Two‐dimensional non‐close‐packed arrays of nanoparticles via core‐shell nanospheres and reactive ion etching

Nanosized PTFE/polystyrene core‐shell particles were prepared by seed emulsion polymerization technique starting from PTFE seeds of 20 nm. At the end of the reaction, no residual PTFE nor secondary nucleation was observed and by appropriately choosing the ratio between the monomer and the PTFE seed it was possible to obtain particles, with predetermined size in the range 60–100 nm, featuring an extremely narrow size distribution. These particles were successfully employed as building blocks for the preparation of large scale nanosized monolayers through the floating technique. Reactive ion etching was further applied to modulate the size characteristics of the resulting 2D ordered nanostructure. Although for relatively short RIE times a peculiar continuous morphology was observed in which the particles are interconnected through thin arms, on further increasing the RIE time a well‐organized 2D arrangement of particles with size of about 30 nm was obtained. Considering the shell as an expendable ordering and spacing tool, the use of core‐shell nanospheres allows a wide variety of controlled morphologies to be designed and prepared thus opening new perspectives for nanostructure fabrication processes through nanosphere lithography (NSL). Copyright © 2011 John Wiley & Sons, Ltd.