Block copolymer self-assembly derived mesoporous magnetic materials with three-dimensionally (3D) co-continuous gyroid nanostructure.

Magnetic nanomaterials are gaining interest for their many applications in technological areas from information science and computing to next-generation quantum energy materials. While magnetic materials have historically been nanostructured through techniques such as lithography and molecular beam epitaxy, there has recently been growing interest in using soft matter self-assembly. In this work, a triblock terpolymer, poly(isoprene-block-styrene-block-ethylene oxide) (ISO), is used as a structure directing agent for aluminosilicate sol nanoparticles and magnetic material precursors to generate organic-inorganic bulk hybrid films with co-continuous morphology. After thermal processing into mesoporous materials, results from a combination of small angle X-ray scattering (SAXS) and scanning electron microscopy (SEM) are consistent with the double gyroid morphology. Nitrogen sorption measurements reveal a type IV isotherm with H1 hysteresis, and yield a specific surface area of around 200 m2 g-1 and an average pore size of 23 nm. The magnetization of the mesostructured material as a function of applied field shows magnetic hysteresis and coercivity at 300 K and 10 K. Comparison of magnetic measurements between the mesoporous gyroid and an unstructured bulk magnetic material, derived from the identical inorganic precursors, reveals the structured material exhibits a coercivity of 250 Oe, opposed to 148 Oe for the unstructured at 10 K, and presence of remnant magnetic moment not conventionally found in bulk hematite; both of these properties are attributed to the mesostructure. This scalable route to mesoporous magnetic materials with co-continuous morphologies from block copolymer self-assembly may provide a pathway to advanced magnetic nanomaterials with a range of potential applications.

Screening for electrically conductive defects in thin functional films using electrochemiluminescence.

Multifunctional thin films in energy-related devices often must be electrically insulating where a single nanoscale defect can result in complete device-scale failure. Locating and characterizing such defects presents a fundamental problem where high-resolution imaging methods are needed to find defects, but imaging with high spatial resolution limits the field of view and thus the measurement throughput. Here, we present a novel high-throughput method for detecting sub-micron defects in insulating thin films by leveraging the electrochemiluminescence (ECL) of luminol. Through a systematic study of reagent concentrations, buffers, voltage, and excitation time, we identify optimized conditions under which it is possible to detect sub-micron defects at high-throughput. Extrapolating from the signal to background observed for detecting 440 nm wide lines and 620 nm diameter circles, we estimate the minimum detectable features to be lines as narrow as 2.5 nm in width and pinholes as small as 70 nm in radius. We further explore this method by using it to characterize a nominally insulating poly(phenylene oxide) film and find conductive defects that are cross-correlated with high-resolution atomic force microscopy to provide feedback to synthesis. Given this assay's inherent parallelizability and scalability, it is expected to have a major impact on the automated discovery of multifunctional films.

Architected Low-Tortuosity Electrodes with Tunable Porosity from Nonequilibrium Soft-Matter Processing.

Mass transport is performance-defining across energy storage devices, often causing limitations at high current rates. To optimize and balance the device-scale energy and power density for a given energy storage demand, tailored electrode architectures with precisely controllable phase dimensions are needed in combination with low-tortuosity channels that maximize the geometric component of diffusion and species flux. A material-agnostic nonequilibrium soft-matter process is reported to fabricate free-standing inorganic composite electrodes with adjustable thicknesses of 100s of µm, featuring straight and accessible channels ranging in diameter from 5-30 µm, coupled with tunable material-to-pore ratios. Such architected anode and cathode electrodes exhibit electrochemical and architectural stability over extended cycling in a full-cell battery. Further, mass-transport constraints appear at high current densities, and the lithiation step is identified as rate-performance limiting, a result of insufficient lithium-ion supply and concentration polarization. The results demonstrate the need for and feasibility of tailored electrode architectures where dimensional ratios between low-tortuosity channels, the charge-storing matrix, and electrode thickness are tunable to meet coupled power and energy-storage requirements.

Dielectrophoretic Characterization of Dynamic Microcapsules and Their Magnetophoretic Manipulation.

In this work, we present dielectrophoresis (DEP) and in situ electrorotation (ROT) characterization of reversibly stimuli-responsive "dynamic" microcapsules that change the physicochemical properties of their shells under varying pH conditions and can encapsulate and release (macro)molecular cargo on demand. Specifically, these capsules are engineered to open (close) their shell under high (low) pH conditions and thus to release (retain) their encapsulated load or to capture and trap (macro)molecular samples from their environment. We show that the steady-state DEP and ROT spectra of these capsules can be modeled using a single-shell model and that the conductivity of their shells is influenced most by the pH. Furthermore, we measured the transient response of the angular velocity of the capsules under rotating electric field conditions, which allows us to directly determine the characteristic time scales of the underlying physical processes. In addition, we demonstrate the magnetic manipulation of microcapsules with embedded magnetic nanoparticles for lab-on-chip tasks such as encapsulation and release at designated locations and the in situ determination of their physicochemical state using on-chip ROT. The insight gained will enable the advanced design and operation of these dynamic drug delivery and smart lab-on-chip transport systems.

Electric field induced macroscopic cellular phase of nanoparticles.

A suspension of nanoparticles with very low volume fraction is found to assemble into a macroscopic cellular phase that is composed of particle-rich walls and particle-free voids under the collective influence of AC and DC voltages. Systematic study of this phase transition shows that it was the result of electrophoretic assembly into a two-dimensional configuration followed by spinodal decomposition into particle-rich walls and particle-poor cells mediated principally by electrohydrodynamic flow. This mechanistic understanding reveals two characteristics needed for a cellular phase to form, namely (1) a system that is considered two dimensional and (2) short-range attractive, long-range repulsive interparticle interactions. In addition to determining the mechanism underpinning the formation of the cellular phase, this work presents a method to reversibly assemble microscale continuous structures out of nanoscale particles in a manner that may enable the creation of materials that impact diverse fields including energy storage and filtration.

Ordered Mesoporous Microcapsules from Double Emulsion Confined Block Copolymer Self-Assembly.

Polymeric microcapsules with shells containing homogeneous pores with uniform diameter on the nanometer scale are reported. The mesoporous microcapsules are obtained from confined self-assembly of amphiphilic block copolymers with a selective porogen in the shell of water-in-oil-in-water double emulsion drops. The use of double emulsion drops as a liquid template enables the formation of homogeneous capsules of 100s of microns in diameter, with aqueous cores encapsulated in a shell membrane with a tunable thickness of 100s of nanometers to 10s of microns. Microcapsules with shells that exhibit an ordered gyroidal morphology and three-dimensionally connected mesopores are obtained from the triblock terpolymer poly(isoprene)-block-poly(styrene)-block-poly(4-vinylpyridine) coassembled with pentadecylphenol as a porogen. The bicontinuous shell morphology yields nanoporous paths connecting the inside to the outside of the microcapsule after porogen removal; by contrast, one-dimensional hexagonally packed cylindrical pores, obtained from a traditional diblock copolymer system with parallel alignment to the surface, would block transport through the shell. To enable the mesoporous microcapsules to withstand harsh conditions, such as exposure to organic solvents, without rupture of the shell, we develop a cross-linking method of the nanostructured triblock terpolymer shell after its self-assembly. The microcapsules exhibit pH-responsive permeability to polymeric solutes, demonstrating their potential as a filtration medium for actively tunable macromolecular separation and purification. Furthermore, we report a tunable dual-phase separation method to fabricate microcapsules with hierarchically porous shells that exhibit ordered mesoporous membrane walls within sponge-like micron-sized macropores to further control shell permeability.

Microfluidic Fabrication of Phase-Inverted Microcapsules with Asymmetric Shell Membranes with Graded Porosity.

Microcapsules with liquid cores and solid shells are attractive as dispersible protective micron-sized containers. Applications that rely on molecular mass transport often require a combination of size selectivity, high permeability, and mechanical stability. Capsule architectures that combine all these features represent a material property, design, and fabrication challenge. In this work, the design of an asymmetric microcapsule shell architecture is reported to achieve a good combination of the desired features. Poly(methyl methacrylate) phase-inverted microcapsules featuring an asymmetric graded macroporous shell covered with a dense skin separation layer are obtained from water-in-oil-in-water double emulsion drops that are phase-inverted in a water-based coagulation bath. The phase-inverted microcapsules exhibit good mechanical stability and allow for high permeability of its shell membrane with molecular size dependence.

Absorbent-Adsorbates: Large Amphiphilic Janus Microgels as Droplet Stabilizers.

Microgel particles are cross-linked polymer networks that absorb certain liquids causing network expansion. The type of swelling fluid and extent of volume change depends on the polymer-liquid interaction and the network's cross-link density. These colloidal gels can be used to stabilize emulsion drops by adsorbing to the interface of two immiscible fluids. However, to enhance the adsorption abilities of these predominantly hydrophilic gel particles, some degree of hydrophobicity is needed. An amphiphilic Janus microgel with spatially distinct lipophilic and hydrophilic sides is desired. Here, we report the fabrication of poly(ethylene glycol) diacrylate/poly(propylene glycol) diacrylate Janus microgels (JM) using microfluidic drop making. The flow streams of the two separate and immiscible monomer solutions are brought into contact and intersected by a third immiscible fluid in a flow-focusing junction to form Janus droplets. The individual droplets are cross-linked via UV irradiation to form monodispersed microgel particles with opposing hydrophilic and hydrophobic 3D-networked polymer matrices. By combining two chemically different polymer gel networks, an amphiphilic emulsion stabilizer is formed that adsorbs to the oil-water interface while its faces absorb their respective water or hydrocarbon solvents. The resulting water-in-oil emulsions are stabilized and destabilized via a thermal-responsive hydrogel. Stimuli-responsive droplets are demonstrated by adding a short-chain oligo ethylene glycol acrylate molecule to the hydrogel formulation on the Janus microgel particle. Droplets stabilized by these particles experience a sudden increase in droplet diameter around 60 °C. This work with absorbent particles may prove useful for applications in bio catalysis, fuel production, and oil transportation.

Stimuli responsive Janus microgels with convertible hydrophilicity for controlled emulsion destabilization.

Although the utilization of rigid particles can afford stable emulsions, some applications require eventual emulsion destabilization to release contents captured in the particle-covered droplet. This destabilizing effect is achieved when using stabilizers that respond to controlled changes in environment. Microgels can be synthesized as stimuli responsive polymeric gel networks that adsorb to oil/water interfaces and stabilize emulsions. These particles are commonly hydrogels that swell and collapse in water in response to environmental changes. However, amphiphilic functionality is desired to enhance the adsorption abilities of these hydrogels while maintaining their stimuli responsivity. Microfluidic techniques are used to synthesize Janus microgels with two opposing stimuli responsive hemispheres. The particles have a temperature responsive domain connected to a pH responsive network where each side changes its hydrophilicity in response to a change in temperature or pH, respectively. The Janus microgels are amphiphilic in acidic conditions at 19 °C and alkaline conditions at 40 °C, while the opposite conditions cause a reduction of the amphiphilicity. By stabilizing emulsions with these dual responsive microgels, "smart" droplets that respond to environmental cues are formed. Emulsion droplets remain stable with smaller diameters when aqueous solution conditions favor amphiphilic particles yet, coalesce to larger droplets upon changing pH or temperature. These responsive Janus microgels represent the advancing technology of responsive droplets and demonstrate the applicability of microgels as emulsion stabilizers.

Hydrogel micromotors with catalyst-containing liquid core and shell.

Methacrylic anhydride-derived hydrogel microcapsules have unique properties, including reversibly tunable permeation, purification, and separation of dissolved molecular species. Endowing these dynamic encapsulant systems with autonomous motion will significantly enhance their efficiency and applicability. Here, hydrogel micromotors are realized using complex water-in-oil-in-water double emulsion drops and oil-in-water emulsion drops from glass capillary microfluidics and subsequent photopolymerization. Three hydrogel micromotor strategies are explored: microcapsules with thin shells and liquid cores with dispersed catalytic Pt nanoparticles, as well as water-cored microcapsules and homogeneous microparticles selectively coated with Ti/Pt catalytic layers. Autonomous motion of hydrogel particles and capsules is realized in hydrogen peroxide solutions, where generated oxygen microbubbles propel the dynamically responsive micromotors. The micromotors are balanced by weight, buoyancy, lateral capillary forces and show specific autonomous behaviours that significantly extend short range dynamic responses of hydrogels. Drop-based microfluidics represent a paradigm shift in the integration of multifunctional subsystems and high-throughput design of chemical micromachines in reasonable quantities towards their desired biomedical, environmental and flow/diffusion microreactor applications.

Synthesis and Formation Mechanism of All-Organic Block Copolymer-Directed Templating of Laser-Induced Crystalline Silicon Nanostructures.

This report describes the generation of three-dimensional (3D) crystalline silicon continuous network nanostructures by coupling all-organic block copolymer self-assembly-directed resin templates with low-temperature silicon chemical vapor deposition and pulsed excimer laser annealing. Organic 3D mesoporous continuous-network resin templates were synthesized from the all-organic self-assembly of an ABC triblock terpolymer and resorcinol-formaldehyde resols. Nanosecond pulsed excimer laser irradiation induced the transient melt transformation of amorphous silicon precursors backfilled in the organic template into complementary 3D mesoporous crystalline silicon nanostructures with high pattern fidelity. Mechanistic studies on laser-induced crystalline silicon nanostructure formation revealed that the resin template was carbonized during transient laser-induced heating on the milli- to nanosecond timescales, thereby imparting enhanced thermal and structural stability to support the silicon melt-crystallization process at temperatures above 1250 °C. Photoablation of the resin material under pulsed excimer laser irradiation was mitigated by depositing an amorphous silicon overlayer on the resin template. This approach represents a potential pathway from organic block copolymer self-assembly to alternative functional hard materials with well-ordered 3D morphologies for potential hybrid photovoltaics, photonic, and energy storage applications.

Pathways to Mesoporous Resin/Carbon Thin Films with Alternating Gyroid Morphology.

Three-dimensional (3D) mesoporous thin films with sub-100 nm periodic lattices are of increasing interest as templates for a number of nanotechnology applications, yet are hard to achieve with conventional top-down fabrication methods. Block copolymer self-assembly derived mesoscale structures provide a toolbox for such 3D template formation. In this work, single (alternating) gyroidal and double gyroidal mesoporous thin-film structures are achieved via solvent vapor annealing assisted co-assembly of poly(isoprene-block-styrene-block-ethylene oxide) (PI-b-PS-b-PEO, ISO) and resorcinol/phenol formaldehyde resols. In particular, the alternating gyroid thin-film morphology is highly desirable for potential template backfilling processes as a result of the large pore volume fraction. In situ grazing-incidence small-angle X-ray scattering during solvent annealing is employed as a tool to elucidate and navigate the pathway complexity of the structure formation processes. The resulting network structures are resistant to high temperatures provided an inert atmosphere. The thin films have tunable hydrophilicity from pyrolysis at different temperatures, while pore sizes can be tailored by varying ISO molar mass. A transfer technique between substrates is demonstrated for alternating gyroidal mesoporous thin films, circumventing the need to re-optimize film formation protocols for different substrates. Increased conductivity after pyrolysis at high temperatures demonstrates that these gyroidal mesoporous resin/carbon thin films have potential as functional 3D templates for a number of nanomaterials applications.

Characterization of Sulfur and Nanostructured Sulfur Battery Cathodes in Electron Microscopy Without Sublimation Artifacts.

Lithium sulfur (Li-S) batteries have the potential to provide higher energy storage density at lower cost than conventional lithium ion batteries. A key challenge for Li-S batteries is the loss of sulfur to the electrolyte during cycling. This loss can be mitigated by sequestering the sulfur in nanostructured carbon-sulfur composites. The nanoscale characterization of the sulfur distribution within these complex nanostructured electrodes is normally performed by electron microscopy, but sulfur sublimates and redistributes in the high-vacuum conditions of conventional electron microscopes. The resulting sublimation artifacts render characterization of sulfur in conventional electron microscopes problematic and unreliable. Here, we demonstrate two techniques, cryogenic transmission electron microscopy (cryo-TEM) and scanning electron microscopy in air (airSEM), that enable the reliable characterization of sulfur across multiple length scales by suppressing sulfur sublimation. We use cryo-TEM and airSEM to examine carbon-sulfur composites synthesized for use as Li-S battery cathodes, noting several cases where the commonly employed sulfur melt infusion method is highly inefficient at infiltrating sulfur into porous carbon hosts.

Functional Microcapsules via Thiol-Ene Photopolymerization in Droplet-Based Microfluidics.

Thiol-ene chemistry was exploited in droplet-based microfluidics to fabricate advanced microcapsules with tunable encapsulation, degradation, and thermal properties. In addition, by utilizing the thiol-ene photopolymerization with tunable cross-link density, we demonstrate the importance of monomer conversion on the retention of omniphilic cargo in double emulsion templated microcapsules. Furthermore, we highlight the rapid cure kinetics afforded by thiol-ene chemistry in a continuous flow photopatterning device for hemispherical microparticle production.

Block copolymer self-assembly-directed synthesis of mesoporous gyroidal superconductors.

Superconductors with periodically ordered mesoporous structures are expected to have properties very different from those of their bulk counterparts. Systematic studies of such phenomena to date are sparse, however, because of a lack of versatile synthetic approaches to such materials. We demonstrate the formation of three-dimensionally continuous gyroidal mesoporous niobium nitride (NbN) superconductors from chiral ABC triblock terpolymer self-assembly-directed sol-gel-derived niobium oxide with subsequent thermal processing in air and ammonia gas. Superconducting materials exhibit a critical temperature (T c) of about 7 to 8 K, a flux exclusion of about 5% compared to a dense NbN solid, and an estimated critical current density (J c) of 440 A cm(-2) at 100 Oe and 2.5 K. We expect block copolymer self-assembly-directed mesoporous superconductors to provide interesting subjects for mesostructure-superconductivity correlation studies.

POROUS MATERIALS. Transient laser heating induced hierarchical porous structures from block copolymer-directed self-assembly.

Development of rapid processes combining hierarchical self-assembly with mesoscopic shape control has remained a challenge. This is particularly true for high-surface-area porous materials essential for applications including separation and detection, catalysis, and energy conversion and storage. We introduce a simple and rapid laser writing method compatible with semiconductor processing technology to control three-dimensionally continuous hierarchically porous polymer network structures and shapes. Combining self-assembly of mixtures of block copolymers and resols with spatially localized transient laser heating enables pore size and pore size distribution control in all-organic and highly conducting inorganic carbon films with variable thickness. The method provides all-laser-controlled pathways to complex high-surface-area structures, including fabrication of microfluidic devices with high-surface-area channels and complex porous crystalline semiconductor nanostructures.

Graded porous inorganic materials derived from self-assembled block copolymer templates.

Graded porous inorganic materials directed by macromolecular self-assembly are expected to offer unique structural platforms relative to conventional porous inorganic materials. Their preparation to date remains a challenge, however, based on the sparsity of viable synthetic self-assembly pathways to control structural asymmetry. Here we demonstrate the fabrication of graded porous carbon, metal, and metal oxide film structures from self-assembled block copolymer templates by using various backfilling techniques in combination with thermal treatments for template removal and chemical transformations. The asymmetric inorganic structures display mesopores in the film top layers and a gradual pore size increase along the film normal in the macroporous sponge-like support structure. Substructure walls between macropores are themselves mesoporous, constituting a structural hierarchy in addition to the pore gradation. Final graded structures can be tailored by tuning casting conditions of self-assembled templates as well as the backfilling processes. We expect that these graded porous inorganic materials may find use in applications including separation, catalysis, biomedical implants, and energy conversion and storage.

One-Pot Synthesis of Hierarchically Macro- and Mesoporous Carbon Materials with Graded Porosity.

Hierarchically porous materials are becoming increasingly important in catalysis, separation, and energy applications due to their advantageous diffusion and flux properties. Here we present the synthesis of hierarchically macro- and mesoporous carbon materials with graded porosity from a one-pot fabrication route. Organic-polymeric hybrids of a carbon precursor and poly(isoprene)-block-poly(styrene)-block-poly(4-vinylpyridine) with graded porosity are obtained via coassembly and nonsolvent-induced phase separation. The membranes were carbonized at temperatures as high as 1100 °C with simultaneous decomposition of the block copolymer. The carbon materials show an open nanoporous top surface with narrow pore-size distribution that opens up into a graded macroporous support with increasing macropore size along the film normal and mesoporous walls, providing for highly accessible porosity with a large surface area of over 500 m2 g-1. Further, we expand the direct synthesis process to form well-dispersed metal nanoparticles (such as nickel and platinum) on the graded, hierarchically porous carbon materials. Our one-pot synthesis offers a facile approach to graded macro- and mesoporous carbons.

Gyroidal mesoporous multifunctional nanocomposites via atomic layer deposition.

We demonstrate the preparation of rationally designed, multifunctional, monolithic and periodically ordered mesoporous core-shell nanocomposites with tunable structural characteristics. Three-dimensionally (3D) co-continuous gyroidal mesoporous polymer monoliths are fabricated from a solution-based triblock terpolymer-resol co-assembly and used as the functional templates for the fabrication of free-standing core-shell carbon-titania composites using atomic layer deposition (ALD). The deposition depth into the torturous gyroidal nanonetwork is investigated as a function of ALD conditions and the resulting composites are submitted to different thermal treatments. Results suggest that ALD can homogenously coat mesoporous templates with well defined pore sizes below 50 nm and thicknesses above 10 µm. Structural tunability like titania shell thickness and pore size control is demonstrated. The ordered nanocomposites exhibit triple functionality; a 3D continuous conductive carbon core that is coated with a crystalline titania shell that in turn is in contact with a 3D continuous mesopore network in a compact monolithic architecture. This materials design is of interest for applications including energy conversion and storage. Gyroidal mesoporous titania monoliths can be obtained through simultaneous titania crystallization and template removal in air.