We present a simple approach for patterning metal nanoparticles into periodic superstructures on flat films spanning centimeter-square areas. Our approach is based on capillary force lithography, a soft lithography method that is used to impart topography to molten polymer films, and applies it to block copolymer films to obtain substrates featuring both topographic and chemical contrasts that can serve as templates for the selective deposition of nanoparticles. Here we show that flattening the films by exposure to solvent vapour prior to nanoparticle deposition not only retains chemical heterogeneity but also provides access to unique hierarchically-organized nanoparticle superstructures that are unattainable by other methods. Such structures could be useful for optical, sensor, and catalytic applications.

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

Controlling complexity in assemblies of metal and semiconductor nanoparticles has the potential to expand the utilization of photonic devices into wavelength regimes that are currently inaccessible. Here we show that casting ultrathin films of asymmetric block copolymers on topographically defined substrates affords four types of mixed patterns through fine control of film thickness. Analysis of top-view and cross-sectional images revealed different morphological behavior of the film in the trench and on the plateau, which was explained by the difference in the type of boundary imposed by each topographic feature. Exposed domains were chemically modified and selectively decorated with gold nanoparticles, giving rise to nanoparticle superstructures with mixed patterns in a controlled fashion. We envisage utilization of such hierarchical superstructures as plasmon waveguides and metasurfaces.

Soft lithography techniques have become leading mesoscale approaches for replicating topographic features in polymer films. So far, the modified polymer films formed by soft lithography only featured topographic heterogeneity. Here we demonstrate the application of soft lithography techniques to block copolymer films, and show that the preferential affinity of one of the blocks to the stamping material leads to chemical heterogeneity that corresponds to the topographic features. Detailed surface and structural characterization of the patterned films provided information on its three-dimensional structure, revealing insights on the domain reorganization that takes place in the block copolymer film concomitantly with topography formation. The formed structures were utilized for selective assembly of gold nanoparticles into hierarchical structures. The versatility of this combined nanofabrication/self-assembly approach was demonstrated by the assembly of two types of metallic nanoparticles into two different arrangements with full control over the location of each type of nanoparticles.

The collective properties of ordered ensembles of anisotropically shaped nanoparticles depend on the morphology of organization. Here, we describe the utilization of block copolymer micelles to bias the natural packing tendency of semiconductor nanorods and organize them into circularly arranged superstructures. These structures are formed as a result of competition between the segregation tendency of the nanorods in solution and in the polymer melt; when the nanorods are highly compatible with the solvent but prefer to segregate in the melt to the core-forming block, they migrate during annealing toward the core–corona interface, and their superstructure is, thus, templated by the shape of the micelle. The nanorods, in turn, exhibit surfactant-like behavior and protect the micelles from coalescence during annealing. Lastly, the influence of the attributes of the micelles on nanorod organization is also studied. The circular nanorod arrangements and the insights gained in this study add to a growing list of possibilities for organizing metal and semiconductor nanorods that can be achieved using rational design.

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

Bottlebrush block copolymers offer unique advantages for polymer-nanoparticle assembly, arising from the stiffness of their backbones and the compositional tunability afforded by the lengths of the grafts in each block independently. The morphologies of ultrathin bottlebrush block copolymer films are extremely sensitive to the chemistry of the substrate. Modifying the substrate with a polymer brush that corresponds to one of the blocks of the bottlebrush copolymer leads to different, often non-bulk morphologies that relate to the interaction of the copolymer with the substrate, which is dictated by the bottlebrush polymer composition. In this work, we investigate the assembly of bottlebrush block copolymers of different compositions with gold nanoparticles, which are modified with polymeric ligands that correspond to one of the blocks. Our results show that the net interaction of the copolymer with the substrate influences the self-assembly process, leading to two types of routes: the co-assembly route, in which the nanoparticles are organized by the polymer into periodic structures, or macrophase separation. In the co-assembly route, selective substrates slightly distort the shape of the domains. The nanoparticles, in turn, influence the kinetics of the process by their interaction with the substrate.

Arrays of alternating metallic nanostructures present hybrid properties, which are useful for applications in photonics and catalysis. Block copolymer films provide versatile templates for fabricating periodic arrays of nanowires. Yet, creating arrays with alternating compositions or structures requires different modifications of domains of the same kind. By controlling the penetration depth of metal precursors into the film we were able to impregnate different layers of copolymer cylinders with different metals. Capitalizing on the hexagonal packing of the cylinders led to simultaneous formation of nanowires with alternating compositions and periodic arrangement on the substrate after plasma etching. Selective deposition of nanoparticles on the film enabled creating alternating bare and decorated nanowires, as well as trimetallic nanowire arrays.

Block copolymer guided assembly of nanoparticles leads to the formation of nanocomposites with periodic arrangement of nanoparticles, which are important for applications such as photonic devices and sensors. However, linear block copolymers offer limited control over the internal arrangement of nanoparticles inside their hosting domains. In contrast, bottlebrush block copolymers possess unique architectural attributes that enable additional ways to control the local organization of nanoparticles. In this work, we studied the coassembly of 8 and 13 nm gold nanoparticles with three bottlebrush block copolymers differing in the asymmetry of their graft lengths. Assembly was performed in ultraconfined films, where it occurs quasi-two-dimensionally. Our results indicate that graft asymmetry could be used as an additional tool to enhance nanoparticle ordering by forcing them to localize at the center of the domain regardless of their size. This behavior is analyzed in terms of the influence of the graft asymmetry on the average conformations of the blocks.

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

Exploiting the full potential of metal and semiconductor nanoparticles for advanced nanotechnological applications requires their organization into predefined structures with high orientational control. Nanofabrication approaches that combine high resolution lithography and self-assembly afford the advantages of accurate placement, compositional diversity, and reduced production costs. This review concentrates on the creation of organized nanoparticle superstructures assisted by recent developments in the directed self-assembly of block copolymers, and delineates possible applications. Copyright (C) 2016 John Wiley & Sons, Ltd.

The construction of nano-sized, two-dimensionally ordered nanoparticle (NP) superstructures is important for various advanced applications such as photonics, sensing, catalysis, or nano-circuitry. Currently, such structures are fabricated using the templated organization approach, in which the templates are mainly created by photo-lithography or laser-lithography and other invasive top-down etching procedures. In this work, we present an alternative bottom-up preparation method for the controlled deposition of NPs into hierarchical structures. Lamellar polystyrene-block-poly(2-vinylpyridinium) thin films featuring alternating stripes of neutral PS and positively charged P2VP domains serve as templates, allowing for the selective adsorption of negatively charged gold NPs. Dense NP assembly is achieved by a simple immersion process, whereas two-dimensionally ordered arrays of NPs are realized by microcontact printing (mu CP), utilizing periodic polydimethylsiloxane wrinkle grooves loaded with gold NPs. This approach enables the facile construction of hierarchical NP arrays with variable geometries. Copyright (C) 2016 John Wiley & Sons, Ltd.

The coassembly of A B diblock copolymers with B’-type nanoparticles (i.e., nanoparticles that are slightly incompatible with the B domain) leads to hierarchical structures, where the block copolymer phase separates first and the nanoparticles create close-packed arrays within the B domains due to a slower, secondary phase separation process. Here we report the results of a comprehensive study, which focused on two aspects: the influence of the nanoparticle shape (spherical vs rod-like) and the effect of the volume composition of the blocks. Three polystyrene-block-poly(methyl methacrylate) (PS-b-PMMA) copolymers featuring similar molecular weights but differing in PS volume fraction were mixed with spherical and rod-shaped poly(ethylene oxide)- (PEO-) capped CdS nanoparticles at different filling fractions and cast as thin films. Our results highlight the mutual influence between the block copolymer and the nanoparticles on the resulting morphology, demonstrating the ability to control the film morphology by the filling fraction of the nanoparticles and their tendency to localize at the film surface, and by confinement-induced nanoparticle aggregation. Most importantly, the results reveal the influence of the nanoparticle shape on the structure of the film.

Tailoring the size and surface chemistry of nanoparticles allows one to control their position in a block copolymer, but this is usually limited to one-dimensional distribution across domains. Here, the hierarchical assembly of poly(ethylene oxide)-stabilized gold nanoparticles (Au-PEO) into hexagonally packed clusters inside mesostructured ultrathin films of polystyrene-block-poly(methyl methacrylate) (PS-b-PMMA) is described. A close examination of the structural evolution at different nanoparticle filling fractions and PEO ligand molecular weights suggests that the mechanism leading to this structure-within-structure is the existence of two phase separation processes operating on different time scales. The length of the PEO ligand is shown to influence not only the interparticle distances but also the phase separation processes. These conclusions are supported by novel mesoscopic simulations, which provide additional insight into the kinetic and thermodynamic factors that are responsible for this behavior.

We investigate the kinetics of block copolymer/nanoparticle composite alignment in an electric field using in situ transmission small-angle X-ray scattering. As a model system, we employ a lamellae forming polystyrene-block-poly(2-vinyl pyridine) block copolymer with different contents of gold nanoparticles in thick films under solvent vapor annealing. While the alignment improves with increasing nanoparticle fraction, the kinetics slows down. This is explained by changes in the degree of phase separation and viscosity. Our findings provide extended insights into the basics of nanocomposite alignment.