Shear alignment of sphere-morphology block copolymer thin films with viscous fluid flow

Nonequilibrium design strategies for functional colloidal assemblies

We use a nonequilibrium variational principle to optimize the steady-state, shear-induced interconversion of self-assembled nanoclusters of DNA-coated colloids. Employing this principle within a stochastic optimization algorithm allows us to identify design strategies for functional materials. We find that far-from-equilibrium shear flow can significantly enhance the flux between specific colloidal states by decoupling trade-offs between stability and reactivity required by systems in equilibrium. For isolated nanoclusters, we find nonequilibrium strategies for amplifying transition rates by coupling a given reaction coordinate to the background shear flow. We also find that shear flow can be made to selectively break detailed balance and maximize probability currents by coupling orientational degrees of freedom to conformational transitions. For a microphase consisting of many nanoclusters, we study the flux of colloids hopping between clusters. We find that a shear flow can amplify the flux without a proportional compromise on the microphase structure. This approach provides a general means of uncovering design principles for nanoscale, autonomous, functional materials driven far from equilibrium.

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.

Rheology of cubic particles suspended in a Newtonian fluid

Many real-world industrial processes involve non-spherical particles suspended in a fluid medium. Knowledge of the flow behavior of these suspensions is essential for optimizing their transport properties and designing processing equipment. In the present work, we explore and report on the rheology of concentrated suspensions of cubic-shaped colloidal particles under steady and dynamic shear flow. These suspensions exhibit a rich non-Newtonian rheology that includes shear thickening and normal stress differences at high shear stresses. Scalings are proposed to connect the material properties of these suspensions of cubic particle to those measured for suspensions of spherical particles. Negative first normal stress differences indicate that lubrication hydrodynamic forces dominate the stress in the shear-thickened state. Accounting for the increased lubrication hydrodynamic interactions between the flat surfaces of the cubic particles allows for a quantitative comparison of the deviatoric stress in the shear-thickened state to that of spherical particles. New semi-empirical models for the viscosity and normal stress difference coefficients are presented for the shear-thickened state. The results of this study indicate that cubic particles offer new and unique opportunities to formulate colloidal dispersions for field-responsive materials.

Direct Immersion Annealing of Thin Block Copolymer Films

We demonstrate ordering of thin block copolymer (BCP) films via direct immersion annealing (DIA) at enhanced rate leading to stable morphologies. The BCP films are immersed in carefully selected mixtures of good and marginal solvents that can impart enhanced polymer mobility, while inhibiting film dissolution. DIA is compatible with roll-to-roll assembly manufacturing and has distinct advantages over conventional thermal annealing and batch processing solvent-vapor annealing methods. We identify three solvent composition-dependent BCP film ordering regimes in DIA for the weakly interacting polystyrene-poly(methyl methacrylate) (PS-PMMA) system: rapid short-range order, optimal long-range order, and a film instability regime. Kinetic studies in the "optimal long-range order" processing regime as a function of temperature indicate a significant reduction of activation energy for BCP grain growth compared to oven annealing at conventional temperatures. An attractive feature of DIA is its robustness to ordering other BCP (e.g. PS-P2VP) and PS-PMMA systems exhibiting spherical, lamellar and cylindrical ordering.

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.

Domain patterns in a diblock copolymer-diblock copolymer mixture with oscillatory particles

We investigate the orientational order transition of striped patterns in microphase structures of diblock copolymer-diblock copolymer mixtures in the presence of periodic oscillatory particles. Under certain conditions, although the macrophase separation of a system is almost isotropic, microphase separation of one diblock copolymer takes place and becomes anisotropic gradually. By changing the oscillatory frequency and amplitude, the orientational order transition of a striped microphase structure from the state parallel to the oscillatory direction to the state perpendicular to the oscillatory direction is observed. We also find that the order transition occurs when we change the initial composition ratio. Furthermore, we examine the domain size and the orientational order parameter of microstructure in the process of orientational order transition. The results may provide guidance for experimentalists. This model system can also give a simple way to realize orientational order transition of soft materials by changing the oscillatory field.

Nanorod self-assembly for tuning optical absorption

Metallic nanoparticles that absorb and concentrate light are leading to greater efficiencies in nanophotonic devices. By confining gold nanorods (Au NRs) in a polymer film, we can control their spacing and orientation and, in turn, the absorption and polarization characteristics of the nanocomposite. In this study, we systematically increase the volume fraction of Au NRs (φrod) (aspect ratio v=3.3) while maintaining a uniform dispersion. As φrod increases from 1 to 16 vol %, the spacing between rods decreases from 120 to 20 nm and scales as φrod φ0.4. Simultaneously, the local 2D orientational order parameter increases linearly with φrod, although the rods are globally isotropic. The Au NR dispersion is found to depend on the enthalpic interactions between poly(ethylene glycol) brush grafted to the Au NRs and the poly(methyl methacrylate) matrix chains. Furthermore, the plasmon resonance exhibits a red shift with increasing φrod, and coupling is observed for separations up to 70 nm. Because NR spacing and orientation can be finely controlled using polymer matrix, these films are ideally suited for understanding fundamental behavior (e.g., plasmon coupling) as well as practical devices (e.g., solar cells).

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.

Phase-field modeling of the formation of lamellar nanostructures in diblock copolymer thin films under inplanar electric fields

Recent experiments show that external inplanar electric field can be employed to guide the molecular self-assembly in diblock copolymer (BCP) thin films to form lamellar nanostructures with potential applications in nanotechnology. We study this self-assembly process through a detailed coarse-grained phase-separation modeling. During the process, the free energy of the BCP films is modeled as the Ginzburg-Landau free energy with nonlocal interaction and electrostatic coupling. The resulting Cahn-Hilliard (CH) equation is solved using an efficient semi-implicit Fourier-spectral algorithm. Numerical results show that the morphology of order parameter formed in either symmetric or asymmetric BCP thin films is strongly influenced by the electric field. For symmetrical BCPs, highly ordered lamellar nanostructures evolved along the direction of the electric field. Phase nucleation and dislocation climbing in the BCP films predicted by the numerical simulation are in a good agreement with those observed in recent BCP electronanolithography. For asymmetrical BCPs, numerical simulation shows that nanodots are guided to align to the electric field. Furthermore, in the case of high electric field, nanodots formed in asymmetrical BCPs may further convert into highly ordered lamellar nanostructures (sphere-to-cylinder transition) parallel to the electric field. Effects of the magnitude of electric field, BCP asymmetry, and molecular interaction of BCPs on the self-assembly process are examined in detail using the numerical scheme developed in this study. The present study can be used for the prediction of the formation of nanostructures in BCP thin films and the quality control of BCP-based nanomanufacturing through optimizing the external electric fields.

Tip-induced orientational order of surfactant micelles on gold

Using liquid-cell atomic force microscopy, we investigate aqueous solutions of alkyltrimethylammonium halide surfactants at the Au111 surface. The long, micellar surfactant surface aggregates cover the gold surface completely and exhibit two types of orientational order for chloride and bromide counterions, respectively. We observe lateral forces perpendicular to the scanning direction, which we explain by anisotropic friction between the probe and the oriented micelles. Conversely, we show that these friction forces can be employed to modify the spatial conformation of the micellar adlayer. Where previous methods have failed to provide control over the orientation down to the level of individual micelles, we use this technique to achieve a very high degree of order over more than 100 micelle diameters.

Unconventional methods for forming nanopatterns

Nanostructured materials have become an increasingly important theme in research, in no small part due to the potential impacts this science holds for applications in technology, including such notable areas as sensors, medicine, and high-performance integrated circuits. Conventional methods, such as the top-down approaches of projection lithography and scanning beam lithography, have been the primary means for patterning materials at the nanoscale. This article provides an overview of unconventional methods - both top-down and bottom-up approaches - for generating nanoscale patterns in a variety of materials, including methods that can be applied to fragile molecular systems that are difficult to pattern using conventional lithographic techniques. The promise, recent progress, advantages, limitations, and challenges to future development associated with each of these unconventional lithographic techniques will be discussed with consideration given to their potential for use in large-scale manufacturing.

Hierarchical nanostructure control in rod-coil block copolymers with magnetic fields

Magnetic field alignment of rod-coil block copolymers is shown to proceed through coupling to the diamagnetic moment of individual rod blocks. Block copolymer self-assembly then leads to alignment of the interfaces perpendicular to the field lines and long range order on a 10 nm lengthscale. This is in contrast to previously demonstrated alignment techniques, which couple to the block copolymer interfaces rather than individual molecules. Furthermore, alignment occurs without direct physical contact to samples millimeters in size.