Self-assembled nanoparticle monolayer formation via ultrasonic spray coating

Background

The self-assembly of nanoparticle monolayers is crucial in applications, such as optoelectronics, photovoltaics, and biomedical devices that require precise and reliable coatings. Traditionally, methods for forming monolayers rely on syringe dispensing needles or pipettes to introduce nanoparticle solutions to an air-water interface. These methods produce relatively large droplets (10-100 mm in diameter) that disrupt the water surface, causing a significant portion of the nanoparticles to disperse into the bulk water instead of forming a monolayer.
This inefficiency hampers the scalability and uniformity of the nanoparticle layers, as increasing the injection rate or volume inevitably leads to greater losses of the colloidal solution. The inability to form consistent, large-scale monolayers restricts the practical application and commercialization of nanoparticle technologies. Therefore, it is crucial to develop a method that can produce high-quality nanoparticle monolayers consistently and efficiently on a large scale, without significant loss of materials or disruption of the monolayer formation process.

Technology overview

This technology highlights an ultra-fast method of forming self-assembled nanoparticle monolayers via ultrasonic spray coating. The efficacy of this technology was demonstrated with SiO2-TiO2 nanoparticle by forming monolayers with the fastest self-assembly rate to date (268 cm2/min, 93 times faster than leading methods) when normalized to a single injection source. This exceptional speed is attributed to the highly efficient transfer of nanoparticles to the air–water interface.
Moreover, this method significantly reduces the amount of consumed NP solution per unit area of monolayer formed by 13.4-fold, achieving exceptional resource efficiency. This technology highlights the potential of ultrasonic spray coating as a fast, efficient, and scalable method for nanoparticle monolayer fabrication.
Figure 1: a) Schematic diagram of aerosolizing nozzle generating micron-scale dispensing droplets carrying submicron colloidal particles. b) Schematic diagram of monolayer self-assembly system. c) Process flow showing self-assembly of submicron colloidal particles self-assembling at an air–water interface as a function of injection time. (Left) Atomized droplets of aqueous alcohol dispensing droplets (orange) impinge on the water's surface (blue). The alcohol generates a surface tension gradient (orange) which propels submicron colloidal particles (white) radially away from the impact point. (Right) Over time, continuous injection causes submicron particles to accumulate into an annulus and self-assemble into an ordered monolayer.

Benefits

  • This technology achieves the fastest self-assembly rate of nanoparticle monolayers reported to date, with rates up to 268 cm2/min.
  • With extremely efficient transfer of nanoparticles to the air–water interface this method significantly reduces the amount of consumed nanoparticle solution, resulting in cost reductions in nanoparticle fabrication processes.
  • By offering precise control over droplet size and distribution, the ultrasonic spray coating method ensures the formation of uniform and high-quality nanoparticle monolayers.

Applications

  • Electronics manufacturing
  • Biomedical device manufacturing

Opportunity

  • This novel nanoparticle monolayer formation method overcomes key limitations of conventional fabrication methods, achieving exceptionally high rates and efficiency.
  • This method is compatible with a variety of nanoparticles, offering versatility in monolayer formation for various applications.
  • Available for exclusive license

Publication

“Massively Scalable Self-Assembly of Nano and Microparticle Monolayers via Aerosol Assisted Deposition” (https://doi.org/10.1002/adma.202309775)
Patent Information:
Direct Link:
https://canberra-ip.technologypublisher.com/tech/Self-assembled_nanoparticle_ monolayer_formation_via_ultrasonic_spray_coating
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For Information, Contact:
Andrei Zorilescu
Sr. Licensing Specialist
University of Texas at Austin
andrei.zorilescu@austin.utexas.edu