Extending Dynamic Range of Block Copolymer Ordering with Rotational Cold Zone Annealing (RCZA) and Ionic Liquids

Scalable and low-cost methods to align and orient block copolymer (BCP) films and membranes are critical for their adaptation for nonlithographic applications. Cold zone annealing (CZA) can align BCP microdomains and is scalable via roll-to-roll (R2R) manufacturing. However, the efficacy of orientation by CZA is strongly dependent on the thermal zone velocity (<i>V</i>_cza). Optimization of this rate can be time-consuming and tedious. To address this shortcoming, we report rotational or radial CZA (RCZA) that provides a combinatorial approach to efficiently determine how linear <i>V</i>_cza rate impacts microdomain orientation. RCZA rapidly identifies the optimal CZA velocities for perpendicular orientation of cylinders in polystyrene-<i>block</i>-poly­(methyl methacrylate) films that previously required tens of measurements [Macromolecules 2012, 45, 7107], demonstrated here with much finer velocity resolution using three overlapping radial regimes. Notably, the efficacy of CZA for perpendicular alignment rapidly decays for <i>V</i>_cza > 10 μm/s. To overcome this limitation, the addition of 2 wt % 1-ethyl-3-methylimidazolium bis­(trifluoro­methyl­sulfonyl)­imide sufficiently alters the surface tension and segmental relaxations via reduced viscosity to increase the processing window for perpendicular cylinders, approximately 75% at <i>V</i>_cza ≈ 330 μm/s, approaching R2R speeds. Further increasing ionic liquid content to 5 wt % leads to mostly parallel orientation due to surface wetting. Ionic liquids can dramatically increase BCP processing speeds for applications, such as membranes, and RCZA can efficiently map out the optimal processing parameters

Morphology Control in Mesoporous Carbon Films Using Solvent Vapor Annealing

Ordered mesoporous (2–50 nm) carbon films were fabricated using cooperative self-assembly of a phenolic resin oligomer with a novel block copolymer template (poly­(styrene-<i>block</i>-<i>N</i>,<i>N</i>-dimethyl-<i>n</i>-octadecylamine <i>p</i>-styrenesulfonate), (PS-<i>b</i>-PSS-DMODA)) synthesized by reversible addition–fragmentation chain transfer (RAFT) polymerization. Due to the high <i>T</i>_g of the PS segment and the strong interactions between the phenolic resin and the PSS-DMODA, the segmental rearrangement is kinetically hindered relative to the cross-linking rate of the phenolic resin, which inhibits long-range ordering and yields a poorly ordered mesoporous carbon with a broad pore size distribution. However, relatively short exposure (2 h) to controlled vapor pressures of methyl ethyl ketone (MEK) yields significant improvements in the long-range ordering and narrows the pore size distribution. The average pore size increases as the solvent vapor pressure during annealing increases, but an upper limit of <i>p</i>/<i>p</i>₀ = 0.85 exists above which the films dewet rapidly during solvent vapor annealing. This approach can be extended using mesityl oxide, which has similar solvent qualities to MEK, but is not easily removed by ambient air drying after solvent annealing. This residual solvent can impact the morphology that develops during cross-linking of the films. These results illustrate the ability to fine-tune the mesostructure of ordered mesoporous carbon films through simple changes in the processing without any compositional changes in the initial cast film

Fabrication of Porous Carbon/TiO₂ Composites through Polymerization-Induced Phase Separation and Use As an Anode for Na-Ion Batteries

Polymerization-induced phase separation of nanoparticle-filled solution is demonstrated as a simple approach to control the structure of porous composites. These composites are subsequently demonstrated as the active component for sodium ion battery anode. To synthesize the composites, we dissolved/dispersed titanium oxide (anatase) nanoparticles (for sodium insertion) and poly­(hydroxybutyl methacrylate) (PHBMA, porogen) in furfuryl alcohol (carbon precursor) containing a photoacid generator (PAG). UV exposure converts the PAG to a strong acid that catalyzes the furfuryl alcohol polymerization. This polymerization simultaneously decreases the miscibility of the PHBMA and reduces the mobility in the mixture to kinetically trap the phase separation. Carbonization of this polymer composite yields a porous nanocomposite. This nanocomposite exhibits nearly 3-fold greater gravimetric capacity in Na-ion batteries than the same titanium oxide nanoparticles that have been coated with carbon. This improved performance is attributed to the morphology as the carbon content in the composite is five times that of the coated nanoparticles. The porous composite materials exhibit stable cyclic performance. Moreover, the battery performance using materials from this polymerization-induced phase separation method is reproducible (capacity within 10% batch-to-batch). This simple fabrication methodology may be extendable to other systems and provides a facile route to generate reproducible hierarchical porous morphology that can be beneficial in energy storage applications

Kinetics of UV Irradiation Induced Chain Scission and Cross-Linking of Coumarin-Containing Polyester Ultrathin Films

Photoresponsive thin films are commonly encountered as high performance coatings as well as critical component, photoresists, for microelectronics manufacture. Despite intensive investigations into the dynamics of thin glassy polymer films, studies involving reactions of thin films have typically been limited by difficulties in decoupling segregation of reacting components or catalysts due to the interfaces. Here, thin films of coumarin polyesters overcome this limitation where the polyester undergoes predominately cross-linking upon irradiation at 350 nm, while chain scission occurs with exposure to 254 nm light. Spectroscopic ellipsometry is utilized to track these reactions as a function of exposure time to elucidate the associated reaction kinetics for films as thin as 15 nm. The cross-linking appears to follow a second order kinetic rate law, while oxidation of the coumarin that accompanies the chain scission and enables this reaction to be tracked spectroscopically appears to be a first order reaction in coumarin concentration. Because of the asymmetry in the coumarin diol monomer and the associated differences in local structure that result during formation of the polyester, two populations of coumarin are required to fit the reaction kinetics; 10–20% of the coumarin is significantly more reactive, but these groups appear to undergo chain scission/oxidation at both wavelengths. These reaction rate constants are nearly independent (within 1 order of magnitude) of film thickness down to 15 nm. There is maximum rate at a finite thickness for the 254 nm exposure, which we attribute to constructive interference of the UV radiation within the polymer film, rather than typical confinement effects; no thickness dependence in reaction rates is observed for the 350 nm exposure. The utilization of a single polymer with two distinct reactions enables unambiguous investigation of thickness effects on reactions

Sulfur Diffusion within Nitrogen-Doped Ordered Mesoporous Carbons Determined by in Situ X‑ray Scattering

The low intrinsic conductivity of sulfur necessitates conductive additives, such as mesoporous carbons, to the cathode to enable high-performance metal–sulfur batteries. Simultaneous efforts to address polysulfide shuttling have introduced nitrogen-doped carbons to provide both conductivity and suppressed shuttling because of their strong interaction with sulfur. The strength of this interaction will impact the ability to fill the mesopores with sulfur via melt infusion. Here, we systematically investigate how nitrogen doping influences the rate that molten sulfur can infiltrate the mesopores and the overall extent of pore filling of highly ordered mesoporous doped carbons using in situ small angle X-ray scattering (SAXS). The similarity in electron density between molten sulfur and the soft carbon framework of the mesoporous material leads to a precipitous decrease in the scattered intensity associated with the ordered structure as voids are filled with sulfur. As the nitrogen doping increases from 1 to 20 at. %, the effective diffusivity of sulfur in the mesopores decreases by an order of magnitude (2.7 × 10^–8 to 2.3 × 10^–9 cm/s). The scattering becomes nearly invariant within 20 min of melt infiltration at 155 °C for all but the most doped carbon, which indicates that submicron-sized mesoporous carbon particles can be filled rapidly. Additionally, the nitrogen doping decreases the sulfur content that can be accommodated within the mesopores from 95% of the mesopores filled without doping to only 64% filled with 20 at. % N as determined by the residual scattering intensity. Sulfur does not crystallize within the mesopores of the nitrogen-doped carbons, which is further indicative of the strong interactions between the nitrogen species and sulfur that can inhibit polysulfide shuttling. In situ SAXS provides insights into the diffusion of sulfur in mesopores and how the surface chemistry of nitrogen-doped carbon appears to significantly hinder the infiltration by sulfur

Enhanced Impact Resistance of Three-Dimensional-Printed Parts with Structured Filaments

Net-shape manufacture of customizable objects through three-dimensional (3D) printing offers tremendous promise for personalization to improve the fit, performance, and comfort associated with devices and tools used in our daily lives. However, the application of 3D printing in structural objects has been limited by their poor mechanical performance that manifests from the layer-by-layer process by which the part is produced. Here, this interfacial weakness is overcome using a structured, core–shell polymer filament where a polycarbonate (PC) core solidifies quickly to define the shape, whereas an olefin ionomer shell contains functionality (crystallinity and ionic) that strengthen the interface between the printed layers. This structured filament leads to improved dimensional accuracy and impact resistance in comparison to the individual components. The impact resistance from structured filaments containing 45 vol % shell can exceed 800 J/m. The origins of this improved impact resistance are probed using X-ray microcomputed tomography. Energy is dissipated by delamination of the shell from PC near the crack tip, whereas PC remains intact to provide stability to the part after impact. This structured filament provides tremendous improvements in the critical properties for manufacture and represents a major leap forward in the impact properties obtainable for 3D-printed parts

Nanoporous Nonwoven Fibril-Like Morphology by Cooperative Self-Assembly of Poly(ethylene oxide)-<i>block</i>-Poly(ethyl acrylate)-<i>block</i>-Polystyrene and Phenolic Resin

Cooperative self-assembly of block copolymers with (in)­organic precursors effectively generates ordered nanoporous films, but the porosity is typically limited by the need for a continuous (in)­organic phase. Here, a network of homogeneous fibrous nanostructures (≈20 nm diameter cylinders) having high porosity (≈ 60%) is fabricated by cooperative self-assembly of a phenolic resin oligomer (resol) with a novel, nonfrustrated, ABC amphiphilic triblock copolymer template, poly­(ethylene oxide)-<i>block</i>-poly­(ethyl acrylate)-<i>block</i>-polystyrene (PEO-<i>b</i>-PEA-<i>b</i>-PS), via a thermally induced self-assembly process. Due to the high glass transition temperature (<i>T</i>_g) of the PS segments, the self-assembly behavior is kinetically hindered as a result of competing effects associated with the ordering of the self-assembled system and the cross-linking of resol that suppresses segmental mobility. The balance in these competing processes reproducibly yields a disordered fibril network with a uniform fibril diameter. This nonequilibrium morphology is dependent on the PEO-<i>b</i>-PEA-<i>b</i>-PS to resol ratio with an evolution from a relatively open fibrous structure to an apparent poorly ordered mixed lamellae-cylinder morphology. Pyrolysis of these former films at elevated temperatures yields a highly porous carbon film with the fibril morphology preserved through the carbonization process. These results illustrate a simple method to fabricate thin films and coatings with a well-defined fiber network that could be promising materials for energy and separation applications

Transport-Limited Adsorption of Plasma Proteins on Bimodal Amphiphilic Polymer Co-Networks: Real-Time Studies by Spectroscopic Ellipsometry

Traditional hydrogels are commonly limited by poor mechanical properties and low oxygen permeability. Bimodal amphiphilic co-networks (β-APCNs) are a new class of materials that can overcome these limitations by combining hydrophilic and hydrophobic polymer chains within a network of co-continuous morphology. Applications that can benefit from these improved properties include therapeutic contact lenses, enzymatic catalysis supports, and immunoisolation membranes. The continuous hydrophobic phase could potentially increase the adsorption of plasma proteins in blood-contacting medical applications and compromise in vivo material performance, so it is critical to understand the surface characteristics of β-APCNs and adsorption of plasma proteins on β-APCNs. From real-time spectroscopic visible (Vis) ellipsometry measurements, plasma protein adsorption on β-APCNs is shown to be transport-limited. The adsorption of proteins on the β-APCNs is a multistep process with adsorption to the hydrophilic surface initially, followed by diffusion into the material to the internal hydrophilic/hydrophobic interfaces. Increasing the cross-linking of the PDMS phase reduced the protein intake by limiting the transport of large proteins. Moreover, the internalization of the proteins is confirmed by the difference between the surface-adsorbed protein layer determined from XPS and bulk thickness change from Vis ellipsometry, which can differ up to 20-fold. Desorption kinetics depend on the adsorption history with rapid desorption for slow adsorption rates (i.e., slow-diffusing proteins within the network), whereas proteins with fast adsorption kinetics do not readily desorb. This behavior can be directly related to the ability of the protein to spread or reorient, which affects the binding energy required to bind to the internal hydrophobic interfaces

Large-Scale Solvent Driven Actuation of Polyelectrolyte Multilayers Based on Modulation of Dynamic Secondary Interactions

Polyelectrolyte multilayers (PEMs), assembled from weak polyelectrolytes, have often been proposed for use as smart or responsive materials. However, such response to chemical stimuli has been limited to aqueous environments with variations in ionic strength or pH. In this work, a large in magnitude and reversible transition in both the swelling/shrinking and the viscoelastic behavior of branched polyethylenimine/poly­(acrylic acid) multilayers was realized in response to exposure with various polar organic solvents (e.g., ethanol, dimethyl sulfoxide, and tetrahydrofuran). The swelling of the PEM decreases with an addition of organic content in the organic solvent/water mixture, and the film contracts without dissolution in pure organic solvent. This large response is due to both the change in dielectric constant of the medium surrounding the film as well as an increase in hydrophobic interactions within the film. The deswelling and shrinking behavior in organic solvent significantly enhances its elasticity, resulting in a stepwise transition from an initially liquid-like film swollen in pure water to a rigid solid in pure organic solvents. This unique and recoverable transition in the swelling/shrinking behaviors and the rheological performances of weak polyelectrolyte multilayer film in organic solvents is much larger than changes due to ionic strength or pH, and it enables large scale actuation of a freestanding PEM. The current study opens a critical pathway toward the development of smart artificial materials

Control of Ordering and Structure in Soft Templated Mesoporous Carbon Films by Use of Selective Solvent Additives

The structure of ordered mesoporous carbons fabricated using poly­(styrene-block-<i>N</i>,<i>N</i>,-dimethyl-<i>n</i>-octadecylamine <i>p</i>-styrenesulfonate) (PS-<i>b</i>-PSS-DMODA) as the template and phenolic resin (resol) as the carbon source can be easily manipulated by inclusion of low concentrations of low volatility selective solvents in the casting solution. Casting from neat methyl ethyl ketone yields a disordered structure even upon thermal annealing. However, addition of both dioctyl phthalate (DOP, PS selective) and dimethyl sulfoxide (DMSO, resol and PSS-DMODA selective) at modest concentrations to this casting solution provides sufficient mobility to produce highly ordered films with cylindrical mesopores. The DOP acts to swell the hydrophobic domain and can more than double the mesopore size, while the DMSO acts to swell the resol phase. Moreover, the surface area of the mesoporous carbons increases significantly as the meosopore size increases. This is a result of the decrease in wall thickness, which can be ascertained by the constant <i>d</i>-spacing of the mesostructure as the pore size increases. This behavior is counter to the typical effect of pore swelling agents that increase the pore size and decrease the surface area. Moreover, with only 4 wt % DOP/DMSO in the solution (20 wt % relative to solids), the scattering profiles exhibit many orders of diffraction, even upon carbonization, which is not typically observed for soft templated films. Variation in the concentration of DOP and DMSO during casting enables facile tuning of the structure of mesoporous carbon films