Preferential Alignment of Incommensurate Block Copolymer Dot Arrays Forming Moiré Superstructures

Sequential Self-Assembly of Polystyrene-block-Polydimethylsiloxane for 3D Nanopatterning via Solvent Annealing

This study aims to develop a strategy for the fabrication of multilayer nanopatterns through sequential self-assembly of lamella-forming polystyrene-block-polydimethylsiloxane (PS-b-PDMS) block copolymer (BCP) from solvent annealing. By simply tuning the solvent selectivity, a variety of self-assembled BCP thin-film morphologies, including hexagonal perforated lamellae (HPL), parallel cylinders, and spheres, can be obtained from single-composition PS-b-PDMS. By taking advantage of reactive ion etching (RIE), topographic SiO2 monoliths with well-ordered arrays of hexagonally packed holes, parallel lines, and hexagonally packed dots can be formed. Subsequently, hole-on-dot and line-on-hole hierarchical textures can be created through a layer-by-layer process with RIE treatment as evidenced experimentally and confirmed theoretically. The results demonstrated the feasibility of creating three-dimensional (3D) nanopatterning from the sequential self-assembly of single-composition PS-b-PDMS via solvent annealing, providing an appealing process for nano-MEMS manufacturing based on BCP lithography.

Non-Bulk Morphologies of Extremely Thin Block Copolymer Films Cast on Topographically Defined Substrates Featuring Deep Trenches: The Importance of Lateral Confinement

Directed self-assembly of block copolymers is evolving toward applications that are more defect-tolerant but still require high morphological control and could benefit from simple, inexpensive fabrication processes. Previously, we demonstrated that simply casting ultra-thin block copolymer films on topographically defined substrates leads to hierarchical structures with dual patterns in a controlled manner and unraveled the dependence of the local morphology on the topographic feature dimensions. In this article, we discuss the extreme of the ultraconfined thickness regime at the border of film dewetting. Additional non-bulk morphologies are observed at this extreme, which further elaborate the arsenal of dual patterns that could be obtained in coexistence with full placement control. It is shown that as the thickness confinement approaches its limit, lateral confinement imposed by the width of the plateaus becomes a critical factor influencing the local morphology.

Competitive Registration Fields for The Development of Complex Block Copolymer Structures by A Layer-by-Layer Approach

Block copolymer (BCP) self-assembly in thin films is an elegant method to generate nanometric features with tunable geometrical configurations. By combining directed assembly and hybridization methods, advances in nano-manufacturing have been attested over the past decades with flagship applications in lithography and optics. Nevertheless, the range of geometrical configurations is limited by the accessible morphologies inherent to the energy minimization process involved in BCP self-assembly. Layering of nanostructured BCP thin films has been recently proposed in order to enrich the span of nanostructures derived from BCP self-assembly with the formation of non-native heterostructures such as double-layered arrays of nanowires or dots-on-line and dots-in-hole hierarchical structures. In this work, the layer-by-layer method is further exploited for the generation of nano-mesh arrays using nanostructured BCP thin films. In particular, a subtle combination of chemical and topographical fields is leveraged in order to demonstrate design rules for the controlled registration of a BCP layer on top of an underneath immobilized one by the precise tuning of the interfacial chemical field between the two BCP layers.

Autonomous discovery of emergent morphologies in directed self-assembly of block copolymer blends

The directed self-assembly (DSA) of block copolymers (BCPs) is a powerful approach to fabricate complex nanostructure arrays, but finding morphologies that emerge with changes in polymer architecture, composition, or assembly constraints remains daunting because of the increased dimensionality of the DSA design space. Here, we demonstrate machine-guided discovery of emergent morphologies from a cylinder/lamellae BCP blend directed by a chemical grating template, conducted without direct human intervention on a synchrotron x-ray scattering beamline. This approach maps the morphology-template phase space in a fraction of the time required by manual characterization and highlights regions deserving more detailed investigation. These studies reveal localized, template-directed partitioning of coexisting lamella- and cylinder-like subdomains at the template period length scale, manifesting as previously unknown morphologies such as aligned alternating subdomains, bilayers, or a "ladder" morphology. This work underscores the pivotal role that autonomous characterization can play in advancing the paradigm of DSA.

Dual Block Copolymer Morphologies in Ultrathin Films on Topographic Substrates: The Effect of Film Curvature

The ability to create mixed morphologies using easily controlled parameters is crucial for the integration of block copolymers in advanced technologies. We have previously shown that casting an ultrathin block copolymer film on a topographically patterned substrate results in different deposited thicknesses on the plateaus and in the trenches, which leads to the co-existence of two patterns. In this work, we highlight the dependence of the dual patterns on the film profile. We suggest that the steepness of the film profile formed across the plateau edge affects the nucleation of microphase-separated domains near the plateau edges, which influences the morphology that develops on the plateau regions. An analysis of the local film thicknesses in multiple samples exhibiting various combinations of plateau and trench widths for different trench depths enabled the construction of phase diagrams, which unraveled the intricate dependence of the formed patterns not only on the curvature of the film profile but also on the fraction of the film that resides in the trenches. Our analysis facilitates the prediction of the patterns that would develop in the trenches and on the plateaus for a given block copolymer film of known thickness from the dimensions of the topographic features.

Modeling the optical properties of twisted bilayer photonic crystals

We demonstrate a photonic analog of twisted bilayer graphene that has ultra-flat photonic bands and exhibits extreme slow-light behavior. Our twisted bilayer photonic device, which has an operating wavelength in the C-band of the telecom window, uses two crystalline silicon photonic crystal slabs separated by a methyl methacrylate tunneling layer. We numerically determine the magic angle using a finite-element method and the corresponding photonic band structure, which exhibits a flat band over the entire Brillouin zone. This flat band causes the group velocity to approach zero and introduces light localization, which enhances the electromagnetic field at the expense of bandwidth. Using our original plane-wave continuum model, we find that the photonic system has a larger band asymmetry. The band structure can easily be engineered by adjusting the device geometry, giving significant freedom in the design of devices. Our work provides a fundamental understanding of the photonic properties of twisted bilayer photonic crystals and opens the door to the nanoscale-based enhancement of nonlinear effects.

van der Waals Epitaxy of Soft Twisted Bilayers: Lattice Relaxation and Mass Density Waves

Interfaces comprising incommensurate or twisted hexagonal lattices are ubiquitous and of great interest, from adsorbed organic/inorganic interfaces in electronic devices, to superlubricants, and more recently to van der Waals bilayer heterostructures (vdWHs) of graphene and other 2D materials that demonstrate a range of properties such as superconductivity and ferromagnetism. Here we show how growth of 2D crystalline domains of soft block copolymers (BCPs) on patterned hard hexagonal lattices provide fundamental insights into van der Waals heteroepitaxy. At moderate registration forces, it is experimentally found that these BCP-hard lattice vdWHs do not adopt a simple moiré superstructure, but instead adopt local structural relaxations known as mass density waves (MDWs). Simulations reveal that MDWs are a primary mechanism of energy minimization and are the origin of the observed preferential twist angle between the lattices.

Self-template-assisted micro-phase segregation in blended liquid-crystalline block copolymers films toward three-dimensional structures

In-plane mesopatterns derived from block-copolymer (BCP) micro-phase segregation in thin films have attracted much interest in practical applications as well as fundamental research programs. However, phase segregation along the film-normal direction has been less studied. Here, we describe a strategy to concurrently, yet independently, control in-plane micro-phase and out-of-plane macro-phase segregation in multiblended films composed of liquid-crystalline BCPs (LCBCPs), affording spontaneously layered three-dimensional (3D) mesostructures. This strategy relies on sequential liquid crystallization during the cooling process in thermal annealing as follows. The constituent LCBCP with the highest isotropic-transition temperature (T _iso) first liquid-crystallizes and segregates from the other LCBCP mixture remaining in isotropic states to form a noncontaminated layer at the top surface. This preformed LCBCP layer preserves its inherent in-plane pattern and acts as a template guiding the subsequent micro-phase segregations of the other low-T _iso LCBCPs underneath. This self-template-assisted micro-phase segregation (STAMPS) readily provides 3D mesostructures, the potential toward rational material design of which is also demonstrated in water-separation applications.

Novel Hybrid Conductor of Irregularly Patterned Graphene Mesh and Silver Nanowire Networks

We prepared the hybrid conductor of the Ag nanowire (NW) network and irregularly patterned graphene (GP) mesh with enhanced optical transmittance (~98.5%) and mechano-electric stability (ΔR/R_o: ~42.4% at 200,000 (200k) cycles) under 6.7% strain. Irregularly patterned GP meshes were prepared with a bottom-side etching method using chemical etchant (HNO₃). The GP mesh pattern was judiciously and easily tuned by the regulation of treatment time (0–180 min) and concentration (0–20 M) of chemical etchants. As-formed hybrid conductor of Ag NW and GP mesh exhibit enhanced/controllable electrical-optical properties and mechano-electric stabilities; hybrid conductor exhibits enhanced optical transmittance (TT = 98.5%) and improved conductivity (ΔR_s: 22%) compared with that of a conventional hybrid conductor at similar TT. It is also noteworthy that our hybrid conductor shows far superior mechano-electric stability (ΔR/R_o: ~42.4% at 200k cycles; TT: ~98.5%) to that of controls (Ag NW (ΔR/R_o: ~293% at 200k cycles), Ag NW-pristine GP hybrid (ΔR/R_o: ~121% at 200k cycles)) ascribed to our unique hybrid structure.

Shape-directed self-assembly of nanodumbbells into superstructure polymorphs

Self-assembly of colloidal nanoparticles into ordered superstructures provides a promising route to create novel/enhanced functional materials. Much progress has been made in self-assembly of anisotropic nanoparticles, but the complexity and tunability of superstructures remain restricted by their available geometries. Here we report the controlled packing of nanodumbbells (NDs) with two spherical lobes connected by one rod-like middle bar into varied superstructure polymorphs. When assembled into two-dimensional (2D) monolayer assemblies, such NDs with specific shape parameters could form orientationally ordered degenerate crystals with a 6-fold symmetry, in which these NDs possess no translational order but three allowed orientations with a rotational symmetry of 120 degrees. Detailed analyses identify the distinct roles of subunits in the ND assembly: the spherical lobes direct NDs to closely assemble together into a hexagonal pattern, and the rod-like connection between the lobes endows NDs with this specific orientational order. Such intralayer assembly features are well maintained in the two-layer superstructures of NDs; however, the interlayer stackings could be adjusted to produce stable bilayer superstructures and a series of metastable moiré patterns. Moreover, in addition to horizontal alignment, these NDs could gradually stand up to form tilted or even vertical packing based on the delicate control over the liquid-liquid interface and ND dimensions. This study provides novel insights into creating superstructures by controlling geometric features of nanoscale building blocks and may spur their novel applications.

Controlled Spacing between Nanopatterned Regions in Block Copolymer Films Obtained by Utilizing Substrate Topography for Local Film Thickness Differentiation

Various types of devices require hierarchically nanopatterned substrates, where the spacing between patterned domains is controlled. Ultraconfined films exhibit extreme morphological sensitivity to slight variations in film thickness when the substrate is highly selective toward one of the blocks. Here, it is shown that using the substrate's topography as a thickness differentiating tool enables the creation of domains with different surface patterns in a fully controlled fashion from a single, unblended block copolymer. This approach is applicable to block copolymers of different compositions and to different topographical patterns and thus opens numerous possibilities for the hierarchical construction of multifunctional devices.