Role of dissimilar interfaces in thin films of cylinder-forming block copolymers

Epitaxial Growth of Surface Perforations on Parallel Cylinders in Terraced Films of Block Copolymer/Homopolymer Blends

Due to incommensurability between initial thickness and interdomain distance, thermal annealing inevitably produces relief surface terraces (islands and holes) of various morphologies in thin films of block copolymers. We have demonstrated three kinds of surface terraces in blend films: polygrain terraces with diffuse edges, polygrain terraces with step edges, and pseudo-monograin terraces with island coarsening. The three morphologies were obtained by three different thermal histories, respectively. The thermal histories were imposed on blend films, which were prepared by mixing a homopolystyrene (hPS, 6.1 kg/mol) with a weakly segregated, symmetry polystyrene-block poly(methyl methacrylate) (PS-b-PMMA, 42 kg/mol) followed by spin coating. At a given weight-fraction ratio of PS-b-PMMA/hPS = 75/25, the interior of the blend films forms parallel cylinders. Nevertheless, the surface of the blend films is always dominated by a skin layer of perforations, which epitaxially grow on top of parallel cylinders. By oxygen plasma etching at various time intervals to probe interior nanodomains, the epitaxial relationship between surface perforations and parallel cylinders has been identified by a scanning electron microscope.

Molecular-weight effects of a homopolymer on the AB- and ABC-stacks of perforations in block copolymer/homopolymer films

We have demonstrated the molecular-weight effects of adding homopolystyrene (hPS) on the evolution of perforated layers and double gyroids in polystyrene-block-poly(methyl methacrylate)-based films during isothermal annealing. Two homopolystyrenes of 2.8 and 17 kg mol-1 were used. To prepare blend films, PS-b-PMMA and hPSx (x: 2.8 or 17) were mixed at a weight-fraction ratio of 75/25 in toluene and then spin-coated at SiOx/Si. Spin coating inevitably produced films with thick edges at the periphery of the substrate. The structural evolution of the spun films was in situ characterized by grazing incidence small-angle X-ray scattering (GISAXS). The annealed films were then characterized using a scanning electron microscope (SEM). We found that thin middle regions behaved differently from thick beads for the films. The middle of the blend films mainly formed perforated layers with different spatial orders and orientations, depending on the molecular weight of added hPS chains. Hexagonally perforated layers quickly formed at 205 °C for PS-b-PMMA/hPS2.8 films. However, when hPS17 was used instead of hPS2.8, perforated layers formed with defects in PS-b-PMMA/hPS17 films annealed at 205 °C. Annealing at 240 °C improved the spatial order and orientation of perforated layers for a PS-b-PMMA/hPS17 film. Nevertheless, annealing at 240 °C inversely depressed the in-plane spatial order of perforated layers for a PS-b-PMMA/hPS2.8 film. The depression in the in-plane spatial order is ascribed to a dilution effect of added short chains. Compared to the middle regions, the thick beads went through several metastable phases, such as perpendicularly oriented perforated layers and double gyroids.

Distributions of Deuterated Polystyrene Chains in Perforated Layers of Blend Films of a Symmetric Polystyrene-block-poly(methyl methacrylate)

We have examined the spatial distributions of polymer chains in blend films of weakly segregated polystyrene-block-poly(methyl methacrylate) [P(S-b-MMA)] and deuterated polystyrene (dPS). By fine-tuning the composition (ϕ_PS+dPS = 63.8 vol %) of the total PS/dPS component and annealing temperature (230 and 270 °C), P(S-b-MMA)/dPS blend films mainly form perforated layers with a parallel orientation (hereafter PLs^//). The distributions of dPS in PLs^// were probed by grazing-incidence small-angle neutron scattering (GISANS) and time-of-flight neutron reflectivity (ToF-NR). GISANS and ToF-NR results offer evidence that dPS chains preferentially locate at the free surface and within the PS layers for blend films that were annealed at 230 °C. Upon annealing at 270 °C, dPS chains distribute within PS layers and perforated PMMA layers. Nevertheless, dPS chains still retain a surface preference for thin films. In contrast, such surface segregation of dPS chains is prohibited for thick films when annealed at 270 °C.

Phase behavior in thin films of weakly segregated block copolymer/homopolymer blends

We have demonstrated the phase behavior of substrate-supported films of a symmetric weakly segregated polystyrene-block-poly (methyl methacrylate), P(S-b-MMA), block copolymer and its blends with homopolymer polystyrene (PS) at different compositions. Upon increasing the content of added PS in the blends, lamellae (L), perforated layers (PL), double gyroid (DG) and cylinders (C) are obtained in sequence for films. Among these nanodomains, PL and DG only exist in a narrow ϕ_PS region (ϕ_PS denotes the volume fraction of PS). At ϕ_PS = 64%, tuning film thickness and annealing temperature can produce parallel PL or DG with {121}_DG lattice planes being parallel to the substrate surface. The effects of annealing temperature and film thickness on the formation of PL and DG are examined. In thin films with n ≈ 3 (n denotes the ratio of initial film thickness to inter-domain spacing), the PL phase solely exists regardless of temperature. However, for thick films with n ≈ 6 and 10, thermal annealing at the most accessible temperature produces films containing both PL and DG of various fractions, but a low temperature tends to favor a greater fraction of PL. The PL phase becomes the only discernible phase if thick films are shortly annealed at 230 °C.

Influence of Osmotic Pressure on Nanostructures in Thin Films of a Weakly-Segregated Block Copolymer and Its Blends with a Homopolymer

We studied the influence of osmotic pressure on nanostructures in thin films of a symmetric weakly-segregated polystyrene-block-poly (methyl methacrylate), P(S-b-MMA), block copolymer and its mixtures with a polystyrene (PS) homopolymer of various compositions. Thin films were deposited on substrates through surface neutralization. The surface neutralization results from the PS mats, which were oxidized and cross-linked by UV-light exposure. Thus, thermal annealing produced perpendicularly oriented lamellae and perforated layers, depending on the content of added PS chains. Nevertheless, a mixed orientation was obtained from cylinders in thin films, where a high content of PS was blended with the P(S-b-MMA). A combination of UV-light exposure and acetic acid rinsing was used to remove the PMMA block. Interestingly, the treatment of PMMA removal inevitably produced osmotic pressure and consequently resulted in surface wrinkling of perpendicular lamellae. As a result, a hierarchical structure with two periodicities was obtained for wrinkled films with perpendicular lamellae. The formation of surface wrinkling is due to the interplay between UV-light exposure and acetic acid rinsing. UV-light exposure resulted in different mechanical properties between the skin and the inner region of a film. Acetic acid rinsing produced osmotic pressure. It was found that surface wrinkling could be suppressed by reducing film thickness, increasing PS content and using high-molecular-weight P(S-b-MMA) BCPs.

Hybrid patterns from directed self-assembly of diblock copolymers by chemical patterns

The surface affinity is a critical factor for controlling the formation of monolayer nanostructures in block copolymer thin films. In general, strong surface affinity tends to induce the formation of domains with low spontaneous curvature. Abiding by this principle, we propose a facile chemoepitaxial scheme for producing large-scale ordered hybrid patterns by the directed self-assembly of diblock copolymers. The guiding chemical pattern is designed as periodic stripes with alternately changing surface affinities. As a consequence, two different geometries of domains are formed on the stripes with different affinities. The self-assembly process of block copolymers guided by the stripe patterns is investigated using cell dynamics simulations based on time-dependent Ginzburg-Landau theory, and the kinetic stability diagram is estimated. Hybrid patterns are successfully achieved with both cylinder-forming and sphere-forming diblock copolymers. In the cylinder-forming system, the major hybrid pattern exhibiting a considerable stability window is composed of parallel cylinders and perforated lamellae, while it is composed of monolayer spheres and parallel cylinders in the other system. Encouragingly, the chemoepitaxial method is valid till the period of the guiding pattern is a large multiple of the domain spacing. The chemoepitaxial scheme demonstrated in this work serves as a nice supplement to the graphoepitaxial one proposed in our previous work.

Self-Assembly of Complex Multimetal Nanostructures from Perforated Lamellar Block Copolymer Thin Films

We introduce a facile and effective fabrication of complex multimetallic nanostructures through block copolymer self-assembly. Two- and three-dimensional complex nanostructures, such as "nanomesh," "double-layered nanomeshes," and "surface parallel cylinders on nanomesh," can be fabricated using the self-assembly of perforated lamellar morphology in block copolymer thin films. Simultaneous integration of various metallic elements, including Pt, Au, and Co, into the self-assembled morphologies generates multimetal complex nanostructures with highly interconnected morphology and a large surface. The resultant metal nanostructures with a large surface area, robust electrical connectivity, and well-defined alloy composition demonstrate a high-performance electrochemical catalysis for hydrogen evolution reaction (current density: 6.27 mA/cm²@0.1 V and Tafel slope: 43 mV/dec).

Electric-field-induced lamellar to hexagonally perforated lamellar transition in diblock copolymer thin films: kinetic pathways

Symmetric block-copolymers, hitherto, are well known to evolve into parallel, perpendicular and mixed lamellar morphologies under the concomitant influence of an electric field and substrate affinity. In the present work, we show that an additional imposed confinement can effectuate a novel parallel lamellar to hexagonally perforated lamellar (HPL) transition in monolayer and bilayer films. Three dimensional numerical studies are performed using the Ohta-Kawasaki functional, complemented with an exact solution of Maxwell's equation. HPL is shown to stabilize at large substrate affinity in a narrow region of the phase diagram between parallel and perpendicular lamellar transitions in ultra-thin films. Additionally, we also identify perforated lamellae as intermediate structures during parallel-to-perpendicular lamellar transition. A systematic analysis using Minkowski functionals yields deeper insights into the associated kinetic pathways.

Structure and Dynamics of Asymmetric Poly(styrene-b-1,4-isoprene) Diblock Copolymer under 1D and 2D Nanoconfinement

The impact of 1- and 2-dimensional (2D) confinement on the structure and dynamics of poly(styrene-b-1,4-isoprene) P(S-b-I) diblock copolymer is investigated by a combination of Scanning Electron Microscopy (SEM), Atomic Force Microscopy (AFM), Grazing-Incidence Small-Angle X-ray Scattering (GISAXS), and Broadband Dielectric Spectroscopy (BDS). 1D confinement is achieved by spin coating the P(S-b-I) to form nanometric thin films on silicon substrates, while in the 2D confinement, the copolymer is infiltrated into cylindrical anodized aluminum oxide (AAO) nanopores. After dissolving the AAO matrix having mean pore diameter of 150 nm, the SEM images of the exposed P(S-b-I) show straight nanorods. For the thin films, GISAXS and AFM reveal hexagonally packed cylinders of PS in a PI matrix. Three dielectrically active relaxation modes assigned to the two segmental modes of the styrene and isoprene blocks and the normal mode of the latter are studied selectively by BDS. The dynamic glass transition, related to the segmental modes of the styrene and isoprene blocks, is independent of the dimensionality and the finite sizes (down to 18 nm) of confinement, but the normal mode is influenced by both factors with 2D geometrical constraints exerting greater impact. This reflects the considerable difference in the length scales on which the two kinds of fluctuations take place.

Diblock and triblock copolymer thin films on a substrate with controlled selectivity

Using self-consistent field theory (SCFT), morphology development in symmetric linear ABC triblock copolymer films on neutral and selective substrates has been studied, and it is compared with the triblock copolymer morphologies in bulk. In particular, the effects of the substrate preferable to B (interior) block on nanopattern formation of the copolymer films are of our central interest. Here, we report various nanopatterns with tunable square morphologies. The domain patterns are much more diverse than those parallel to the substrate with substrate selectivity for end-block or those vertical to the substrate without substrate selectivity. Furthermore, in order to figure out an economical and efficient way to fabricate useful passive pattern transfer layers, which have potential applications in microelectronic processes and ultrahigh density storage media, we propose a two-step strategy and scrutinize the conditions for generating square symmetries using cylinder-forming or lamella-forming AB diblock copolymers deposited on substrates created from ABC triblock copolymer films. It is found that a thinner film with weak incompatibility can produce square patterns.

Dynamic assembly of block-copolymers

Block copolymers (BCs) are well-known building blocks for the creation of a large variety of nanostructured materials or objects through a dynamic assembly stage which can be either autonomous or guided by an external force. Today's nanotechnologies require sharp control of the overall architecture from the nanoscale to the macroscale. BCs enable this dynamic assembly through all the scales, from few aggregated polymer chains to large bulk polymer materials. Since the discovery of controlled methods to polymerize monomers with different functionalities, a broad diversity of BCs exists, giving rise to many different nanoobjects and nanostructured materials. This chapter will explore the potentialities of block copolymer chains to be assembled through dynamic interactions either in solution or in bulk.

Effect of film thickness on the phase behaviors of diblock copolymer thin film

A phase diagram was constructed for a polystyrene-block-polyisoprene (PS-b-PI, M(W) = 32 700, f(PI) = 0.670) in thin films on Si wafer as a function of film thickness over the range of 150-2410 nm (7-107L(0) (L(0): domain spacing)). The PS-b-PI exhibits a variety of ordered phases from hexagonally perforated lamellar (HPL) via double gyroid (DG) to hexagonally packed cylinder (HEX) before going to the disordered (DIS) phase upon heating. The morphology of the PS-b-PI in thin film was investigated by grazing incidence small-angle X-ray scattering, transmission electron microscopy, and transmission electron microtomography. In thin film, the phase transition temperature is difficult to be determined unequivocally with in situ heating processes since the phase transition is slow and two phases coexist over a wide temperature range. Therefore, in an effort to find an "equilibrium" phase, we determined the long-term stable phase formed after cooling the film from the DIS phase to a target temperature and annealing for 24 h at the temperature. The temperature windows of stable ordered phases are strongly influenced by the film thickness. As the film thickness decreases, the temperature window of layer-like structures such as HPL and HEX becomes wider, whereas that of the DG stable region decreases. For the films thinner than 160 nm (8L(0)), only the HPL phase was found. In the films exhibiting DG phase, a perforated layer structure at the free surface was found, which gradually converts to the internal DG structure. The relief of interfacial tension by preferential wetting appears to play an important role in controlling the morphology in very thin films.

Block copolymer nanocontainers

Using cell dynamics computer simulation, we perform a systematic study of thin block copolymer films around a nanoparticle. Lamellar-, cylinder-, and sphere-forming block copolymers are investigated with respect to different film thicknesses, particle radii, and boundary conditions at the film interfaces. The obtained structures include standing lamellae and cylinders, "onions", cylinder "knitting balls", "golf ball", layered spherical, "virus"-like and mixed morphologies with T-junctions and U-type defects. The kinetics of the structure formation and difference with planar thin films are discussed. Our simulations suggest that novel porous nanocontainers can be formed by the coating of a sacrificial nanobead by a block copolymer layer with a well-controlled nanostructure. In addition, first scanning force microscopy experiments on a model system reveal surface structures similar to those predicted by our simulations.

Specific features of defect structure and dynamics in the cylinder phase of block copolymers

We present a systematic study of defects in thin films of cylinder-forming block copolymers upon long-term thermal or solvent annealing. In particular, we consider in detail the peculiarities of both classical and specific topological defects, and conclude that there is a strong "defect structure-chain mobility" relationship in block copolymers. In the systems studied, representative defect configurations provide connectivity of the minority phase in the form of dislocations with a closed cylinder end or classical disclinations with incorporated alternative, nonbulk structures with planar symmetry. In solvent-annealed films with enhanced chain mobility, the neck defects (bridges between parallel cylinders) were observed. This type of nonsingular defect has not been identified in block copolymer systems before. We argue that topological arguments and 2D defect representation, sufficient for lamellar systems, are not sufficient to determine the stability and mobility of defects in the cylindrical phase. In-situ scanning force microscopy measurements are compared with the simulations based on the dynamic self-consistent mean field theory. The close match between experimental measurements and simulation results suggests that the lateral defect motion is diffusion-driven. In addition, 3D simulations demonstrated that the bottom (wetting) layer is only weakly involved into the structure ordering at the free surface. Finally, the morphological evolution is considered with the focus on the motion and interaction of the representative defect configurations.

Visualizing the dynamics of complex spatial networks in structured fluids

We present a data reduction and visualization approach for the microdomain dynamics in block copolymers and similar structured fluids. Microdomains are reduced to thin smooth lines with colored branching points and visualized with a tool for protein visualization. As a result the temporal evolution of large volume data sets can be perceived within seconds. This approach is demonstrated with simulation results based on the dynamic density functional theory of the ordering of microdomains in a thin film of block copolymers. As an example we discuss the dynamics at the cylinder-to-gyroid grain boundary and compare it to the epitaxial cylinder-to-gyroid phase transition predicted by Matsen [Phys. Rev. Lett. 80, 4470 (1998)].

Monte Carlo Simulations of Cylinder-Forming ABC Triblock Terpolymer Thin Films

We systematically study the cylinder-forming ABC triblock terpolymer thin films using canonical ensemble Monte Carlo simulations. The simulated annealing procedure is applied to the self-assembling process. By judicious choice of the system dimensions, we elaborately investigate the effect of film thickness on the orientation of the cylinders. This confined triblock terpolymer system exhibits different phase behavior under the weak and strong surface fields. In addition, we also investigate the ensemble-averaged chain orientations and relative density profiles.

Dynamics of terrace formation in a nanostructured thin block copolymer film

We have used dynamic self-consistent field (DSCF) theory to investigate the structural evolution of an ABA block copolymer thin film placed between a solid substrate and a free surface. In line with the few existing theoretical studies for pure homopolymers and mixtures, the free interface is introduced by a void component. In our calculations, the free surface experiences surface roughening and eventually the formation of terraces, as in the experiments. The kinetic pathway of the microstructures was compared to findings of an existing detailed experimental study (Knoll, A.; Lyakhova, K. S.; Horvat, A.; Krausch, G.; Sevink, G. J. A.; Zvelindovsky, A. V.; Magerle, R. Nat. Mater. 2004, 3, 886) and was found to be equivalent in detail. This corroborates our assumption in this earlier work that the pathway due to changing film thickness is similar to a pathway due to changing surface energetics. Moreover, our calculations show for the first time that microstructural transitions are a driving force of polymer/air interface curving and the formation of terraces.