Photoinitiated Polymerization-Induced Microphase Separation for the Preparation of Nanoporous Polymer Films

Effect of Block Copolymer Self-Assembly on Phase Separation in Photopolymerizable Epoxy Blends

Directing self-assembly of photopolymerizable systems is advantageous for controlling polymer nanostructure and material properties, but developing techniques for inducing ordered structure remains challenging. In this work, well-defined diblock or random copolymers were incorporated into cationic photopolymerizable epoxy systems to investigate the impact of copolymer architecture on self-assembly and phase separated nanostructures. Copolymers consisting of poly(hydroxyethyl acrylate)-x-(butyl acrylate) were prepared using photoiniferter polymerization to control functional group placement and molecular weight/polydispersity. Prepolymer configuration and concentration induced distinctly different effects on the resin flow and photopolymerization kinetics. The diblock copolymer self-assembled into nanostructured phases within the resin matrix, whereas the random copolymer formed an isotropic mixture. Rapid photopolymerization and ambient temperature conditions during cure facilitated retention of the self-assembled phases, leading to considerably different composite morphology and thermomechanical behavior. Increased loading of the diblock copolymer induced long-range ordered cocontinuous structures. Even with nearly identical prepolymer composition, controlled nanophase separation resulted in significantly enhanced tensile properties relative to those of the isotropic system. This work demonstrates that controlling phase separation with a block copolymer architecture allows access to nanostructured photopolymers with unique and enhanced properties.

Effect of Macromolecular Structure on Phase Separation Regime in 3D Printed Materials

In this study, the fabrication of 3D-printed polymer materials with controlled phase separation using polymerization induced microphase separation (PIMS) via photoinduced 3D printing is demonstrated. While many parameters affecting the nanostructuration in PIMS processes are extensively investigated, the influence of the chain transfer agent (CTA) end group, i.e., Z-group, of macromolecular chain transfer agent (macroCTA) remains unclear as previous research has exclusively employed trithiocarbonate as the CTA end group. Herein, the effect of macroCTAs containing four different Z-groups on the formation of nanostructure of 3D printed materials is explored. The results show that the different Z-groups lead to distinct network formation and phase separation behaviors between the resins, influencing both the 3D printing process and the resulting material properties. Specifically, less reactive macroCTAs toward acrylic radical addition, such as O-alkyl xanthate and N-alkyl-N-aryl dithiocarbamate, result in translucent and brittle materials with macrophase separation morphology. In contrast, more reactive macroCTAs such as S-alkyl trithiocarbonate and 4-chloro-3,5-dimethylpyrazo dithiocarbamate produce transparent and rigid materials with nano-scale morphology. Findings of this study provide a novel approach to manipulate the nanostructure and properties of 3D printed PIMS materials, which can have important implications for materials science and engineering.

Polymerization Induced Microphase Separation for the Fabrication of Nanostructured Materials

Polymerization induced microphase separation (PIMS) is a strategy used to develop unique nanostructures with highly useful morphologies through the microphase separation of emergent block copolymers during polymerization. In this process, nanostructures are formed with at least two chemically independent domains, where at least one domain is composed of a robust crosslinked polymer. Crucially, this synthetically simple method is readily used to develop nanostructured materials with the highly coveted co-continuous morphology, which can also be converted into mesoporous materials by selective etching of one domain. As PIMS exploits a block copolymer microphase separation mechanism, the size of each domain can be tightly controlled by modifying the size of block copolymer precursors, thus providing unparalleled control over nanostructure and resultant mesopore sizes. Since its inception 11 years ago, PIMS has been used to develop a vast inventory of advanced materials for an extensive range of applications including biomedical devices, ion exchange membranes, lithium-ion batteries, catalysis, 3D printing, and fluorescence-based sensors, among many others. In this review, we provide a comprehensive overview of the PIMS process, summarize latest developments in PIMS chemistry, and discuss its utility in a wide variety of relevant applications.

On-Demand Tunability of Microphase Separation Structure of 3D Printing Material by Reversible Addition/Fragmentation Chain Transfer Polymerization

Controlling the phase-separated structure of polymer alloys is a promising method for tailoring the properties of polymers. However, controlling the morphology of phase-separated structures is challenging. Recently, phase-separated structures have been fabricated via 3D printing; however, only a few methods that enable on-demand control of phase separation have been reported. In this study, laser-scanning stereolithography, a vat photopolymerization method, is used to form a phase-separated structure via polymerization-induced microphase separation by varying the scanning speed and using macro-reversible addition/fragmentation chain transfer (macro-RAFT) agents with different average molar masses, along with multiarmed macro-RAFT agents; such structures were used to fabricate 3D-printed parts. Various phase-separated morphologies including sea-island and reverse sea-island were achieved by controlling the laser scanning speed and RAFT type. Heterogeneous structures with different material properties were also achieved by simply changing the laser scanning speed. As the deformation due to shrinkage in the process of cleaning 3D-printed parts depends on the laser scanning speed, shape correction was introduced to suppress the effect of shrinkage and obtain the desired shape.

Nano- to macro-scale control of 3D printed materials via polymerization induced microphase separation

Although 3D printing allows the macroscopic structure of objects to be easily controlled, controlling the nanostructure of 3D printed materials has rarely been reported. Herein, we report an efficient and versatile process for fabricating 3D printed materials with controlled nanoscale structural features. This approach uses resins containing macromolecular chain transfer agents (macroCTAs) which microphase separate during the photoinduced 3D printing process to form nanostructured materials. By varying the chain length of the macroCTA, we demonstrate a high level of control over the microphase separation behavior, resulting in materials with controllable nanoscale sizes and morphologies. Importantly, the bulk mechanical properties of 3D printed objects are correlated with their morphologies; transitioning from discrete globular to interpenetrating domains results in a marked improvement in mechanical performance, which is ascribed to the increased interfacial interaction between soft and hard domains. Overall, the findings of this work enable the simplified production of materials with tightly controllable nanostructures for broad potential applications.

Nanostructure Control in 3D Printed Materials

Currently, there are no straightforward methods to 3D print materials with nanoscale control over morphological and functional properties. Here, a novel approach for the fabrication of materials with controlled nanoscale morphologies using a rapid and commercially available Digital Light Processing 3D printing technique is demonstrated. This process exploits reversible deactivation radical polymerization to control the in-situ-polymerization-induced microphase separation of 3D printing resins, which provides materials with complex architectures controllable from the macro- to nanoscale, resulting in the preparation of materials with enhanced mechanical properties. This method does not require specialized equipment or process conditions and thus represents an important development in the production of advanced materials via additive manufacturing.

Downsizing of Block Polymer-Templated Nanopores to One Nanometer via Hyper-Cross-Linking of High χ-Low N Precursors

Synthesizing nanoporous polymer from the block polymer template by selective removal of the sacrificial domain offers straightforward pore size control as a function of the degree of polymerization (N). Downscaling pore size into the microporous regime (<2 nm) has been thermodynamically challenging, because the low N drives the system to disorder and the small-sized pore is prone to collapse. Herein, we report that maximizing cross-linking density of a block polymer precursor with an increased interaction parameter (χ) can help successfully stabilize the structure bearing pore sizes of 1.1 nm. We adopt polymerization-induced microphase separation (PIMS) combined with hyper-cross-linking as a strategy for the preparation of the bicontinuous block polymer precursors with a densely cross-linked framework by copolymerization of vinylbenzyl chloride with divinylbenzene and also Friedel-Crafts alkylation. Incorporating 4-vinylbiphenyl as a higher-χ comonomer to the sacrificial polylactide (PLA) block and optimizing the segregation strength versus cross-linking density allow for further downscaling. Control of pore size by N of PLA is demonstrated in the range of 9.9-1.1 nm. Accessible surface area to fluorescein-tagged dextrans is regulated by the relative size of the pore to the guest, and pore size is controlled. These findings will be useful for designing microporous polymers with tailored pore size for advanced catalytic and separation applications.

Next-Generation Ultrafiltration Membranes Enabled by Block Polymers

Reliable and equitable access to safe drinking water is a major and growing challenge worldwide. Membrane separations represent one of the most promising strategies for the energy-efficient purification of potential water sources. In particular, porous membranes are used for the ultrafiltration (UF) of water to remove contaminants with nanometric sizes. However, despite exhibiting excellent water permeability and solution processability, existing UF membranes contain a broad distribution of pore sizes that limit their size selectivity. To maximize the potential utility of UF membranes and allow for precise separations, improvements in the size selectivity of these systems must be achieved. Block polymers represent a potentially transformative solution, as these materials self-assemble into well-defined domains of uniform size. Several different strategies have been reported for integrating block polymers into UF membranes, and each strategy has its own set of materials and processing considerations to ensure that uniform and continuous pores are generated. This Review aims to summarize and critically analyze the chemistries, processing techniques, and properties required for the most common methods for producing porous membranes from block polymers, with a particular focus on the fundamental mechanisms underlying block polymer self-assembly and pore formation. Critical structure-property-performance metrics will be analyzed for block polymer UF membranes to understand how these membranes compare to commercial UF membranes and to identify key research areas for continued improvements. This Review is intended to inform readers of the capabilities and current challenges of block polymer UF membranes, while stimulating critical thought on strategies to advance these technologies.

Porous Graphene Oxide Films Prepared via the Breath-Figure Method: A Simple Strategy for Switching Access of Redox Species to an Electrode Surface

Porous materials can be modified with physical barriers to control the transport of ions and molecules through channels via an external stimulus. Such capability has brought attention toward drug delivery, separation methods, nanofluidics, and point-of-care devices. In this context, gated platforms on which access to an electrode surface of species in solution can be reversibly hindered/unhindered on demand are appearing as promising materials for sensing and microfluidic switches. The preparation of a reversible gated device usually requires mesoporous materials, nanopores, or molecularly imprinted polymers. Here, we show how the breath-figure method assembly of graphene oxide can be used as a simple strategy to produce gated electrochemical materials. This was achieved by forming an organized porous thin film of graphene oxide onto an ITO surface. Localized brushes of thermoresponsive poly(N-isopropylacrylamide) were then grown to specific sites of the porous film by in situ reversible addition-fragmentation chain-transfer polymerization. The gating mechanism relies on the polymeric chains to expand and contract depending on the thermal stimulus, thus modulating the accessibility of redox species inside the pores. The resulting platform was shown to reversibly hinder or facilitate the electron transfer of solution redox species by modulating temperature from the room value to 45 °C or vice versa.

Synthetic route-dependent intramolecular segregation in heteroarm core cross-linked star polymers as Janus-like nanoobjects

Polymerization-induced intramolecular segregation can be realized during the “in–out” synthesis of heteroarm core cross-linked star polymers to facilitate well-defined microphase separation.

Functionalization-Induced Self-Assembly of Block Copolymers for Nanoparticle Synthesis

Nanoparticle synthesis was demonstrated via functionalization-induced self-assembly (FISA) of block copolymers using Suzuki-Miyaura cross-coupling. In situ self-assembly was triggered in organic media by the progressive installation of solvophobic pendant groups onto an initially soluble diblock copolymer, rendering the reactive block insoluble and causing the formation of spherical polymeric micelles. Self-assembly was found to depend on the percent functionalization (f_%), where after a critical threshold micelles were accessible that increased in size with increasing f_% values. We found the chemical nature of the installed functional group to be crucial for conducting FISA and for controlling the solution morphology, with relatively solvophilic adducts remaining as unimers and increasingly solvophobic adducts trending toward larger micelles, from ca. 40 to 100 nm in diameter. The core and corona of the anticipated micellar structure were visualized using fluorine mapping through electron energy loss spectroscopy, in conjunction with FISA achieved through pendent trifluorophenyl functionality. This work establishes FISA as a new, versatile synthetic strategy to create nanoparticles having tunable morphologies with potential application as molecular payload delivery vehicles.

Creation of micropores by RAFT copolymerization of conjugated multi-vinyl cross-linkers

Copolymerization of conjugated multi-vinyl cross-linkers with styrene creates a fluorescent and microporous cross-linked network, useful for the synthesis of hierarchically porous polymers.

Copolymerization on Selective Substrates: Experimental Test and Computer Simulations

We explore the influence of a selective substrate on the composition and sequence statistics during the free radical copolymerization. In particular, we study the radical copolymerization of styrene and acrylic acid in bulk and in silica pores of different sizes. We show that the substrate affects both polymer composition and sequence statistics. We use dissipative particle dynamics simulations to study the polymerization process in detail, trying to pinpoint the parameters responsible for the observed differences in the polymer chain composition and sequences. The magnitude of the observed effect depends on the fraction of adsorbed monomer units, which cannot be described in the framework of the copolymerization theories based on the terminal unit model.

Alcoholic Photoinitiated Polymerization-Induced Self-Assembly (Photo-PISA): A Fast Route toward Poly(isobornyl acrylate)-Based Diblock Copolymer Nano-Objects

We report a fast alcoholic photoinitiated polymerization-induced self-assembly (photo-PISA) formulation via photoinitiated RAFT dispersion polymerization of isobornyl acrylate (IBOA) in an ethanol/water mixture at 40 °C using a monomethoxy poly(ethylene glycol) (mPEG) based chain transfer agent. Polymerization proceeded rapidly via the exposure to visible light irradiation (405 nm, 0.5 mW/cm²), and high monomer conversion (>95%) was achieved within 30 min. Kinetic studies confirmed that good control was maintained during the photo-PISA process, and the polymerization can be activated or deactivated by light. Finally, we demonstrated that a diverse set of complex morphologies (spheres, worms, or vesicles) could be achieved by varying reaction parameters, and a phase diagram was constructed.

Heteroarm core cross-linked star polymers via RAFT copolymerization of styrene and bismaleimide

Core cross-linked star polymer containing polystyrene and polylactide arms can be prepared by alternating RAFT copolymerization and self-assembles into superstructures.