Polymerization Induced Microphase Separation for the Fabrication of Nanostructured Materials

Polymerization-induced self-assembly enables access to diverse highly ordered structures through kinetic and thermodynamic pathways

Polymerization-induced self-assembly (PISA) has emerged as a powerful technique for generating microphase-separated structures, but research has primarily focused on systems exhibiting "disordered" structures. Here, we demonstrate the facile construction of various highly ordered microphase-separated structures via PISA, with and without kinetic control through manipulation of the glass transition temperature (T g) of the core-forming blocks. We synthesized diblock copolymers in an ionic liquid (40 wt% solute) by polymerizing styrene or 2-hydroxyethyl acrylate from one end of poly(ethylene glycol). When using polystyrene as the core-forming block, its high T g relative to the polymerization temperature resulted in the formation of kinetically trapped structures, including pure hexagonal close-packed (HCP) spheres exhibiting X-ray diffraction peaks up to the 17th-order. Conversely, lower-T g core-forming block [poly(2-hydroxyethyl acrylate)] led to thermodynamically stable, highly ordered structures, including a double-gyroid morphology. These results highlight the efficacy of PISA for generating diverse, highly ordered microphase-separated structures from simple diblock copolymers and demonstrate its potential to access structures unattainable through conventional ex situ polymerization.

Covalent Crosslinker-Free Photo-Curing 3D Printing of Liquid Metal Composite Hydrogels Based On SI-photoATRP

Photocurable 3D printing (SLA or DLP) materials have garnered considerable attention due to their remarkable efficiency and precision in manufacturing. However, the presence of covalent crosslinking makes the recycling and reuse of printed materials extremely challenging. Here a novel approach to covalent crosslinker-free photo-curing 3D printing (via DLP) of liquid metal (LM) composite hydrogels is reported, leveraging surface-initiated photoinduced atom radical transfer polymerization (SI-photoATRP). The pre-synthesized PHEA-Br macroinitiators are grafted onto the surfaces of LM nanoparticles (LMNPs) by mechanical sonication, stabilizing the LMNPs within the resin solution while simultaneously generating active sites for SI-photoATRP. During the SI-photoATRP process, polymer chains of sufficient length form hydrogen bonds with multiple LMNPs, effectively transforming the LMNPs into crosslinking points. By integrating the aqueous photoATRP system catalyzed by carbon dots, LM@polymer composite hydrogel with complex structures are successfully established through DLP technology. The versatility of the 3D printed hydrogel is investigated by employing HEA, OEGA480, and AAm as the monomers in resin solution, respectively. Notably, all the LM@polymer composite hydrogels can be degraded in aqueous NaOH solution. Furthermore, LM@polymer-based networks exhibit self-repairing capabilities, serve as underwater adhesives, and conduct electricity. This work offers new insights into designing 3D printing materials and sustainable photocurable technology.

Large Scale Printing of Robust HPLC Medium via Layer-by-Layer Stereolithography

The manufacture of high-performance liquid chromatography (HPLC) medium has long been viewed as an art rather than science; this raised a great challenge in securing separation consistency, method transferability, and scaling-up in purification of biomolecules. Herein, we report a large scale layer-by-layer manufacturing strategy for a high performance chromatography medium utilizing 3D-printing technology. Combining stereolithography 3D printing and porogenic chemistry, the strategy enables parallel production of high-performance separation medium in diverse scales, shapes, and throughput. Between 1,000 printed devices, high performance consistency was demonstrated by column-to-column and batch-to-batch reproducibility (coefficient of variation of retention time, 2.04%). Fast separations of intact proteins were realized in reversed-phase chromatography: within 1 min, resolution > 1.5 was achieved, and nondenatured antibody separation was realized in hydrophobic interaction chromatography. Purification of native proteins was directly amplified by 3 orders of magnitude: 12 mg of hemeproteins was isolated in 8 min at negligible scaling-up cost, supporting liter-scale processing of fermentation within 7 h on one 20 mm i.d. printed column. With advantages in automatic and parallel production capacity, high-fidelity microstructure across dimensions, and highly efficient method transfer and scaling-up, the stereolithographically printed high performance chromatography medium may open a new path to speeding up separation and purification processes from primary analysis to mass-purification of biomolecular entities, as demanded in the biosynthesis and pharmaceutical industries.

Protein Cage-like Vesicles Fabricated via Polymerization-Induced Microphase Separation of Amphiphilic Diblock Copolymers

Highly symmetric protein cages represent one of the most artistic architectures formed by biomolecules. However, the underlying reasons for the formation of some of these architectures remain unknown. The present study aims to investigate the significance behind their morphological formation by fabricating protein cage-like vesicles using a synthetic polymer. The vesicles were synthesized by combining polymerization-induced self-assembly (PISA) with polymerization-induced microphase separation (PIMS), employing an amphiphilic poly(methacrylic acid)-block-poly(n-butyl methacrylate-random-cyclohexyl methacrylate-random-methacrylic acid) diblock copolymer, PMAA-b-P(BMA-r-CMA-r-MAA). The copolymer, with a 60 mol% molar ratio of CMA to the BMA units, produced clathrin-like vesicles with angular windows in their shell, resulting from the segregation of the hard CMA units from the soft BMA matrix in the hydrophobic phase of the vesicle. These vesicles were highly stable against rising temperatures. In contrast, the vesicles with a 30 mol% CMA ratio dissociated upon heating to 50 °C into triskelion-like segments due to intramolecular microphase separation. These findings indicate that designing synthetic polymers can mimic living organ morphologies, aiding in elucidating their morphological significance and inspiring the development of new materials utilizing these morphologies.

Polar groups promoting in-situ polymerization phase separation for solid electrolytes enabling solid-state lithium batteries

Plastic-crystal-embedded elastomer electrolytes (PCEEs), produced through polymerization-induced phase separation (PIPS), are gaining popularity as solid polymer electrolytes (SPEs). However, it remains to be investigated whether all monomer molecules can achieve polymerization-induced phase separation and the corresponding differences in lithium metal battery performance. Herein, we prepared PCEEs with different functional groups (OH, CN, F) through in situ polymerization. Research findings show that PCEE containing - CN or - F achieves the separation of the plastic crystalline phase and succinonitrile (SN) phase, whereas PCEE containing OH cannot due to hydrogen bonding with the SN phase. Notably, the PCEE synthesized with the F monomer (FBA-PCEE) exhibited exceptional interfacial stability with lithium metal anodes and lithium iron phosphate (LFP) cathodes, due to its unique coordination mechanism with lithium ions. The FBA-PCEE demonstrated a high ionic conductivity (2.02 × 10-3 S cm-1) and lithium-ion migration number ( [Formula: see text]  = 0.75). Moreover, lithium symmetric cells incorporating FBA-PCEE demonstrated stable cycling performance for more than 1000 h at a current density of 0.1 mA cm-2, resulting in the development of a solid electrolyte interphase (SEI) rich in LiF, Li3N, and Li2CO3 over time. Additionally, incorporating FBA-PCEE facilitated the stable cycling of LPF over 1000 cycles at 0.5C, maintaining a capacity retention of 77.38 % after 500 cycles. When coupled with high-voltage Nickel Cobalt Manganese Oxide (NCM-622) cathodes and lithium metal anodes, a discharge capacity of 119.70 mAh g-1 at 0.1C was sustained after 100 cycles, exhibiting a capacity retention of 78.95 %. This study elucidates the critical role of monomer design in achieving PIPS, offering valuable insights into developing high-performance polymer composite electrolytes for advanced lithium metal batteries.

RAFT Polymerization for Advanced Morphological Control: From Individual Polymer Chains to Bulk Materials

Control of the morphology of polymer systems is achieved through reversible-deactivation radical polymerization techniques such as Reversible Addition-Fragmentation chain Transfer (RAFT). Advanced RAFT techniques offer much more than just "living" polymerization - the RAFT toolkit now enables morphological control of polymer systems across many decades of length-scale. Morphological control is explored at the molecular-level in the context of syntheses where individual monomer unit insertion provides sequence-defined polymers (single unit monomer insertion, SUMI). By being able to define polymer architectures, the synthesis of bespoke shapes and sizes of nanostructures becomes possible by leveraging self-assembly (polymerization induced self-assembly, PISA). Finally, it is seen that macroscopic materials can be produced with nanoscale detail, based on phase-separated nanostructures (polymerization induced microphase separation, PIMS) and microscale detail based on 3D-printing technologies. RAFT control of morphology is seen to cross from molecular level to additive manufacturing length-scales, with complete morphological control over all length-scales.

Phase-separated structures of tunable thermoresponsive and matrix polymers for large-scale temperature monitoring coatings

Temperature monitoring is significant and fundamental in the fields of healthcare and medicine. In surgery, ultrasonic cutting devices are used for cutting, coagulation, and hemostasis. However, surgeons are concerned about the collateral thermal damages. For example, due to the limited space during endoscopic surgery, thermal damage is caused by touching the surrounding tissues of the targeted organ with the heated shaft of the ultrasonic cutting device. The present work exhibits thermoresponsive and reversible color-change coatings for temperature-distribution imaging. The phase-separated structures of the layered conjugated and matrix polymers enable both the tuned thermoresponsivity and large-scale coating. Layered polydiacetylene (PDA) with intercalated guests exhibits reversible and thermoresponsive gradual color changes from blue to red. A matrix polymer facilitates formation of the phase-separated layered PDA and large-scale coating. Spraying the precursor solution containing the diacetylene monomer, guest molecule, and matrix polymer provides the self-organized large-scale coatings on substrates. The temperature distribution on the shaft of an ultrasonic cutting device is monitored using the coatings. The phase-separated structure of thermoresponsive and matrix polymers can be applied to tunable temperature monitoring in a variety of fields.

Scalable all polymer dielectrics with self-assembled nanoscale multiboundary exhibiting superior high temperature capacitive performance

Polymers are key dielectric materials for energy storage capacitors in advanced electronics and electric power systems due to their high breakdown strengths, low loss, great reliability, lightweight, and low cost. However, their electric and dielectric performance deteriorates at elevated temperatures, making them unable to meet the rising demand for harsh-environment electronics such as electric vehicles, renewable energy, and electrified transportation. Here, we present an all-polymer nanostructured dielectric material that achieves a discharged energy density of 7.1 J/cm³ with a charge-discharge efficiency of 90% at 150°C, outperforming the existing dielectric polymers and representing more than a twofold improvement in discharged energy density compared with polyetherimide. The self-assembled nano-scale multiboundaries effectively impede the charge injection and excitation, leading to more than one order of magnitude lower leakage current density than the pristine polymer matrix PEI at high electric fields and elevated temperature. In addition, the film processing is simple, straightforward, and low cost, thus this all-polymer nanostructured dielectric material strategy is suitable for the mass production of dielectric polymer films for high-temperature capacitive energy storage.

TDP-43 Amyloid Fibril Formation via Phase Separation-Related and -Unrelated Pathways

Intrinsically disordered regions (IDRs) in proteins can undergo liquid-liquid phase separation (LLPS) for functional assembly, but this increases the chance of forming disease-associated amyloid fibrils. Not all amyloid fibrils form through LLPS however, and the importance of LLPS relative to other pathways in fibril formation remains unclear. We investigated this question in TDP-43, a motor neuron disease and dementia-causing protein that undergoes LLPS, using thioflavin T (ThT) fluorescence, NMR, transmission electron microscopy (TEM), and wide-angle X-ray scattering (WAXS) experiments. Using a fluorescence probe modified from ThT strategically designed for targeting protein assembly rather than β-sheets and supported by TEM images, we propose that the biphasic ThT signals observed under LLPS-favoring conditions are due to the presence of amorphous aggregates. These aggregates represent an intermediate state that diverges from the direct pathway to β-sheet-dominant fibrils. Under non-LLPS conditions in contrast (at low pH or at physiological conditions in a construct with key LLPS residues removed), the protein forms a hydrogel. Real-time WAXS data, ThT signals, and TEM images collectively demonstrate that the gelation process circumvents LLPS and yet still results in the formation of fibril-like structural networks. We suggest that the IDR of TDP-43 forms disease-causing amyloid fibrils regardless of the formation pathway. Our findings shed light on why both LLPS-promoting and LLPS-inhibiting mutants are found in TDP-43-related diseases.

Heterogeneous Acrylic Resins with Bicontinuous Nanodomains as Low-Modulus Flexible Adhesives

Adhesives play a critical role in the assembly of electronic devices, particularly as devices become more diverse in form factors. Flexible displays require highly transparent and rapidly recoverable adhesives with a certain stiffness. In this study, novel structured adhesives are developed that incorporate bicontinuous nanodomains to fabricate flexible adhesives with low moduli. This structure is obtained via polymerization-induced microphase separation using a macro chain transfer agent (CTA). Phase separation is characterized using small-angle X-ray scattering, transmission electron microscopy, and dynamic mechanical analysis. By optimizing the length of the macro CTA, an adhesive with both hard and soft nanodomains is produced, resulting in exceptional flexibility (strain recovery = 93%) and minimal modulus (maximum stress/applied strain = 7 kPa), which overperforms traditional adhesives. The optimized adhesive exhibits excellent resilience under extensive strain, as well as strong adhesion and transparency. Furthermore, dynamic folding tests demonstrate the exceptional stability of the adhesive under various temperature and humidity conditions, which is attributed to its unique structure. In summary, the distinct bicontinuous phase structure confers excellent transparency, flexibility, and reduced stiffness to the adhesive, rendering it well-suited for commercial foldable displays and suggesting potential applications in stretchable displays and wearable electronics.

Tuning the Mechanical Properties of 3D-printed Objects by Mixing Chain Transfer Agents in Radical Promoted Cationic RAFT Polymerization

The utilization of (cationic) reversible addition-fragmentation chain transfer (RAFT) polymerization in photoinduced three-dimensional (3D) printing has emerged as a robust technique for fabricating a variety of stimuli-responsive materials. However, methods for precisely adjusting the mechanical properties of these materials remain limited, thereby constraining their broader applicability. In this study, a facile way is introduced to modulate the mechanical properties of 3D printed objects by mixing two chain transfer agents (CTAs) within a radical-promoted cationic RAFT (RPC-RAFT) polymerization-based 3D printing process. Through systematic investigations employing tensile testing and dynamic mechanical analysis (DMA), the influence of CTA concentration and molar ratio between two CTAs on the mechanical behavior of the printed objects are explored. These findings demonstrate that higher concentrations of CTAs or a greater molar ratio of the more active CTA within the mixed CTAs result in decreased Young's modulus and glass transition temperatures of the printed objects. Moreover, the tensile failure strain increased with the increasing CTA content, i.e., the samples became more ductile. This methodology broadens the toolbox available for tailoring the mechanical properties of 3D printed materials.

A Strong and Highly Transparent Ionogel Electrolyte Enabled by In Situ Polymerization-Induced Microphase Separation for High-Performance Electrochromic Devices

Electrochromic devices built with ionogel electrolytes are seen as a pivotal step toward the future of quasi-solid electrochromic devices, due to their striking properties like exceptional safety and high ionic conductivity. Yet, the poor mechanical strength of electrolyte of these devices remains a constraint that hampers their advancement. As a resolution, this research explores the use of a robust, transparent ionogel electrolyte, which is designed using an in situ microphase separation strategy. The ionogels are highly transparent and robust and exhibit excellent physicochemical stability, including a wide electrochemical window and high temperature tolerance. Benefitting from these properties, a high-performance electrochromic device is fabricated through in situ polymerization with the ionogels, PPRODOT as the electrochromic layer, and PEDOT: PSS as the ion storage layer, achieving high transmittance contrast (43.1%), fast response (1/1.7 s), high coloring efficiency (1296.4 cm2 C-1), and excellent cycling endurance (>99.9% retention after 2000 cycles). In addition, using ITO-poly(ethylene terephthalate) as flexible substrates, a deformable electrochromic device displaying high stability is realized, highlighting the potential use in functional wearables.

Semi-crystalline polymers with supramolecular synergistic interactions: from mechanical toughening to dynamic smart materials

Semi-crystalline polymers (SCPs) with anisotropic amorphous and crystalline domains as the basic skeleton are ubiquitous from natural products to synthetic polymers. The combination of chemically incompatible hard and soft phases contributes to unique thermal and mechanical properties. The further introduction of supramolecular interactions as noncovalently interacting crystal phases and soft dynamic crosslinking sites can synergize with covalent polymer chains, thereby enabling effective energy dissipation and dynamic rearrangement in hierarchical superstructures. Therefore, this review will focus on the design principles of SCPs by discussing supramolecular construction strategies and state-of-the-art functional applications from mechanical toughening to sophisticated functions such as dynamic adaptivity, shape memory, ion transport, etc. Current challenges and further opportunities are discussed to provide an overview of possible future directions and potential material applications.

From Unregulated Networks to Designed Microstructures: Introducing Heterogeneity at Different Length Scales in Photopolymers for Additive Manufacturing

Photopolymers have been optimized as protective and decorative coating materials for decades. However, with the rise of additive manufacturing technologies, vat photopolymerization has unlocked the use of photopolymers for three-dimensional objects with new material requirements. Thus, the originally highly cross-linked, amorphous architecture of photopolymers cannot match the expectations for modern materials anymore, revealing the largely unanswered question of how diverse properties can be achieved in photopolymers. Herein, we review how microstructural features in soft matter materials should be designed and implemented to obtain high performance materials. We then translate these findings into chemical design suggestions for enhanced printable photopolymers. Based on this analysis, we have found microstructural heterogenization to be the most powerful tool to tune photopolymer performance. By combining the chemical toolbox for photopolymerization and the analytical toolbox for microstructural characterization, we examine current strategies for physical heterogenization (fillers, inkjet printing) and chemical heterogenization (semicrystalline polymers, block copolymers, interpenetrating networks, photopolymerization induced phase separation) of photopolymers and put them into a material scientific context to develop a roadmap for improving and diversifying photopolymers' performance.

Long-lifespan Zinc-ion Capacitors Enabled by Anodes Integrated with Interconnected Mesoporous Chitosan Membranes through Electrophoresis-driven Phase Separation

The advancement of highly secure and inexpensive aqueous zinc ion energy storage devices is impeded by issues, including dendrite growth, hydrogen evolution and corrosion of zinc anodes. It is essential to modify the interface of zinc anodes that homogenizes ion flux and facilitates highly reversible zinc planarized deposition and stripping. Herein, by coupling zinc ion coordination with acid-base neutralization under the driving of electrophoresis, manageable mesoscopic phase separation for constructing chitosan frameworks was achieved, thereby fabricating interconnected mesoporous chitosan membranes based heterogeneous quasi-solid-state electrolytes integrated with anodes. The framework is constructed by twisted chitosan nanofiber bundles, forming a three-dimensional continuous spindle-shaped pore structure. With this framework, the electrolyte provides exceptional ion conductivity of 25.1 mS cm-1 , with a puncture resistance strength of 2.3 GPa. In addition, the amino groups of chitosan molecule can make the surface of the framework positively charged. Thus, reversible zinc planarized deposition is successfully induced by the synergistic effect of stress constraint and electrostatic modulation. As a result, as-assembled zinc ion capacitor has an excellent cycle life and sustains the capacity by over 95 % after 20000 cycles at a current density of 5 A g-1 . This research presents a constructive strategy for stable electrolytes-integrated zinc anodes.

Tuning the Mechanical Properties of 3D-printed Objects by the RAFT Process: From Chain-Growth to Step-Growth

Photoinduced 3D printing based on the reversible addition-fragmentation chain transfer (RAFT) process has emerged as a robust method for creating diverse functional materials. However, achieving precise control over the mechanical properties of these printed objects remains a critical challenge for practical application. Here, we demonstrated a RAFT step-growth polymerization of a bifunctional xanthate and bifunctional vinyl acetate. Additionally, we demonstrated photoinduced 3D printing through RAFT step-growth polymerization with a tetrafunctional xanthate and a bifunctional vinyl acetate. By adjusting the molar ratio of the components in the printing resins, we finely tuned the polymerization mechanism from step-growth to chain-growth. This adjustment resulted in a remarkable range of tunable Young's moduli, ranging from 7.6 MPa to 997.1 MPa. Moreover, post-functionalization and polymer welding of the printed objects with varying mechanical properties opens up a promising way to produce tailor-made materials with specific and tunable properties.