Fabrication of Flexible PDMS Films with Micro-Convex Structure for Light Extraction from Organic Light-Emitting Diodes

In this study, we demonstrated organic light-emitting diodes (OLEDs) outcoupling with a flexible polydimethylsiloxane (PDMS) film with a micro-convex structure using the breath figure (BF) method. We can easily control the micro-convex pattern by adjusting the concentration of polystyrene and the humidity during the BF process. As process conditions to fabricate the micro-convex structure, polymer concentrations of 10, 20, 40, and 80 mg/mL and 60, 70, and 80% relative humidity were used. To evaluate the optical properties, we analyzed the transmission, diffusion, and electroluminescence with or without the micro-convex structure on the OLEDs. The shape and density of the micro-convex structure are related to its optical properties and outcoupling and we have experimentally demonstrated this. By applying a micro-convex structure, it achieved up to a 42% improvement in the external quantum efficiency compared to bare OLEDs (without any light extraction film). We expect the fabricated flexible light extraction film to be effective for outcoupling and applicable to flexible devices.

Biopolymer Honeycomb Microstructures: A Review

In this review, we present a comprehensive summary of the formation of honeycomb microstructures and their applications, which include tissue engineering, antibacterial materials, replication processes or sensors. The history of the honeycomb pattern, the first experiments, which mostly involved the breath figure procedure and the improved phase separation, the most recent approach to honeycomb pattern formation, are described in detail. Subsequent surface modifications of the pattern, which involve physical and chemical modifications and further enhancement of the surface properties, are also introduced. Different aspects influencing the polymer formation, such as the substrate influence, a particular polymer or solvent, which may significantly contribute to pattern formation, and thus influence the target structural properties, are also discussed.

The surface morphology and dynamic impact properties with rebounding and splashing of water droplet on phase separation and breath figure assisted electrospinning films

Electrospinning provides a versatile, efficient and low-cost method for the preparation of continuous nanofibres from various polymers. In this study, the polyhedral oligomeric silsesquioxanes (POSS) block copolymer was synthesized via atom transfer radical polymerization. The smooth fiber, porous fiber or hierarchically porous microspheres were prepared by electrospinning from POSS block copolymer, poly(vinylidene fluoride) (PVDF) and aluminium oxide (Al₂O₃). The influence of copolymer concentration, the ratio of the solvents, the diameter and concentration of the Al₂O₃ on the surface morphology were investigated. Porous fibers and porous microspheres were prepared by regulating the ratio of the solvents from the phase separation and breath figure methods. The dynamic behavior of the water droplet with the constant volume impacting on the electrospinning films were reported. The morphology evolution, restitution coefficient, the change of energy of the water droplets are examined. The droplet bounces several times on the superhydrophobic surface, while the droplet remains pinned and does not rebound when the contact angles was lower than 150°. On the other hand, the water droplets were splashed on the Al₂O₃ based electrospinning films. Finally, the mechanical properties of the electrospinning films were investigated.

Fabrication of Pore-Selective Metal-Nanoparticle-Functionalized Honeycomb Films via the Breath Figure Accompanied by In Situ Reduction

Honeycomb films pore-filled with metal (Au, Ag, and Cu) nanoparticles were successfully prepared by combining the breath figure method and an in situ reduction reaction. First, a polyhedral oligomeric silsesquioxane (POSS)-based star-shaped polymer solution containing metal salt was cast under humid conditions for the formation of honeycomb films pore-filled with metal salt through the breath figure method. The morphology of the honeycomb films was mainly affected by the polymer molecular structure and the metal salt. Interestingly, the promoting effect of the metal salt in the breath figure process was also observed. Then, honeycomb films pore-filled with metal nanoparticles were obtained by in situ reduction of the honeycomb films pore-filled with metal salt using NaBH4. Notably, the metal nanoparticles can be selectively functionalized in the pores or on the surface of the honeycomb films by controlling the concentration of the NaBH4. Metal-nanoparticle-functionalized honeycomb films can prospectively be used in catalysis, flexible electrodes, surface-enhanced Raman spectroscopy (SERS), and wettability patterned surfaces.

Ultrasound-Assisted Hydroxyapatite-Decorated Breath-Figure Polymer-Derived Ceramic Coatings for Ti6Al4V Substrates

The introduction of nanoparticles (NPs) into the breath-figure-templated self-assembly (BFTSA) process is an increasingly common method to selectively decorate a surface porous structure. In the field of prosthetic devices, besides controlling the morphology and roughness of the structure, NPs can enhance the osteointegration mechanism because of their specific ion release. Among the most widely used NPs, there are silica and hydroxyapatite (HAp). In this work, we propose a novel one-stage method to fabricate NP-decorated surface porous structures that are suitable for prosthetic coating applications. This technique combines the classical direct BFTSA process with the cavitation effect induced by an ultrasonic atomizer that generates a mist of water droplets with embedded NPs. Coatings were successfully obtained by combining a UV cross-linkable polymer precursor, alkoxy silicone, with synthesized HAp NPs, on Ti6Al4V alloy discs. The cross-linked polymeric surface porous structures at selected concentrations were then pyrolyzed in an ammonia atmosphere to obtain a silicon oxynitride (SiON) ceramic coating. Herein, we report the chemical and morphological analyses of both the polymeric and ceramic coatings as well as the effect of NPs at the interface.

Self-Assembled GO Honeycomb Microarray for Selective Cancer Cell Capture and Single Cell Analysis of Proteolytic Expression

Proteolytic enzymes expressed by circulating tumor cells are proved to facilitate their invasion into multiple organs via cleaving natural ECM networks, leading to consequent metastasis colonization and malignant lethality. Recent evidence suggests the rare metastasis initiating cells with higher proteolytic levels among circulating tumor cells (CTCs) may strongly increase the risk of metastasis. Beyond selective CTC capture, the heterogeneity in proteases expression provides a promising indicator for metastasis happening. To this end, the graphene oxide (GO) honeycomb microarray with single CTC matched sizes is fabricated via the self-assembly breath figure approach, which serves as an integrated protocol for selective CTC capture and single-cell analysis of protease activity. Contributing to synergistic effects of structure and chemistry, CTCs can be efficiently isolated and individually trapped in each honeycomb hole. Meanwhile, the crosstalk among CTCs can be erased by blocking direct cell-to-cell contact, which offers promising potentials in the single-cell analysis of protease expression. Integrating specific capture and in situ analysis of single CTCs on GO micropatterned surface is of significant importance in various biological and clinical applications such as cancer diagnostics and cancer therapeutic evaluation.

Nanoparticle-Induced Self-Assembly of Block Copolymers into Nanoporous Films at the Air-Water Interface

Herein, we report the cooperative self-assembly of nanoparticles and block copolymers at the air-water interface, which can generate highly uniform and readily transferable composite films with tunable nanoscale architecture and functionalities. Interestingly, the incorporation of nanoparticles significantly affects the self-assembly of block copolymers at the interface. The nanoparticle-induced morphology change occurs through distinct mechanisms depending on the volume fraction of the hydrophobic block. For block copolymers with a relatively small hydrophobic volume fraction, the morphology transition occurs through the nanoparticle-induced swelling of a selective block. When the hydrophobic volume fraction is large enough, added nanoparticles promote the breath figure assembly, which generates uniform honeycomb-like porous structures with unusual nanoscale periodicity. This approach is generally applicable to various types of nanoparticles, constituting a simple one-step method to porous thin films with various functionalities.

Gas-Permeable, Ultrathin, Stretchable Epidermal Electronics with Porous Electrodes

We present gas-permeable, ultrathin, and stretchable electrodes enabled by self-assembled porous substrates and conductive nanostructures. An efficient and scalable breath figure method is employed to introduce the porous skeleton, and then silver nanowires (AgNWs) are dip-coated and heat-pressed to offer electric conductivity. The resulting film has a transmittance of 61%, sheet resistance of 7.3 Ω/sq, and water vapor permeability of 23 mg cm^-2 h^-1. With AgNWs embedded below the surface of the polymer, the electrode exhibits excellent stability in the presence of sweat and after long-term wear. We demonstrate the promising potential of the electrode for wearable electronics in two representative applications: skin-mountable biopotential sensing for healthcare and textile-integrated touch sensing for human-machine interfaces. The electrode can form conformal contact with human skin, leading to low skin-electrode impedance and high-quality biopotential signals. In addition, the textile electrode can be used in a self-capacitance wireless touch sensing system.

Three-Dimensional Conformal Porous Microstructural Engineering of Textile Substrates with Customized Functions of Brick Materials and Inherent Advantages of Textiles

The conventional use of textiles as substrates for the incorporation of brick materials (i.e., polymers and nanomaterials) is ubiquitously developed with primary purposes for introducing desired technical/functional performance rather than maintaining the aesthetic/decorative characteristics and inherent advantages (i.e., flexibility and permeability) of textiles. Such kinds of modified textiles with typical solid coating layers, however, are becoming more and more unsuitable for some emerging applications, such as smart wearable devices. Herein, we presented a brand-new kind of modified textiles with brick materials formed contouring to the nonplanar fiber surfaces of a fabric substrate as a three-dimensional (3D) conformal layer of porous microstructures by a unique breath figure self-assembling strategy of employing water microdroplet arrays as soft dynamic templates that can be controlled, formed, and removed spontaneously. In this paper, the main influential factors such as solution concentration, relative humidity, temperature, brick materials, and fabric substrates were studied systematically to control and adjust the formation of 3D conformal porous microstructures (3CPMs). The obtained 3D conformal porous microstructured textiles (3CPMTs) hierarchically combining the inherent texture features of the porous network of textiles and honeycomb porous microstructures templated from water microdroplet arrays not only possess new functions of introduced brick materials (such as triboelectric performance and wettability) and maintain the excellent inherent advantages (such as flexibility, air permeability, water vapor permeability, and unique texture features) of fabrics but also enhance the tensile strength and thermal insulation performance of substrates. Taking advantage of the introduced functions, they can be either used for conventional applications (i.e., oil/water separation) with enhanced performance or explored for new applications (i.e., self-powered sensors with textile breathability and comfort) with truly wearable potential. We believe this efficient, robust, and versatile strategy opens up numerous possibilities for designing and developing a broad range of advanced multifunctional textiles upon end uses.

Droplet clusters: nature-inspired biological reactors and aerosols

Condensed microdroplets play a prominent role in living nature, participating in various phenomena, from water harvesting by plants and insects to microorganism migration in bioaerosols. Microdroplets may also form regular self-organized patterns, such as the hexagonally ordered breath figures on a solid surface or levitating monolayer droplet clusters over a locally heated water layer. While the breath figures have been studied since the nineteenth century, they have found a recent application in polymer surface micropatterning (e.g. for superhydrophobicity). Droplet clusters were discovered in 2004, and they are the subject of active research. Methods to control and stabilize droplet clusters make them suitable for the in situ analysis of bioaerosols. Studying life in bioaerosols is important for understanding microorganism origins and migration; however, direct observation with traditional methods has not been possible. We report preliminary results on direct in situ observation of microorganisms in droplet clusters. We also present a newly observed transition between the hexagonally ordered and chain-like states of a droplet cluster. This article is part of the theme issue 'Bioinspired materials and surfaces for green science and technology (part 2)'.

Controlled ATRP Synthesis of Novel Linear-Dendritic Block Copolymers and Their Directed Self-Assembly in Breath Figure Arrays

Herein, we report the formation and characterization of novel amphiphilic linear-dendritic block copolymers (LDBCs) composed of hydrophilic dendritic poly(ether-ester), PEE, blocks and hydrophobic linear poly(styrene), PSt. The LDBCs are synthesized via controlled atom transfer radical polymerization (ATRP) initiated by a PEE macroinitiator. The copolymers formed have narrow molecular mass distributions and are designated as LGn-PSt Mn, in which LG represents the PEE fragment, n denotes the generation of the dendron (n = 1⁻3), and Mn refers to the average molecular mass of the LDBC (Mn = 3.5⁻68 kDa). The obtained LDBCs are utilized to fabricate honeycomb films by a static "breath figure" (BF) technique. The copolymer composition strongly affects the film morphology. LDBCs bearing acetonide dendron end groups produce honeycomb films when the PEE fraction is lower than 20%. Pore uniformity increases as the PEE content decreases. For LDBCs with hydroxyl end groups, only the first generation LDBCs yield BF films, but with a significantly smaller pore size (0.23 μm vs. 1⁻2 μm, respectively). Although higher generation LDBCs with free hydroxyl end groups fail to generate honeycomb films by themselves, the use of a cosolvent or addition of homo PSt leads to BF films with a controllable pore size (3.7⁻0.42 μm), depending on the LDBC content. Palladium complexes within the two triazole groups in each of the dendron's branching moieties can also fine-tune the morphology of the BF films.

Microdrop-Assisted Microdomain Hydrophilicization of Superhydrophobic Surfaces for High-Efficiency Nucleation and Self-Removal of Condensate Microdrops

Superhydrophobic-hydrophilic hybrid surfaces have attracted intensive interest because of their significant academic and commercial values. However, almost all reported microdomain hydrophilicization methods rely on costly micropatterning techniques that need special instruments. Here, we report a microdrop-assisted method for microdomain hydrophilicization of a low-adhesive superhydrophobic surface and demonstrate its utility in high-efficiency nucleation and self-removal of condensate microdrops. Micrometer-sized fogdrops containing polyvinyl alcohol molecules can be selectively captured by breath figures of superhydrophobic surfaces with specific sizes and spatial distributions and can be converted into desired hydrophilic microdomains after thermal evaporation. After exploring the influence of hydrophilic microdomains' distributions and sizes to surface wettability, adhesion, and condensation dynamics, we achieved an optimal hybrid surface, which possesses 240% average microdrop density, 387% microdrop self-removal rate, and 75% average microdrop diameter as compared to the contrast superhydrophobic surface with uniform chemistry nature. This method is dispensed with special equipment, easy to implement, very cheap, and eco-friendly, which would help develop other superhydrophobic-hydrophilic hybrid surfaces with different functions such as water harvesting, dehumidification, and heat exchange.

Designing 3D Biological Surfaces via the Breath-Figure Method

The fabrication of biointerfaces that mimic cellular physiological environments is critical to understanding cell behaviors in vitro and for the design of tissue engineering. Breath figure is a self-assemble method that uses water droplets condensed from moisture as template and ends up with a highly ordered hexagonal pore array; this approach is used to fabricate various biological substrates. This progress report provides an overview of strategies to achieve topographical modifications and chemical-patterned arrays, such as modulation of the pore size, shape and selective decoration of the honeycomb holes. Using recent results in the biological fields, potential future applications and developments of honeycomb structures are commented upon.

Au Nanoparticles Immobilized on Honeycomb-Like Polymeric Films for Surface-Enhanced Raman Scattering (SERS) Detection

We have successfully developed novel surface-enhanced Raman scattering (SERS) substrates with three-dimensional (3D) porous structures for effectively improving the sensitivity and reproducibility of SERS, which can rapidly detect small molecules (rhodamine 6G as an example). Periodical arrays of the honeycomb-like substrates were fabricated by self-assembling polyurethane-co-azetidine-2,4-dione (PU-PAZ) polymers. PU-PAZ comprising amphiphilic dendrons could stabilize the phase separation between the water droplets and polymer solution, and then organize into regular porous structures during the breath figure method. Subsequently, SERS substrates were fabricated by immobilizing gold nanoparticles (AuNPs) onto the honeycomb-like films with various 3D porous structures, controlled by the different PU-PAZ concentrations and relative humidities. Results show that surface enhancement factors of honeycomb-like substrates were 20 times higher than that of flat-film substrates (control group) due to enormous hot-spots resonance effects by the 3D porous structure, verified through Raman mapping at various positions of the z-axis. Furthermore, the particle size effects were evaluated by immobilized 12 and 67 nm of AuNPs on the honeycomb-like substrates, indicating larger AuNPs could induce more pronounced hot-spots effects. The generation of hot-spots resonance to enhance Raman intensity is strongly dependent on the diameter of AuNPs and the pore size of the honeycomb-like and 3D porous substrates for label-free and rapid SERS detection.

Multiphase Media Antiadhesive Coatings: Hierarchical Self-Assembled Porous Materials Generated Using Breath Figure Patterns

The cleaning of interface pollutants typically consumes a large amount of energy. Therefore, the development of multiphase media antiadhesive materials is urgently required to meet the demand of energy savings and environmental protection. In this study, the antiadhesive properties toward several liquid droplets and bubbles in multiple media are demonstrated on a porous Fe₂O₃ coating, which is prepared via a facile spin-coating-assisted breath figure approach and a phase separation strategy. The prominent antiadhesive characteristic of these porous surfaces lies in their high-surface-energy hierarchical micro/nanoscale structure, which easily entraps one medium (oil or water) in the pore and repels other unmixable liquids and air bubbles. In addition, we successfully demonstrate an antifouling application of the coating, which shows excellent antiadhesive and super-antiwetting characteristics under multiple liquids. Our work extends relevant antiadhesion research from a single medium to multiple media and promises to broaden the applications of antiadhesive materials in sophisticated activities performed under complicated liquid environments, such as marine antifouling or pipeline transportation.

Copper Mesh Templated by Breath-Figure Polymer Films as Flexible Transparent Electrodes for Organic Photovoltaic Devices

Metal mesh is a significant candidate of flexible transparent electrodes to substitute the current state-of-the-art material indium tin oxide (ITO) for future flexible electronics. However, there remains a challenge to fabricate metal mesh with order patterns by a bottom-up approach. In this work, high-quality Cu mesh transparent electrodes with ordered pore arrays are prepared by using breath-figure polymer films as template. The optimal Cu mesh films present a sheet resistance of 28.7 Ω·sq(-1) at a transparency of 83.5%. The work function of Cu mesh electrode is tuned from 4.6 to 5.1 eV by Ag deposition and the following short-time UV-ozone treatment, matching well with the

PEDOT

PSS (5.2 eV) hole extraction layer. The modified Cu mesh electrodes show remarkable potential as a substitute of ITO/PET in the flexible OPV and OLED devices. The OPV cells constructed on our Cu mesh electrodes present a similar power conversion efficiency of 2.04% as those on ITO/PET electrodes. The flexible OLED prototype devices can achieve a brightness of 10 000 cd at an operation voltage of 8 V.

Self-removal of condensed water on the legs of water striders

The ability to control drops and their movements on phobic surfaces is important in printing or patterning, microfluidic devices, and water-repellent materials. These materials are always micro-/nanotextured, and a natural limitation of repellency occurs when drops are small enough (as in a dew) to get trapped in the texture. This leads to sticky Wenzel states and destroys the superhydrophobicity of the material. Here, we show that droplets of volume ranging from femtoliter (fL) to microliter (μL) can be self-removed from the legs of water striders. These legs consist of arrays of inclined tapered setae decorated by quasi-helical nanogrooves. The different characteristics of this unique texture are successively exploited as water condenses, starting from self-penetration and sweeping effect along individual cones, to elastic expulsion between flexible setae, followed by removal at the anisotropic leg surface. We envision that this antifogging effect at a very small scale could inspire the design of novel applicable robust water-repellent materials for many practical applications.

In vitro degradation and release characteristics of spin coated thin films of PLGA with a "breath figure" morphology

Poly (lactic-co-glycolic acid) (PLGA) coatings on implant materials are widely used in controlled drug delivery applications. Typically, such coatings are made with non-porous films. Here, we have synthesized a thin PLGA film coating with a highly ordered microporous structure using a simple and inexpensive water templating "breath figure" technique. A single stage process combining spin coating and breath figure process was used to obtain drug incorporated porous thin films. The films were characterized by scanning electron microscope (SEM) to observe the surface and bulk features of porosity and also, degradation pattern of the films. Moreover, the effect of addition of small amount of poly (ethylene glycol) (PEG) into PLGA was characterized. SEM analysis revealed an ordered array of ~2 µm sized pores on the surface with the average film thickness measured to be 20 µm. The incorporation of hydrophilic poly (ethylene glycol) (PEG) enhances pore structure uniformity and facilitates ingress of water into the structure. A five week in vitro degradation study showed a gradual deterioration of the breath figure pores. During the course of degradation, the surface pore structure deteriorates to initially flatten the surface. This is followed by the formation of new pinprick pores that eventually grow into a macroporous film prior to film breakup. Salicylic acid (highly water soluble) and Ibuprofen (sparingly water soluble) were chosen as model drug compounds to characterize release rates, which are higher in films of the breath figure morphology rather than in non-porous films. The results are of significance in the design of biodegradable films used as coatings to modulate delivery.

Polymer blend lithography: A versatile method to fabricate nanopatterned self-assembled monolayers

A rapid and cost-effective lithographic method, polymer blend lithography (PBL), is reported to produce patterned self-assembled monolayers (SAM) on solid substrates featuring two or three different chemical functionalities. For the pattern generation we use the phase separation of two immiscible polymers in a blend solution during a spin-coating process. By controlling the spin-coating parameters and conditions, including the ambient atmosphere (humidity), the molar mass of the polystyrene (PS) and poly(methyl methacrylate) (PMMA), and the mass ratio between the two polymers in the blend solution, the formation of a purely lateral morphology (PS islands standing on the substrate while isolated in the PMMA matrix) can be reproducibly induced. Either of the formed phases (PS or PMMA) can be selectively dissolved afterwards, and the remaining phase can be used as a lift-off mask for the formation of a nanopatterned functional silane monolayer. This "monolayer copy" of the polymer phase morphology has a topographic contrast of about 1.3 nm. A demonstration of tuning of the PS island diameter is given by changing the molar mass of PS. Moreover, polymer blend lithography can provide the possibility of fabricating a surface with three different chemical components: This is demonstrated by inducing breath figures (evaporated condensed entity) at higher humidity during the spin-coating process. Here we demonstrate the formation of a lateral pattern consisting of regions covered with 1H,1H,2H,2H-perfluorodecyltrichlorosilane (FDTS) and (3-aminopropyl)triethoxysilane (APTES), and at the same time featuring regions of bare SiO(x). The patterning process could be applied even on meter-sized substrates with various functional SAM molecules, making this process suitable for the rapid preparation of quasi two-dimensional nanopatterned functional substrates, e.g., for the template-controlled growth of ZnO nanostructures [1].