A compound eye-like morphology formed through hexagonal array of hemispherical microparticles where an alkyl-fullerene derivative self-assembled at atmosphere-sealed air/water interface

Self-assembly processes are widely used in nature to form hierarchically organized structures, prompting us to investigate such processes at the macroscopic scale. We report an unprecedented approach toward the self-assembly of alkyl-fullerene (C60) derivatives into a hexagonal array of hemispherical microparticles akin to the morphology of a compound eye. The method includes casting solvated alkyl-C60compound on an air/water interface followed by controlled evaporation of the solvent under atmosphere-sealed conditions. This leads to the formation of a thin film floating on water with a diameter of up to 1.3 centimeters and exhibiting a hexagonally-packed hemispherical structure with a diameter of approximately 38µm. Various measurements of the formed film reveal that amorphousness is necessary for suppressing uncontrollable crystallization, which affects the microparticle size and film formation mechanism. We tested the feasibility of this approach for the self-assembly of a relatively common C60derivative, [6,6]-phenyl-C61-butyric acid methyl ester (PC61BM), resulting in the formation of a film with a similar pattern of hexagonally-packed larger microparticles approximately 152µm in size of diameter.

Exploiting breath figure reversibility for in situ pattern modulation and hierarchical design

The breath figure (BF) method employs condensation droplets as dynamic templates for patterning polymer films. In the classical approach, dropwise condensation and film solidification are simultaneously induced through solvent evaporation, leading to empirically derived patterns with limited predictability of the final design. Here we use the temporally arrested BF methodology, controlling condensation and polymerisation independently to create diverse BF patterns with varied pore size, arrangement and distribution. External temperature control enables us to further investigate and exploit the inherent reversibility of the phase change process that governs the pattern formation. We modulate the level of subcooling and superheating to achieve subsequent regimes of condensation and evaporation, permitting in situ regulation of the droplet growth and shrinkage kinetics. The full reversibility of the phase change processes joined with active photopolymerisation in the current approach thus allows arresting of predictable BF kinetics at intermediate stages, thereby accessing patterns with varied pore size and spacing for unchanged material properties and environmental conditions. This simultaneous active control over both the kinetics of phase change and polymer solidification offers affordable routes for the fabrication of diverse predictable porous surfaces; manufacture of monolithic hierarchical BF patterns are ultimately facilitated through the advanced control of the BF assembly using the method presented here.

Increasing the ionic conductivity and lithium-ion transport of photo-cross-linked polymer with hexagonal arranged porous film hybrids

High ionic conductivity, suitable mechanical strength, and electrochemical stability are the main requirements for high-performance poly(ethylene oxide)-based electrolytes. However, the low ionic conductivity owing to the crystallinity of the ethylene oxide chain that limits the discharge rate and low-temperature performance has restricted the development and commercialization of these electrolytes. Lithium electrolytes that combine high ionic conductivity with a high lithium transference number are rare and are essential for high-power batteries. Here, we report hexagonal arranged porous scaffolds for holding prototype polyethylene glycol-based composite electrolytes containing solvate ionic liquid. The appealing electrochemical and thermal properties indicate their potential as electrolytes for safer rechargeable lithium-ion batteries. The porous scaffolds in the composite electrolytes ensure better electrochemical performance towing to their shortened pores (sizes of 3-14 μm), interconnected pathways, and improved lithium mobility. We demonstrate that both molecular design and porous microstructures are essential for improving performance in polymer electrolytes.

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Robust HCPE films were fabricated using the breath-figure method

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HCPE shows high ionic conductivity of 6.66 × 10⁻⁴ S cm⁻¹

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HCPE exhibits ESW of 4.7 V vs Li+/Li at 60°C and excellent compatibility with Li

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Molecular design and porous-microstructures are essential for electrolyte performance

Synthesis of ABA triblock copolymer nanoparticles by polymerization induced self-assembly and their application as an efficient emulsifier

ABA triblock copolymer nanoparticles of PHPMA-b-PS-b-PHPMA were synthesized by PISA and demonstrated to be an efficient emulsifier.

Site-Selective Wettability Control of Honeycomb Films by UV-O3-Assisted Sol-Gel Coating

Wettability control of porous materials is significant in lateral flow immunoassay, microfluidic systems, microdroplet manipulation, and so on. In this report, formation of metal oxide layers on self-organized polymer honeycomb films to control surface wettability by simple sol-gel coating and UV-O₃ treatment was demonstrated. By the combination of bottom-up and top-down processes, silica thin layers can be formed by retaining their original three-dimensional honeycomb structures. Furthermore, photopatterning of metal oxides on honeycomb films can be achieved by UV irradiation through photomasks. Site-selective wettability control of honeycomb films was realized by patterning silica layers on the surface of the film.

Underwater Bubble and Oil Repellency of Biomimetic Pincushion and Plastron-Like Honeycomb Films

Underwater highly bubble and oil-repellent surfaces were prepared based on honeycomb- and pincushion-structured films prepared by breath figure technique and post modifications including UV-ozone treatment and peeling the top layer. Furthermore, bubble generation from the plastron-like honeycomb gas chamber by attaching oil droplet onto the surface of honeycomb films was first observed. Both controlling gas bubbles and oil droplets underwater are important issues in the field of microfluidics since they are useful and may solve the maleficence to liquid transportation in narrow microchannels.

One step fabrication of mesh-reinforced hierarchic perforated microporous honeycomb films with tunable filtering property

Highly ordered porous films whose pore size ranges from submicron to micron scale have always been an extensive area of research due to their broad range of application to photonic crystals, cell culturing scaffolds, filtration and separation membranes, just to name a few. However, the fragile nature of such a functional porous film has hindered its implementation to advanced uses. Inspired by the hierarchic structure in nature which offers both robustness and functionality, we created in a single fabrication step a mesh-reinforced hierarchic perforated honeycomb film with highly ordered micron pores using the breath figure method. By using the elastomer 1,2-polybutadiene as the material for the film in the combination of the mesh grid, the pore size of the obtained film can be tuned upon stretching. Tubular structures made from the mesh-reinforced hierarchic perforated porous honeycomb film with tunable pore size have been demonstrated.

Controlled Bulk Properties of Composite Polymeric Solutions for Extensive Structural Order of Honeycomb Polysulfone Membranes

This work provides additional insights into the identification of operating conditions necessary to overcome a current limitation to the scale-up of the breath figure method, which is regarded as an outstanding manufacturing approach for structurally ordered porous films. The major restriction concerns, indeed, uncontrolled touching droplets at the boundary. Herein, the bulk of polymeric solutions are properly managed to generate honeycomb membranes with a long-range structurally ordered texture. Water uptake and dynamics are explored as chemical environments are changed with the intent to modify the hydrophilic/hydrophobic balance and local water floatation. In this context, a model surfactant such as the polyoxyethylene sorbitan monolaurate is used in combination with alcohols at different chain length extents and a traditional polymer such as the polyethersufone. Changes in the interfacial tension and kinematic viscosity taking place in the bulk of composite solutions are explored and examined in relation to competitive droplet nucleation and growth rate. As a result, extensive structurally ordered honeycomb textures are obtained with the rising content of the surfactant while a broad range of well-sized pores is targeted as a function of the hydrophilic-hydrophobic balance and viscosity of the composite polymeric mixture. The experimental findings confirm the consistency of the approach and are expected to give propulsion to the commercially production of breath figures films shortly.

Highly Ordered Honeycomb Film Formation of Linear Polymers by the Breath Figure Technique

Highly ordered, porous honeycomb (HC) films were prepared by the breath figure technique from linear polymers poly(methyl methacrylate) (PMMA) and polystyrene (PS). Typically HC films are difficult to form from such simple linear polymers. The addition of a novel fluorinated polymer (FP) additive with as little as 1 wt-% to PMMA or 5 wt-% to PS was required to obtain regular porous HC films. Through investigation of the influence of the additive on the polymer properties, three parameters based on interfacial tension, polymer solution viscosity, and polymer solidification rate were identified as key factors affecting the ability of polymer systems to form regular porous HC films. A new hypothesis was subsequently developed based on the relationships of these parameters to explain the unusual behaviour associated with HC film formation from linear PMMA and PS with addition of FP additive. This work will provide a new tool to guide the formation of HC films and will greatly broaden the range of polymers used to form HC films in the future.

Formation of breath figure arrays in methanol vapor assisted by surface active agents

Breath figure (BF) process is a promising technique for fabricating honeycomb polymer films. It is usually conducted in water vapor. While, in organic vapors only unique polymer can be used to prepare BF arrays as reported in our previous article (Breath Figure in Nonaqueous Vapor. Soft Matter, 2013, 506-514), although new structure features are induced in the film. In this paper, a universal modified BF processing is devised for preparing porous films in methanol vapor with conventional polymers, by adding a small amount of surface active agent into the casting solution, such as siloxane- and fluorine-containing block copolymers. The pores in the PS films prepared with this method are of cylindrical shape with large depth-diameter aspect ratio, and the diameter and depth of pores can be well controlled by the experiment conditions. Based on these results, the formation mechanism of honeycomb structure in methanol vapor is discussed.

Tuning the pore composition by two simultaneous interfacial self-assembly processes: breath figures and coffee stain

In the current paper, we prepared microstructured porous films by the breath figures approach using polymer blends consisting of polystyrene as the major component and an amphiphilic additive, either a synthetic block copolymer {two different polystyrene-b-poly[poly(ethylene glycol) methyl ether methacrylate] copolymers} or a series of commercial surfactants. Tetrahydrofuran was employed as the solvent. Confocal micro-Raman spectroscopy demonstrated the preferential location of the amphiphilic additives in the cavities of the film as a consequence of the breath figures mechanism. However, the distribution of the copolymer within the cavities varies depending upon the structure and, more precisely, the surface properties of the additives, leading to three different situations. First of all, the copolymer with a larger polystyrene segment, insoluble in the condensed water droplets, is homogeneously distributed along the whole surface of the cavities. On the contrary, when the copolymer is soluble in water (shorter polystyrene segment), it migrates inside the droplet and a coffee-stain phenomenon takes place during the water droplet evaporation, conducting to a ring-like deposition on the top edge of the cavities. Finally, when a water-soluble surfactant with high surface activity is used, the surfactant is solubilized inside the water droplets, which provokes a decrease on the surface tension and the coffee-ring effect is modified. In this situation, the copolymer covers the bottom of the pore.

Formation and control of line defects caused by tectonics of water droplet arrays during self-organized honeycomb-patterned polymer film formation

This study describes the formation of macro-scale defects of the honeycomb-patterned polymer film and we discovered two types of new line defects which differ from the defects reported in the past studies. We examined the formation mechanisms of the line defects and clarified two types of formation mechanisms of the "Divergent" mode line defects and the "Convergent" mode line defects caused by the "tectonics" of water droplet arrays on polymer solutions. The regions causing the macro-scale line defects are made clear in the phase diagram represented by the radius and the density of the micro-scale water droplets. In addition, the results of our calculations made it possible to theoretically predict the water droplet growth time for the water droplets to grow to the ideal size for uniform packing that is necessary for fabrication of the defect-free honeycomb-patterned polymer film. With the use of these techniques, A4-sized, defect-free, honeycomb-patterned polymer films can be fabricated.

Advances in Fabrication Materials of Honeycomb Structure Films by the Breath-Figure Method

Creatures in nature possess almost perfect structures and properties, and exhibit harmonization and unification between structure and function. Biomimetics, mimicking nature for engineering solutions, provides a model for the development of functional surfaces with special properties. Recently, honeycomb structure materials have attracted wide attention for both fundamental research and practical applications and have become an increasingly hot research topic. Though progress in the field of breath-figure formation has been reviewed, the advance in the fabrication materials of bio-inspired honeycomb structure films has not been discussed. Here we review the recent progress of honeycomb structure fabrication materials which were prepared by the breath-figure method. The application of breath figures for the generation of all kinds of honeycomb is discussed.

Robust anisotropic polymer meshes prepared by stretching and photo-crosslinking of poly(1,2-butadiene) honeycomb films

Anisotropic polymer meshes, which have micrometre-scale rectangular pores, were prepared by simple stretching and photo-crosslinking of poly(1,2-butadiene) honeycomb films. First, honeycomb films with pores of uniform size were prepared by a simple self-organization process. Then, after stretching and UV photo-crosslinking, anisotropic polymer meshes were formed. These anisotropic polymer meshes had high chemical and thermal stability, and exhibited anisotropic wettability. Moreover, by using a photo-crosslinking process, the anisotropic meshes could be photo-patterned. These anisotropic polymer meshes are expected to be applicable to digital microfluidic devices, cell aligners, and other such devices.