Toward Large‐Scale Alignment of Electrohydrodynamic Patterning of Thin Polymer Films

To pattern thin polymer films via electrohydrodynamic instabilities, we design and utilize two different kinds of mask patterns to guide pillars into alignment over regions much greater in extent than their natural domain sizes. First, narrow protruding ridges that intersect to form regular patterns on the mask trigger the growth of pillars beneath. Later, square and triangular packings of pillars develop in the regions enclosed by those ridges, preserving the registry from one domain to the next over a much larger area than within individual domains in unpatterned portions of the mask. Second, small square protrusions that are prealigned into a large regular array on the mask guide the formation of square packings of pillars in domains that conform to the mask, forming a large array of pillars. Novel structures involving a combination of linear ridges and pillars are also produced mainly due to the dynamic merging among preformed pillars. Finally, we find vertex symmetry of the mask pattern is necessary for generating and preserving ordered patterns on the polymer film.     

Cover Picture: Fabrication of Stable Metallic Patterns Embedded in Poly(dimethylsiloxane) and Model Applications in Non‐Planar Electronic and Lab‐on‐a‐Chip Device Patterning (Adv. Funct. Mater. 4/2005)

A composite image is shown that highlights examples of device architectures that either incorporate or exploit polymer‐embedded metallic microstructures. In work reported by Nuzzo and co‐workers on p. 557, new applications of soft lithography, in conjunction with advanced forms of multilayer metallization, are used to construct these exceptionally durable structures. They are suitable for use in non‐planar lithographic patterning, and as device components finding applications ranging from microelectronics to Lab‐on‐a‐Chip analytical systems. This article describes the fabrication of durable metallic patterns that are embedded in poly(dimethylsiloxane) (PDMS) and demonstrates their use in several representative applications. The method involves the transfer and subsequent embedding of micrometer‐scale gold (and other thin‐film material) patterns into PDMS via adhesion chemistries mediated by silane coupling agents. We demonstrate the process as a suitable method for patterning stable functional metallization structures on PDMS, ones with limiting feature sizes less than 5 μm, and their subsequent utilization as structures suitable for use in applications ranging from soft‐lithographic patterning, non‐planar electronics, and microfluidic (lab‐on‐a‐chip, LOC) analytical systems. We demonstrate specifically that metal patterns embedded in both planar and spherically curved PDMS substrates can be used as compliant contact photomasks for conventional photolithographic processes. The non‐planar photomask fabricated with this technique has the same surface shape as the substrate, and thus facilitates the registration of structures in multilevel devices. This quality was specifically tested in a model demonstration in which an array of one hundred metal oxide semiconductor field‐effect transistor (MOSFET) devices was fabricated on a spherically curved Si single‐crystalline lens. The most significant opportunities for the processes reported here, however, appear to reside in applications in analytical chemistry that exploit devices fabricated using the methods of soft lithography. Toward this end, we demonstrate durably bonded metal patterns on PDMS that are appropriate for use in microfluidic, microanalytical, and microelectromechanical systems. We describe a multilayer metal‐electrode fabrication scheme (multilaminate metal–insulator–metal (MIM) structures that substantially enhance performance and stability) and use it to enable the construction of PDMS LOC devices using electrochemical detection. A polymer‐based microelectrochemical analytical system, one incorporating an electrode array for cyclic voltammetry and a microfluidic system for the electrophoretic separation of dopamine and catechol with amperometric detection, is demonstrated.     

Cover Picture: High Definition Digital Fabrication of Active Organic Devices by Molecular Jet Printing (Adv. Funct. Mater. 15/2007)

A new method for direct patterning of organic optoelectronic/electronic devices using a reconfigurable and scalable printing method is reported by Vladimir Bulovic and co‐workers on p. 2722. The printing technique is applied to the fabrication of high‐resolution printed organic light emitting devices (OLEDs) and organic field effect transistors (OFETs). Remarkably, the final print‐deposited films are evaporated onto the substrate (rather than solvent printed), giving high‐quality, solvent‐free, molecularly flat structures that match the performance of comparable high‐performance unpatterned films. We introduce a high resolution molecular jet (MoJet) printing technique for vacuum deposition of evaporated thin films and apply it to fabrication of 30 μm pixelated (800 ppi) molecular organic light emitting devices (OLEDs) based on aluminum tris(8‐hydroxyquinoline) (Alq₃) and fabrication of narrow channel (15 μm) organic field effect transistors (OFETs) with pentacene channel and silver contacts. Patterned printing of both organic and metal films is demonstrated, with the operating properties of MoJet‐printed OLEDs and OFETs shown to be comparable to the performance of devices fabricated by conventional evaporative deposition through a metal stencil. We show that the MoJet printing technique is reconfigurable for digital fabrication of arbitrary patterns with multiple material sets and high print accuracy (of better than 5 μm), and scalable to fabrication on large area substrates. Analogous to the concept of “drop‐on‐demand” in Inkjet printing technology, MoJet printing is a “flux‐on‐demand” process and we show it capable of fabricating multi‐layer stacked film structures, as needed for engineered organic devices.     

Cover Picture: Three‐Dimensional SiCN Ceramic Microstructures via Nano‐Stereolithography of Inorganic Polymer Photoresists (Adv. Funct. Mater. 9/2006)

An inorganic polymer photoresist was successfully synthesized for the first time with high photosensitivity and a high ceramic yield. Furthermore, it is shown by Kim, Yang, and co‐workers on p. 1235 that a nano‐stereolithography process linked with careful pyrolysis of this resin paves the way for the fabrication of 2D and 3D ceramic microstructures (examples of which are shown on the cover) with high spatial resolution. We report a newly synthesized inorganic polymer photoresist with a high ceramic yield by the functionalization of polyvinylsilazane (KiON VL20) with 2‐isocyanatoethyl methacrylate via linkage or insertion reaction routes. The chemistry of the synthesis and the pyrolytic conversion as well as the mechanical evaluation were investigated by using various analytical instruments. We show for the first time that this photosensitive resin is a novel precursor for the fabrication of complex 3D SiCN ceramic microstructures with a 210 nm resolution via a two‐photon absorbed crosslinking process and subsequent pyrolysis at 600 °C under a nitrogen atmosphere. Moreover, the dimensional deformation during pyrolysis was significantly reduced by adding silica nanoparticles as a filler. In particular, the ceramic microstructures containing 40 wt % silica nanoparticles exhibited a relatively isotropic shrinkage owing to its sliding free from the substrate during pyrolysis.     

Inside Front Cover: Optical Control and Patterning of Gold‐Nanorod–Poly(vinyl alcohol) Nanocomposite Films (Adv. Funct. Mater. 7/2005)

The micropatterning of optical structures into thin films of poly (vinyl alcohol) (PVA) containing gold nanorods is demonstrated by Pérez‐Juste, Liz‐Marzán, and co‐workers on p. 1065. The nanorods are uniformly distributed in the thin films and can be aligned by stretching the films. The inside cover shows how irradiation with a nanosecond laser, using a TEM grid as mask, selectively reshapes the nanorods into nanospheres (upper and lower TEM images, respectively). Gold nanorods with well‐defined aspect ratios are homogeneously incorporated within poly(vinyl alcohol) thin films and subsequently aligned by heating and stretching the nanocomposite films. The spatial alignment of the nanorods is directly proved using transmission electron microscopy. The polarization‐dependent optical response of the rods is measured and compared with a dipole model. Excellent agreement is found. Additionally, irradiation of the film with nanosecond laser pulses (1064 nm) leads to selective reshaping of the nanorods into nanospheres, and we demonstrate that this effect can be used to micropattern optical structures into the films.     

Cover Picture: Formation of Metal Nano‐ and Micropatterns on Self‐Assembled Monolayers by Pulsed Laser Deposition Through Nanostencils and Electroless Deposition (Adv. Funct. Mater. 10/2006)

The cover illustrates two‐step fabrication of metal micro‐ and nanostructures on self‐assembled monolayers (SAMs) by pulsed laser deposition and electroless deposition. Metal–SAM–metal junctions are a key component of molecular electronic devices. Pt was deposited in a micropattern by pulsed laser deposition through a stencil. XPS maps show how the Pt pattern is developed into a Cu pattern using electroless deposition as reported by Ravoo, Brugger, Reinhoudt, Blank, and co‐workers on p. 1337. The Cu pattern can also be observed by optical microscopy (background). Patterns of noble‐metal structures on top of self‐assembled monolayers (SAMs) on Au and SiO₂ substrates have been prepared following two approaches. The first approach consists of pulsed laser deposition (PLD) of Pt, Pd, Au, or Cu through nano‐ and microstencils. In the second approach, noble‐metal cluster patterns deposited through nano‐ and microstencils are used as catalysts for selective electroless deposition (ELD) of Cu. Cu structures are grown on SAMs on both Au and SiO₂ substrates and are subsequently analyzed using X‐ray photoelectron spectroscopy element mapping, atomic force microscopy, and optical microscopy. The combination of PLD through stencils on SAMs followed by ELD is a new method for the creation of (sub)‐micrometer‐sized metal structures on top of SAMs. This method minimizes the gas‐phase deposition step, which is often responsible for damage to, or electrical shorts through, the SAM.     

Inside Front Cover: Perfect Bi4Ti3O12 Single‐Crystal Films via Flux‐Mediated Epitaxy (Adv. Funct. Mater. 4/2006)

Flux‐mediated epitaxy has been developed for ferroelectric Bi₄Ti₃O₁₂ single‐crystal film growth, as shown on the inside cover. The key point is the selection of an appropriate flux material. A combinatorial high‐throughput screening technique reported by Matsumoto and co‐workers on p. 485 has led to the successful discovery of the novel flux composition, Bi–Cu–O, for Bi₄Ti₃O₁₂ single‐crystal film growth. This flux‐mediated epitaxy is not limited to oxide epitaxy, but is also widely applicable to various promising materials for the realization of non‐Si‐based electronics, such as nitrides, carbides, and halides. Excellent crystallinity of material films and atomic control of their surface/interface, sufficient for the realization of their optimal physical properties, are technological premises for modern functional‐device applications. Bi₄Ti₃O₁₂ and related compounds attract much interest as highly insulating, ferroelectric materials for use in ferroelectric random‐access memories. However, it has been difficult thus far for Bi₄Ti₃O₁₂ films to satisfy such requirements when formed using vapor‐phase epitaxy, owing to the high volatility of Bi in a vacuum. Here, we demonstrate that flux‐mediated epitaxy is one of the most promising and widely applicable concepts to overcome this inevitable problem. The key point of this process is the appropriate selection of a multi‐component flux system. A combinatorial approach has led to the successful discovery of the novel flux composition of Bi–Cu–O for Bi₄Ti₃O₁₂ single‐crystal film growth. The perfect single‐crystal nature of the stoichiometric Bi₄Ti₃O₁₂ film formed has been verified through its giant grain size and electric properties, equivalent to those of bulk single crystals. This demonstration has broad implications, opening up the possibility of preparing stoichiometric single‐crystal oxide films via vapor‐phase epitaxy, even if volatile constituents are required.     

Cover Picture: Tuning the Dimensions of C60‐Based Needlelike Crystals in Blended Thin Films (Adv. Funct. Mater. 6/2006)

A new ordered structure of the C₆₀ derivative PCBM is obtained in thin films based on the blend PCBM:P3HT, as detailed by Swinnen, Manca, and co‐workers on p. 760. Needlelike crystalline PCBM structures, whose dimensions and spatial distribution ca be tuned by adjusting the blend ratio and annealing conditions, are formed. In typical solar‐cell applications of these blended films, these results indicate that during long‐term operation under normal conditions (50–70 °C) morphology changes and a decrease in cell performance could occur. A new ordered structure of the C₆₀ derivative PCBM ([6‐6]‐phenyl C₆₁‐butyric acid methyl ester) is obtained in thin films based on the blend PCBM:regioregular P3HT (poly(3‐hexylthiophene)). Rapid formation of needlelike crystalline PCBM structures of a few micrometers up to 100 μm in size is demonstrated by submitting the blended thin films to an appropriate thermal treatment. These structures can grow out to a 2D network of PCBM needles and, in specific cases, to spectacular PCBM fans. Key parameters to tune the dimensions and spatial distribution of the PCBM needles are blend ratio and annealing conditions. The as‐obtained blended films and crystals are probed using atomic force microscopy, transmission electron microscopy, selected area electron diffraction, optical microscopy, and confocal fluorescence microscopy. Based on the analytical results, the growth mechanism of the PCBM structures within the film is described in terms of diffusion of PCBM towards the PCBM crystals, leaving highly crystalline P3HT behind in the surrounding matrix.     

Cover Picture: Solution‐Processed Organic Tandem Solar Cells (Adv. Funct. Mater. 14/2006)

The fabrication of a solution‐processed polymer tandem cell by stacking two single cells in series is reported by de Boer and co‐workers on p. 1897. The bottom and top cell are complementary with respect to their absorption spectra and the layer thickness of the bottom cell was optimized in order to create an optical cavity that efficiently transmits the required wavelength for the top cell. The combination of this tandem architecture with more efficient small‐bandgap materials will enable the realization of highly efficient organic solar cells. A solution‐processed polymer tandem cell fabricated by stacking two single cells in series is demonstrated. The two bulk‐heterojunction subcells have complementary absorption maxima at λ_max ～ 850 nm and λ_max ～ 550 nm, respectively. A composite middle electrode is applied that serves both as a charge‐recombination center and as a protecting layer for the first cell during spin‐coating of the second cell. The subcells are electronically coupled in series, which leads to a high open‐circuit voltage of 1.4 V, equal to the sum of each subcell. The layer thickness of the first (bottom) cell is tuned to maximize the optical absorption of the second (top) cell. The performance of the tandem cell is presently limited by the relatively low photocurrent generation in the small‐bandgap polymer of the top cell. The combination of our tandem architecture with more efficient small‐bandgap materials will enable the realization of highly efficient organic solar cells in the near future.     

Transparent Poly(methyl methacrylate)/Single‐Walled Carbon Nanotube (PMMA/SWNT) Composite Films with Increased Dielectric Constants

Poly(methyl methacrylate)/single‐walled carbon nanotube (PMMA/SWNT) composites were prepared via in situ polymerization induced either by heat, ultraviolet (UV) light, or ionizing (gamma) radiation. The composites dissolved in methylene chloride and then cast into films exhibited enhanced transparency as compared with the melt‐blended composite material. UV/visible spectroscopy was used to quantitatively analyze the transparency of the composites. The dielectric constant (ε′) was measured via dielectric analysis (DEA) and correlated to the refractive‐index values using Maxwell's relationship. The dielectric constant increased in the composite samples as compared with the neat PMMA samples prepared by the same methods. Scanning electron microscopy (SEM) and transmission electron microscopy (TEM) provided images of the polymer–nanotube composites and single‐walled CNTs, respectively.     

Cover Picture: Controlled Encapsulation of Hydrophobic Liquids in Hydrophilic Polymer Nanofibers by Co‐electrospinning (Adv. Funct. Mater. 16/2006)

The cover shows an optical image of co‐electrospun nanofibers of poly(vinyl pyrrolidone) (outside) and hydrophobic oil (inside), irradiated by UV light. The resulting non‐woven mats present monosized beads regularly distributed along the nanofibers in work reported by Loscarteles and co‐workers on p. 2110. Only the beads fluoresce, due to special markers added to the oil, indicating that the oil is indeed wholly encapsulated inside the beads. There are many technical situations, such as various biological or medical applications, in which a hydrophobic fluid must be encapsulated inside a hydrophilic polymer shell in the form of tiny microscopic pieces. A novel approach is presented, based on the co‐electrospinning of the hydrophilic polymer melt (outside) and the hydrophobic fluid (inside), which results in beaded micro‐ and nanofibers, such that the hydrophobic fluid is efficiently encapsulated inside the beads. For the selected fluid couple, the low liquid–liquid surface tension and the high viscosity of the melt prevent the varicose break‐up of inner fluid in the coaxial electrified jet until the very end of the co‐electrospinning process. The resulting fibers present beads filled with the hydrophobic fluid, separated by a rather uniform distance whose length depends partially on the melt flow rate. The bead diameter grows with the inner flow rate, going from a monosized to a bisized distribution. In the case under study, the maximum relative (inner‐to‐outer) flow rate is one. The diameter of the solid fibers between beads scales well with existing theories for simple electrospinning.     

Cover Picture: Self‐Organization of Ink‐jet‐Printed Triisopropylsilylethynyl Pentacene via Evaporation‐Induced Flows in a Drying Droplet (Adv. Funct. Mater. 2/2008)

Charge carrier transport in organic electronic devices is influenced by the crystalline microstructure and morphology of the organic semiconductor film. Evaporation behavior during drying plays a vital role in controlling the film morphology and the distribution of solute in inkjet‐printed films. On p. 229, Kilwon Cho and co‐workers demonstrate the influence of the evaporation‐induced flow in a single droplet on the crystalline microstructure and film morphology of inkjet‐printed 6,13‐bis((triisopropylsilylethynyl) pentacene. The results provide an excellent method for direct‐write fabrication of high‐performance organic electronics. We have demonstrated the influence of evaporation‐induced flow in a single droplet on the crystalline microstructure and film morphology of an ink‐jet‐printed organic semiconductor, 6,13‐bis((triisopropylsilylethynyl) pentacene (TIPS_PEN), by varying the composition of the solvent mixture. The ringlike deposits induced by outward convective flow in the droplets have a randomly oriented crystalline structure. The addition of dichlorobenzene as an evaporation control agent results in a homogeneous film morphology due to slow evaporation, but the molecular orientation of the film is undesirable in that it is similar to that of the ring‐deposited films. However, self‐aligned TIPS_PEN crystals with highly ordered crystalline structures were successfully produced when dodecane was added. Dodecane has a high boiling point and a low surface tension, and its addition to the solvent results in a recirculation flow in the droplets that is induced by a Marangoni flow (surface‐tension‐driven flow), which arises during the drying processes in the direction opposite to the convective flow. The field‐effect transistors fabricated with these self‐aligned crystals via ink‐jet printing exhibit significantly improved performance with an average effective field‐effect mobility of 0.12 cm² V^–1 s^–1. These results demonstrate that with the choice of appropriate solvent ink‐jet printing is an excellent method for the production of organic semiconductor films with uniform morphology and desired molecular orientation for the direct‐write fabrication of high‐performance organic electronics.