Large-Area Fabrication of Porous Graphene Networks on Carbon Fabric via Millisecond Photothermal Processing of Polyaniline for Supercapacitors.

Supercapacitors demonstrate promising potential for flexible, multi-functional energy storage devices; however, their widespread adoption is confronted by fabrication challenges. To access a combination of desirable device qualities such as flexibility, lightweight, structural stability, and enhanced electrochemical performance, carbon fiber (CF) can be utilized as a current collector, alongside graphene as an electrochemically active material. Yet achieving a cost-effective, large-scale graphene production, particularly on CF, remains challenging. Here, a rapid (<1 min) photothermal approach is developed for the large-scale production of graphene directly onto CF, utilizing polyaniline (PANI) as a polymer precursor. The in situ electropolymerization of PANI on CF facilitates its rapid synthesis on large areas, followed by conversion into graphene networks, enabling the binder-free fabrication of supercapacitor devices. These devices exhibit an areal capacitance of 180 mF cm-2 (at 2 mA cm-2 in 1 m H2SO4), an order of magnitude higher than other fabric-based devices. Moreover, the devised photothermal strategy allows for one-step preparation of supercapacitor devices on areas exceeding 100 cm-2, yielding an absolute areal capacitance of 4.5 F. The proportional increase in capacitance with device area facilitates scaling and indicates the commercial viability of this approach for low-cost, energy-efficient, and high-throughput production of lightweight, high-performance graphene-based multi-functional supercapacitor devices.

Bottlebrush Networks: A Primer for Advanced Architectures.

Bottlebrush networks (BBNs) are an exciting new class of materials with interesting physical properties derived from their unique architecture. While great strides have been made in our fundamental understanding of bottlebrush polymers and networks, an interdisciplinary approach is necessary for the field to accelerate advancements. This review aims to act as a primer to BBN chemistry and physics for both new and current members of the community. In addition to providing an overview of contemporary BBN synthetic methods, we developed a workflow and desktop application (LengthScale), enabling bottlebrush physics to be more approachable. We conclude by addressing several topical issues and asking a series of pointed questions to stimulate conversation within the community.

Adhesion and mechanical properties of poly(dimethylsiloxane) bottlebrush elastomers.

Poly(dimethylsiloxane) (PDMS) bottlebrush elastomers (BBEs) are attractive soft materials with well-controlled bulk mechanical properties. However, their surface and interfacial properties have not been studied in depth. We report a detailed study of the adhesion of PDMS BBEs to glass using a contact adhesion test to determine the critical energy release rates, Gc, as a function of interfacial separation velocity. For BBEs, Gc for initiating separation, G0, was found to be independent of the crosslink density. We hypothesize that the monomer chemistry of side chains plays a primary role in defining surface properties for this materials system. After crack initiation, BBEs showed a significantly lower Gc and less velocity dependence than linear chain networks. Scaling analysis attributes these properties to the faster dissipative relaxation mechanisms within the BBEs. These findings demonstrate that the adhesion properties of BBEs can be finely tuned through the monomer chemistry and side chain length for potential applications.

Silicone elastomers and the Persson-Brener adhesion model.

Many modern anti-icing and anti-fouling coatings rely on soft, low surface energy elastomeric materials such as polydimethylsiloxane for their functionality. While the low surface energy is desirable for reducing adhesion, very little work considers the larger contribution to adhesive failure caused by the viscoelastic nature of elastomers. Here we examine several different siloxane elastomers using a JKR adhesion test, which was operated over a range of different speeds and temperatures. Additionally, we characterize the dynamic mechanical modulus over a large range of frequencies for each material. We note that surface energies of the materials are all similar, but variation in adhesion strength is clear in the data. The variation at low speeds is related to elastomer architecture but the speed dependence itself is independent of architecture. Qualitative correlations are noted between the JKR adhesion measurements and the dynamic moduli. Finally, an attempt is made to directly compare moduli and adhesion through the recent Persson-Brener model. Approximations of the model are shown to be inaccurate. The full model is found to be accurate at low speeds, although it fails to precisely capture higher speed behaviour.

Roll-to-roll nanoimprint lithography using a seamless cylindrical mold nanopatterned with a high-speed mastering process.

The advanced optical and wetting properties of metamaterials, plasmonic structures, and nanostructured surfaces have been repeatedly demonstrated in lab-scale experiments. Extending these exciting discoveries to large-area surfaces can transform technologies ranging from solar energy and virtual reality to biosensors and anti-microbial surfaces. Although photolithography is ideal for nanopatterning of small, expensive items such as computer chips, nanopatterning of large-area surfaces is virtually impossible with traditional lithographic techniques due to their exceptionally slow patterning rates and high costs. This article presents a high-throughput process that achieves large-area nanopatterning by combining roll-to-roll (R2R) nanoimprint lithography (NIL) and nanocoining, a process that can seamlessly nanopattern around a cylinder hundreds of times faster than electron-beam lithography. Here, nanocoining is used to fabricate a cylindrical mold with nanofeatures spaced by 600 nm and microfeatures spaced by 2 µm. This cylindrical drum mold is then used on a R2R NIL setup to pattern over 60 feet of polymer film. Microscopy is used to compare the feature shapes throughout the process. This scalable process offers the potential to transfer exciting lab-scale demonstrations to industrial-scale manufacturing without the prohibitively high cost usually associated with the fabrication of a master mold.

Low-cost, durable master molds for thermal-NIL, UV-NIL, and injection molding.

Mold cost and mold lifetime are essential concerns for mass production of micro/nano-patterned surfaces by nanoimprint lithography or micro/nanoinjection molding. Master molds are typically produced by subtractive processing using wafer-based clean room techniques. For imprint lithography, polymer copies of such molds can often be employed, but the durability of such molds is quite limited. The conditions of high temperature and pressure for injection molding require use of the durable masters created in stainless steel, nickel or other robust materials, but such approaches are challenged by the high cost of patterning these substrates and limited lifetime. Here, we report the fabrication of durable crystalline zirconium dioxide (ZrO2) masters via a simple direct imprint technique. ZrO2 nanoparticles (NPs) were formulated into an ink and imprinted on a variety of substrates using a solvent-assisted patterning technique and subsequently annealed to increase the mechanical durability of the mold. The hardness and modulus values of the ZrO2 coatings reached 11 ± 2 GPa and 120 ± 10 GPa, respectively after annealing. The hard ZrO2 mold was then employed for precision patterning of polymer surfaces by thermal and UV nanoimprinting lithography (NIL) techniques, and by injection molding. High fidelity pattern transfer continued throughout 115 000 injection molding cycles, there was no evidence of delamination, breakage or wear in the ZrO2 mold. Our simple imprint patterning technique using ZrO2 NPs inks enable us to fabricate robust molds with excellent thermal and mechanical properties as easily as imprinting simple polymer replicas. This simple and low-cost approach to mold preparation can enable a large variety of high throughput or large area nano-replication technologies.

Gradient Photonic Materials Based on One-Dimensional Polymer Photonic Crystals.

In nature, animals such as chameleons are well-known for the complex color patterns of their skin and the ability to adapt and change the color by manipulating sophisticated photonic crystal systems. Artificial gradient photonic materials are inspired by these color patterns. A concept for the preparation of such materials and their function as tunable mechanochromic materials is presented in this work. The system consists of a 1D polymer photonic crystal on a centimeter scale on top of an elastic poly(dimethylsiloxane) substrate with a gradient in stiffness. In the unstrained state, this system reveals a uniform red reflectance over the entire sample. Upon deformation, a gradient in local strain of the substrate is formed and transferred to the photonic crystal. Depending on the magnitude of this local strain, the thickness of the photonic crystal decreases continuously, resulting in a position-dependent blue shift of the reflectance peak and hence the color in a rainbow-like fashion. Using more sophisticated hard-soft-hard-soft-hard gradient elastomers enables the realization of stripe-like reflectance patterns. Thus, this approach allows for the tunable formation of reflectance gradients and complex reflectance patterns. Envisioned applications are in the field of mechanochromic sensors, telemedicine, smart materials, and metamaterials.

Ordered Nanoporous Carbons with Broadly Tunable Pore Size Using Bottlebrush Block Copolymer Templates.

We report the preparation of ordered porous carbon materials with tailored pore sizes selected between 16 and 108 nm using bottlebrush block copolymers (BBCPs) as templates. The nanoporous carbons are prepared via the cooperative assembly of polydimethylsiloxane-block-poly(ethylene oxide) (PDMS-b-PEO) BBCPs with phenol-formaldehyde resin yielding ordered precursor films, followed by carbonization. The assembly of PDMS-b-PEO BBCPs with the resin leads to films exhibiting a spherical morphology (PDMS as the minor domain) with uniform domain sizes between 18 and 150 nm in the bulk. The assembled PDMS sphere diameters scale linearly with BBCPs molecular weights, allowing precise control of domain size. Access to very large ordered domains is an enabling hallmark of BBCPs self-assembly, but reports of well-ordered spherical domains are not common. Carbonization of the ordered precursor films yields nanoporous carbon with uniform and tunable pore size. These nanoporous carbons are shown to exhibit excellent performance as supercapacitor electrodes with capacitance reaching up to 254 F g-1 at a current density of 2 A g-1.

Rapid, Large-Area Synthesis of Hierarchical Nanoporous Silica Hybrid Films on Flexible Substrates.

We report a simple strategy for the creation of large-area nanoporous hybrid films of silica, carbon, and gold on polyethylene terephthalate via photothermal processing. This method enables the selective heating of light-absorbing thin films on low-temperature substrates using sub-millisecond light pulses generated by a xenon flash lamp. The film contains gold nanoparticles as the nanoheaters to convert light energy to heat, a sacrificial block copolymer surfactant to generate mesopores, and cross-linked polyhedral oligomeric silsesquioxane as the silica source to form the skeleton of the porous structure. Hierarchical porous structures are achieved in the films after photothermal treatment, with uniform mesopores (44-48 nm) on the surface and interconnected macropores (>50 nm) underneath resulting from a foaming effect during release of gaseous decomposition products. The loading of gold nanoparticles is up to 43 wt % in the product, with less than 2 wt % organic residue. This rapid and large-area process for the synthetis of porous structures is compatible with roll-to-roll manufacturing for the fabrication of flexible devices.

Large-Volume Self-Organization of Polymer/Nanoparticle Hybrids with Millimeter-Scale Grain Sizes Using Brush Block Copolymers.

We report that an exceptionally large volume of highly ordered arrays (single grains) on the order of millimeters in scale can be rapidly created through a unique innate guiding mechanism of brush block copolymers (BBCPs). The grain volume is over 10(9) times larger than that of typical self-assembled linear BCPs (LBCPs). The use of strong interactions between nanoparticles (NPs) and BBCPs enables high loadings of functional materials, up to 76 wt % (46 vol %) in the target domain, while maintaining excellent long-range order. Overall, this work provides a simple method to precisely control the spatial orientation of functionalities at nanometer length scales over macroscopic volumes, thereby enabling the production of hybrid materials for many important applications.

Controlled supramolecular self-assembly of large nanoparticles in amphiphilic brush block copolymers.

To date the self-assembly of ordered metal nanoparticle (NP)/block copolymer hybrid materials has been limited to NPs with core diameters (D(core)) of less than 10 nm, which represents only a very small fraction of NPs with attractive size-dependent physical properties. Here this limitation has been circumvented using amphiphilic brush block copolymers as templates for the self-assembly of ordered, periodic hybrid materials containing large NPs beyond 10 nm. Gold NPs (D(core) = 15.8 ± 1.3 nm) bearing poly(4-vinylphenol) ligands were selectively incorporated within the hydrophilic domains of a phase-separated (polynorbornene-g-polystyrene)-b-(polynorbornene-g-poly(ethylene oxide)) copolymer via hydrogen bonding between the phenol groups on gold and the PEO side chains of the brush block copolymer. Well-ordered NP arrays with an inverse cylindrical morphology were readily generated through an NP-driven order-order transition of the brush block copolymer.

Controlled integration of oligo- and polythiophenes at the molecular scale.

High molecular weight PBTTT-C12 is blended with the pure trimer, BTTT-3, to enhance intergrain connectivity and charge transport. Analysis of the morphology and crystallinity of the blends shows that the polymer and oligomer are well-integrated, leading to high hole mobilities, greater than 0.1 cm(2) V(-1) s(-1), in films that contain as much as 83% oligomer.

Simple ligand exchange reactions enabling excellent dispersibility and stability of magnetic nanoparticles in polar organic, aromatic, and protic solvents.

The use of magnetic nanoparticles (MNPs) in real-world applications is often limited by the lack of stable solutions of monodisperse NPs in appropriate solvents. We report a facile one-pot ligand exchange reaction that is fast, efficient, and thorough for the synthesis of hydrophilic MNPs that are readily dispersed in polar organic and protic solvents (polarity index = 3.9-7.2) including alcohols, THF, DMF, and DMSO for years without precipitation. We emphasize the rational selection of small-molecule ligands such as 4-hydroxybenzoic acid (HBA), 3-(4-hydroxyphenyl)propionic acid (HPP), and gallic acid (GAL) that provide strong bonding with the MNP (FePt and FeOx) surfaces, hydrophilic termini to match the polarity of target solvents, and offer the potential for hydrogen-bonding interactions to facilitate incorporation into polymers and other media. Areal ligand densities (Σ) calculated based on the NP core size from transmission electron microscopy (TEM) images, and the inorganic fractions of NPs derived from thermogravimetric analysis (TGA) indicated a significant (2-4 times) increase in the ligand coverage after the exchange reactions. Fourier transform infrared spectrometry (FTIR) and (1)H nuclear magnetic resonance (NMR) studies also confirmed anchoring of carboxyl groups on NP surfaces. In addition, we demonstrate a facile one-step in situ synthesis of FePt NPs with aromatic ligands for better dispersibility in solvents of intermediate polarity (polarity index = 1.0-3.5) such as toluene, chlorobenzene, and dichloromethane. The creation of stable dispersions of NPs in solvents across the polarity spectrum opens up new applications and new processing widows for creating NP composites in a variety of host materials.

Mesoporous Single Atom-Cluster Fe-N/C Oxygen Evolution Electrocatalysts Synthesized with Bottlebrush Block Copolymer-Templated Rapid Thermal Annealing.

Current electrocatalysts for oxygen evolution reaction (OER) are either expensive (such as IrO2, RuO2) or/and exhibit high overpotential as well as sluggish kinetics. This article reports mesoporous earth-abundant iron (Fe)-nitrogen (N) doped carbon electrocatalysts with iron clusters and closely surrounding Fe-N4 active sites. Unique to this work is that the mechanically stable mesoporous carbon-matrix structure (79 nm in pore size) with well-dispersed nitrogen-coordinated Fe single atom-cluster is synthesized via rapid thermal annealing (RTA) within only minutes using a self-assembled bottlebrush block copolymer (BBCP) melamine-formaldehyde resin composite template. The resulting porous structure and domain size can be tuned with the degree of polymerization of the BBCP backbone, which increases the electrochemically active surface area and improves electron transfer and mass transport for an effective OER process. The optimized electrocatalyst shows a required potential of 1.48 V (versus RHE) to obtain the current density of 10 mA/cm2 in 1 M KOH aqueous electrolyte and a small Tafel slope of 55 mV/decade at a given overpotential of 250 mV, which is significantly lower than recently reported earth-abundant electrocatalysts. Importantly, the Fe single-atom nitrogen coordination environment facilitates the surface reconstruction into a highly active oxyhydroxide under OER conditions, as revealed by X-ray photoelectron spectroscopy and in situ Raman spectroscopy, while the atomic clusters boost the single atoms reactive sites to prevent demetalation during the OER process. Density functional theory (DFT) calculations support that the iron nitrogen environment and reconstructed oxyhydroxides are electrocatalytically active sites as the kinetics barrier is largely reduced. This work has opened a new avenue for simple, rapid synthesis of inexpensive, earth-abundant, tailorable, mechanically stable, mesoporous carbon-coordinated single-atom electrocatalysts that can be used for renewable energy production.

Relating chemical structure to device performance via morphology control in diketopyrrolopyrrole-based low band gap polymers.

We investigated the structure-morphology-performance relationship of diketopyrrolopyrrole (DPP)-based low band gap polymers with different donor cores in organic field effect transistors (OFETs) and organic photovoltaics (OPVs). The change in the chemical structure led to strong physical property differences, such as crystalline behavior, blend morphology, and device performance. In addition, the choice of solvents and additives enabled one to fine tune the properties of these materials in the condensed state. For instance, when thin films were processed from solvent mixtures, both in the pure polymer and in a blend, we observed an enhanced edge-on orientation and the formation of thinner and longer polymer fibrils. In the BHJ blends, processing from a solvent mixture reduced the size scale of the phase separation and promoted the formation of a fibrillar network morphology, having a polymer-PCBM mixture filling the interfibrillar regions. The characteristic length scale of the fibrillar network dictated the specific inner surface area, which directly correlated to the performance in the OPV devices. When the BHJ mixture was processed from a single solvent, a large-scale phase separated morphology was observed that was stratified, normal to the film surface. A strong scattering anisotropy was observed in the resonant soft X-ray scattering of the blends that provided insight into the packing of the polymer chains within the fibrils. The morphology and performance trend in OPVs paralleled the performance in an OFET, suggesting that similar processing conditions should be considered in OFET fabrication.

Hydrophobization of inorganic oxide surfaces using dimethylsilanediol.

Dimethylsilanediol is a stable crystalline solid that was described in 1953. As the monomer of an important class of commercial products (poly(dimethylsiloxanes)-silicones, PDMS) and as a simple molecule in its own right (the silicon analog of acetone hydrate), it has been neglected by several fields of fundamental and applied research including the hydrophobization of inorganic oxide surfaces. We report that dimethylsilanediol is a useful reagent for the surface modification (hydrophobization) of oxidized silicon and other oxidized metal surfaces and compare the wetting properties of modified solids with those of conventionally modified surfaces. That water is the only byproduct of this modification reaction suggests that this and likely other silanediols are useful surface-modification agents, particularly when substrate corrosion or the competitive adsorption of byproducts is an issue. We note that dimethylsilanediol is volatile with a significant vapor pressure at room temperature. Vapor-phase surface modifications are also reported.

Large-area, continuous roll-to-roll nanoimprinting with PFPE composite molds.

Successful implementation of a high-speed roll-to-roll nanoimprinting technique for continuous manufacturing of electronic devices has been hindered due to lack of simple substrate preparation steps, as well as lack of durable and long lasting molds that can faithfully replicate nanofeatures with high fidelity over hundreds of imprinting cycles. In this work, we demonstrate large-area high-speed continuous roll-to-roll nanoimprinting of 1D and 2D micron to sub-100 nm features on flexible substrate using perfluoropolyether (PFPE) composite molds on a custom designed roll-to-roll nanoimprinter. The efficiency and reliability of the PFPE based mold for the dynamic roll-to-roll patterning process was investigated. The PFPE composite mold replicated nanofeatures with high fidelity and maintained superb mold performance in terms of dimensional integrity of the nanofeatures, nearly defect free pattern transfer and exceptional mold recovering capability throughout hundreds of imprinting cycles.

Large Area Millisecond Preparation of High-Quality, Few-Layer Graphene Films on Arbitrary Substrates via Xenon Flash Lamp Photothermal Pyrolysis and Their Application for High-Performance Micro-supercapacitors.

We report a method for fast, efficient, and scalable preparation of high-quality, large area, few-layer graphene films on arbitrary substrates via high-intensity pulsed xenon flash lamp photothermal pyrolysis of thin precursor films at ambient conditions in millisecond time frames. The precursors comprised poly(2,2-bis(3,4-dihydro-3-phenyl-1,3-benzoxazine)), and cyclized polyacrylonitrile and possess significant absorption cross section within the bandwidth of the emission spectrum of a xenon flash lamp. By localizing light absorption to the precursor films, the process enabled the preparation of few-layer graphene films on any substrate, including thermally sensitive substrates without the need for any catalytic substrate as in chemical vapor deposition-based approaches or conductive electrodes as in electrochemical method-based approaches. The extent of conversion of the precursor films to graphene was strongly dependent on pulse energy and the local temperature achieved due to photothermal effect, which were controlled via pulse power modulation; it also depended on structural properties of the precursor and to a lesser extent on the substrate. The cPAN showed a higher efficiency for conversion to graphene, as confirmed by Raman spectra (ID/IG ∼ 0.3), and sheet resistance of 0.1 Ω cm. To demonstrate the utility of the process, graphene film electrodes prepared photothermally on carbon fiber current collector were used for the fabrication of micro-supercapacitors with a very high areal supercapacitance of 3.5 mF/cm2. Subsequent deposition of manganese oxide onto the fabricated electrodes significantly increased the energy storage capability of the supercapacitor, yielding a device with exceptionally high capacitance of 80 F/g at 1 mA current, good rate capability, and long cycle life.

Photoinduced ordering of block copolymers.

Photoinduced ordering of disordered block copolymers (BCPs) would provide an on-demand, nonintrusive route for formation of well-ordered nanostructures in arbitrarily defined regions of an otherwise disordered material. Here we achieve this objective using a rapid and simple approach in which photoconversion of an additive blended with the BCP introduces strong interactions between the additive and one of the chain segments and induces strong order in the BCP blend. The strategy is generally applicable to block copolymers containing chain segments capable of hydrogen bonding with the additive.

The Impact of Polymerization Chemistry on the Mechanical Properties of Poly(dimethylsiloxane) Bottlebrush Elastomers.

We compare the low-strain mechanical properties of bottlebrush elastomers (BBEs) synthesized using ring-opening metathesis and free radical polymerization. Through comparison of experimentally measured elastic moduli and those predicted by an ideal, affine model, we evaluate the efficiency of our networks in forming stress-supporting strands. This comparison allowed us to develop a structural efficiency ratio that facilitates the prediction of mechanical properties relative to polymerization chemistry (e.g., softer BBEs when polymerizing under dilute conditions). This work highlights the impact that polymerization chemistry has on the structural efficiency ratio and the resultant mechanical properties of BBEs with identical side chains, providing another "knob" by which to control polymer network properties.