Formation of a polymer particle monolayer by continuous self-assembly from a colloidal solution

Abstract: The preparation of two-dimensional monolayers of polymer particles over a large area was demonstrated via a facile solution process. Polymer microspheres were continuously self-assembled into a close-packed monolayer from a colloidal solution confined between two plates such that the top plate was carefully dragged at a constant velocity in the direction opposite that of the monolayer growth. In situ direct observation of the particle movement during the coating process confirmed that particle transport was directed toward the contact line of the solution meniscus by evaporation-induced convective flow. Sliding of the top plate apparently effectively counterbalanced the convective flow to provide the particles with a contact line for growth of a monolayer particle array. The influence of particle concentration, sliding speed of the top plate, and surface wettability of the bottom substrate were investigated and optimized. Monolayer particle arrays were successfully demonstrated as a template for the preparation of ZnO films with ordered hollow hemispherical structures. This approach is applicable to the fabrication of ordered structures of monodispersed particles composed of various materials over large areas. [Copyright &y& Elsevier]