Flexible Embedded Metal Meshes by Sputter-Free Crack Lithography for Transparent Electrodes and Electromagnetic Interference Shielding.

A facile and novel fabrication method is demonstrated for creating flexible poly(ethylene terephthalate) (PET)-embedded silver meshes using crack lithography, reactive ion etching (RIE), and reactive silver ink. The crack width and spacing in a waterborne acrylic emulsion polymer are controlled by the thickness of the polymer and the applied stress due to heating and evaporation. Our innovative fabrication technique eliminates the need for sputtering and ensures stronger adhesion of the metal meshes to the PET substrate. Crack trench depths over 5 µm and line widths under 5 µm have been achieved. As a transparent electrode, our flexible embedded Ag meshes exhibit a visible transmission of 91.3% and sheet resistance of 0.54 Ω/sq as well as 93.7% and 1.4 Ω/sq. This performance corresponds to figures of merit (σDC/σOP) of 7500 and 4070, respectively. For transparent electromagnetic interference (EMI) shielding, the metal meshes achieve a shielding efficiency (SE) of 42 dB with 91.3% visible transmission and an EMI SE of 37.4 dB with 93.7% visible transmission. We demonstrate the highest transparent electrode performance of crack lithography approaches in the literature and the highest flexible transparent EMI shielding performance of all fabrication approaches in the literature. These metal meshes may have applications in transparent electrodes, EMI shielding, solar cells, and organic light-emitting diodes.

Substrate-embedded metal meshes for ITO-free organic light emitting diodes.

Organic light-emitting diodes (OLEDs) have great potential for use in large-area display and lighting applications, but their widespread adoption for large areas is hindered by the high cost and insufficient performance of indium tin oxide (ITO) anodes. In this study, we introduce an alternative anode material - a silver mesh embedded in glass - to facilitate production of large-area OLEDs. We present a facile, scalable manufacturing technique to create high aspect ratio micromeshes embedded in glass to provide the planar geometry needed for OLED layers. Our phosphorescent green OLEDs achieve a current efficiency of 51.4 cd/A at 1000 cd/m2 and reach a slightly higher external quantum efficiency compared to a standard ITO/glass reference sample. Notably, these advancements are achieved without any impact on the viewing angle of the OLEDs. These findings represent a promising advancement towards ITO-free, high-efficiency OLEDs for various high performance, large-area applications, such as lighting and displays.

Black silicon spacing effect on bactericidal efficacy against gram-positive bacteria.

The morphology of regular and uniform arrays of black silicon structures was evaluated for bactericidal efficacy against gram-positive, non-motileStaphylococcusepidermidis(S.epidermidis). In this study, uniform and regular arrays of black silicon structures were fabricated using nanosphere lithography and deep reactive ion etching. The effects of nanomorphology on bacterial killing were systematically evaluated using silicon nanostructures with pitches ranging from 300 to 1400 nm pitch on spherical cocci approximately 500 to 1000 nm in diameter. Our results show that nanostructure morphology factors such as height and roughness do not directly determine bactericidal efficacy. Instead, the spacing between nanostructures plays a crucial role in determining how bacteria are stretched and lysed. Nanostructures with smaller pitches are more effective at killing bacteria, and an 82 ± 3% enhancement in bactericidal efficacy was observed for 300 nm pitch nanoneedles surface compared to the flat control substrates.

Silver Meshes for Record-Performance Transparent Electromagnetic Interference Shielding.

We present a simulation and experimental study of silver meshes to determine their performance for transparent electromagnetic interference (EMI) shielding. Simulations were employed to study the effects of the silver mesh's width, pitch, and thickness on EMI shielding efficiency (SE) in the 8-18 GHz frequency range and transparency in the visible spectrum. We demonstrate a scalable, facile fabrication method that involves embedding meshes in glass by etching trenches in glass and filling and curing reactive particle-free silver ink in these trenches. Our silver meshes achieve 58.4 dB EMI SE with 83% visible light transmission and 48.3 dB EMI SE with 90.3% visible transmission. The combination of high-conductivity silver, small widths (1.3 to 5 µm), and large thicknesses (0.5 to 2.0 µm) enables the best performance of metal meshes as well as single-sided shielding materials for transparent EMI shielding, as reported in the literature.

Bayesian optimization of nanophotonic electromagnetic shielding with very high visible transparency.

Transparent electromagnetic interference (EMI) shielding is needed in many optoelectronic applications to protect electronic devices from surrounding radiation while allowing for high visible light transmission. However, very high transmission (over 92.5%), high EMI shielding efficiency (over 30 dB) structures have yet to be achieved in the literature. Bayesian optimization is used to optimize different nanophotonic structures for high EMI shielding efficiency (SE) and high visible light transmission (T¯ v i s ). Below 90% average visible light transmission, sandwich structures consisting of high index dielectric/silver/high index dielectric films are determined to be optimal, where they are able to achieve 43.1 dB SE and 90.0% T¯ v i s . The high index of refraction dielectric layers reduce absorption losses in the silver and can be engineered to provide for antireflection through destructive interference. However, for optimal EMI shielding with T¯ v i s above 90%, the reflection losses at the air/dielectric interfaces need to be further reduced. Optimized double sided nanocone sandwich structures are determined to be best where they can achieve 41.2 dB SE and 90.8% T¯ v i s as well as 35.6 dB SE and 95.1% T¯ v i s . K-means clustering is utilized to show the performance of characteristic near-Pareto optimal structures. Double sided nanocone structures are shown to exhibit omnidirectional visible transmission with SE = 35.6 dB and over 85% T¯ v i s at incidence angles of 70 ∘.

Detailed balance analysis of vertical GaAs nanowire array solar cells: exceeding the Shockley Queisser limit.

We performed detailed balance analysis using rigorous coupled-wave analysis (RCWA) on vertical GaAs nanowire (NW) arrays. Both freestanding NW arrays as well as NW arrays on a perfect back reflector are assessed. Both types of vertical NW arrays demonstrate efficiencies that exceed the Shockley Queisser (SQ) or radiative efficiency limit when the NWs are sufficiently long. The use of a back reflector enhances the efficiency of NW solar cells by increasing solar absorption and suppressing emission from the backside of the solar cell. We study the light trapping and material reduction advantages of NWs. Furthermore, we compare simulations that evaluate detailed balance efficiency with ultimate efficiency and show that ultimate efficiency studies can determine near-optimal solar cells while vastly reducing the number of simulations that need to be performed. While open circuit voltages above the radiative limit can be achieved, tradeoffs with short circuit current must be carefully considered. We also compare our simulation results to other claims in the literature that NWs are capable of exceeding the SQ limit.

Reactive silver inks for antiviral, repellent medical textiles with ultrasonic bleach washing durability compared to silver nanoparticles.

Medical textiles are subject to particularly harsh disinfection procedures in healthcare settings where exposure risks are high. This work demonstrates a fabric treatment consisting of a reactive silver ink and low surface energy PDMS polymer that provides for superhydrophobicity and antiviral properties against enveloped herpes simplex virus stocks even after extended ultrasonic bleach washing. The antiviral properties of reactive silver ink has not been previously reported or compared with silver nanoparticles. The fabric treatment exhibits high static contact angles and low contact angle hysteresis with water, even after 300 minutes of ultrasonic bleach washing. Similarly, after this bleach washing treatment, the fabric treatment shows reductions of infectious virus quantities by about 2 logs compared to controls for enveloped viruses. The use of silver ink provides for better antiviral efficacy and durability compared to silver nanoparticles due to the use of reactive ionic silver, which demonstrates more conformal coverage of fabric microfibers and better adhesion. This study provides insights for improving the wash durability of antiviral silver fabric treatments and demonstrates a bleach wash durable, repellent antiviral treatment for reusable, functional personal protective equipment applications.

Surface nanostructuring of alkali-aluminosilicate Gorilla display glass substrates using a maskless process.

This paper reports on the formation of moth-eye nanopillar structures on surfaces of alkali-aluminosilicate Gorilla glass substrates using a self-masking plasma etching method. Surface and cross-section chemical compositions studies were carried out to study the formation of the nanostructures. CFxinduced polymers were shown to be the self-masking material during plasma etching. The nanostructures enhance transmission at wavelengths over 525 nm may be utilized for fluid-induced switchable haze. Additional functionalities associated with nanostructures may be realized such as self-cleaning, anti-fogging, and stain-resistance.

Challenges and Prospects of Bio-Inspired and Multifunctional Transparent Substrates and Barrier Layers for Optoelectronics.

Bio-inspiration and advances in micro/nanomanufacturing processes have enabled the design and fabrication of micro/nanostructures on optoelectronic substrates and barrier layers to create a variety of functionalities. In this review article, we summarize research progress in multifunctional transparent substrates and barrier layers while discussing future challenges and prospects. We discuss different optoelectronic device configurations, sources of bio-inspiration, photon management properties, wetting properties, multifunctionality, functionality durability, and device durability, as well as choice of materials for optoelectronic substrates and barrier layers. These engineered surfaces may be used for various optoelectronic devices such as touch panels, solar modules, displays, and mobile devices in traditional rigid forms as well as emerging flexible versions.

Superhemophobic and Antivirofouling Coating for Mechanically Durable and Wash-Stable Medical Textiles.

Medical textiles have a need for repellency to body fluids such as blood, urine, or sweat that may contain infectious vectors that contaminate surfaces and spread to other individuals. Similarly, viral repellency has yet to be demonstrated and long-term mechanical durability is a major challenge. In this work, we demonstrate a simple, durable, and scalable coating on nonwoven polypropylene textile that is both superhemophobic and antivirofouling. The treatment consists of polytetrafluoroethylene (PTFE) nanoparticles in a solvent thermally sintered to polypropylene (PP) microfibers, which creates a robust, low-surface-energy, multilayer, and multilength scale rough surface. The treated textiles demonstrate a static contact angle of 158.3 ± 2.6° and hysteresis of 4.7 ± 1.7° for fetal bovine serum and reduce serum protein adhesion by 89.7 ± 7.3% (0.99 log). The coated textiles reduce the attachment of adenovirus type 4 and 7a virions by 99.2 ± 0.2% and 97.6 ± 0.1% (2.10 and 1.62 log), respectively, compared to noncoated controls. The treated textiles provide these repellencies by maintaining a Cassie-Baxter state of wetting where the surface area in contact with liquids is reduced by an estimated 350 times (2.54 log) compared to control textiles. Moreover, the treated textiles exhibit unprecedented mechanical durability, maintaining their liquid, protein, and viral repellency after extensive and harsh abrasion and washing. The multilayer, multilength scale roughness provides for mechanical durability through self-similarity, and the samples have high-pressure stability with a breakthrough pressure of about 255 kPa. These properties highlight the potential of durable, repellent coatings for medical gowning, scrubs, or other hygiene textile applications.

Flexible nanograss with highest combination of transparency and haze for optoelectronic plastic substrates.

Transparent polymer substrates have recently received increased attention for various flexible optoelectronic devices. Optoelectronic applications such as solar cells and light emitting-diodes would benefit from substrates with both high transparency and high haze, which increase how much light scatters into or out of the underlying photoactive layers. In this letter, we demonstrate a new flexible nanograss plastic substrate that displays the highest combination of transparency and haze in the literature for polyethylene terephthalate (PET). As opposed to other nanostructures that increase haze at the expense of transparency, our nanograss demonstrates the potential to improve both haze and transparency. Furthermore, the monolithic nanograss may be fabricated in a facile scalable maskless reactive ion etching process without the need for additional lithography or synthesis of nanostructures. Our 9 µm height nanograss sample exhibits a transparency and haze of 92.4% and 89.4%, respectively, and our 34 µm height nanograss displays a transparency and haze of 91.0% and 97.1%, respectively. We also performed durability experiments that demonstrate these nanostructured PET substrates are robust from bending and show similar transmission and haze values after 5000 cycles of bending.

Critical heat flux enhancement in pool boiling through increased rewetting on nanopillar array surfaces.

Boiling is a key heat transfer process for a variety of power generation and thermal management technologies. We show that nanopillar arrays fabricated on a substrate enhance both the critical heat flux (CHF) and the critical temperature at CHF of the substrate and thus, effectively increase the limit of boiling before the boiling crisis is triggered. We reveal that the enhancement in both the CHF and the critical temperature results from an intensified rewetting process which increases with the height of nanopillars. We develop a predictive model based on experimental measurements of rewetting velocity to predict the enhancement in CHF and critical temperature of the nanopillar substrates. This model is critical for understanding how to control boiling enhancement and designing various nanostructured surfaces into specific applications.

Engineering inverse woodpile and woodpile photonic crystal solar cells for light trapping.

We demonstrate that inverse woodpile and woodpile photonic crystal nanocrystalline silicon structures may be engineered for light trapping in solar cells. We use finite-difference tim-domain simulations to show that the geometry of these photonic crystals may be varied such that absorption in the infrared, visible, and ultraviolet parts of the spectrum may all be improved. The short-circuit current density and ultimate efficiency are also improved. We found a 77.1% and 106% absorption enhancement in the optimized inverse woodpile and woodpile structures respectively, compared to a nanocrystalline silicon thin film of the equivalent thickness. The inverse woodpile structures may be approximated as a thin film with effective index of refraction, whereas the woodpile structures exhibit resonances from the coupling of TE and TM leaky modes in the stacked cylinders. Woodpile photonic crystal structures exhibit improved performance compared to inverse woodpile structures over a range of equivalent thicknesses and incidence angles. The performance of woodpile structures is also generally insensitive to the diameter, pitch and number of layers, whereas inverse woodpile structures are much more sensitive to morphology.

Hierarchical graphene/metal grid structures for stable, flexible transparent conductors.

We report an experimental study on the fabrication and characterization of hierarchical graphene/metal grid structures for transparent conductors. The hierarchical structure allows for uniform and local current conductivity due to the graphene and exhibits low sheet resistance because the microscale silver grid serves as a conductive backbone. Our samples demonstrate 94% diffusive transmission with a sheet resistance of 0.6 Ω/sq and a direct current to optical conductivity ratio σdc/σop of 8900. The sheet resistance of the hierarchical structure may be improved by over 3 orders of magnitude and with little decrease in transmission compared with graphene. Furthermore, the graphene protects the silver grid from thermal oxidation and better maintains the sheet resistance of the structure at elevated temperature. The graphene also strengthens the adhesion of the metal grid with the substrate such that the structure is more resilient under repeated bending.

Comparative study of absorption in tilted silicon nanowire arrays for photovoltaics.

Silicon nanowire arrays have been shown to demonstrate light trapping properties and promising potential for next-generation photovoltaics. In this paper, we show that the absorption enhancement in vertical nanowire arrays on a perfectly electric conductor can be further improved through tilting. Vertical nanowire arrays have a 66.2% improvement in ultimate efficiency over an ideal double-pass thin film of the equivalent amount of material. Tilted nanowire arrays, with the same amount of material, exhibit improved performance over vertical nanowire arrays across a broad range of tilt angles (from 38° to 72°). The optimum tilt of 53° has an improvement of 8.6% over that of vertical nanowire arrays and 80.4% over that of the ideal double-pass thin film. Tilted nanowire arrays exhibit improved absorption over the solar spectrum compared with vertical nanowires since the tilt allows for the excitation of additional modes besides the HE 1m modes that are excited at normal incidence. We also observed that tilted nanowire arrays have improved performance over vertical nanowire arrays for a large range of incidence angles (under about 60°).

Designing metal hemispheres on silicon ultrathin film solar cells for plasmonic light trapping.

We systematically investigate the design of two-dimensional silver (Ag) hemisphere arrays on crystalline silicon (c-Si) ultrathin film solar cells for plasmonic light trapping. The absorption in ultrathin films is governed by the excitation of Fabry-Perot TEMm modes. We demonstrate that metal hemispheres can enhance absorption in the films by (1) coupling light to c-Si film waveguide modes and (2) exciting localized surface plasmon resonances (LSPRs). We show that hemisphere arrays allow light to couple to fundamental TEm and TMm waveguide modes in c-Si film as well as higher-order versions of these modes. The near-field light concentration of LSPRs also may increase absorption in the c-Si film, though these resonances are associated with significant parasitic absorption in the metal. We illustrate how Ag plasmonic hemispheres may be utilized for light trapping with 22% enhancement in short-circuit current density compared with that of a bare 100 nm thick c-Si ultrathin film solar cell.

Strong broadband absorption in GaAs nanocone and nanowire arrays for solar cells.

We studied the influence of geometric parameters on the optical absorption of gallium arsenide (GaAs) nanocone and nanowire arrays via finite difference time domain simulations. We optimized the structural parameters of the nanocone and nanowire arrays to maximize the ultimate efficiency across a range of lengths from 100 to 1000 nm. Nanocone arrays were found to have improved solar absorption, short-circuit current density, and ultimate efficiencies over nanowire arrays for a wide range of lengths. Detailed simulations reveal that nanocones have superior absorption due to reduced reflection from their smaller tip and reduced transmission from their larger base. Breaking the vertical mirror symmetry of nanowires results in a broader absorption spectrum such that overall efficiencies are enhanced for nanocones. We also evaluated the electric field intensity, carrier generation and angle-dependent optical properties of nanocones and nanowires. The carrier generation in nanocone arrays occurs away from the surface and is more uniform over the entire structure, which should result in less recombination losses than in nanowire arrays.

Uniform and ordered copper nanomeshes by microsphere lithography for transparent electrodes.

We report a comprehensive simulation and experimental study on the optical and electronic properties of uniform and ordered copper nanomeshes (Cu NMs) to determine their performance for transparent conductors. Our study includes simulations to determine the role of propagating modes in transmission and experiments that demonstrate a scalable, facile microsphere-based method to fabricate NMs on rigid quartz and flexible polyethylene terephthalate substrates. The fabrication method allows for precise control over NM morphology with near-perfect uniformity and long-range order over large areas on rigid substrates. Our Cu NMs demonstrate 80% diffuse transmission at 17 Ω/square on quartz, which is comparable to indium tin oxide. We also performed durability experiments that demonstrate these Cu NMs are robust from bending, heating, and abrasion.

The role of propagating modes in silver nanowire arrays for transparent electrodes.

Silver nanowires have been shown to demonstrate enhanced transmission and promising potential for next-generation transparent electrodes. In this paper, we systematically investigated the electrical and optical properties of 1D and 2D silver nanowire arrays as a function of diameter and pitch and compared their performance to that of silver thin films. Silver nanowires were found to exhibit enhanced transmission over thin films due to propagating resonance modes between nanowires. We evaluated the angular dependence and dispersion relation of these propagating modes and demonstrate that larger nanowire diameters and pitches are favored for achieving higher solar transmission at a particular sheet resistance. Silver nanowires may achieve achieve solar transmission > 90% with sheet resistances of a few Ω/sq and figure of merit σdc/σop > 1000.