Non‐Lithography Hydrodynamic Printing of Micro/Nanostructures on Curved Surfaces

A key issue of micro/nano devices is how to integrate micro/nanostructures with specified chemical components onto various curved surfaces. Hydrodynamic printing of micro/nanostructures on three‐dimensional curved surfaces is achieved with a strategy that combines template‐induced hydrodynamic printing and self‐assembly of nanoparticles (NPs). Non‐lithography flexible wall‐shaped templates are replicated with microscale features by dicing a trench‐shaped silicon wafer. Arising from the capillary pumped function between the template and curved substrates, NPs in the colloidal suspension self‐assemble into close‐packed micro/nanostructures without a gravity effect. Theoretical analysis with the lattice Boltzmann model reveals the fundamental principles of the hydrodynamic assembly process. Spiral linear structures achieved by two kinds of fluorescent NPs show non‐interfering photoluminescence properties, while the waveguide and photoluminescence are confirmed in 3D curved space. The printed multiconstituent micro/nanostructures with single‐NP resolution may serve as a general platform for optoelectronics beyond flat surfaces.     

Generation of a library of particles having controlled sizes and shapes via the mechanical elongation of master templates

Herein we describe a versatile and readily scalable approach for the fabrication of particles with a variety of shapes and sizes from a single master template by augmenting the particle replication in nonwetting templates (PRINT) method with mechanical elongation. Repetition of the elongation steps in one direction leads to the fabrication of linear particles with high aspect ratio (AR), over 40 times greater than in the original master, while a range of particle shapes can be obtained by repeating the elongation procedure while changing the stretching direction, generating diamond, rectangular, curved parallelogram particles from a single cubic master.     

Non-Lithography Hydrodynamic Printing of Micro/Nanostructures on Curved Surfaces

A key issue of micro/nano devices is how to integrate micro/nanostructures with specified chemical components onto various curved surfaces. Hydrodynamic printing of micro/nanostructures on three-dimensional curved surfaces is achieved with a strategy that combines template-induced hydrodynamic printing and self-assembly of nanoparticles (NPs). Non-lithography flexible wall-shaped templates are replicated with microscale features by dicing a trench-shaped silicon wafer. Arising from the capillary pumped function between the template and curved substrates, NPs in the colloidal suspension self-assemble into close-packed micro/nanostructures without a gravity effect. Theoretical analysis with the lattice Boltzmann model reveals the fundamental principles of the hydrodynamic assembly process. Spiral linear structures achieved by two kinds of fluorescent NPs show non-interfering photoluminescence properties, while the waveguide and photoluminescence are confirmed in 3D curved space. The printed multiconstituent micro/nanostructures with single-NP resolution may serve as a general platform for optoelectronics beyond flat surfaces.     

Contact angles of drops on curved superhydrophobic surfaces

Superhydrophobic surfaces have contact angles that exceed 150 degrees and are known to reduce surface fouling, protect surfaces, and improve liquid-liquid separations. Electrospun sub-micron fiber mats can perform as superhydrophobic surfaces. Superhydrophobic behavior is typically measured on planar surfaces, whereas applications may require curved surfaces. This paper discuses the measurement of water contact angles of fiber mats formed on cylindrical surfaces to create superhydrophobic behavior on curved surfaces. Equations are derived that relate the radius of curvature of spherical and cylindrical surfaces and drop size to the observed contact angle on the curved surfaces. Calculations from the equations agree well with experimental observations on spherical surfaces reported in literature and on cylindrical surfaces created in our lab.     

Investigation of the role of template features on the electrically induced structure formation (EISF) for a faithful duplication

Electrically induced structure formation, as a physical approach to fabricate micro/nanostructures, has attracted much attention because of the simple process, low‐cost, high‐efficiency, and wide applications on electronics, microfluidics, and so forth. Hitherto, the influence of some process parameters, such as voltage, air gap, film thickness, polymer properties, on the polymeric behavior, and the structure formation has been explored, neglecting the effects of the template features, which affect the polymer deformation. Especially for the conductive protrusions directly contacting the polymer, the phenomenon of electric breakdown may occur, leading to a failure of structure formation. The limitation of the research on the template features triggers the necessity to study its influence for a faithful deformation. In this paper, three types of patterned template are studied based on the electric field at the air‐polymer interface, consisting of completely conductive template, partially conductive template, and dielectric template. Comprehensive consideration of the electric intensity for a sufficient driving pressure and the leaky current for preventing damaging the polymer, some guiding opinions on the template material and geometry can be provided to design the patterned template for the electrically induced structure formation process with a purpose for a faithful structure.     

Thermoplastic polyurethane/silica nanocomposite fibers by electrospinning

Thermoplastic polyurethane/silica nanocomposite fibers with good mechanical properties were prepared by electrospinning, using colloidal silica as the source of silica and dimethyl formamide as the solvent. The fiber morphology was examined by field emission scanning electron microscopy. The average fiber diameter is about 0.8 μm with 0–10 wt % silica, and silica nanoparticles were observed on all fiber surfaces. X‐ray photoelectron spectroscopy analysis of Si in combination with transmission electron microscopy observation suggest that silica nanoparticles have a fairly uniform distribution in the fibers rather than enriching on the fiber surfaces. Tensile tests show that the incorporation of silica nanoparticles can bring about a significant reinforcing effect without decreasing the ductility. The reinforcing effect is further confirmed by dynamic mechanical analysis. The thermoplastic polyurethane/silica composite fiber mats can adsorb gold nanoparticles after further treatment with 3‐aminopropyltriethoxysilane, demonstrating that the composite fibers could be used as functional fibers by using the properties of silica nanoparticles. © 2011 Wiley Periodicals, Inc. J Polym Sci Part B: Polym Phys, 2011     

Pressure/electric-field-assisted micro/nanocasting method for replicating a lotus leaf

An electric field-aided process was introduced for a curable casting process. As a micro/nanosized pattern mask, a lotus leaf, which has a hierarchical structure, was used. The process consists of two steps: (1) applying an electric field to a liquid polymer and solidifying the polymer for use as a negative mold, and (2) using the negative polymer mold to fabricate a replicated poly(ethylene oxide) (PEO) surface in the original shape of the lotus leaf. In this process, the applied electric field induces unstable vibration of the liquid polymer, due to electrokinetic phenomena. The electrokinetic fluid motion resulted in well-replicated PEO surfaces. The quality of the fabricated surface was highly dependent on the applied field and pressure. We believe that this technique improves the quality of the standard nanocasting method and will be useful for fabricating micro/nanosized structures.     

Simultaneously reinforce and toughen polypropylene by in‐situ introducing polylactic acid microfibrils

A petroleum‐based polymer, isotactic polypropylene (iPP), and a biodegradable polymer, poly(lactic acid) (PLA), were compounded and molded into parts through the micro‐injection technique. A systematic structural investigation indicated that the microfibrillation of PLA minor phase depended on the operation parameter of inter‐mixer, ie, rotor speed. The higher rotor speed, the lower viscosity ratio of the PLA/iPP pair was favorable for microfibrillation occurred during micro‐injection process. The PLA microfibrils with high aspect ratio was successfully introduced into iPP matrix, and the tensile strength and strain at break of iPP/PLA blends were simultaneously improved. This study suggests a promising method for designing special microfibrillar morphology in polymer blend by using conventional melt processing techniques.     

Peristome‐Mimetic Curved Surface for Spontaneous and Directional Separation of Micro Water‐in‐Oil Drops

Separation of micro‐scaled water‐in‐oil droplets is important in environmental protection, bioassays, and saving functional inks. So far, bulk oil–water separation has been achieved by membrane separation and sponge absorption, but micro‐drop separation still remains a challenge. Herein we report that instead of the “plug‐and‐go” separation model, tiny water‐in‐oil droplets can be separated into pure water and oil droplets through “go‐in‐opposite ways” on curved peristome‐mimetic surfaces, in milliseconds, without energy input. More importantly, this overflow controlled method can be applied to handle oil‐in‐oil droplets with surface tension differences as low as 14.7 mN m⁻¹ and viscous liquids with viscosities as high as hundreds centipoises, which markedly increases the range of applicable liquids for micro‐scaled separation. Furthermore, the curved peristome‐mimetic surface guides the separated drops in different directions with high efficiency.     

Modulated pattern formation of phospholipid monolayers on curved surfaces

Langmuir-Blodgett transfer of a dipalmitoylphosphatidylcholine monolayer onto macroscopically curved mica surfaces results in microscopic patterns of the transferred monolayer that differ from those of films transferred onto a flat mica substrate. On curved surfaces a modulated horizontal striped pattern evolves that has a zigzag boundary at the liquid condensed front of the stripe and a continuous straight boundary at the liquid condensed rear. We propose that the sensitivity of the pattern to the macroscopic curvature of the sample is due to a flow-controlled hydrodynamic instability caused by the subphase flow close to the three-phase contact line.     

Pattern replication in blends of semiconducting and insulating polymers casted by horizontal dipping

Pattern replication in solution‐deposited thin films of insulating and conjugated polymer mixtures might provide an alternative to spatially resolved printing techniques for the fabrication of polymer‐based circuitries. Though it has been previously shown that phase separation in the course of spin‐casting leads to the formation of domain structures resembling the chemical patterns pre‐set on the film substrate, finding optimal casting conditions is a tedious process, which requires multiple sample preparations. Here, we have demonstrated pattern replication in a mixture of poly(3,3′′′‐didodecyl quarter thiophene) (PQT‐12) and deuterated poly(styrene‐co?4‐bromostyrene) (dPBrS) deposited by horizontal‐dipping on substrates, patterned with self‐assembling molecules by micro‐contact printing. Moreover, we show that casting conditions for accomplishing pattern replication can be efficiently screened by preparing thickness gradient samples. We have optimized the reconstruction of the substrate pattern in the PQT‐12:dPBrS film. Our results prove that desired structures of semiconducting and insulating polymers can be produced in a simple, high‐throughput technological process. © 2013 Wiley Periodicals, Inc. J. Polym. Sci., Part B: Polym. Phys. 2013, 51, 1419–1426     

Effect of exposure dose on the replication fidelity and profile of very high aspect ratio microchannels in SU-8

We are interested in using SU-8 dense gratings with very high aspect ratio microchannels as the master mold for fabrication of child molds needed for replication. For such applications, the sidewall taper angle and mask replication fidelity of SU-8 are very important. Increasing the exposure time was experimentally observed to decrease the width of the microchannel and the sidewall angle of SU-8 bars. A new diffraction-refraction-reflection model was also developed. The calculated microchannel width and sidewall angle at high exposure dose agreed well with the experimentally observed values indicating that reflection at the silicon substrate was significant. The larger than calculated actual microchannel width for low exposure dose was shown to be due to leaching of unreacted SU-8 in the developer. Dense gratings of high aspect ratio SU-8 bars separated by high aspect ratio (19.1) microchannels were also demonstrated.     

Formation of artificial micro‐pits on Al alloy with the photon rupture method and the localized corrosion behavior of the formed pits

An in situ artificial micro‐pit fabrication method with an area selective electrochemical measurement technique was applied to investigate the effect of the geometry of artificially formed pits on their localized corrosion behavior in anodized 1000 series aluminum. This technique enables the fabrication of artificial micro‐pits with different aspect ratios (pit depth/pit diameter) in solutions. The aspect ratios of the fabricated artificial micro‐pits in this experiment could be varied from 0.13 to 1.83 by controlling the irradiation time of the focused pulsed YAG laser beam. By applying a constant potential to the final laser‐beam‐irradiated spot in chloride environments, localized dissolution occurred only at the laser beam irradiated area, because the anodic oxide film acted as an insulator. The corrosion current and charge increase with increasing aspect ratio at any applied potential. Copyright © 2010 John Wiley & Sons, Ltd.     

Continuous dielectrophoretic separation of particles in a spiral microchannel

Particle separation is a fundamental operation in the areas of biology and physical chemistry. A variety of force fields have been used to separate particles in microfluidic devices, among which electric field may be the most popular one due to its general applicability and adaptability. So far, however, electrophoresis‐based separations have been limited primarily to batchwise processes. Dielectrophoresis (DEP)‐based separations require in‐channel micro‐electrodes or micro‐insulators to produce electric field gradients. This article introduces a novel particle separation technique in DC electrokinetic flow through a planar double‐spiral microchannel. The continuous separation arises from the cross‐stream dielectrophoretic motion of particles induced by the non‐uniform electric field inherent to curved channels. Specifically, particles are focused by DEP to one sidewall of the first spiral, and then dielectrophoretically deflected toward the other sidewall of the second spiral at a particle‐dependent rate, leading to focused particle streams along different flow paths. This DEP‐based particle separation technique is demonstrated in an asymmetric double‐spiral microchannel by continuously separating a mixture of 5/10 μm particles and 3/5 μm particles.     

Curvature modulates the self-assembly of amphiphilic molecules

In this work, we used lattice Monte Carlo simulations and theoretical model calculations to show how the self-assembly of adsorbed amphiphilic molecules is affected by the local curvature of solid surfaces. It is found that, beyond a critical curvature value, solid surface geometry governs the spatial ordering of aggregates and may induce the morphological transitions. The simulation results show how the curvature of solid surfaces modulates the distribution of aggregates: the anisotropy in local curvature along and perpendicular to the cylindrical surfaces tends to generate orientationally ordered cylindrical micelles. To account for the morphological transitions induced by the local curvature of solid surfaces, we constructed a theoretical model which includes the Helfrich bending energy, the deformation energy of aggregates induced by solid surfaces, and the adsorption energy. The model calculations indicate that on highly curved solid surfaces the bending energy for bilayer structure sharply increases with surface curvature, which in turn induces the morphological transition from bilayer to cylindrical structure. Our results suggest that the local curvature provides a means of controlling the spatial organization of amphiphilic molecules.     

Wetting Phenomena and their Effect on the Electrochemical Performance of Surface‐Tailored Lithium Metal Electrodes in Contact with Cross‐linked Polymeric Electrolytes

Li metal batteries (LMBs) containing cross‐linked polymer electrolytes (PEs) are auspicious candidates for next‐generation batteries. However, the wetting behavior of PEs on uneven Li metal surfaces has been neglected in most studies. Herein, it is shown that microscale defect sites with curved edges play an important role in a wettability‐dependent electrodeposition. The wettability and the viscoelastic properties of PEs are correlated, and the impact of wettability on the nucleation and diffusion near the Li|PE interface is distinguished. It is found that the curvature of the edges is a key factor for the investigation of wetting phenomena. The appearance of microscale defects and phase separation are identified as main causes for erratic nucleation. It is emphasized that the implementation of stable and consistent long‐term cycling performance of LMBs using PEs requires a deeper understanding of the “soft‐solid”–solid contact between PEs and inherently rough Li metal surfaces.     

A perturbation analysis of rate theory of self-regulating genes and signaling networks

A thorough kinetic analysis of the rate theory for stochastic self-regulating gene networks is presented. The chemical master equation kinetic model in terms of a coupled birth-death process is deconstructed into several simpler kinetic modules. We formulate and improve upon the rate theory of self-regulating genes in terms of perturbation theory. We propose a simple five-state scheme as a faithful caricature that elucidates the full kinetics including the "resonance phenomenon" discovered by Walczak et al. [Proc. Natl. Acad. Sci. U.S.A. 102, 18926 (2005)]. The same analysis can be readily applied to other biochemical networks such as phosphorylation signaling with fluctuating kinase activity. Generalization of the present approach can be included in multiple time-scale numerical computations for large biochemical networks.     

Replication and surface properties of micro injection molded PLA/MWCNT nanocomposites

Multi-walled carbon nanotube (MWCNT) reinforced polylactide (PLA) nanocomposites were injected molded into a mold with micro needle patterns. In order to alleviate the hesitation effect caused by an increased melt viscositgy of PLA/CNT nanocomposites, the effects of the injection speed and holding pressure on the replication property were investigated. The effects of MWCNTs on the crystallization, thermal behavior, replication properties, replication and surface properties of micro injection molded PLA/CNT nanocomposites were investigated. An analysis of crystallinity and thermal behavior indicated that the MWCNTs promoted the unique α’ to α crystal transition of PLA, leading to an enhancement of surface modulus and hardness, as measured using a nanoindentation technique. The specific interaction between PLA and MWCNTs was characterized using an equilibrium melting point depression technique. Furthermore, the MWCNTs increased the activation energy for thermal degradation of PLA due to the physical barrier effect. The improved replication quality of the microfeatures in the PLA/MWCNT nanocomposites has been achieved by elevating injection speed and holding pressure, which enhances the polymer filling ability within the micro cavity. A replication ratio greater than 96% for the micro injection molded PLA/CNT nanocomposites were achieved at holding pressure of 100 MPa and injection speed of 120 mm/s. This study shows that processing conditions significantly influence the replication and surface properties of micro injection molded PLA/CNT nanocomposites.     

Modeling electrokinetics in ionic liquids

Using direct numerical simulations, we provide a thorough study regarding the electrokinetics of ionic liquids. In particular, modified Poisson–Nernst–Planck equations are solved to capture the crowding and overscreening effects characteristic of an ionic liquid. For modeling electrokinetic flows in an ionic liquid, the modified Poisson‐Nernst‐Planck equations are coupled with Navier–Stokes equations to study the coupling of ion transport, hydrodynamics, and electrostatic forces. Specifically, we consider the ion transport between two parallel charged surfaces, charging dynamics in a nanopore, capacitance of electric double‐layer capacitors, electroosmotic flow in a nanochannel, electroconvective instability on a plane ion‐selective surface, and electroconvective flow on a curved ion‐selective surface. We also discuss how crowding and overscreening and their interplay affect the electrokinetic behaviors of ionic liquids in these application problems.     

Electrochemical Deposition onto Self‐Assembled Monolayers: New Insights into Micro‐ and Nanofabrication

Pattern transfer with high resolution is a frontier topic in the emerging field of nanotechnologies. Electrochemical molding is a possible route for nanopatterning metal, alloys and oxide surfaces with high resolution in a simple and inexpensive way. This method involves electrodeposition onto a conducting master covered by a self‐assembled alkanethiolate monolayer (SAMs). This molecular film enables direct surface–relief pattern transfer from the conducting master to the inner face of the electrodeposit, and also allows an easy release of the electrodeposited film due their excellent anti‐adherent properties. Replicas of the original conductive master can be also obtained by a simple two‐step procedure. SAM quality and stability under electrodeposition conditions combined with the formation of smooth electrodeposits are crucial to obtain high‐quality pattern transfer with sub‐50 nm resolution.