Polymer Nanostructures by Forced Assembly: Process, Structure, and Properties

The process of micro- and nanolayer coextrusion of polymeric systems with good layer uniformity is described. Coextrusion through a series of layer multiplying die elements has enabled the production of films containing tens to thousands of layers with individual layer thicknesses from the micro- to the nanoscale. Improvements in layer uniformity are discussed through optimization of layer multiplier die design, selection of viscosity matched polymer systems, and incorporation of surface layer capabilities. Design of 'uneven' split layer multiplication dies has enabled the coextrusion of layered films with a wide variety of layer thickness distributions having up to a 10× difference in the individual film layer thicknesses. Coextrusion of layered polymer films with individual layer thicknesses down to the nanoscale has resulted in the production of novel systems with improved properties. Nanolayered polymer films were utilized to develop an all-plastic polymer laser, to fabricate gradient refractive index lenses, and to investigate gas barrier enhancement of crystalline polymer nanolayers confined to induce a high aspect ratio, in-plane, single-crystal-like lamellar structure.