Your browser doesn't support javascript.
loading
Show: 20 | 50 | 100
Results 1 - 20 de 83
Filter
Add more filters










Publication year range
1.
Adv Mater ; 36(8): e2306665, 2024 Feb.
Article in English | MEDLINE | ID: mdl-37738605

ABSTRACT

The initiated chemical vapor deposition (iCVD) technique is an all-dry method for designing organic and hybrid polymers. Unlike methods utilizing liquids or line-of-sight arrival, iCVD provides conformal surface modification over intricate geometries. Uniform, high-purity, and pinhole-free iCVD films can be grown with thicknesses ranging from >15 µm to <5 nm. The mild conditions permit damage-free growth directly onto flexible substrates, 2D materials, and liquids. Novel iCVD polymer morphologies include nanostructured surfaces, nanoporosity, and shaped particles. The well-established fundamentals of iCVD facilitate the systematic design and optimization of polymers and copolymers. The functional groups provide fine-tuning of surface energy, surface charge, and responsive behavior. Further reactions of the functional groups in the polymers can yield either surface modification, compositional gradients through the layer thickness, or complete chemical conversion of the bulk film. The iCVD polymers are integrated into multilayer device structures as desired for applications in sensing, electronics, optics, electrochemical energy storage, and biotechnology. For these devices, hybrids offer higher values of refractive index and dielectric constant. Multivinyl monomers typically produce ultrasmooth and pinhole-free and mechanically deformable layers and robust interfaces which are especially promising for electronic skins and wearable optoelectronics.

2.
Front Bioeng Biotechnol ; 9: 632753, 2021.
Article in English | MEDLINE | ID: mdl-33634089

ABSTRACT

This review will focus on the controlled release of pharmaceuticals and other organic molecules utilizing polymeric nanolayers grown by initiated chemical vapor deposited (iCVD). The iCVD layers are able conform to the geometry of the underlying substrate, facilitating release from one- and two-dimensional nanostructures with high surface area. The reactors for iCVD film growth can be customized for specific substrate geometries and scaled to large overall dimensions. The absence of surface tension in vapor deposition processes allows the synthesis of pinhole-free layers, even for iCVD layers <10 nm thick. Such ultrathin layers also provide rapid transport of the drug across the polymeric layer. The mild conditions of the iCVD process avoid damage to the drug which is being encapsulated. Smart release is enabled by iCVD hydrogels which are responsive to pH, temperature, or light. Biodegradable iCVD layers have also be demonstrated for drug release.

3.
Nat Commun ; 11(1): 5092, 2020 Oct 09.
Article in English | MEDLINE | ID: mdl-33037193

ABSTRACT

The combination of inorganic semiconductors with organic thin films promises new strategies for the realization of complex hybrid optoelectronic devices. Oxidative chemical vapor deposition (oCVD) of conductive polymers offers a flexible and scalable path towards high-quality three-dimensional inorganic/organic optoelectronic structures. Here, hole-conductive poly(3,4-ethylenedioxythiophene) (PEDOT) grown by oxidative chemical vapor deposition is used to fabricate transparent and conformal wrap-around p-type contacts on three-dimensional microLEDs with large aspect ratios, a yet unsolved challenge in three-dimensional gallium nitride technology. The electrical characteristics of two-dimensional reference structures confirm the quasi-metallic state of the polymer, show high rectification ratios, and exhibit excellent thermal and temporal stability. We analyze the electroluminescence from a three-dimensional hybrid microrod/polymer LED array and demonstrate its improved optical properties compared with a purely inorganic microrod LED. The findings highlight a way towards the fabrication of hybrid three-dimensional optoelectronics on the sub-micron scale.

4.
Sci Adv ; 5(11): eaay0414, 2019 11.
Article in English | MEDLINE | ID: mdl-31803838

ABSTRACT

For semicrystalline poly(3,4-ethylene dioxythiophene) (PEDOT), oxidative chemical vapor deposition (oCVD) enables systematic control over the b-axis lattice parameter (π-π stacking distance). Decreasing the b-axis lattice parameter increases the charge transfer integral, thus enhancing intracrystallite mobility. To reduce the barrier to intercrystallite transport, oCVD conditions were tailored to produce pure face-on crystallite orientation rather than the more common edge-on orientation. The face-on oriented oCVD PEDOT with the lowest b-axis lattice parameter displayed the highest in-plane electrical conductivity (σdc = 2800 S/cm), largest optical bandgap (2.9 eV), and lowest degree of disorder as characterized by the Urbach band edge energy. With the single step oCVD process at growth conditions compatible with direct deposition onto flexible plastic substrates, the ratio σdc/σop reached 50. As compared to spun-cast PEDOT:polystyrene sulfonate, integration of oCVD PEDOT as a hole transport layer (HTL) improved both the power conversion efficiency (PCE) and shelf-life stability of inverted perovskite solar cells (PSC).

5.
Adv Mater ; 31(30): e1901916, 2019 Jul.
Article in English | MEDLINE | ID: mdl-31157472

ABSTRACT

Nanocarbon electronic conductors combined with pseudocapacitive materials, such as conducting polymers, display outstanding electrochemical properties and mechanical flexibility. These characteristics enable the fabrication of flexible electrodes for energy-storage devices; that is, supercapacitors that are wearable or can be formed into shapes that are easily integrated into vehicle parts. To date, most nanocarbon materials such as nanofibers are randomly dispersed as a network in a flexible matrix. This morphology inhibits ion transport, particularly under the high current density necessary for devices requiring high power density. Novel flexible densified horizontally aligned carbon nanotube arrays (HACNTs) with controlled nanomorphology for improved ion transport are introduced and combined with conformally coated poly(3-methylthiophene) (P3MT) conducting polymer to impart pseudocapacitance. The resulting P3MT/HACNT nanocomposite electrodes exhibit high areal capacitance of 3.1 F cm-2 at 5 mA cm-2 , with areal capacitance remaining at 1.8 F cm-2 even at a current density of 200 mA cm-2 . The asymmetric supercapacitor cell also delivers more than 1-2 orders of magnitude improvement in both areal energy and power density over state-of-the-art cells. Furthermore, little change in cell performance is observed under high strain, demonstrating the mechanical and electrochemical stability of the electrodes.

6.
Sci Rep ; 9(1): 2237, 2019 Feb 19.
Article in English | MEDLINE | ID: mdl-30783115

ABSTRACT

Bulk polytetrafluoroethylene (PTFE) possesses excellent chemical stability and dielectric properties. Indeed, thin films with these same characteristics would be ideal for electret applications. Previously, the electret properties of PTFE-like thin films produced by rf sputtering or plasma enhanced chemical vapor deposition were found to deteriorate due to structural changes and surface oxidation. In this article, the technique of initiated chemical vapor deposition (iCVD) is evaluated for electret applications for the first time. The iCVD method is known for its solvent-free deposition of conformal, pinhole-free polymer thin films in mild process conditions. It is shown that PTFE thin films prepared in this way, show excellent agreement to commercial bulk PTFE with regard to chemical properties and dielectric dissipation factors. After ion irradiation in a corona discharge the iCVD PTFE thin films exhibit stable electret properties, which can be tailored by the process parameters. Due to the mild deposition conditions, the iCVD technique is suitable for deposition on flexible organic substrates for the next-generation electret devices. It is also compatible with state-of-the-art microelectronic processing lines due to the characteristics of conformal growth and easy scaling up to larger size substrates.

7.
ACS Appl Mater Interfaces ; 11(7): 7330-7337, 2019 Feb 20.
Article in English | MEDLINE | ID: mdl-30689336

ABSTRACT

Blockage of pipelines due to accretion of salt particles is detrimental in desalination and water-harvesting industries as they compromise productivity, while increasing maintenance costs. We present a micro-/nanoscale approach to study fundamentals of scale formation, deposition, and adhesion to engineered surfaces with a wide range of surface energies fabricated using the initiated chemical vapor deposition method. Silicon wafers and steel substrates are coated with poly(1 H,1 H,2 H,2 H-perfluorodecylacrylate) or pPFDA, poly(tetravinyl-tetramethylcyclotetrasilohexane) or pV4D4, poly(divinylbenzene) or pDVB, poly(1,3,5,7-tetravinyl-1,3,5,7-tetramethylcyclotetrasilohexane) or pV3D3, and cross-linked copolymers of poly(2-hydroxyethylmethacrylate) and poly(ethylene glycol) diacrylate or p(PHEMA- co-EGDA). Particles of salt (CaSO4·2H2O) are formed and shaped with a focused ion beam and adhered to a tipless cantilever beam using a micromanipulator setup to study their adhesion strength with a molecular force probe (MFP). Adhesion forces were measured on the substrates in wet and dry conditions to evaluate the effects of interfacial fluid layers and capillary bridges on net adhesion strength. The adhesion between salt particles and the pPFDA coatings decreased by 5.1 ± 1.15 nN in wet states, indicating the influence of capillary bridging between the particle and the liquid layer. In addition, scale nucleation and growth on various surfaces is examined using a quartz crystal microbalance (QCM), where supersaturated solution of CaSO4·2H2O is passed over bare and polymer-coated quartz substrates while mass gain is measured in real time. The salt accretion decreased by 2 folds on pPFDA-coated substrates when compared to that on p(HEMA- co-EGDA) coatings. Both MFP and QCM studies are essential in studying the impact of surface energy and roughness on the extent of scale formation and adhesion strength. This study can pave way for the design of scale-resistant surfaces with potential applications in water treatment, energy harvesting, and purification industries.

8.
Sci Adv ; 4(9): eaat5780, 2018 09.
Article in English | MEDLINE | ID: mdl-30225366

ABSTRACT

Air-stable, lightweight, and electrically conductive polymers are highly desired as the electrodes for next-generation electronic devices. However, the low electrical conductivity and low carrier mobility of polymers are the key bottlenecks that limit their adoption. We demonstrate that the key to addressing these limitations is to molecularly engineer the crystallization and morphology of polymers. We use oxidative chemical vapor deposition (oCVD) and hydrobromic acid treatment as an effective tool to achieve such engineering for conducting polymer poly(3,4-ethylenedioxythiophene) (PEDOT). We demonstrate PEDOT thin films with a record-high electrical conductivity of 6259 S/cm and a remarkably high carrier mobility of 18.45 cm2 V-1 s-1 by inducing a crystallite-configuration transition using oCVD. Subsequent theoretical modeling reveals a metallic nature and an effective reduction of the carrier transport energy barrier between crystallized domains in these thin films. To validate this metallic nature, we successfully fabricate PEDOT-Si Schottky diode arrays operating at 13.56 MHz for radio frequency identification (RFID) readers, demonstrating wafer-scale fabrication compatible with conventional complementary metal-oxide semiconductor (CMOS) technology. The oCVD PEDOT thin films with ultrahigh electrical conductivity and high carrier mobility show great promise for novel high-speed organic electronics with low energy consumption and better charge carrier transport.

9.
Langmuir ; 34(23): 6687-6696, 2018 06 12.
Article in English | MEDLINE | ID: mdl-29762037

ABSTRACT

Initiated chemical vapor deposition (iCVD) allows for the formation of highly cross-linked, polymer thin films on a variety of substrates. Here, we study the impact of substrate stage temperature and filament temperature on the deposition and cross-linking characteristics of iCVD from divinyl benzene. Maintaining a constant monomer surface concentration reveals that deposition rates upward of 15 nm/min can be achieved at substrate stage temperatures of 50 °C. The degree of cross-linking is limited by the rate of initiation of the pendant vinyl bonds. At a filament temperature of 200 °C, the pendant vinyl bond conversion is highly sensitive to the surface concentration of initiator radicals. A significant decrease of the pendant vinyl bond conversion is observed with increasing stage temperatures. At higher filament temperatures, the pendant vinyl bond conversion appears to plateau at approximately 50%. However, faster deposition rates yield lower conversion. This trade-off is mitigated by increasing the filament temperature to increase initiator radical production. A higher flux of initiator radicals toward the surface at a constant deposition rate increases the rate of initiation of pendant vinyl bonds and therefore their overall conversion. At a deposition rate of ∼7 nm/min, an increase in the filament temperature from 200 to 240 °C results in an 18% increase in the pendant vinyl bond conversion.

10.
Sci Adv ; 4(3): eaar3031, 2018 03.
Article in English | MEDLINE | ID: mdl-29670943

ABSTRACT

Traditional polymers are both electrically and thermally insulating. The development of electrically conductive polymers has led to novel applications such as flexible displays, solar cells, and wearable biosensors. As in the case of electrically conductive polymers, the development of polymers with high thermal conductivity would open up a range of applications in next-generation electronic, optoelectronic, and energy devices. Current research has so far been limited to engineering polymers either by strong intramolecular interactions, which enable efficient phonon transport along the polymer chains, or by strong intermolecular interactions, which enable efficient phonon transport between the polymer chains. However, it has not been possible until now to engineer both interactions simultaneously. We report the first realization of high thermal conductivity in the thin film of a conjugated polymer, poly(3-hexylthiophene), via bottom-up oxidative chemical vapor deposition (oCVD), taking advantage of both strong C=C covalent bonding along the extended polymer chain and strong π-π stacking noncovalent interactions between chains. We confirm the presence of both types of interactions by systematic structural characterization, achieving a near-room temperature thermal conductivity of 2.2 W/m·K, which is 10 times higher than that of conventional polymers. With the solvent-free oCVD technique, it is now possible to grow polymer films conformally on a variety of substrates as lightweight, flexible heat conductors that are also electrically insulating and resistant to corrosion.

11.
Langmuir ; 34(15): 4494-4502, 2018 04 17.
Article in English | MEDLINE | ID: mdl-29561155

ABSTRACT

Directed self-assembly (DSA) of block copolymer (BCP) thin films is a promising approach to enable next-generation patterning at increasingly smaller length scales. DSA utilizes interfacial wetting layers to force the BCP domains to self-assemble with the desired orientation with respect to the substrate. Here, we demonstrate that initiated chemical-vapor-deposited (iCVD) polydivinylbenzene (pDVB) ultrathin films can direct the self-assembly of poly(styrene- block-methylmethacrylate). We found that the methyl radicals formed at increased filament temperatures during the iCVD process result in the backbone methylation of pDVB. By tuning the degree of backbone methylation, we systematically changed the wetting properties of the iCVD pDVB from a slight poly(methylmethacrylate) preference to complete poly(styrene) preference. Additionally, we utilize the conformal nature of the iCVD to form a wetting layer over a topographical line and space pattern, which is subsequently used to produce self-assembled BCP films with both perpendicular orientation and long-range alignment.

12.
Soft Matter ; 14(18): 3443-3454, 2018 May 09.
Article in English | MEDLINE | ID: mdl-29547674

ABSTRACT

Ice formation and accumulation on surfaces can result in severe problems for solar photovoltaic installations, offshore oil platforms, wind turbines and aircrafts. In addition, blockage of pipelines by formation and accumulation of clathrate hydrates of natural gases has safety and economical concerns in oil and gas operations, particularly at high pressures and low temperatures such as those found in subsea or arctic environments. Practical adoption of icephobic/hydrate-phobic surfaces requires mechanical robustness and stability under harsh environments. Here, we develop durable and mechanically robust bilayer poly-divinylbenzene (pDVB)/poly-perfluorodecylacrylate (pPFDA) coatings using initiated chemical vapor deposition (iCVD) to reduce the adhesion strength of ice/hydrates to underlying substrates (silicon and steel). Utilizing a highly-cross-linked polymer (pDVB) underneath a very thin veneer of fluorine-rich polymer (pPFDA) we have designed inherently rough bilayer polymer films that can be deposited on rough steel substrates resulting in surfaces which exhibit a receding water contact angle (WCA) higher than 150° and WCA hysteresis as low as 4°. Optical profilometer measurements were performed on the films and root mean square (RMS) roughness values of Rq = 178.0 ± 17.5 nm and Rq = 312.7 ± 23.5 nm were obtained on silicon and steel substrates, respectively. When steel surfaces are coated with these smooth hard iCVD bilayer polymer films, the strength of ice adhesion is reduced from 1010 ± 95 kPa to 180 ± 85 kPa. The adhesion strength of the cyclopentane (CyC5) hydrate is also reduced from 220 ± 45 kPa on rough steel substrates to 34 ± 12 kPa on the polymer-coated steel substrates. The durability of these bilayer polymer coated icephobic and hydrate-phobic substrates is confirmed by sand erosion tests and examination of multiple ice/hydrate adhesion/de-adhesion cycles.

13.
ACS Appl Mater Interfaces ; 9(49): 43287-43299, 2017 Dec 13.
Article in English | MEDLINE | ID: mdl-29131948

ABSTRACT

Scalable manufacturing of structured materials with engineered nanoporosity is critical for applications in energy storage devices (i.e., batteries and supercapacitors) and in the wettability control of surfaces (i.e., superhydrophobic and superomniphobic surfaces). Patterns formed in arrays of vertically aligned carbon nanotubes (VA-CNTs) have been extensively studied for these applications. However, the as-deposited features are often undesirably altered upon liquid infiltration and evaporation because of capillarity-driven aggregation of low density CNT forests. Here, it is shown that an ultrathin, conformal, and low-surface-energy layer of poly perfluorodecyl acrylate, poly(1H,1H,2H,2H-perfluorodecyl acrylate) (pPFDA), makes the VA-CNTs robust against surface-tension-driven aggregation and densification. This single vapor-deposition step allows the fidelity of the as-deposited VA-CNT patterns to be retained during wet processing, such as inking, and subsequent drying. It is demonstrated how to establish omniphobicity or liquid infiltration by controlling the surface morphology. Retaining a crust of entangled CNTs and pPFDA aggregates on top of the patterned VA-CNTs produces micropillars with re-entrant features that prevent the infiltration of low-surface-tension liquids and thus gives rise to stable omniphobicity. Plasma treatments before and after polymer deposition remove the crust of entangled CNTs and pPFDA aggregates and attach hydroxyl groups to the CNT tips, enabling liquid infiltration yet preventing densification of the highly porous CNTs. The latter observation demonstrates the protective character of the pPFDA coating with the potential application of these surfaces for direct contact printing of microelectronic features.

14.
Langmuir ; 33(40): 10623-10631, 2017 10 10.
Article in English | MEDLINE | ID: mdl-28933863

ABSTRACT

Fouling has been a persistent issue within applications ranging from membrane separation to biomedical implantation. Research to date focuses on fouling-resistant coatings, where electrical conductivity is unnecessary. In this study, we report the synthesis of multifunctional thin films with both fouling resistance and electrical conductivity for their potential applications in the electrolysis-based self-cleaning of separation membranes and in the field of bioelectronics. This unique combination of properties results in multifunctional coatings that are a zwitterionic derivative of intrinsically conductive polymer poly(3,4-ethylenedioxythiophene) (PEDOT) synthesized via oxidative chemical vapor deposition (oCVD). Their fouling resistance is shown to be comparable to that of known dielectric fouling-resistant surfaces, such as a poly(4-vinylpyridine)-co-divinylbenzene (p4VP-DVB)-derived zwitterionic coating, an amphiphilic poly(1H,1H,2H,2H-perfluorodecyl acrylate-co-2-hydroxyethyl methacrylate) (pPFDA-HEMA) coating, and a glass surface, and are far superior to the fouling resistance of gold or polydimethylsiloxane (PDMS) surfaces. The fouling resistances of seven surfaces are quantitatively characterized by molecular force probe (MFP) analysis. In addition, four-point probe electrical measurements, Fourier transform infrared spectroscopy (FTIR), X-ray photoelectron spectroscopy (XPS), variable-angle spectroscopic ellipsometry (VASE), profilometry, water contact angle (WCA) measurements, surface ζ-potential measurements, and atomic force microscopy (AFM) were employed to characterize the physiochemical properties and morphology of the different surfaces.

15.
Beilstein J Nanotechnol ; 8: 723-735, 2017.
Article in English | MEDLINE | ID: mdl-28487816

ABSTRACT

Vapor phase syntheses, including parylene chemical vapor deposition (CVD) and initiated CVD, enable the deposition of conformal polymer thin films to benefit a diverse array of applications. This short review for nanotechnologists, including those new to vapor deposition methods, covers the basic theory in designing a conformal polymer film vapor deposition, sample preparation and imaging techniques to assess film conformality, and several applications that have benefited from vapor deposited, conformal polymer thin films.

16.
Nanotechnology ; 28(24): 24LT01, 2017 Jun 16.
Article in English | MEDLINE | ID: mdl-28485304

ABSTRACT

Here, we report the fabrication of aligned carbon nanotube (A-CNT)/conducting polymer (CP) heterostructures with both uniform conformal and periodic beaded polymer morphologies via oxidative chemical vapor deposition of poly(ethylenedioxythiophene). Periodic beaded CP morphologies are realized utilizing the Plateau-Rayleigh instability to transform the original uniform conformal film, yielding a beaded CP morphology with a >50% enhancement in specific surface area (SSA). Modeling indicates that this SSA increase originates from the internal volume of the A-CNTs becoming available for adsorption, and that these internal A-CNT surfaces, if they could be made accessible to electrolyte ions, could lead to >30% enhancement of specific gravimetric and volumetric capacitances of current state-of-the-art A-CNT/CP heterostructures.

17.
Adv Mater ; 29(19)2017 May.
Article in English | MEDLINE | ID: mdl-28295681

ABSTRACT

A novel approach to fabricate supercapacitors (SCs) via vapor printing, specifically oxidative chemical vapor deposition (oCVD), is demonstrated. Compared to stacking multiple layers into a SC, this method enables the monolithic integration of all components into a single-sheet substrate, minimizing the inactive materials and eliminating the possibility of multilayer delamination. Electrodes comprised of pseudocapacitive material, poly(3,4-ethylenedioxythiophene) (PEDOT), are deposited into both sides of a sheet of flexible porous substrate. The film deposition and patterning are achieved in a single step. The oCVD PEDOT penetrates partially into the porous substrate from both surfaces, while leaving the interior of the substrate serving as a separator. Near the surface, the PEDOT coating conforms to the substrate's structure without blocking the pores, resembling the substrate's intrinsic morphology with high surface area. The porously structured PEDOT coating, paired with in situ ion gel electrolyte synthesis, gives enhanced electrode-electrolyte interfaces. The monolithic device demonstrates high volumetric capacitance (11.3 F cm-3 ), energy density (2.98 mWh cm-3 ), and power density (0.42 W cm-3 ). These outstanding performance metrics are attributed to the large loading of active materials, minimization of inactive materials, and good electrode-electrolyte interfaces. SC arrays can be printed on a single substrate without the use of wire interconnects.

18.
Nat Nanotechnol ; 12(6): 575-581, 2017 07.
Article in English | MEDLINE | ID: mdl-28346456

ABSTRACT

Directed self-assembly (DSA) of the domain structure in block copolymer (BCP) thin films is a promising approach for sub-10-nm surface patterning. DSA requires the control of interfacial properties on both interfaces of a BCP film to induce the formation of domains that traverse the entire film with a perpendicular orientation. Here we show a methodology to control the interfacial properties of BCP films that uses a polymer topcoat deposited by initiated chemical vapour deposition (iCVD). The iCVD topcoat forms a crosslinked network that grafts to and immobilizes BCP chains to create an interface that is equally attractive to both blocks of the underlying copolymer. The topcoat, in conjunction with a chemically patterned substrate, directs the assembly of the grating structures in BCP films with a half-pitch dimension of 9.3 nm. As the iCVD topcoat can be as thin as 7 nm, it is amenable to pattern transfer without removal. The ease of vapour-phase deposition, applicability to high-resolution BCP systems and integration with pattern-transfer schemes are attractive properties of iCVD topcoats for industrial applications.

19.
Adv Mater ; 29(11)2017 Mar.
Article in English | MEDLINE | ID: mdl-28032923

ABSTRACT

Chemical vapor deposition (CVD) polymerization directly synthesizes organic thin films on a substrate from vapor phase reactants. Dielectric, semiconducting, electrically conducting, and ionically conducting CVD polymers have all been readily integrated into devices. The absence of solvent in the CVD process enables the growth of high-purity layers and avoids the potential of dewetting phenomena, which lead to pinhole defects. By limiting contaminants and defects, ultrathin (<10 nm) CVD polymeric device layers have been fabricated in multiple laboratories. The CVD method is particularly suitable for synthesizing insoluble conductive polymers, layers with high densities of organic functional groups, and robust crosslinked networks. Additionally, CVD polymers are prized for the ability to conformally cover rough surfaces, like those of paper and textile substrates, as well as the complex geometries of micro- and nanostructured devices. By employing low processing temperatures, CVD polymerization avoids damaging substrates and underlying device layers. This report discusses the mechanisms of the major CVD polymerization techniques and the recent progress of their applications in devices and device fabrication, with emphasis on initiated CVD (iCVD) and oxidative CVD (oCVD) polymerization.

20.
Sci Adv ; 2(12): e1601660, 2016 Dec.
Article in English | MEDLINE | ID: mdl-27957542

ABSTRACT

Since its invention in ancient times, relief printing, commonly called flexography, has been used to mass-produce artifacts ranging from decorative graphics to printed media. Now, higher-resolution flexography is essential to manufacturing low-cost, large-area printed electronics. However, because of contact-mediated liquid instabilities and spreading, the resolution of flexographic printing using elastomeric stamps is limited to tens of micrometers. We introduce engineered nanoporous microstructures, comprising polymer-coated aligned carbon nanotubes (CNTs), as a next-generation stamp material. We design and engineer the highly porous microstructures to be wetted by colloidal inks and to transfer a thin layer to a target substrate upon brief contact. We demonstrate printing of diverse micrometer-scale patterns of a variety of functional nanoparticle inks, including Ag, ZnO, WO3, and CdSe/ZnS, onto both rigid and compliant substrates. The printed patterns have highly uniform nanoscale thickness (5 to 50 nm) and match the stamp features with high fidelity (edge roughness, ~0.2 µm). We derive conditions for uniform printing based on nanoscale contact mechanics, characterize printed Ag lines and transparent conductors, and achieve continuous printing at a speed of 0.2 m/s. The latter represents a combination of resolution and throughput that far surpasses industrial printing technologies.

SELECTION OF CITATIONS
SEARCH DETAIL
...