Membranes with highly ordered straight nanopores by selective swelling of fast perpendicularly aligned block copolymers

Assembling Vertical Block Copolymer Nanopores via Solvent Vapor Annealing on Homopolymer-Functionalized Substrates

Utilizing the self-assembly of block copolymers with large Flory-Huggins interaction parameters (χ) for nanofabrication is a formidable challenge due to the attendant large surface energy differences between the blocks. This work reports a robust protocol for the fabrication of thin films with highly ordered cylindrical nanopore arrays via the self-assembly of an asymmetric poly(styrene-block-4-vinylpyridine) (PS-b-P4VP) diblock copolymer blended with a P4VP homopolymer. The desired vertical domain orientation is achieved at the air-polymer interface by controlled solvent vapor annealing (SVA) using acetone, a solvent with weak selectivity for PS over P4VP, and at the substrate interface by functionalization using a hydroxy-terminated poly(2-vinylpyridine) (P2VP-OH) homopolymer brush. In contrast, the vertical cylinder orientation is unstable during acetone SVA on substrates functionalized using hydroxy-terminated poly(methyl methacrylate) (PMMA-OH). Although PMMA exhibits more balanced interfacial energies between PS and P4VP than P2VP in the dry state, it is also swollen more selectively by acetone. We hypothesize that the nearly balanced solvent swelling of the three polymers (P2VP, P4VP, and PS) stabilizes the vertical cylinder orientation, while unbalanced swelling (PMMA > P4VP and PS) does not. We further characterize pore formation by addition of a P4VP homopolymer and its postassembly extraction using ethanol, revealing a narrow window of pore size tunability. Notably, minimal differences in nanopore morphologies are observed for P4VP volume fractions as high as 0.1, regardless of the P4VP molar mass. However, further increasing the P4VP volume fraction results in domain reorientation or macrophase separation when its molar mass is less than or greater than the P4VP block molar mass, respectively. Using a P4VP homopolymer that is nearly equal in length to the P4VP block enables the fabrication of well-ordered arrays of vertical, through-film nanopores with high aspect ratios (>10), small periods (<23 nm), and diameters less than 10 nm.

Effects of Carbon Spacer Length on Conformational Transitions and Protein Adsorption of Polyzwitterions

The properties of polyzwitterions are closely linked to their carbon spacer length (CSL) between oppositely charged groups. A thorough understanding of the effect of CSL on the properties of polyzwitterion-functionalized membranes is important for their fouling resistance and separation performances. In this work, polyzwitterion-functionalized membranes with different CSLs are prepared by coupling selective swelling-induced pore generation with zwitterionization, and the investigation is focused on comprehending the molecular mechanisms underlying protein resistance and conformational transitions within polyzwitterions under varying CSLs. The zwitterionized films show an enhancement in the surface negative potential with the increase of CSL, attributed to the negatively charged groups distanced from the positively charged groups. Quartz crystal microbalance with dissipation (QCM-D) demonstrates that zwitterionized films with different CSLs display distinct levels of resistance to protein adsorption. The trimethylamine N-oxide-derived polymer (PTMAO, CSL = 0) zwitterionized film shows the highest resistance compared to the poly(3-[dimethyl(2'-methacryloyloxyethyl] ammonio) ethanesulfonate (PMAES, CSL = 2) zwitterionized film and the poly(sulfobetaine methacrylate) (PSBMA, CSL = 3) zwitterionized film, owing to its electrical neutrality and pronounced hydrophilicity. Moreover, analysis of the anti-polyelectrolyte behaviors reveals that PTMAO does not undergo a significant conformation transition in deionized water and salt solutions, while the conformations of PMAES and PSBMA display to be more salt-dependent as the CSL increases, attributed to their increased polarization and dipole moment. As a result, the permeability of zwitterionized membranes exhibits enhanced salt responsiveness with the increase in CSL. The findings of this study are expected to facilitate the design of adsorption-resistant surfaces desired in diverse fields.

Perpendicular Alignment of Covalent Organic Framework (COF) Pore Channels by Solvent Vapor Annealing

Covalent organic frameworks (COFs) have showcased great potential in diverse applications such as separation and catalysis, where mass transfer confined in their pore channels plays a significant role. However, anisotropic orientation usually occurs in polycrystalline COFs, and perpendicular alignment of COF pore channels is ultimately desired to maximize their performance. Herein, we demonstrate a strategy, solvent vapor annealing, to reorient COF pore channels from anisotropic orientation to perpendicular alignment. COF thin films are first synthesized to have flexible N-H bonds in their skeletons, thus having structural mobility to enable molecular rearrangement. A solvent with low relative permittivity and a conjugated structure is then identified to have a strong affinity toward the COFs, allowing its vapor to easily penetrate into the COF interlayers. The solvent vapor weakens the π-π interaction and consequently allows the COF monolayers to dissociate. The COF monolayers undergo a reorientation process that converts from random stacking into the face-on stacking fashion, in which the through COF pores are perpendicularly aligned. The aligned COF film exhibits high separation precision toward ions featuring a size difference down to 2 Å, which is 8 times higher than that of the anisotropically oriented counterpart. This work opens up an avenue for COF orientation regulation by solvent vapor annealing and reveals the essential role of the perpendicular alignment of COF pore channels to enable precision separations.

Film Instability Induced by Swelling and Drying

Poly(2-vinyl pyridine), P2VP, films display a surface pattern of craters in a dried state after being immersed in aqueous solutions containing HAuCl₄ and its mixtures with low contents of K₂CO₃. The morphologies of craters indicate that the formation of craters involves three stages through film blistering and drying: (i) the permeability of water and solutes to swell P2VP films, (ii) partial wetting of liquid droplets near the substrate interface in the presence of the P2VP film, and (iii) evaporation-driven flows. The three stages produce the swelling pressure, Laplace pressure, and interplays among capillary flows, Marangoni flows, and pinning effects, respectively, by which craters of different dimensions and morphologies are obtained. The first stage softens the P2VP films and produces swelling pressure. This stage relies on interactions between AuCl₄^- ions, water, and protonated P2VP chains. The second stage produces liquid droplets inside the film and near the substrate interface. The surface tensions of those liquid droplets at contact lines deform swollen P2VP films. Changing film thicknesses or substrate types alters craters' lateral dimension and depth. The results indicate that film thicknesses and substrate interface energies influence the shape and dimension of liquid droplets on the substrate interface. The third stage determines morphologies of craters through interplays among capillary flows, Marangoni flows, and pinning/depinning events.

Porous but Mechanically Robust All-Inorganic Antireflective Coatings Synthesized using Polymers of Intrinsic Microporosity

Here, we introduce polymer of intrinsic microporosity 1 (PIM-1) to design single-layer and multilayered all-inorganic antireflective coatings (ARCs) with excellent mechanical properties. Using PIM-1 as a template in sequential infiltration synthesis (SIS), we can fabricate highly uniform, mechanically stable conformal coatings of AlO_x with porosities of ∼50% and a refractive index of 1.41 compared to 1.76 for nonporous AlO_x that is perfectly suited for substrates commonly used in high-end optical systems or touch screens (e.g., sapphire, conductive glass, bendable glass, etc.). We show that such films can be used as a single-layer ARC capable of reduction of the Fresnel reflections of sapphire to as low as 0.1% at 500 nm being deposited only on one side of the substrate. We also demonstrate that deposition of the second layer with higher porosity using block copolymers enables the design of graded-index double-layered coatings. AlO_x structures with just two layers and a total thickness of less than 200 nm are capable of reduction of Fresnel reflections under normal illumination to below 0.5% in a broad spectral range with 0.1% reflection at 700 nm. Additionally, and most importantly, we show that highly porous single-layer and graded-index double-layered ARCs are characterized by high hardness and scratch resistivity. The hardness and the maximum reached load were 7.5 GPa and 13 mN with a scratch depth of about 130 nm, respectively, that is very promising for the structures consisting of two porous AlO_x layers with 50% and 85% porosities, correspondingly. Such mechanical properties of coatings can also allow their application as protective layers for other optical coatings.

Potential of Functionalized Polyolefins in a Sustainable Polymer Economy: Synthetic Strategies and Applications

ConspectusPolymers play a crucial role in our modern life as no other material exists that is so versatile, moldable, and lightweight. Consequently, the demand for polymers will continue to grow with the human population, modernization, and technological developments. However, depleted fossil resources, increasing plastic waste production, ocean pollution, and related growing emission of greenhouse gases has led to a change in the way we think about the use of polymers. Although polymers were never designed to be recycled, it is clear that a linear polymers economy is no longer sustainable. The design for recycling and reuse and life-cycle analyses will become increasingly important factors when deciding on which polymer to choose for a certain application. Of all polymers, polyolefins have the lowest life-cycle environmental impact and even outperform renewable polymers. However, polyolefins are chemically inert and reveal a low surface energy. Combining their excellent mechanical properties with the ability to adhere to other materials or create self-assembled or nanostructured materials would widen the application window of polyolefins even more.This Account covers part of our personal account in the field of functionalized polyolefin synthesis and their application development. We start with addressing the challenge of finding suitable catalysts that tolerate nucleophilic functionalities, which tends to poison most electrophilic catalysts even when passivated with, for example, an aluminum alkyl. We argued that lowering of the oxidation state of a titanium-based catalyst might lower the electrophilicity of the metal center. Indeed, this simple approach resulted in an unprecedentedly high tolerance toward aluminum alkyl-passivated alkenols during their copolymerization with ethylene. Interestingly, catalyst deactivation was much less pronounced during the copolymerization of propylene and aluminum-passivated alkenols, clearly demonstrating the protective effect of the methyl branch in the growing polymer. Because the use of randomly functionalized polypropylenes is rather underdeveloped, as compared to the corresponding randomly functionalized polyethylenes, we focused on potential applications of the former material. Atactic or low-crystalline hydroxyl- and carboxylic acid-functionalized propylene-based co- and terpolymers form elastomers with interesting properties that can be influenced by enhancing the hydrogen bonding within the system or by creating ionomers. The polar functionalities cluster together in domains that can host small polar molecules such as, for example, a pH indicator, thus affording useful sensors. The functionalized polyolefins can also be used as precursors for amphiphilic graft copolymers, undergoing self-assembly and therefore being suitable for nanoporous membrane preparation. The graft copolymers also proved to be effective compatibilizers in various polymer blends.

Metal nanoparticle arrays via a water-based lift-off scheme using a block copolymer template

Metalnanoparticles(NPs) can exhibit unique electronic, magnetic, optical, and catalytic properties. Highly ordered, dense arrays of non-close-packed, surface-supported metal NPs are thus of potential use in a wide range of applications. Implementing such arrays over large surfaces can, however, be both technologically challenging and prohibitively expensive using conventional top-down nanofabrication techniques. Moreover, many existing patterning methods are too harsh for sensitive substrate surfaces and their applications. To address this, we here investigate a fabrication protocol involving a water-based lift-off scheme in which the template pattern generation is rapidly and inexpensively achieved throughblock copolymer(BCP) self-assembly. A three-layer lift-off stack consisting of, from top to bottom, a poly(styrene-block-2-vinyl pyridine) template, a SiO_xintermediate hardmask, and a water-soluble poly(vinyl alcohol) sacrificial layer is employed in this endeavor.Solvent-induced surface reconstruction(SISR) is used to generate an initial surface topography in the BCP template which is subsequently transferred to the layers beneath in a sequence of reactive ion etching steps. Through judicious selection of stack materials and dry etch chemistries, a layered, high-aspect-ratio, nanoporous mask is thus implemented. After metal deposition, the mask and excess material are simply removed in a lift-off step by dissolving the bottommost sacrificial layer in water. The incorporation of an intermediate hardmask and a water-soluble sacrificial layer obviates the need for harmful and/or corrosive lift-off solvents and decouples the BCP self-assembly process from the influence of substrate properties. We demonstrate the generation of well-ordered arrays of Au NPs capable of supporting sharp, localized surface plasmon resonances. We also investigate improvements to large-scale uniformity, as this is found sensitive to the SISR termination step in the original protocol. Extensions of the technique to other BCP morphologies and materials deposited ought to be straightforward.

Block Copolymer Nanopatterning for Nonsemiconductor Device Applications

Block copolymer (BCP) nanopatterning has emerged as a versatile nanoscale fabrication tool for semiconductor devices and other applications, because of its ability to organize well-defined, periodic nanostructures with a critical dimension of 5-100 nm. While the most promising application field of BCP nanopatterning has been semiconductor devices, the versatility of BCPs has also led to enormous interest from a broad spectrum of other application areas. In particular, the intrinsically low cost and straightforward processing of BCP nanopatterning have been widely recognized for their large-area parallel formation of dense nanoscale features, which clearly contrasts that of sophisticated processing steps of the typical photolithographic process, including EUV lithography. In this Review, we highlight the recent progress in the field of BCP nanopatterning for various nonsemiconductor applications. Notable examples relying on BCP nanopatterning, including nanocatalysts, sensors, optics, energy devices, membranes, surface modifications and other emerging applications, are summarized. We further discuss the current limitations of BCP nanopatterning and suggest future research directions to open up new potential application fields.

Light-Enabled Reversible Shape Transformation of Block Copolymer Particles

Confined self-assembly of block copolymers (BCPs) is effective to manipulate various shapes of particles. In emulsion confined self-assembly, reversibly light-trigged switchable BCP particles are extremely expected, yet rarely reported. Herein, a novel strategy is developed to realize reversibly light-responsive shape-transformation of BCP particles by constructing functional surfactants with light-active azobenzene (azo) groups in the confined self-assembly of BCPs within emulsion droplet. Ultraviolet and visible lights can reversibly modulate the amphiphilicity and interfacial affinity of the surfactants to different blocks, triggering the reversible microphase structure transformation of BCP particles with high temporal-spatial resolution. We can realize shape and morphological transitions of BCP particles from onion-shaped spherical particles to striped ellipsoids and, ultimately, to inverse onion-like particles by ultraviolet irradiation. More importantly, this shape transformation is reversible by the irradiation of visible light, attributed to the reversible trans-cis isomerization of azo groups. We also demonstrate that the light-triggered shape transformation of BCP particles can be employed in a controllable drug release through a noncontacted and programmed manner, showing promising potential in clinic and biomedicine.

Downsizing of Block Polymer-Templated Nanopores to One Nanometer via Hyper-Cross-Linking of High χ-Low N Precursors

Synthesizing nanoporous polymer from the block polymer template by selective removal of the sacrificial domain offers straightforward pore size control as a function of the degree of polymerization (N). Downscaling pore size into the microporous regime (<2 nm) has been thermodynamically challenging, because the low N drives the system to disorder and the small-sized pore is prone to collapse. Herein, we report that maximizing cross-linking density of a block polymer precursor with an increased interaction parameter (χ) can help successfully stabilize the structure bearing pore sizes of 1.1 nm. We adopt polymerization-induced microphase separation (PIMS) combined with hyper-cross-linking as a strategy for the preparation of the bicontinuous block polymer precursors with a densely cross-linked framework by copolymerization of vinylbenzyl chloride with divinylbenzene and also Friedel-Crafts alkylation. Incorporating 4-vinylbiphenyl as a higher-χ comonomer to the sacrificial polylactide (PLA) block and optimizing the segregation strength versus cross-linking density allow for further downscaling. Control of pore size by N of PLA is demonstrated in the range of 9.9-1.1 nm. Accessible surface area to fluorescein-tagged dextrans is regulated by the relative size of the pore to the guest, and pore size is controlled. These findings will be useful for designing microporous polymers with tailored pore size for advanced catalytic and separation applications.

Shear-Rolling Process for Unidirectionally and Perpendicularly Oriented Sub-10-nm Block Copolymer Patterns on the 4 in Scale

Shear alignment of the block copolymer (BCP) thin film is one of the promising directed self-assembly (DSA) methodologies for the unidirectional alignment of sub-10 nm microdomains of BCPs for next-generation nanolithography and nanowire-grid polarizers. However, because of the differences in the surface/interfacial energies at the top surface/bottom interface, the shear-induced ordering of BCP nanopatterns has been restricted to BCPs with spherical and cylindrical nanopatterns and cannot be realized for high-aspect-ratio perpendicular lamellar structures, which is essential for practical application to semiconductor pattern processes. It is still a difficult challenge to fabricate the unidirectional alignment in a short time over a large area. In this study, we propose an approach for combining the shear-rolling process with the filtered plasma treatment of BCP films for the fabrication of unidirectionally aligned and perpendicularly oriented lamellar nanostructures. This approach enables fabrication within 1 min on a 4 in scale. We treated filtered plasma on the BCP film for perpendicular orientation and executed the hot-rolling process with different roller and stage speeds. Large-scale shear was generated only at the location where the BCP film was in contact with both the roller and stage, effectively applying shear stress to a large area of the BCP film within a short time. The repeated application of this shear-rolling process can achieve a higher level of unidirectional alignment. Our aligned BCP vertical lamellae were used to fabricate a high-aspect-ratio sub-10-nm-wide metallic nanowire array via dry/wet processes. In addition, shear-rolling with chemoepitaxy patterns can achieve higher orientational order and lower defectivity.

Ordered Mesoporous Microcapsules from Double Emulsion Confined Block Copolymer Self-Assembly

Polymeric microcapsules with shells containing homogeneous pores with uniform diameter on the nanometer scale are reported. The mesoporous microcapsules are obtained from confined self-assembly of amphiphilic block copolymers with a selective porogen in the shell of water-in-oil-in-water double emulsion drops. The use of double emulsion drops as a liquid template enables the formation of homogeneous capsules of 100s of microns in diameter, with aqueous cores encapsulated in a shell membrane with a tunable thickness of 100s of nanometers to 10s of microns. Microcapsules with shells that exhibit an ordered gyroidal morphology and three-dimensionally connected mesopores are obtained from the triblock terpolymer poly(isoprene)-block-poly(styrene)-block-poly(4-vinylpyridine) coassembled with pentadecylphenol as a porogen. The bicontinuous shell morphology yields nanoporous paths connecting the inside to the outside of the microcapsule after porogen removal; by contrast, one-dimensional hexagonally packed cylindrical pores, obtained from a traditional diblock copolymer system with parallel alignment to the surface, would block transport through the shell. To enable the mesoporous microcapsules to withstand harsh conditions, such as exposure to organic solvents, without rupture of the shell, we develop a cross-linking method of the nanostructured triblock terpolymer shell after its self-assembly. The microcapsules exhibit pH-responsive permeability to polymeric solutes, demonstrating their potential as a filtration medium for actively tunable macromolecular separation and purification. Furthermore, we report a tunable dual-phase separation method to fabricate microcapsules with hierarchically porous shells that exhibit ordered mesoporous membrane walls within sponge-like micron-sized macropores to further control shell permeability.

Next-Generation Ultrafiltration Membranes Enabled by Block Polymers

Reliable and equitable access to safe drinking water is a major and growing challenge worldwide. Membrane separations represent one of the most promising strategies for the energy-efficient purification of potential water sources. In particular, porous membranes are used for the ultrafiltration (UF) of water to remove contaminants with nanometric sizes. However, despite exhibiting excellent water permeability and solution processability, existing UF membranes contain a broad distribution of pore sizes that limit their size selectivity. To maximize the potential utility of UF membranes and allow for precise separations, improvements in the size selectivity of these systems must be achieved. Block polymers represent a potentially transformative solution, as these materials self-assemble into well-defined domains of uniform size. Several different strategies have been reported for integrating block polymers into UF membranes, and each strategy has its own set of materials and processing considerations to ensure that uniform and continuous pores are generated. This Review aims to summarize and critically analyze the chemistries, processing techniques, and properties required for the most common methods for producing porous membranes from block polymers, with a particular focus on the fundamental mechanisms underlying block polymer self-assembly and pore formation. Critical structure-property-performance metrics will be analyzed for block polymer UF membranes to understand how these membranes compare to commercial UF membranes and to identify key research areas for continued improvements. This Review is intended to inform readers of the capabilities and current challenges of block polymer UF membranes, while stimulating critical thought on strategies to advance these technologies.

Strategy for Enhancing Ultrahigh-Molecular-Weight Block Copolymer Chain Mobility to Access Large Period Sizes (>100 nm)

Assembling ultrahigh-molecular-weight (UHMW) block copolymers (BCPs) in rapid time scales is perceived as a grand challenge in polymer science due to slow kinetics. Through surface engineering and identifying a nonvolatile solvent (propylene glycol methyl ether acetate, PGMEA), we showcase the impressive ability of a series of lamellar poly(styrene)-block-poly(2-vinylpyridine) (PS-b-P2VP) BCPs to self-assemble directly after spin-coating. In particular, we show the formation of large-period (≈111 nm) lamellar structures from a neat UHMW PS-b-P2VP BCP. The significant influence of solvent-polymer solubility parameters are explored to enhance the polymer chain mobility. After optimization using solvent vapor annealing, increased feature order of ultralarge-period PS-b-P2VP BCP patterns in 1 h is achieved. Isolated metallic and dielectric features are also demonstrated to exemplify the promise that large BCP periods offer for functional applications. The methods described in this article center on industry-compatible patterning schemes, solvents, and deposition techniques. Thus, our straightforward UHMW BCP strategy potentially paves a viable and practical path forward for large-scale integration in various sectors, e.g., photonic band gaps, polarizers, and membranes that demand ultralarge period sizes.

Co-Casting Highly Selective Dual-Layer Membranes with Disordered Block Polymer Selective Layers

Highly selective and water permeable dual-layer ultrafiltration (UF) membranes comprising a disordered poly(methyl methacrylate-stat-styrene)-block-poly(lactide) selective layer and a polysulfone (PSF) support layer were fabricated using a co-casting technique. A dilute solution of diblock polymer was spin coated onto a solvent-swollen PSF layer, rapidly heated to dry and disorder the block polymer layer, and subsequently immersed into an ice water coagulation bath to kinetically trap the disordered state in the block polymer selective layer and precipitate the support layer by nonsolvent-induced phase separation. Subsequent removal of the polylactide block generated porous membranes suitable for UF. The permeability of these dual-layer membranes was modulated by tuning the concentration of the PSF casting solution, while the size-selectivity was maintained because of the narrow pore size distribution of the self-assembled block polymer selective layer. Elimination of the thermal annealing step resulted in a dramatic increase in the water permeability without adversely impacting the size-selectivity, as the disordered nanostructure present in the concentrated casting solution was kinetically trapped upon rapid drying. The co-casting strategy outlined in this work may enable the scalable fabrication of block polymer membranes with both high permeability and high selectivity.

Vertical Lamellae Formed by Two-Step Annealing of a Rod-Coil Liquid Crystalline Block Copolymer Thin Film

Silicon-containing block copolymer thin films with high interaction parameter and etch contrast are ideal candidates to generate robust nanotemplates for advanced nanofabrication, but they typically form in-plane oriented microdomains as a result of the dissimilar surface energies of the blocks. Here, we describe a two-step annealing method to produce vertically aligned lamellar structures in thin film of a silicon-containing rod-coil thermotropic liquid crystalline block copolymer. The rod-coil block copolymer with the volume fraction of the Si-containing block of 0.22 presents an asymmetrical lamellar structure in which the rod block forms a hexatic columnar nematic liquid crystalline phase. A solvent vapor annealing step first produces well-ordered in-plane cylinders of the Si-containing block, then a subsequent thermal annealing promotes the phase transition from in-plane cylinders to vertical lamellae. The pathways of the order-order transition were examined by microscopy and in situ using grazing incidence small-angle X-ray scattering and wide-angle X-ray scattering.

Nanorod position and orientation in vertical cylinder block copolymer films

The self-assembly of gold nanorods (AuNRs) of different sizes with a block copolymer (BCP) is studied. Polystyrene-block-poly(2-vinylpyridine) (PS-b-P2VP) films containing P2VP functionalized AuNRs are solvent annealed resulting in a BCP morphology of vertical P2VP cylinders in a PS matrix. At the surface of the PS-b-P2VP films long AuNRs are found in the bridging and vertical states. The bridging state is where the long axis of the AuNR is parallel to the film surface, the AuNR is embedded in the film, and each end of the AuNR is at the top of nearest neighbor P2VP cylinders. The vertical state is where the AuNR is localized within a vertical P2VP cylinder, the AuNR long axis is perpendicular to the film surface and the upper tip of the AuNR is at the film surface. Short AuNRs were found in the bridging and vertical states as well as in a state not observed for the long AuNRs, the centered state. The centered state is where an AuNR has its long axis parallel to the film surface, is embedded in the film, and is centered over a vertical P2VP cylinder. Hybrid particle-field theory (HPFT) simulations modeling the experimental system predict that for the long AuNRs only the bridging state should be observed while for the short AuNRs only the bridging and centered states should be observed. Possible explanations for why the vertical state is observed in experiments despite being thermodynamically unfavorable in simulations are discussed. HPFT simulations also show that when a nanorod is in the bridging state the two cylinders it bridges remain intact and extend from the nanorod to the substrate. Further, the minority block of the BCP is shown to wet the bottom of the bridging nanorod. The bridging state is very promising for the future development of self-assembled nanoscale devices.

Enabling Covalent Organic Framework Nanofilms for Molecular Separation: Perforated Polymer-Assisted Transfer

Covalent organic frameworks (COFs) with ordered arrays of sub-2 nm regular pores are drawing increasing attention in membrane separation, and it remains highly desirable for effective and controllable strategies to fabricate COF-based membranes. Herein, we demonstrate a perforated polymer-assisted transfer strategy enabling COF nanofilms for molecular separation. Solvothermal synthesis is used for the confined growth of TpPa, a stable, imine-linked COF, on the smooth surfaces of silicon substrates. Continuous, crystalline COF nanofilms are obtained, and their thicknesses are tunable in the range from a few tens to several hundred nanometers depending on monomer concentrations and reaction time. A block copolymer layer is coated on the COF nanofilms, which is then perforated to produce interconnected mesopores by the mechanism of selective swelling-induced pore generation. The perforated polymer coating functions as a protective but permeable layer enabling the easy transfer of the COF nanofilm onto porous substrates. Thus, we obtain a new type of composite membranes with the microporous COF nanofilm as the selective layer, sandwiched between the macroporous substrate and the mesoporous protective layer. The composite membranes exhibit good separation performances with water permeance up to ∼51 L m^-2 h^-1 bar^-1 and high rejection rates to various dyes. This work demonstrates a new method to prepare COF-based membranes for molecular separation, and the invented perforated polymer-assisted transfer technology is expected to find applications in transferring other ultrathin materials to demanded substrates.

Temperature-Controlled Solvent Vapor Annealing of Thin Block Copolymer Films

Solvent vapor annealing is as an effective and versatile alternative to thermal annealing to equilibrate and control the assembly of polymer chains in thin films. Here, we present scientific and practical aspects of the solvent vapor annealing method, including the discussion of such factors as non-equilibrium conformational states and chain dynamics in thin films in the presence of solvent. Homopolymer and block copolymer films have been used in model studies to evaluate the robustness and the reproducibility of the solvent vapor processing, as well as to assess polymer-solvent interactions under confinement. Advantages of utilizing a well-controlled solvent vapor environment, including practically interesting regimes of weakly saturated vapor leading to poorly swollen states, are discussed. Special focus is given to dual temperature control over the set-up instrumentation and to the potential of solvo-thermal annealing. The evaluated insights into annealing dynamics derived from the studies on block copolymer films can be applied to improve the processing of thin films of crystalline and conjugated polymers as well as polymer composite in confined geometries.

Universal perpendicular orientation of block copolymer microdomains using a filtered plasma

Sub-10 nm patterns prepared by directed self-assembly (DSA) of block copolymer (BCP) thin films offer a breakthrough method to overcome the limitations of photolithography. Perpendicular orientation of the BCP nanostructures is essential for lithographic applications, but dissimilar surface/interfacial energies of two blocks generally favour parallel orientations, so that the perpendicular orientation could only be obtained under very limited conditions. Here, we introduce a generalized method for creating perpendicular orientations by filtered plasma treatment of the BCP films. By cross-linking the surface of disordered BCP films using only physical collisions of neutral species without ion bombardment or UV irradiation, neutral layers consistent with the BCP volume fraction are produced that promote the perpendicular orientations. This method works with BCPs of various types, volume fractions, and molecular weights individually at the top and bottom interfaces, so it was applied to orientation-controlled 3D multilayer structures and DSA processes for sub-10 nm line-spacing patterns.

Continuous Gradient Nanoporous Film Enabled by Delayed Directional Diffusion of Solvent and Selective Swelling

Nature-inspired porous structures are highly desired in the fields of new materials, sustainable energy, biological and chemical science, and so forth. Here, a new strategy for the fabrication of continuous, gradient nanoporous polystyrene- block-poly(2-vinylpyridine) (PS- b-P2VP) film is established. The continuous nanopore gradient along the direction of film thickness (∼120 μm) is achieved via delayed directional diffusion of dynamic binary solvent of ethanol/water and selective swelling of P2VP domains. Ethanol in binary solvent diffuses into the film from one side to another, which is retarded by the water gate as water is concentrated at the film surface. The delayed diffusion matches the swelling rate of P2VP domains, forming the continuous nanopore gradient normal to the film surface.

Effect of the Micelle Opening in Self-assembled Amphiphilic Block Co-polymer Films on the Infiltration of Inorganic Precursors

Infiltration of the polymer templates with inorganic precursors using the selective vapor-phase infiltration approach, or sequential infiltration synthesis (SIS), allows the design of materials with advanced properties. Swelling of the block co-polymer (BCP) templates enables the additional control of the structure, porosity, and thickness of the composite or inorganic materials. Here, we use the highly precise quartz crystal microbalance (QCM) technique to investigate quantitatively the effect of the micelle opening by swelling and inorganic precursor infiltrating on the evolution of porosity in amphiphilic BCPs. We show that swelling of the polystyrene- block-poly-4-vinyl pyridine (PS- b-P4VP) BCP in ethanol at 75 °C occurs rapidly and results in a stable polymer structure in 30 min. By using an alumina model system, we found that swelling enables access to all available polar domains of the PS- b-P4VP film leading to an increase in the SIS-infiltrated alumina mass as compared to the nonswelled BCP layer. Our results demonstrate that swelling of the 110 nm thick BCP template results in the formation of 192 nm thick alumina films with 2 times larger alumina mass and 4 times larger effective pore volume than in case of the nonswelled sample. In the case of the thicker polymer template, the difference due to swelling becomes even more substantial because the fraction of accessible polymer is increased much more than in thin films. Our findings provide important insights into the mechanism of the infiltration of the inorganic precursors into swelled and nonswelled, spin-coated BCP templates enabling the design of highly porous thick ceramic films by SIS.

Liquid crystalline moiety-assisted perpendicular orientation of cylindrical domains within P4VP-b-PMA(Az) films with high aspect ratio

Block copolymer (BCP) films with perpendicularly aligned cylindrical domains of high aspect ratio have important applications in diverse fields. However, an aspect ratio of the cylinders as high as 200 has rarely been reported so far. Here we demonstrate an efficient route to the formation of normally aligned P4VP cylinders with high aspect ratio surrounded by a matrix of azobenzene-containing block (PMA(Az)) via hierarchical self-assembly. A crisscross structure, consisting of parallelly aligned liquid crystalline (LC) layers and normally aligned self-assembly domains, is expected to assist the formation of well-defined nanostructures. The LC layers in the cylindrical films self-assemble to form smectic phase after solvent annealing, as confirmed by WAXD and UV-vis spectra. We found that the aspect ratio of the vertical P4VP cylinders is up to 200 and the film thickness reaches 6 μm. P4VP is a functional polymer, making this P4VP-b-PMA(Az) film more suitable for advanced filters, multi-nanochannels, nanolithography, and high-density storage media, etc.

Nitrogen reactive ion etch processes for the selective removal of poly-(4-vinylpyridine) in block copolymer films

Self-assembling block copolymer (BCP) patterns are one of the main contenders for the fabrication of nanopattern templates in next generation lithography technology. Transforming these templates to hard mark materials is key for pattern transfer and in some cases, involves selectively removing one block from the nanopattern. For poly(styrene)-block-poly(4-vinylpyridine) (PS-b-P4VP), a high χ BCP system which could be potentially incorporated into semiconductor nanofabrication, this selective removal is predominantly done by a wet etch/activation process. Conversely, this process has numerous disadvantages including lack of control and high generation of waste leading to high cost. For these reasons, our motivation was to move away from the wet etch process and optimise a dry etch which would overcome the limitations associated with the activation process. The work presented herein shows the development of a selective plasma etch process for the removal of P4VP cores from PS-b-P4VP nanopatterned film. Results have shown that a nitrogen reactive ion etch plasma has a selectivity for P4VP of 2.2:1 and suggest that the position of the nitrogen in the aromatic ring of P4VP plays a key role in this selectivity. In situ plasma etching and x-ray photoelectron spectrometry measurements were made without breaking vacuum, confirming that the nitrogen plasma has selectivity for removal of P4VP over PS.

Substrate Patterning Using Regular Macroporous Block Copolymer Monoliths as Sacrificial Templates and as Capillary Microstamps

Polystyrene-block-poly(2-vinylpyridine) (PS-b-P2VP) monoliths containing regular arrays of macropores (diameter ≈1.1 µm, depth ≈0.7 µm) at their surfaces are used to pattern substrates by patterning modes going beyond the functionality of classical solid elastomer stamps. In a first exemplary application, the macroporous PS-b-P2VP monoliths are employed as sacrificial templates for the deposition of NaCl nanocrystals and topographically patterned iridium films. One NaCl nanocrystal per macropore is formed by evaporation of NaCl solutions filling the macropores followed by iridium coating. Thermal PS-b-P2VP decomposition yields topographically patterned iridium films consisting of ordered arrays of hexagonal cells, each of which contains one NaCl nanocrystal. For the second exemplary application, spongy-continuous mesopore systems are generated in the macroporous PS-b-P2VP monoliths by selective-swelling induced pore generation. Infiltrating the spongy-continuous mesopore systems with ink allows capillary microstamping of continuous ink films with holes at the positions of the macropores onto glass slides compatible with advanced light microscopy. Capillary microstamping can be performed multiple times under ambient conditions without reinking and without quality deterioration of the stamped patterns. The macroporous PS-b-P2VP monoliths are prepared by double replication of primary macroporous silicon molds via secondary polydimethylsiloxane molds.

Responsive Block Copolymer Photonic Microspheres

Responsive photonic crystals (PCs) have attracted much attention due to their broad applications in the field of chemical and physical sensing through varying optical properties when exposed to external stimuli. In particular, assembly of block copolymers (BCPs) has proven to be a robust platform for constructing PCs in the form of films or bulk. Here, the generation of BCPs photonic microspheres is presented with 3D periodical concentric lamellar structures through confined self-assembly. The structural color of the spherical PCs can be tuned by selective swelling of one block, yielding large change of optical property through varying both layer thickness and refraction index of the domains. The as-formed spherical PCs demonstrate large reflection wavelength shift (≈400-700 nm) under organic solvent permeation and pH adjustment. Spherical shape and structural symmetry endow the formed spherical PCs with rotation independence and monochrome, which is potentially useful in the fields of displays, sensing, and diagnostics.