamic equilibrium. The kinetics of self-assembly, however, often results in initial morphologies with defects, and the subsequent ordering is protracted. Different strategies have been devised to direct the self-assembly of copolymer materials by external fields to align and perfect the self-assembled nanostructures. Understanding and controlling the thermodynamics of defects, their response to external fields, and their dynamics is important because applications in microelectronics either require extremely low defect densities or aim at generating specific defects at predetermined locations to fabricate irregular device-oriented structures for integrated circuits. In this review, we discuss defect morphologies of block copolymers in the bulk and thin films, highlighting (a) analogies to and differences from defects in other crystalline materials, (b) the stability of defects and their dynamics, and (c) the influence of external fields.

Orientational order in cylinder-forming block copolymer thin films

Shear can impart a high degree of orientational order to supported block copolymer thin films containing one or more layers of cylindrical microdomains, leading to a striped pattern with a period of tens of nanometers extending over macroscopic (centimeter-squared) areas. Though the as-deposited films have a polygrain structure, after shearing at sufficiently high stresses the only defects which remain are isolated dislocations, and the orientational order can be quite high (nematic or twofold orientational order parameter >0.99, as measured by tapping-mode atomic force microscopy). The effect of isolated dislocations on orientational order is adequately captured by an isotropic elastic continuum model of the structure surrounding the dislocation, producing a linear decrease of order parameter with dislocation density. Even at zero dislocation density, however, the order parameter does not quite reach unity, due to small-amplitude undulations of the cylinders about their axes which persist in the transverse direction over several cylinder periods.

Formation and ordering of topological defect arrays produced by dilatational strain and shear flow in smectic-A liquid crystals

A microscale shear cell is used to study the formation of parabolic focal conic defects in the thermotropic smectic-A liquid crystal 8CB (4-octyl-4'-cyanobiphenyl). Defects are produced by four distinct methods: by the application of dilatational strain alone, by shear flow alone, by dilatational strain and subsequent shear flow, and by the simultaneous application of dilatational strain and shear flow. We confirm that defects originate within the bulk, consistent with the previously suggested undulation instability mechanism. In the presence of a shear flow, we observe that defect formation requires micrometer-level dilatations, whose magnitude depends on the sample thickness. The size and ordering of both disordered and ordered defect arrays is quantified using a pair distribution function. Deviations from the predictions of linear stability theory are observed that have not been reported previously. For example, defects form a square array with greater ordering in the principal flow direction. Ordering due to shear flow does not change the average defect size. It has been shown previously that the principal defect sizes of ordered defects scale differently with sample thickness than the wavelength of the small amplitude undulations. We find that disordered defects show a similar deviation from this predicted wavelength.

Dynamics of dislocations in a two-dimensional block copolymer system with hexagonal symmetry

Block copolymer thin films have attracted considerable attention for their ability to self-assemble into nanometre-scale architectures. Recent advances in the use of block copolymer thin films as nano-lithographic masks have driven research efforts in order to have better control of long-range ordering in the plane of the film. Irrespective of the method of sample preparation, different quasi-two-dimensional systems with hexagonal symmetry unavoidably contain translational defects, called dislocations. Dislocations control the process of coarsening in the nano/meso-scales and provide one of the most important mechanisms of length-scale selection in hexagonal patterns. Although in the last decade the nonlinear dynamics of topological defects in quasi-two-dimensional systems has witnessed significant progress, still little is known about the role of external fields on the creation and annihilation mechanisms involved in the relaxation process towards equilibrium states. In this paper, the dynamics of dislocations in non-optimal hexagonal patterns is studied in the framework of the Ohta-Kawasaki model for a diblock copolymer. Measurements of the climb and glide velocities as a function of the wave vector deformation reveal the main mechanisms of relaxation associated with the motion of dislocations.

Controlling Order in Block Copolymer Thin Films for Nanopatterning Applications

An attractive “unconventional” lithographic technique to pattern periodic, sub-100 nm features uses self-assembled block copolymer thin films as etch masks. Unfortunately, as-cast films lack the orientational and positional order of the microphase-separated domains that are necessary for many desired applications. Reviewed herein are techniques developed to guide the self-assembly process in thin films, which permit varying degrees of control over the patterns formed by the microdomains. Techniques that can control the out-of-plane order of the microdomains are first summarized. Then, techniques that control the lateral ordering are reviewed, beginning with those that generate large defect-free grains, then those that impart orientational order to the microdomains, and finally those that can control both the orientation and position of individual microdomains. Each technique is summarized with experimental examples and discussions regarding the mechanism of the guided self-assembly process.

Shear alignment and realignment of sphere-forming and cylinder-forming block-copolymer thin films

In common with many other structured fluids, block copolymers can be effectively oriented by shear. This susceptibility to shear alignment has previously been shown to hold even in thin films, containing as few as two layers of spherical microdomains, or even a single layer of cylindrical microdomains. A phenomenological model has been proposed [M. W. Wu, R. A. Register, and P. M. Chaikin, Phys. Rev. E 74, 040801(R) (2006)] to describe the alignment of such block-copolymer films, yielding the microdomain lattice order parameter as a function of shearing temperature, stress, and time. Here we directly test the central idea of that model, that the grains which are most misaligned with the shear direction are selectively destroyed, to reform in a direction more closely aligned with the shear. Films are first shear aligned from a polygrain state into a monodomain orientation and are then subjected to a second shear, at a variable stress (sigma) and misorientation angle (deltatheta) relative to the monodomain director, allowing the effects of sigma and deltatheta to be independently and systematically probed. For both cylinder-forming and sphere-forming block copolymers, these experiments confirm the basic premise of the model, as the stress required for realignment increases monotonically as deltatheta becomes smaller. For a cylinder-forming block copolymer, we find that the characteristic stress sigma(c) required to realign cylinders from one monodomain orientation to another is indistinguishable from that required to generate a monodomain orientation from the polygrain state. By contrast, the hexagonal lattice of spheres requires a value of sigma(c) more than 3 times as high for reorientation than for generation of the initial monodomain orientation.

Block copolymer nanolithography: translation of molecular level control to nanoscale patterns

The self-asembly of block copolymers is a promising platform for the "bottom-up" fabrication of nanostructured materials and devices. This review covers some of the advances made in this field from the laboratory setting to applications where block copolymers are in use.

Relaxational dynamics of smectic phases on a curved substrate

We study the dynamics of pattern formation of two-dimensional smectic systems constrained to lie on a substrate with sinusoidal topography. We observe a coupling between defects and geometry that induces the preferential location of positive (negative) defects onto regions with positive (negative) Gaussian curvature. For the curvatures studied here we observe unbinding and self-organization of disclination pairs. The local orientation of the pattern and the location of topological defects can be accurately controlled with the curvature of the underlying substrate. Thus, long-range interactions arising from the geometry of the substrate lead to ordered patterns with potential applications to nanotechnology.