High-resolution patterning of solution-processable materials via externally engineered pinning of capillary bridges

Turing patterns with high-resolution formed without chemical reaction in thin-film solution of organic semiconductors

Regular patterns can form spontaneously in chemical reaction-diffusion systems under non-equilibrium conditions as proposed by Alan Turing. Here, we found that regular patterns can be generated in uphill-diffusion solution systems without a chemical reaction process through both in-situ and ex-situ observations. Organic semiconductor solution is confined between two parallel plates with controlled micron/submicron-meter distance to minimize convection of the liquid and avoid spinodal precipitation at equilibrium. The solvent evaporation concentrates the solution gradually into an oversaturated non-equilibrium condition, under which a phase-transition occurs and ordered concentration-waves are generated. By proper tuning of the experimental parameter, multiple regular patterns with micro/nano-meter scaled features (line, square-grid, zig-zag, and fence-like patterns etc.) were observed. We explain the observed phenomenon as Turing-pattern generation resulted from uphill-diffusion and solution oversaturation. The generated patterns in the solutions can be condensed onto substrates to form structured micro/nanomaterials. We have fabricated organic semiconductor devices with such patterned materials to demonstrate the potential applications. Our observation may serve as a milestone in the progress towards a fundamental understanding of pattern formation in nature, like in biosystem, and pave a new avenue in developing self-assembling techniques of micro/nano structured materials.

Alignment of organic conjugated molecules for high-performance device applications

High-performance organic semiconductor materials as the electroactive components of optoelectronic devices have attracted much attention and made them ideal candidates for solution-processable, large-area, and low-cost flexible electronics. Especially, organic field-effect transistors (OFETs) based on conjugated semiconductor materials have experienced stunning progress in device performance. To make these materials economically viable, comprehensive knowledge of charge transport mechanisms is required. The alignment of organic conjugated molecules in the active layer is vital to charge transport properties of devices. The present review highlights the recent progress of processing-structure-transport correlations that allow the precise and uniform alignment of organic conjugated molecules over large areas for multiple electronic applications, including OFETs, organic thermoelectric devices (OTEs), and organic phototransistors (OPTs). Different strategies for regulating crystallinity and macroscopic orientation of conjugated molecules are introduced to correlate the molecular packing, the device performance and charge transport anisotropy in multiple organic electronic devices. This article is protected by copyright. All rights reserved.

Semiconducting Polymer Nanowires with Highly Aligned Molecules for Polymer Field Effect Transistors

Conjugated polymers have emerged as promising materials for next-generation electronics. However, in spite of having several advantages, such as a low cost, large area processability and flexibility, polymer-based electronics have their own limitations concerning low electrical performance. To achieve high-performance polymer electronic devices, various strategies have been suggested, including aligning polymer backbones in the desired orientation. In the present paper, we report a simple patterning technique using a polydimethylsiloxane (PDMS) mold that can fabricate highly aligned nanowires of a diketopyrrolopyrrole (DPP)-based donor–acceptor-type copolymer (poly (diketopyrrolopyrrole-alt-thieno [3,2-b] thiophene), DPP-DTT) for high-performance field effect transistors. The morphology of the patterns was controlled by changing the concentration of the DPP-based copolymer solution (1, 3, 5 mg mL−1). The molecular alignment properties of three different patterns were observed with a polarized optical microscope, polarized UV-vis spectroscopy and an X-ray diffractometer. DPP-DTT nanowires made with 1 mg mL−1 solution are highly aligned and the polymer field-effect transistors based on nanowires exhibit more than a five times higher charge carrier mobility as compared to spin-coated film-based devices.

Dual Surface Architectonics for Directed Self-Assembly of Ultrahigh-Resolution Electronics

The directed self-assembly of electronic circuits using functional metallic inks has attracted intensive attention because of its high compatibility with extensive applications ranging from soft printed circuits to wearable devices. However, the typical resolution of conventional self-assembly technologies is not sufficient for practical applications in the rapidly evolving additively manufactured electronics (AMEs) market. Herein, an ultrahigh-resolution self-assembly strategy is reported based on a dual-surface-architectonics (DSA) process. Inspired by the Tokay gecko, the approach is to endow submicrometer-scale surface regions with strong adhesion force toward metallic inks via a series of photoirradiation and chemical polarization treatments. The prepared DSA surface enables the directed self-assembly of electronic circuits with unprecedented 600 nm resolution, suppresses the coffee-ring effect, and results in a reliable conductivity of 14.1 ± 0.6 µΩ cm. Furthermore, the DSA process enables the layer-by-layer fabrication of fully printed organic thin-film transistors with a short channel length of 1 µm, which results in a large on-off ratio of 10⁶ and a high field-effect mobility of 0.5 cm²  V^-1  s^-1 .

Variety of Ordered Patterns in Donor-Acceptor Polymer Semiconductor Films Crystallized from Solution

A huge challenge is to control the nucleation of crystallites/aggregates in the solution during polymer film formation to generate desired structures. In this work, we investigate crystallization of P(NDI2OD-T2), a donor-acceptor polymer semiconductor, with controlled solution flow along the contact line between the drying film and solution through a seesaw-like pivoting of samples during polymer drying. By controlling the pivoting frequency/amplitude, various types of line patterns can be observed: (I) an array of fishbone-like stripes oriented in the film-growth direction; (II) the pinning-depinning of contact line (PDCL)-mechanism-defined patterned wires along the contact line; and (III) periodic twined crystalline line pattern oriented in the direction of the contact line. The rich variety of pattern formation observed is attributed to the distinctiveness of the donor-acceptor conjugated polymer structure. The result measured from thin-film transistors made of the generated films/structures showed that the charge mobility of P(NDI2OD-T2) does not change much with the film morphology, which supports recent controversy over the charge-transportation mechanism of some donor-acceptor polymer semiconductors.

Height of a liquid drop on a wetting stripe

Adsorption of liquid on a planar wall decorated by a hydrophilic stripe of width L is considered. Under the condition that the wall is only partially wet (or dry) while the stripe tends to be wet completely, a liquid drop is formed above the stripe. The maximum height ℓ_{m}(δμ) of the drop depends on the stripe width L and the chemical potential departure from saturation δμ where it adopts the value ℓ_{0}=ℓ_{m}(0). Assuming a long-range potential of van der Waals type exerted by the stripe, the interfacial Hamiltonian model is used to show that ℓ_{0} is approached linearly with δμ with a slope which scales as L^{2} over the region satisfying L≲ξ_{∥}, where ξ_{∥} is the parallel correlation function pertinent to the stripe. This suggests that near the saturation there exists a universal curve ℓ_{m}(δμ) to which the adsorption isotherms corresponding to different values of L all collapse when appropriately rescaled. Although the series expansion based on the interfacial Hamiltonian model can be formed by considering higher order terms, a more appropriate approximation in the form of a rational function based on scaling arguments is proposed. The approximation is based on exact asymptotic results, namely, that ℓ_{m}∼δμ^{-1/3} for L→∞ and that ℓ_{m} obeys the correct δμ→0 behavior in line with the results of the interfacial Hamiltonian model. All the predictions are verified by the comparison with a microscopic density functional theory (DFT) and, in particular, the rational function approximation-even in its simplest form-is shown to be in a very reasonable agreement with DFT for a broad range of both δμ and L.

Orientation Control of Semiconducting Polymers Using Microchannel Molds

The molecular orientation of organic semiconductors (OSCs) is of fundamental importance to anisotropic electrical behavior as well as superior properties in practical applications. Here, a simple and effective method is demonstrated to fabricate highly oriented semiconducting polymers, poly(3-hexylthiophene) (P3HT) and poly{[N,N'-bis(2-octyldodecyl)-1,4,5,8-naphthalenediimide-2,6-diyl]-alt-5,5'-(2,2'-bithiophene)} (P(NDI2OD-T2)), by mass transfer effect under microchannel molds by diffusion and convection. Furthermore, parallel or perpendicular molecular arrangements relative to the channel direction were achieved by varying the widths of the microchannels, which are directly observed using polarized optical microscopy and two-dimensional grazing-incidence X-ray diffraction experiments. The method could enable the fabrication of organic field-effect transistors that exhibit anisotropic electrical properties indicating inter- or intrachain charge transport. The resulting platform will provide a simple approach for multidirectional orientations of anisotropic OSCs.

High-Resolution Electrochemical Transistors Defined by Mold-Guided Drying of PEDOT:PSS Liquid Suspension

Ion-sensitive transistors with nanoscale or microscale dimensions are promising for high-resolution electrophysiological recording and sensing. Technology that can pattern polymer functional materials directly from a solution can effectively avoid any chemical damage induced by conventional lithography techniques. The application of a mold-guided drying technique to pattern PEDOT:PSS-based transistors with high resolution directly from the water-based suspension is presented in this paper. Gold electrodes with short channels were first defined by creating high-resolution polymer lines with mold-guided drying followed by pattern transfer through a lift-off process. Then, PEDOT:PSS lines were subsequently created through an identical mold-guided drying process on the predefined electrodes. Small-scale transistor devices with both shortened channel length and width exhibited a good high-frequency response because of the weak capacitive effect. This is particularly advantageous for electrochemical transistors since the use of conventional fabrication techniques is extremely challenging in this case. In addition, modified polymer chain alignment of the assembled PEDOT:PSS lines during the drying process was observed by optical and electrical measurement. The mold-guided drying technique has been proven to be a promising method to fabricate small-scale devices, especially for biological applications.

Sensing of Oxygen Partial Pressure in Air with ZnO Nanoparticles

The demand for sensors in response to oxygen partial pressure in air is increasingly high in recent years and small-size sensors on a micrometer scale and even a nanometer scale are particularly desirable. In this paper, the sensing of oxygen partial pressure in air was realized by a solution-processed ZnO nanoparticle (NP). Thin-film ZnO NP was prepared by spin-coating and a highly sensitive sensor was then fabricated. The oxygen sensing performance was characterized in air and compared with that in nitrogen, which showed an increase in electrical conductance by more than 100 times as a result of decreasing oxygen partial pressure from 10³ mBar to 10⁻⁵ mBar. Moreover, higher sensitivity was achieved by increasing the annealing temperature and the effect of thermal annealing was also investigated. Furthermore, ZnO NP lines with 7 μm in width were successfully patterned with low cost by a mould-guided drying technique from ZnO NP dispersion, which makes ZnO NP extremely promising for miniaturized and integrated sensing applications.

Density Modulation of Embedded Nanoparticles via Spatial, Temporal, and Chemical Control Elements

Nanoparticle polymer composites have enabled material multifunctionalities that are difficult to obtain otherwise. A simple modification to a commercially available resin system enables a universal methodology to embed nanoparticles in resins via spatial, temporal, thermal, concentration, and chemical control parameters. Changes in nanoparticle density distribution are exploited to demonstrate dynamic optical and electronic properties that can be processed on-demand, without the need for expensive equipment or cleanroom facilities. This strategy provides access to the control of optical (cooperative plasmonic effects), electronic (insulator to a conductor), and chemical parameters (multimetal patterning). Using the same composite resin system, the followings are fabricated: i) diffraction gratings with tuneable diffraction efficiencies (10-78% diffraction efficiencies), ii) organic electrochemical transistors with a low drive voltage, and iii) embedded electrodes in confined spaces for potential diagnostic applications.

Micro-to-nanometer patterning of solution-based materials for electronics and optoelectronics

Technologies for micro-to-nanometer patterns of solution-based materials (SBMs) contribute to a wide range of practical applications in the fields of electronics and optoelectronics. Here, state-of-the-art micro-to-nanometer scale patterning technologies of SBMs are disseminated. The utilisation of patterning for a wide-range of SBMs leads to a high level of control over conventional solution-based film fabrication processes that are not easily accessible for the control and fabrication of ordered micro-to-nanometer patterns. In this review, various patterning procedures of SBMs, including modified photolithography, direct-contact patterning, and inkjet printing, are briefly introduced with several strategies for reducing their pattern size to enhance the electronic and optoelectronic properties of SBMs explained. We then conclude with comments on future research directions in the field.

Control of Droplet Evaporation on Oil-Coated Surfaces for the Synthesis of Asymmetric Supraparticles

Controlling the droplet evaporation on surfaces is desired to get uniform depositions of materials in many applications, for example, in two- and three-dimensional printing and biosensors. To explore a new route to control droplet evaporation on surfaces and produce asymmetric particles, sessile droplets of aqueous dispersions were allowed to evaporate from surfaces coated with oil films. Here, we applied 1-50 μm thick films of different silicone oils. Two contact lines were observed during droplet evaporation: an apparent liquid-liquid-air contact line and liquid-liquid-solid contact line. Because of the oil meniscus covering part of the rim of the drop, evaporation at the periphery is suppressed. Consequently, the droplet evaporates mainly in the central region of the liquid-air interface rather than at the droplet's edge. Colloidal particles migrate with the generated upward flow inside the droplet and are captured by the receding liquid-air interface. A uniform deposition ultimately forms on the substrate. With this straightforward approach, asymmetric supraparticles have been successfully fabricated independent of particle species.

Mitigating Meniscus Instabilities in Solution-Sheared Polymer Films for Organic Field-Effect Transistors

Semiconducting donor-acceptor copolymers are considered to be a promising material class for solution-coated, large-scale organic electronic applications. A large number of works have shown that the best-performing organic field-effect transistors (OFETs) are obtained on low-surface-energy substrates. The meniscus instabilities that occur when coating on such surfaces considerably limit the effective deposition speeds. This represents a limiting factor for the upscaling of device fabrication for mass production, an issue that needs to be addressed if organic electronic devices are ever to become commercially relevant. In this work, we present a method to increase the accessible window of coating speeds for the solution shearing of donor-acceptor semiconductor polymers for the fabrication of OFETs. By incorporating a piezo crystal that is capable of producing high-frequency vibrations into the coating head, we are able to mitigate contact line instabilities due to the depinning of the contact line, thereby suppressing the commonly encountered "stick-and-slip" phenomenon.

Controlled open-cell two-dimensional liquid foam generation for micro- and nanoscale patterning of materials

Liquid foam consists of liquid film networks. The films can be thinned to the nanoscale via evaporation and have potential in bottom-up material structuring applications. However, their use has been limited due to their dynamic fluidity, complex topological changes, and physical characteristics of the closed system. Here, we present a simple and versatile microfluidic approach for controlling two-dimensional liquid foam, designing not only evaporative microholes for directed drainage to generate desired film networks without topological changes for the first time, but also microposts to pin the generated films at set positions. Patterning materials in liquid is achievable using the thin films as nanoscale molds, which has additional potential through repeatable patterning on a substrate and combination with a lithographic technique. By enabling direct-writable multi-integrated patterning of various heterogeneous materials in two-dimensional or three-dimensional networked nanostructures, this technique provides novel means of nanofabrication superior to both lithographic and bottom-up state-of-the-art techniques.

Efficient camera self-calibration method for remote sensing photogrammetry

Internal parameter calibration of remote sensing cameras (RSCs) is a necessary step in remote sensing photogrammetry. On-orbit camera calibration widely adopts external ground control points (GCPs) to measure its internal parameters. However, accessible and available GCPs are not easy to achieve when cameras work on a satellite platform. In this paper, we propose an efficient camera self-calibration method using a micro-transceiver in conjunction with deep learning. A supervised learning set is produced by the micro-transceiver, where multiple two-dimensional diffraction grids are produced and transformed into multiple auto-collimating sub-beams equivalent to infinite target-point training examples. A deep learning network is used to invert the learnable internal parameters. The micro-transceiver can be easily integrated into the internal structure of RSCs allowing to calibrate them independently on external ground control targets.