Why do drying films crack?

Suppression of cracking in drying colloidal suspensions with chain-like particles

The prevention of drying-induced cracking is crucial in maintaining the mechanical integrity and functionality of colloidal deposits and coatings. Despite exploring various approaches, controlling drying-induced cracking remains a subject of great scientific interest and practical importance. By introducing chain-like particles composed of the same material and with comparable size into commonly used colloidal suspensions of spherical silica nanoparticles, we can significantly reduce the cracks formed in dried particle deposits and achieve a fivefold increase in the critical cracking thickness of colloidal silica coatings. The mechanism underlying the crack suppression is attributed to the increased porosity and pore sizes in dried particle deposits containing chain-like particle, which essentially leads to reduction in internal stresses developed during the drying process. Meanwhile, the nanoindentation measurements reveal that colloidal deposits with chain-like particles exhibit a smaller reduction in hardness compared to those reported using other cracking suppression approaches. This work demonstrates a promising technique for preparing colloidal coatings with enhanced crack resistance while maintaining desirable mechanical properties.

Programming crack patterns with light in colloidal plasmonic films

Crack formation observed across diverse fields like geology, nanotechnology, arts, structural engineering or surface science, is a chaotic and undesirable phenomenon, resulting in random patterns of cracks generally leading to material failure. Limiting the formation of cracks or "programming" the path of cracks is a great technological challenge since it holds promise to enhance material durability or even to develop low cost patterning methods. Drawing inspiration from negative phototropism in plants, we demonstrate the capability to organize, guide, replicate, or arrest crack propagation in colloidal films through remote light manipulation. The key consists in using plasmonic photothermal absorbers to generate "virtual" defects enabling controlled deviation of cracks. We engineer a dip-coating process coupled with selective light irradiation enabling simultaneous deposition and light-directed crack patterning. This approach represents a rare example of a robust self-assembly process with long-range order that can be programmed in both space and time.

Morphologies of electric-field-driven cracks in dried dispersions of ellipsoids

We report an experimental and theoretical study of the morphology of desiccation cracks formed in deposits of hematite ellipsoids dried in an externally applied alternating current (ac) electric field. A series of transitions in the crack morphology is observed by modulating the frequency and the strength of the applied field. We also found a clear transition in the morphology of cracks as a function of the aspect ratio of the ellipsoid. We show that these transitions in the crack morphology can be explained by a linear stability analysis of the equation describing the effective dynamics of an ellipsoid placed in an externally applied ac electric field.

Effect of Colloidal Surface Charge on Desiccation Cracks

We report the effect of polarity and surface charge density on the nucleation and growth kinetics of desiccation cracks in deposits of colloids formed by drying. We show that the average spacing between desiccation cracks and crack opening are higher for the deposit of positively charged colloids than that of negatively charged colloids. The temporal evolution of crack growth is found to be faster for positively charged particle deposits. The distinct crack patterns and their kinetics are understood by considering the spatial arrangement of particles in the deposit, which is strongly influenced by the substrate-particle and particle-particle interactions. Interestingly, the crack spacing, the crack opening, and the rate at which the crack widens are found to increase upon decreasing the surface charge of the colloids.

Cracked Film Lithography with CuGaOx Buffers for Bifacial CdTe Photovoltaics

Bifacial CdTe solar cells with greater power density than the monofacial baselines are demonstrated by using a CuGaO_x rear interface buffer that passivates while reducing sheet resistance and contact resistance. Inserting CuGaO_x between the CdTe and Au increases mean power density from 18.0 ± 0.5 to 19.8 ± 0.4 mW cm^-2 for one sun front illumination. However, coupling CuGaO_x with a transparent conductive oxide leads to an electrical barrier. Instead, CuGaO_x is integrated with cracked film lithography (CFL)-patterned metal grids. CFL grid wires are spaced narrowly enough (≈10 µm) to alleviate semiconductor resistance while retaining enough passivation and transmittance for a bifacial power gain: bifacial CuGaO_x /CFL grids generate 19.1 ± 0.6 mW cm^-2 for 1 sun front + 0.08 sun rear illumination and 20.0 ± 0.6 mW cm^-2 at 1 sun front + 0.52 sun rear-the highest reported power density at field albedo conditions for a scaled polycrystalline absorber.

Interplay of Consolidation Fronts and Cracks in Drying Colloidal Coatings and Its Application in Controlling Crack Pattern Formation

Cracks are frequently observed in drying colloidal coatings. Although a rich collection of crack patterns has been reported, the systematic study on how cracks grow into the final morphology during the drying process remains elusive. In this work, we use directional drying channels with wedge-shaped edges of different angles to study the interplay of advancing consolidation fronts and propagating cracks. We found that although the shape of the advancing consolidation fronts is altered by the drying edge, the growth direction of the following cracks remains perpendicular to the consolidation fronts during the whole drying process, resulting in cracks with a large curvature. We rationalize the evolution of consolidation fronts with the distribution of capillary pressure revealed by a Laplace model. Further, the growth direction of cracks can be explained by the fracture mechanics mechanism that the main orientation of internal tensile stresses developed during the consolidation determines the crack growth direction. Utilizing this understanding, wavy crack patterns are generated in rectangular drying channels with an alternating temperature field, demonstrating a feasible method of designing and controlling drying-induced crack patterns for micro-/nano-fabrication applications.

Effect of the Shape of the Confining Boundary and Particle Shape Anisotropy on the Morphology of Desiccation Cracks

The control of the morphology of desiccation cracks is fascinating not only from the application point of view but also from the rich physics behind it. Here, we present a seemingly simple method to tailor the morphology of desiccation cracks by exploitation of the combined effect of particle shape anisotropy and the shape of the confining boundary. This allows us to make circular, square, and triangular-shaped desiccation cracks in the vicinity of the confining boundaries. As the colloidal dispersion dries in confined wells, a drying front appears at the center of the well. With further evaporation, the drying front recedes toward the boundary from the center of the well. We show that the temporal evolution of the drying front is strongly influenced by the shape of the well. Subsequently, desiccation cracks appear in the penultimate stage of drying, and the morphology of the cracks is governed by the shape of the drying front and hence by the shape of the wells. The spatial evolution of the crack pattern is quantified by estimation of the curvature of the cracks, which suggests that the influence of the confining boundary on crack formation is long-ranged. However, the cracks in the dried deposit consisting of spherical particles remain unaffected by the shape of the well, and the cracks are always radial. We establish a one-to-one correspondence between the shape of the drying front and the morphology of the crack pattern in the final dried deposit of ellipsoids.

Criteria for Crack Formation and Air Invasion in Drying Colloidal Suspensions

The drying of sessile drops of aqueous colloidal suspensions leads to the formation of a close-packed particle deposit. As water evaporates, a solidification front propagates from the edge of the drop toward the center, leaving behind a thin disk-shaped deposit. For drops with sufficiently large particle volume fractions, the deposit eventually covers the entire wetted area. In this regime, the dynamics of the deposit growth is governed by volume conservation across a large range of particle volume fractions and drying times. During drying, water flows radially through the deposit to compensate for evaporation over the solid's surface, creating a negative pore pressure in the deposit which we rationalize with a hydrodynamic model. We show that the pressure inside the deposit controls both the onset of crack formation and the onset of air invasion. Two distinct regimes of air invasion occur, which we can account for using the same model that further provides a quantitative criterion for the crossover between the two regimes.

Research progress and applications of silica-based aerogels - a bibliometric analysis

Silica aerogels are three-dimensional porous materials that were initially produced in 1931. During the past nearly 90 years, silica aerogels have been applied extensively in many fields. In order to grasp the progress of silica-based aerogels, we utilize bibliometrics and visualization methods to analyze the research hotspots and the application of this important field. Firstly, we collect all the publications on silica-based aerogels and then analyze their research trends and performances by a bibliometric method regarding publication year/citation, country/institute, journals, and keywords. Following this, the major research hotspots of this area with a focus on synthesis, mechanical property regulation, and the applications for thermal insulation, adsorption, and Cherenkov detector radiators are identified and reviewed. Finally, current challenges and directions in the future regarding silica-based aerogels are also proposed.

Silica aerogels are three-dimensional porous materials that were initially produced in 1931. During the past nearly 90 years, silica aerogels have been applied extensively in many fields.

Advances in Flexible Metallic Transparent Electrodes

Transparent electrodes (TEs) are pivotal components in many modern devices such as solar cells, light-emitting diodes, touch screens, wearable electronic devices, smart windows, and transparent heaters. Recently, the high demand for flexibility and low cost in TEs requires a new class of transparent conductive materials (TCMs), serving as substitutes for the conventional indium tin oxide (ITO). So far, ITO has been the most used TCM despite its brittleness and high cost. Among the different emerging alternative materials to ITO, metallic nanomaterials have received much interest due to their remarkable optical-electrical properties, low cost, ease of manufacturing, flexibility, and widespread applicability. These involve metal grids, thin oxide/metal/oxide multilayers, metal nanowire percolating networks, or nanocomposites based on metallic nanostructures. In this review, a comparison between TCMs based on metallic nanomaterials and other TCM technologies is discussed. Next, the different types of metal-based TCMs developed so far and the fabrication technologies used are presented. Then, the challenges that these TCMs face toward integration in functional devices are discussed. Finally, the various fields in which metal-based TCMs have been successfully applied, as well as emerging and potential applications, are summarized.

Cracking of Colloidal Films to Generate Rectangular Fragments

Cracks are common in nature. Cracking is known as an irreversible and uncontrollable process. To control the cracking patterns, many researchers have proposed methods to prepare notches for stress localization on films. In this work, we investigate a method of controlling cracks by making microscale pyramid patterns that have notches between the pyramids. After preparing pyramid patterns consisting of colloidal particles with organic residue, we annealed them to induce volume shrinkage and cracking between the pyramids. We studied the effect of film thickness on cracking and the generation of rectangular fragments consisting of multiple pyramids. The area of rectangular fragments was in good agreement with the results of scaling analysis. The concept of controlling cracks by imprinting notches on a film and the relationship with the film thickness can guide the study of cracking phenomena.

Structure and Optical Properties of Opal Films Made by an Out-of-Plane Electric Field-Assisted Capillary Deposition Method

Self-assembled opals that are considered as a promising candidate for three-dimensional photonic crystals often suffer from the existence of internal defects. Defects influence optical properties and limit the applicability of opal films. Directed assembly using external fields may offer a certain degree of tunability in the opal formation process. We investigate the effect of an out-of-plane electric field on the formation and optical properties of opal films deposited using the capillary deposition method. The application of an electric field of intermediate strength (20-30 V/cm) can improve opal quality. The quality of opal films was found to depend on the polarity of the bottom substrate resulting from the beneficial influence of an asymmetry between the growths and the interplay with gravity. The negatively charged bottom substrate results in slightly better opal quality. This finding shows the potential of electric fields to tune opal formation in order to reduce the defect content.

How the interplay of molecular and colloidal scales controls drying of microgel dispersions

Bringing an aqueous dispersion or solution into open air leads to water evaporation. The resulting drying process initiates the buildup of spatial heterogeneities, as nonvolatile solutes and colloids concentrate. Such composition gradients associate with mesostructure gradients, which, in turn, impact flows within these multicomponent systems. In this work, we investigate the drying of microgel dispersions in respect to two reference systems, a colloidal dispersion and a polymer solution, which, respectively, involve colloidal and molecular length scales. We evidence an intermediate behavior in which a film forms at the air/liquid interface and is clearly separated from bulk by a sharp drying front. However, complex composition and mesostructure gradients develop throughout the drying film, as evidenced by Raman and small-angle X-ray scattering mapping. We show that this results from the soft colloidal structure of microgel, which allows them to interpenetrate, deform, and deswell. As a result, water activity and water transport are drastically decreased in the vicinity of the air/liquid interface. This notably leads to diffusional drying kinetics that are nearly independent on the air relative humidity. The interplay between water fraction, water activity, and mesostructure on water transport is generic and, thus, shown to be pivotal in order to master evaporation in drying complex fluids.

Crack morphologies in drying suspension drops

A drop of an aqueous suspension of nanoparticles placed on a substrate forms a solid deposit as it dries. For dilute suspensions, particles accumulate within a narrow ring at the drop edge, whereas a uniform coating covering the entire wetted area forms for concentrated suspensions. In between these extremes, we report two additional regimes characterized by non-uniform deposit thicknesses and by distinct crack morphologies. We show that both the deposit shape and the number of cracks are controlled exclusively by the initial particle volume fraction. The different regimes share a common avalanche-like crack propagation dynamics, as a result of the delamination of the deposit from the substrate.

Pattern formation in drying blood drops

Patterns in dried droplets are commonly observed as rings left after spills of dirty water or coffee have evaporated. Patterns are also seen in dried blood droplets and the patterns have been shown to differ from patients afflicted with different medical conditions. This has been proposed as the basis for a new generation of low-cost blood diagnostics. Before these diagnostics can be widely used, the underlying mechanisms leading to pattern formation in these systems must be understood. We analyse the height profile and appearance of dispersions prepared with red blood cells (RBCs) from healthy donors. The red cell concentrations and diluent were varied and compared with simple polystyrene particle systems to identify the dominant mechanistic variables. Typically, a high concentration of non-volatile components suppresses ring formation. However, RBC suspensions display a greater volume of edge deposition when the red cell concentration is higher. This discrepancy is caused by the consolidation front halting during drying for most blood suspensions. This prevents the standard horizontal drying mechanism and leads to two clearly defined regions in final crack patterns and height profile. This article is part of a discussion meeting issue 'A cracking approach to inventing new tough materials: fracture stranger than friction'.

Printed and Laser-Activated Liquid Metal-Elastomer Conductors Enabled by Ethanol/PDMS/Liquid Metal Double Emulsions

Soft electronic systems require stretchable, printable conductors for applications in soft robotics, wearable technologies, and human-machine interfaces. Gallium-based room-temperature liquid metals (LMs) have emerged as promising candidates, and recent liquid metal-embedded elastomers (LMEEs) have demonstrated favorable properties such as stable conductivity during strain, cyclic durability, and patternability. Here, we present an ethanol/polydimethylsiloxane/liquid metal (EtOH/PDMS/LM) double emulsion ink that enables a fast, scalable method to print LM conductors with high conductivity (7.7 × 10⁵ S m^-1), small resistance change when strained, and consistent cyclic performance (over 10,000 cycles). EtOH, the carrier solvent, is leveraged for its low viscosity to print the ink onto silicone substrates. PDMS resides at the EtOH/LM interface and cures upon deposition and EtOH evaporation, consequently bonding the LM particles to each other and to the silicone substrate. The printed PDMS-LM composite can be subsequently activated by direct laser writing, forming high-resolution electrically conductive pathways. We demonstrate the utility of the double emulsion ink by creating intricate electrical interconnects for stretchable electronic circuits. This work combines the speed, consistency, and precision of laser-assisted manufacturing with the printability, high conductivity, strain insensitivity, and mechanical robustness of the PDMS-LM composite, unlocking high-yield, high-throughput, and high-density stretchable electronics.

From colloidal particles to photonic crystals: advances in self-assembly and their emerging applications

Over the last three decades, photonic crystals (PhCs) have attracted intense interests thanks to their broad potential applications in optics and photonics. Generally, these structures can be fabricated via either "top-down" lithographic or "bottom-up" self-assembly approaches. The self-assembly approaches have attracted particular attention due to their low cost, simple fabrication processes, relative convenience of scaling up, and the ease of creating complex structures with nanometer precision. The self-assembled colloidal crystals (CCs), which are good candidates for PhCs, have offered unprecedented opportunities for photonics, optics, optoelectronics, sensing, energy harvesting, environmental remediation, pigments, and many other applications. The creation of high-quality CCs and their mass fabrication over large areas are the critical limiting factors for real-world applications. This paper reviews the state-of-the-art techniques in the self-assembly of colloidal particles for the fabrication of large-area high-quality CCs and CCs with unique symmetries. The first part of this review summarizes the types of defects commonly encountered in the fabrication process and their effects on the optical properties of the resultant CCs. Next, the mechanisms of the formation of cracks/defects are discussed, and a range of versatile fabrication methods to create large-area crack/defect-free two-dimensional and three-dimensional CCs are described. Meanwhile, we also shed light on both the advantages and limitations of these advanced approaches developed to fabricate high-quality CCs. The self-assembly routes and achievements in the fabrication of CCs with the ability to open a complete photonic bandgap, such as cubic diamond and pyrochlore structure CCs, are discussed as well. Then emerging applications of large-area high-quality CCs and unique photonic structures enabled by the advanced self-assembly methods are illustrated. At the end of this review, we outlook the future approaches in the fabrication of perfect CCs and highlight their novel real-world applications.

Synergy between the crack pattern and substrate elasticity in colloidal deposits

Desiccation cracks in colloidal deposits occur to release the excess strain energy arising from the competition between the drying induced shrinkage of the deposit and its adhesion to the substrate. Here we report remarkably different morphology of desiccation cracks in the dried patterns formed by the evaporation of sessile drops containing colloids on elastomer (soft) or glass (stiff) substrates. The change in the crack pattern, i.e., from radial cracks on stiff substrates to circular cracks on soft substrates, is shown to arise solely due to the variation in elasticity of the underlying substrates. Our experiments and calculations reveal an intricate correlation between the desiccation crack patterns and the substrate's elasticity. The mismatch in modulus of elasticity between the substrate and that of the particulate deposit significantly alters the energy release rate during the nucleation and propagation of cracks. The stark variation in crack morphology is attributed to the tensile or compressive nature of the drying-induced in-plane stresses.

Edge-Rich Interconnected Graphene Mesh Electrode with High Electrochemical Reactivity Applicable for Glucose Detection

The development of graphene structures with controlled edges is greatly desired for understanding heterogeneous electrochemical (EC) transfer and boosting EC applications of graphene-based electrodes. We herein report a facile, scalable, and robust method to produce graphene mesh (GM) electrodes with tailorable edge lengths. Specifically, the GMs were fabricated at 850 °C under a vacuum level of 0.6 Pa using catalytic nickel templates obtained based on a crack lithography. As the edge lengths of the GM electrodes increased from 5.48 to 24.04 m, their electron transfer rates linearly increased from 0.08 to 0.16 cm∙s⁻¹, which are considerably greater than that (0.056 ± 0.007 cm∙s⁻¹) of basal graphene structures (defined as zero edge length electrodes). To illustrate the EC sensing potentiality of the GM, a high-sensitivity glucose detection was conducted on the graphene/Ni hybrid mesh with the longest edge length. At a detection potential of 0.6 V, the edge-rich graphene/Ni hybrid mesh sensor exhibited a wide linear response range from 10.0 μM to 2.5 mM with a limit of detection of 1.8 μM and a high sensitivity of 1118.9 μA∙mM⁻¹∙cm⁻². Our findings suggest that edge-rich GMs can be valuable platforms in various graphene applications such as graphene-based EC sensors with controlled and improved performance.

Elastic plastic fracture mechanics investigation of toughness of wet colloidal particulate materials: Influence of saturation

HYPOTHESIS

Previous use of linear elastic fracture mechanics to estimate toughness of wet particulate materials underestimates the toughness because it does not account for plastic deformation as a dissipation mechanism. Plastic deformation is responsible for the majority of energy dissipated during the fracture of wet colloidal particulate materials. Plastic deformation around the crack tip increases with saturation of the particulate body. The toughness of the body increases with increasing saturation.

EXPERIMENTS

Elastic plastic fracture mechanics using the J-integral approach was used for the first time to measure the fracture toughness (J_IC) of wet micron sized alumina powder bodies as a function of saturation. The samples were prepared by slip casting. The saturation was controlled by treatment in a humidity chamber. The elastic modulus (E) and the energy dissipated by plastic flow (A_pl) were measured in uniaxial compression. The critical stress intensity factor (K_IC) was measured using a diametral compression sample with a flaw of known size. The fracture toughness (J_IC) was calculated from these measured quantities and the geometry of the specimen.

FINDINGS

Elastic plastic fracture mechanics was used for the first time to quantitively account for plastic deformation of wet particulate materials. The linear elastic fracture mechanics approach previously used accounted for less than 1% of the total energy dissipated in fracture. Toughness (J_IC) was found to increase with increasing saturation due to plastic deformation that increased with saturation level. The improved understanding of toughness as a function of saturation will aid in providing quantitative analysis of cracking in drying colloidal films and bodies.

Cracking to curling transition in drying colloidal films

Drying-induced cracking is widely encountered in nature and is of fundamental interest in industrial applications. During desiccation, the evolution of water content is nonlinear. Considering the inhomogeneous procedure of desiccation, it is worth considering whether water content will affect the crack pattern formation. To address this concern, in this paper, we report an experimental investigation on the effect of water content on the failure mode in drying colloidal films. A distinct failure transition from random cracking to curling is found when the initial water content increases gradually. When the water content is below a critical value for given film thickness, random desiccation cracking driven by shrinkage is observed. Beyond this critical water content, the film curls with the advent of several main cracks. It is also found that the critical water content corresponding to the transition point depends on the film thickness. In order to qualitatively interpret the experimental observation, a theoretical model is established by adopting the fracture mechanics based on the energy method. The model is found to agree well with the experimental results, elucidating the effects of initial water content on the crack patterns and the transition of failure modes.

Patterning Metal Grids for GaAs Solar Cells with Cracked Film Lithography: Quantifying the Cost/Performance Tradeoff

We introduce cracked film lithography (CFL) as a way to reduce the cost of III-V photovoltaics (PV). We spin-coat nanoparticle suspensions onto GaAs thin-film device stacks. The suspensions dry in seconds, forming crack networks that we use as templates through which to electroplate the solar cells' front metal grids. For the first time, we show that heating the crack template allows it to flow and refill cracks, which decreases crack footprint and improves final grid transmittance. We demonstrate 24.7%-efficient single-junction GaAs solar cells using vacuum-free CFL grids. These devices are only 1.7% (absolute) less efficient than the baseline grids patterned by photolithography with the loss mostly resulting from the reduced transparency of the CFL pattern. Additional optimization could decrease this difference. Initial cost modeling suggests that CFL is more scalable than photolithography: In particular, CFL's lower materials and equipment costs could greatly reduce the levelized cost of electricity of III-V PV at scale, a potential step toward terrestrial deployment.

Thick Free-Standing Metallic Inverse Opals Enabled by New Insights into the Fracture of Drying Particle Films

Metallic inverse opals are porous materials with enhanced mechanical, chemical, thermal, and photonic properties used to improve the performance of many technologies, such as battery electrodes, photonic devices, and heat exchangers. Cracking in the drying opal templates used to fabricate inverse opals, however, is a major hindrance to the use of these materials for practical and fundamental studies. In this work, we conduct desiccation experiments on polystyrene particle opals self-assembled on indium-tin oxide coated substrates to study their fracture mechanisms, which we describe using an energy-conservation fracture model. The model incorporates film yielding, particle order, and interfacial friction to explain several experimental observations, including thickness-dependent crack spacings, cracking stresses, and order-dependent crack behavior. Guided by this model, we are the first to fabricate 120 μm thick free-standing metallic inverse opals, which are 4 times thicker than previously reported non-free-standing metallic inverse opals. Moreover, by controlling cracks, we achieve a crack-free single-crystal domain up to 1.35 mm², the largest ever reported in metallic inverse opals. This work improves our understanding of fracture mechanics in drying particle films, provides guidelines to reduce crack formation in opal templates, and enables the fabrication of free-standing large-area single-crystal inverse opals.

Crack density in bloodstains

We construct a theoretical framework to understand the crack density of bloodstains by modeling whole blood as a suspension of binary size colloid particles. Our analysis based upon theories of soft capillarity and porous flows explains the observed increase of the crack density with increase of blood viscosity and decrease of environmental humidity. The results have direct implications on forensic science and medical diagnosis.

Macroscopic Nonuniformities in Metal Grids Formed by Cracked Film Lithography Result in 19.3% Efficient Solar Cells

Cracked film lithography (CFL) is an emerging method for patterning transparent conductive metal grids. CFL can be vacuum- and Ag-free, and it forms more durable grids than nanowire approaches. In spite of CFL's promising transmittance/grid sheet resistance/wire spacing tradeoffs, previous solar cell demonstrations have had relatively low performance. This work introduces macroscopic nonuniformities in the grids to improve the short-circuit current density/fill factor tradeoff in small area Cu(In,Ga)Se₂ cells. The performance of optimized baseline grids is matched by CFL grids with microscopic openings and macroscopic patterns, culminating in a 19.3% efficient cell. Simulations show that uniform CFL grids are enhanced by patterning because it leads to better balance among shadowing, grid resistance, and transparent conductive oxide resistance losses. Thin-film module efficiency calculations are performed to highlight the performance gains that metal grids can enable by eliminating the transparent conductive oxide losses and widening monoliths. Adding the patterned CFL grids demonstrated in this work to CIGS modules is predicted to reach 0.7% higher efficiency (absolute) than screen-printed grids.

Active and Deformable Organic Electronic Devices based on Conductive Shape Memory Polyimide

Smart, deformable, and transparent electrodes are a significant part of flexible optoelectronic devices. In this work, a novel approach to making highly transparent, smooth, and conductive shape memory polyimide hybrids has been proposed. Colorless shape memory polyimide (CSMPI) with high optical transparency and high heat resistance is served as the substrate for flexible electronic devices for the first time. A hybrid (Au/Ag) metal grid electrode embedded in CSMPI (BMG/CSMPI) is first fabricated via self-cracking template and solution-coating, the advantages of which include ultrasmooth surface, superior mechanical flexibility and durability, strong surface adhesion, and excellent chemical stability due to the unique embedded hybrid structure. The resulting white polymer light emitting diodes (WPLEDs) based on BMG/CSMPI with shape memory effect are active and deformable, and are converted from 2D device into 3D devices depending on its variable stiffness characteristics. The deformed 3D devices could actively recover to the original shape upon heating. Furthermore, ultrathin and flexible 3D optoelectronic devices fabricated using shape memory polymers can promote the development of advanced optoelectronic applications in the future.

Fundamentals of Using Cracked Film Lithography to Pattern Transparent Conductive Metal Grids for Photovoltaics

The fundamentals of using cracked film lithography (CFL) to fabricate metal grids for transparent contacts in solar cells were studied. The underlying physics of drying-induced cracks were well-predicted by an empirical correlation relating crack spacing to capillary pressure. CFL is primarily controlled by varying the crack template thickness, which establishes a three-way tradeoff between the areal density of cracks, crack width, and spacing between cracks, which in turn determine final grid transmittance, grid sheet resistance, and the semiconductor resistance for a given solar cell. Since CFL uses a lift-off process, an additional constraint is that the metal thickness must be less than 1/3 of the crack template thickness. The transmittance/grid sheet resistance/wire spacing tradeoffs measured in this work were used to calculate solar cell performance: CFL-patterned grids should outperform screen-printed grids for narrow cells (0.5-2 cm wide) and/or cells with high semiconductor sheet resistance (≥100 Ω/sq), making CFL attractive for monolithically integrated thin-film photovoltaic modules.

Semi-Flooded Sulfur Cathode with Ultralean Absorbed Electrolyte in Li-S Battery

Lean electrolyte (small E/S ratio) is urgently needed to achieve high practical energy densities in Li-S batteries, but there is a distinction between the cathode's absorbed electrolyte (AE) which is cathode-intrinsic and total added electrolyte (E) which depends on cell geometry. While total pore volume in sulfur cathodes affects AE/S and performance, it is shown here that pore morphology, size, connectivity, and fill factor all matter. Compared to conventional thermally dried sulfur cathodes that usually render "open lakes" and closed pores, a freeze-dried and compressed (FDS-C) sulfur cathode is developed with a canal-capillary pore structure, which exhibits high mean performance and greatly reduces cell-to-cell variation, even at high sulfur loading (14.2 mg cm-2) and ultralean electrolyte condition (AE/S = 1.2 µL mg-1). Interestingly, as AE/S is swept from 2 to 1.2 µL mg-1, the electrode pores go from fully flooded to semi-flooded, and the coin cell still maintains function until (AE/S)min ≈ 1.2 µL mg-1 is reached. When scaled up to Ah-level pouch cells, the full-cell energy density can reach 481 Wh kg-1 as its E/S ≈ AE/S ratio can be reduced to 1.2 µL mg-1, proving high-performance pouch cells can actually be working in the ultralean, semi-flooded regime.

Cracking in drying films of polymer solutions

Thin films of polymer coatings have important industrial applications ranging from paints and coatings to pharmaceuticals. In many applications, the coatings are obtained by applying thin films of dilute polymer solutions, wherein the solvent evaporates to leave behind a thin polymer film. In some cases, the thin films may crack due to shrinkage stresses developed during drying. While a number of studies have focused on the stress development, the phenomenon of cracking in polymer films is not fully investigated. In the present work, thin films of a silicone polymer solution were cast on substrates of varying Young's moduli and investigated for cracking as a function of film thickness and substrate modulus. Micro-Raman spectroscopy measurements show that thin films dry uniformly while thick films form a skin at the top surface leading to slow drying rates. Transverse stresses were measured using the cantilever technique and related to the extent of cracking in the film. We investigated the influence of substrate rigidity on the cracking behavior and found that decreasing the stiffness of the substrate increases the extent of cracking.

Enhanced covalent p-phenylenediamine crosslinked graphene oxide membranes: Towards superior contaminant removal from wastewaters and improved membrane reusability

The increasing depletion of freshwater necessitates the re-use and purification of wastewaters. Among the existing separation membrane materials, graphene oxide (GO) is a promising candidate, owing to its tunable physicochemical properties. However, the widening of GO membranes pore gap in aqueous environments is a major limitation. Crosslinking agents can be incorporated to alleviate this problem. This study describes a comparative analysis of uncrosslinked and p-Phenylenediamine (PPD) crosslinked GO membranes' water purification performance. Dip-coating and dip-assisted layer-by-layer methods were used to fabricate the uncrosslinked and crosslinked membranes respectively. The covalent interaction between GO and PPD was confirmed by Fourier Transform Infra-Red and X-ray Photoelectron Spectroscopy. The excellent membrane topographical continuity and intactness was assessed by means of Scanning Electron Microscopy, while water contact angle measurements were undertaken to evaluate and confirm membrane hydrophilicity. The improvement impact of the crosslinker was manifested on the enhancement of the stability and performance of the membranes during nanofiltration tests of aqueous solutions of methylene blue in a homemade nanofiltration cell operated at 1 bar.

Narrowing Desiccating Crack Patterns by an Azeotropic Solvent for the Fabrication of Nanomesh Electrodes

Desiccation of a colloidal layer produces crack patterns because of stress arising out of solvent evaporation. Associated with it is the rearrangement of particles, while adhesion to the substrate resists such movements. The nature of solvent, which is often overlooked, plays a key role in the process as it dictates evaporation and wetting properties of the colloidal film. Herein, we study the crack formation process by using a mixture of solvents, water, and isopropyl alcohol (IPA). Among the various ratios, a water/IPA mixture (15:85 by volume) close to the azeotropic composition possesses unusual evaporation and wetting properties, leading to narrower cracks with widths down to ∼162 nm, uncommon among the known crackle patterns. The dense and narrow crack patterns have been used as sacrificial templates to obtain metal meshes on transparent substrates for optoelectronic applications.

Scaling Law for Cracking in Shrinkable Granular Packings

Hydrated granular packings often crack into discrete clusters of grains when dried. Despite its ubiquity, an accurate prediction of cracking remains elusive. Here, we elucidate the previously overlooked role of individual grain shrinkage-a feature common to many materials-in determining crack patterning using both experiments and simulations. By extending classical Griffith crack theory, we obtain a scaling law that quantifies how cluster size depends on the interplay between grain shrinkage, stiffness, and size-applicable to a diverse array of shrinkable granular packings.

Film Formation of High Tg Latex Using Hydroplasticization: Explanations from NMR Relaxometry

The film formation of acrylic latex dispersions, containing different amounts of carboxylic acid functional groups by the incorporation of methacrylic acid (MAA), was studied with GARField ¹H NMR at various relative humidities (RH). Polymer particles with glass-transition temperatures in the range from 26 to 50 °C formed films at room temperature because of hydroplasticization. It was found that with an increased drying rate due to lower RH, the evaporation flux of water was limited by the latex polymer. Only in the second stage of drying this phenomenon was more obvious with increasing MAA content. ¹H NMR relaxometry was used to study the change of hydrogen mobilities during film formation and hardening of the films. This showed that the drying rate itself had no impact on the hydrogen mobility in the latex films as measured via the T₂ relaxation time. Hydrogen mobilities of water and the mobile polymer phase only significantly decrease after most water has evaporated. This implies that the rigidity of the polymers increases with the evaporation of water that otherwise plasticizes the polymer through hydrogen bonding with the carboxylic acid groups. This hardening of the polymer phase is essential for applications in a coating. The hydrogen mobilities were affected by the MAA concentration. Densities of mobile hydrogens increase with increasing MAA content. This is expected if the mobile protons are contained in the MAA groups. The result thus confirms the role of carboxylic acid groups in hydrogen bonding and plasticization of the copolymers. Hydrogen mobilities, however, decrease with increasing MAA content, which is hypothesized to be caused by the formation of dimers of carboxylic acid groups that still hold water. They still enable short-range polymer hydrogen mobility due to hydroplasticization but limit long-range polymer mobility due to interaction between the carboxylic acid groups.

Influence of the drying configuration on the patterning of ellipsoids - concentric rings and concentric cracks

Evaporation of colloidal dispersions leading to patterning of particles is a simple and elegant route for controlling the self-assembly of particles on a solid surface. In this article, we demonstrate that the configuration in which a colloidal dispersion is dried greatly influences the patterning of particles on a solid surface after complete evaporation of the solvent. Evaporation experiments are carried out using well-characterized stable aqueous dispersions of hematite ellipsoids and polystyrene spheres. The drying of particle laden sessile drops always give a "coffee-ring" deposit irrespective of the particle concentration. At a particle concentration ≥0.3 wt% circular cracks appear in the annular region of the coffee-ring deposit owing to the ordered arrangement of ellipsoids. In stark contrast, the deposits formed by drying the dispersion of ellipsoids in the sphere-on-plate configuration show a transition from "concentric rings" to "concentric cracks" in the micro-structure of the particulate film with an increase in the concentration of particles. Further, our experimental findings reveal that long-range circular cracks and long-range assemblies of particles can be achieved by drying of the dispersion in the sphere-on-plate configuration. While the nature of patterns - that is - coffee-rings and concentric rings - is independent of the shape of the particles, a strikingly different crack morphology is shown to be dictated by the shape of the particles in the dispersion. The results presented show that the drying of colloidal dispersions in the sphere-on-plate configuration enables the fabrication of a long range ordered assembly of particles over an area as large as few square millimeters.

The solute mechanical properties impact on the drying of dairy and model colloidal systems

The evaporation of colloidal solutions is frequently observed in nature and in everyday life. The investigation of the mechanisms taking place during the desiccation of biological fluids is currently a scientific challenge with potential biomedical and industrial applications. In the last few decades, seminal works have been performed mostly on dried droplets of saliva, urine and plasma. However, the full understanding of the drying process in biocolloids is far from being achieved and, notably, the impact of solute properties on the morphological characteristics of the evaporating droplets, such as colloid segregation, skin formation and crack pattern development, is still to be elucidated. For this purpose, the use of model colloidal solutions, whose rheological behavior is more easily deducible, could represent a significant boost. In this work, we compare the drying of droplets of whey proteins and casein micelles, the two main milk protein classes, to that of dispersions of silica particles and polymer-coated silica particles, respectively. The mechanical behavior of such biological colloids and model silica dispersions was investigated through the analysis of crack formation, and the measurements of their mechanical properties using indentation testing. The study reveals numerous analogies between dairy and the corresponding model systems, thus confirming the latter as a plausible powerful tool to highlight the signature of the matter at the molecular scale during the drying process.

Imbibition on a porous layer: dynamical and mechanical characterization

Solvent penetration in porous layers was analyzed using dynamical and mechanical characterization. Spreading dynamics of a solvent drop in a porous substrate provided parameters of the porous medium such as permeability and porosity. These measurements are relevant for many porous systems, for example paintings or porous varnishes and resins… We present direct visualizations of the drop as well as of the wet zone during the imbibition process and we evidence three distinct regimes. Experiments performed with various porous systems and different solvents highlight a universal behavior. The mechanical properties during the imbibition process are deduced through indentation testing measurements. We show that solvent penetration is responsible for the appearance of a viscous component in the system. A characteristic time depending on the solvent and on the porous medium is then deduced. The system recovers its initial mechanical properties and no swelling nor cracking is observed contrary to the case of paintings. This result tends to prove that visco-plastic properties are required to observe swelling or cracking.

Structuration of the Surface Layer during Drying of Colloidal Dispersions

During evaporative drying of a colloidal dispersion, the structural behavior at the air-dispersion interface is of particular relevance to the understanding of the consolidation mechanism and the final structural and mechanical properties of the porous media. The drying interface constitutes the region of initial drying stress that, when accumulated over a critical thickness, leads to crack formation. This work presents an experimental study of top-down drying of colloidal silica dispersions with three different sizes (radius 5, 8, and 13 nm). Using specular neutron reflectivity, we focus on the structural evolution at the free drying front of the dispersion with a macroscopic drying surface and demonstrate the existence of a thick concentrated surface layer induced by heterogeneous evaporation. The reflectivity profile contains a strong structure peak due to scattering from particles in the interfacial region, from which the interparticle distance is deduced. A notable advantage of these measurements is the direct extraction of the corresponding dispersion concentration from the critical total reflection edge, providing a straightforward access to a structure-concentration relation during the drying process. The bulk reservoir of this experimental configuration renders it possible to verify the evaporation-diffusion balance to construct the surface layer and also to check reversibility of particle ordering. We follow the structural evolution of this surface layer from a sol to a soft wet-gel that is the precursor of a fragile skin and the onset of significant particle aggregation that precedes formation of the wet-crust. Separate complementary measurements on the structural evolution in the bulk dispersion are also carried out by small-angle neutron scattering, where the particle concentration is also extracted directly from the experimental curves. The two sets of data reveal similar structural evolution with concentration at the interface and in the bulk and an increase in the degree of ordering with the particle size.

Universal scaling of polygonal desiccation crack patterns

Polygonal desiccation crack patterns are commonly observed in natural systems. Despite their quotidian nature, it is unclear whether similar crack patterns which span orders of magnitude in length scales share the same underlying physics. In thin films, the characteristic length of polygonal cracks is known to monotonically increase with the film thickness; however, existing theories that consider the mechanical, thermodynamic, hydrodynamic, and statistical properties of cracking often lead to contradictory predictions. Here we experimentally investigate polygonal cracks in drying suspensions of micron-sized particles by varying film thickness, boundary adhesion, packing fraction, and solvent. Although polygonal cracks were observed in most systems above a critical film thickness, in cornstarch-water mixtures, multiscale crack patterns were observed due to two distinct desiccation mechanisms. Large-scale, primary polygons initially form due to capillary-induced film shrinkage, whereas small-scale, secondary polygons appear later due to the deswelling of the hygroscopic particles. In addition, we find that the characteristic area of the polygonal cracks, A_{p}, obeys a universal power law, A_{p}=αh^{4/3}, where h is the film thickness. By quantitatively linking α with the material properties during crack formation, we provide a robust framework for understanding multiscale polygonal crack patterns from microscopic to geologic scales.

Laser Sintering of Liquid Metal Nanoparticles for Scalable Manufacturing of Soft and Flexible Electronics

Soft, flexible, and stretchable electronics are needed to transmit power and information, and track dynamic poses in next-generation wearables, soft robots, and biocompatible devices. Liquid metal has emerged as a promising material for these applications due to its high conductivity and liquid phase state at room temperature; however, surface oxidation of liquid metal gives it unique behaviors that are often incompatible with scalable manufacturing techniques. This paper reports a rapid and scalable approach to fabricate soft and flexible electronics composed of liquid metal. Compared to other liquid metal patterning approaches, this approach has the advantages of compatibility with a variety of substrates, ease of scalability, and efficiency through automated processes. Nonconductive liquid metal nanoparticle films are sintered into electrically conductive patterns by use of a focused laser beam to rupture and ablate particle oxide shells, and allow their liquid metal cores to escape and coalesce. The laser sintering phenomenon is investigated through comparison with focused ion beam sintering and by studying the effects of thermal propagation in sintered films. The effects of laser fluence, nanoparticle size, film thickness, and substrate material on resistance of the sintered films are evaluated. Several devices are fabricated to demonstrate the electrical stability of laser-patterned liquid metal traces under flexing, multilayer circuits, and intricately patterned circuits. This work merges the precision, consistency, and speed of laser manufacturing with the material benefits of liquid conductors on elastic substrates to demonstrate decisive progress toward commercial-scale manufacturing of soft electronics.