Open Access Article
Norihiro
Mizoshita
* and
Yuri
Yamada
Toyota Central R&D Labs., Inc., Nagakute, Aichi 480-1192, Japan. E-mail: nmizoshita@mosk.tytlabs.co.jp
First published on 13th March 2023
Sol–gel processes have been widely used for synthesizing functional inorganic and organic–inorganic hybrid materials. However, it has been challenging to apply mechanical nano-processing to sol–gel materials due to the rapid polycondensation and curing of concentrated precursors. In this study, a versatile polycondensation process for sol–gel precursors with intrinsic high reactivity has been developed by combining acid-catalyzed transesterification of metal alkoxides with addition of basic amine compounds. The reaction mixtures prepared using naphthalimide-derived alkoxysilanes result in long-term stable unhardened films after the removal of solvents, and their curing can be thermally restarted at the desired timing. Using this reaction method, nanoimprinted porous films have been obtained reproducibly from various organosilane precursors as well as some metal tetraalkoxides. The present approach would be applicable to a wide range of sol–gel reactions involving metal alkoxide species.
Tuning the reactivity of metal alkoxide species is the key to the sol–gel process. Alkoxysilane compounds with moderate reactivity easily afford stable sol solutions that are available for synthesizing various silica-based materials.13 On the other hand, it is challenging to control sol–gel reactions of highly reactive precursors, such as organosilanes exhibiting strong intermolecular interactions and low solubility due to large aromatic moieties and/or hydrogen-bonding groups,14–16 and metal alkoxides with center metals except for silicon.17–19 Their high reactivities lead to prompt hardening of the framework, which is problematic for the morphological control of products, including uniform thin film coatings, ordered porous materials and periodic surface nanostructures, unless semi-solid substances are generated from precursor mixtures.20,21 Reaction systems that are less reactive during film formation or surface molding and can shift to a highly reactive state at the desired timing are greatly attractive toward opening up new possibilities for traditional sol–gel materials.22–24
In the present study, we show that sol–gel reactions of highly reactive organosilane precursors can be stopped and restarted by acid-catalyzed transesterification of metal alkoxide groups and subsequent addition/removal of amine compounds (Fig. 1). Recently we developed naphthalimide-based aromatic organosilane precursors (1) and applied their sol–gel films to nanoimprinting.25,26 The nanoimprinted porous organosilica films were proven to function successfully as analytical substrates in laser desorption/ionization mass spectrometry.25,26 However, the nanoimprinting of the sol–gel films was successful only under limited conditions. For 1c, the reaction conditions of the sol solution had to be carefully adjusted according to the hydrolysis and condensation behavior of the precursor.25 For hydrogen-bonding 1a and 1b (1b forms a diol group after acid-catalyzed deprotection of the acetal group), nanoimprinting was unsuccessful under conventional acidic sol–gel conditions. In the conventional process where reactivity is controlled based on hydrolytic conditions, highly reactive Si–OH species are generated at a high concentration, which makes curing control difficult because the polycondensation of the concentrated Si–OH species proceeds quickly. In this study, we achieve stop and progress of the curing of organosilica films by tuning moisture-sensitivity of precursor/catalyst mixtures prior to hydrolysis. Here, triisopropoxysilyl groups are introduced into the organosilane precursors to prevent undesired polycondensation during the synthesis and purification of the precursors. We utilize transesterification of the alkoxysilyl groups to tune the reactivity of the reaction mixtures without forming concentrated Si–OH species. This makes it possible to prepare nanoimprinted films reproducibly from highly reactive precursors. The reaction mechanism is investigated and discussed, focusing on the study of 1. Moreover, we extend the present reaction method to other metal alkoxides and demonstrate nanoscale surface molding of ceramic films.
Transesterification of alkoxysilyl groups was used to suppress the reactivity of the precursors without forming the silanol-rich state. The transesterification approach is effective to tune the reactivity, solubility and crystallinity of the alkoxysilane compounds.27–30 In order to increase the fluidity of the films after spin-coating, transesterification of 1a and 1b (90 mg) was first carried out using 2-methoxyethanol having a flexible oxyethylene unit (2-ME, 1.0 mL; boiling point: 124 °C) and p-toluenesulfonic acid monohydrate (TsOH·H2O, 2 mg, 0.01 mmol) as an acid catalyst. The transesterification reaction using excess 2-ME at 130 °C for 15–60 min gave stable precursor solutions, which formed no precipitates for more than 24 h at room temperature. However, when spin-coated films were formed using the transesterified precursor solutions (denoted as TE method), unexpectedly, the films (1a-TE, 1b-TE) were cured rapidly and no fluid state was induced. TsOH likely functioned as a strong acid catalyst in the spin-coated films and promoted the polycondensation of the precursors under the influence of trace amounts of water contained in the catalyst, solvents and air.
We discovered that temporary stop and heat-driven restart of the sol–gel polycondensation reactions could be achieved by adding basic amine compounds to the transesterified reaction mixtures (Fig. 1a, denoted as TE/A method). Triethylamine (10 μL, 0.07 mmol) was added to the reaction mixtures (1.0 mL) to suppress the acidity of TsOH. Moisture from the reagents or the atmosphere was sufficient to cause curing of the films, so no additional water was required. Fig. 1b shows photographs of the spin-coated films prepared using 1a. The spin-coating of the reaction mixture containing transesterified 1a, TsOH and triethylamine resulted in an unhardened fluid film (Fig. 1b, C). The film was easily removed by rubbing with a cotton wool applicator, even 30 min after the preparation (Fig. 1b, D). The fluid state was maintained for more than 20 h at room temperature (humidity: 50–60%). Interestingly, after heating the film at 80–100 °C for 1–3 min, the film (1a-TE/A) hardened rapidly and became resistant to the surface rubbing (Fig. 1b, E). Thus, the TE/A method realizes the formation of long-term stable fluid films from highly reactive sol–gel precursors and the rapid curing of the films at the desired timing. Since the polycondensation in the TE/A method is affected by atmospheric moisture, the fluid state could be maintained for 2–3 days in low humidity (ca. 30%) environments. Storage of the precursor films under reduced pressure further suppressed the generation of silanol species, thus retaining the fluid state.
The stop and restart behavior of the sol–gel reaction was applied to the nanoimprinting of 1a-TE/A and 1b-TE/A films (Fig. 1c). As mentioned above, nanoimprinting of the 1a-SG and 1b-SG films was unsuccessful. When the polymer mold with a nanopillar array (height: 250 nm) was pressed into the 1a-SG and 1b-SG films just after spin-coating, only distorted and shallow hollows (depth: 15–20 nm) were formed on the surface due to their rapid curing (Fig. 1c). In contrast, the use of the TE/A method enabled the nanoimprinting of the organosilica films. Vertically oriented nanopore arrays with different structural periodicities (pitch: 460 nm or 250 nm) and a line-and-space pattern (pitch: 140 nm) were clearly formed on the 1a-TE/A and 1b-TE/A films by the structural transfer from the polymer molds (Fig. 1c). The depth of the nanopatterns (holes: 170–200 nm; line-and-space: 110 nm) was 75–85% of the height of the surface patterns of the molds, whereas the in-plane shrinkage was relatively suppressed probably due to constraints by the substrate. This volume shrinkage was due to the elimination of 2-ME from the transesterified precursors and the subsequent dehydration condensation.
The introduction of bulky and flexible –Si(OCH2CH2OCH3)3 (–Si(ME)3) groups surrounding the large organic moiety by transesterification of 1 with 2-ME leads to the great enhancement of solubility and hydrolytic reactivity of the precursors. The spectral analysis in solutions was performed mainly for 1c having a simple alkyl substituent. 29Si NMR measurements indicate that monomeric species (T0) with –Si(ME)3 and –Si(ME)2(OiPr) groups are present as the main components in the precursor solution, with a small amount (∼35%) of T1 species mixed in (Fig. 2b, A → B and Scheme 1, A → B). If the precursor is concentrated without adding amine compounds, TsOH acts as a strong acid catalyst, and hydrolysis and polycondensation proceed (Scheme 1, C). Fig. 2c shows that 1c-TE forms a well-crosslinked framework and its degree of condensation is 67%. When triethylamine in excess to TsOH is added to the sol mixtures, the formation of the salt (HN+Et3·TsO−) suppresses the high catalytic activity of TsOH (Scheme 1, D). It has also been confirmed that polycondensation of 1 is not promoted in the presence of triethylamine under the present spin-coating conditions. There are almost no M–OH species in the reaction mixtures prepared by the TE/A method; therefore, the polycondensation reaction does not proceed easily after the evaporation of the solvents. When the reaction mixture was exposed to the atmosphere for 3 h after the evaporation of solvent, the T0-rich unhardened state was maintained, although a slight increase in chemical species containing Si–OH groups was observed probably due to the influence of moisture (Fig. 2b, C). The amount of water is insufficient to hydrolyze all –Si(ME)3 groups, which may lead to the formation of the T1-rich framework after curing. While transesterification of alkoxysilane compounds results not in a single precursor component but in precursor mixtures, their sol–gel polycondensation affords homogeneous films probably due to the formation of a T1-rich organosilica framework.
The heat-driven polycondensation in the TE/A method was confirmed to be catalyzed by the salt HN+Et3·TsO− (Scheme 1, D → E). When the spin-coated fluid films are heated, excessive triethylamine evaporates and the salt remains. We have checked that the salt HN+Et3·TsO− does not decompose upon heating at 100 °C for 2 h (Fig. S13, ESI†). It has also been confirmed that this salt exhibits moderate acidity (pH = 3–4) in a 5 wt% aqueous solution (Table S1, ESI†). In other words, the acidic salt acts as a catalyst to restart the polycondensation reaction of the transesterified precursors. The introduction of –Si(ME)3 groups into the precursors probably increased the compatibility with the salt. The catalytic activity of the salt for –Si(ME)3 species was verified by observing the polycondensation behavior of Me–Si(ME)3 in the presence of the salt and/or triethylamine (Table S2, ESI†). It is reasonable that the degree of condensation of 1-TE/A became lower than those obtained by the SG and TE methods including strong acid catalysts (HCl or TsOH). The degree of condensation can be increased to the same extent by post-treatments such as exposure to hydrochloric acid vapor after curing (Fig. S9, ESI†). Compared to the SG method using silanol-rich precursor mixtures, film formation by the TE/A method delays the timing of curing because the reaction proceeds with exposure to the ambient moisture. However, the degree of condensation of the product was strongly dependent on the catalytic species rather than the amount of water used or atmospheric exposure time. The steric effect of the bulky organosilane precursors may hinder the polycondensation reaction. As a reference sample, triethylamine was added to a sol solution prepared by the conventional SG method (denoted as SG/A method). The acid catalyst (HCl) was neutralized and the degree of condensation of the spin-coated film was decreased to 52% (Fig. 2d). However, no fluid film was obtained because the reaction mixture contained a high concentration of reactive Si–OH species and the curing reaction occurred immediately after the evaporation of solvents. These results indicate that the stop and restart of the sol–gel reaction are realized by adopting the appropriate procedures to control the subsequent steps as shown in Scheme 1. The effects of acid and base catalysts on reaction kinetics and microstructures of products have been investigated in conventional hydrolysis and polycondensation processes.31 In the present study, addition of acid/base mixed catalysts to organosilane precursors prior to hydrolysis led to the construction of a new processing method of sol–gel thin films.
Moreover, we used amines with different basicities (triethylamine (pKa: 10.7), imidazole (pKa: 7.0) and pyridine (pKa: 5.3)) in the TE/A method and the curing times of transesterified 1a were measured at room temperature to confirm the effect of basic compounds for suppressing the catalytic activity of the acids (Table S3, ESI†). The curing times were longer when stronger bases were used, which indicates that the presence of a strong base is necessary to stop the hardening of the films.
We further expected that the present approach could be effective for sol–gel reactions using other metal alkoxide precursors. The TE/A method was applied to the synthesis of nanoimprinted TiO2, ZrO2 and GeO2 films (TiO2-TE/A, ZrO2-TE/A and GeO2-TE/A) from Ti(OBu)4, Zr(OiPr)4 and Ge(OiPr)4, respectively. These metal tetraalkoxides are more reactive than tetraalkoxysilanes. When the SG method was applied to these metal tetraalkoxides, the sol mixtures resulted in precipitates of polycondensed materials immediately after the addition of hydrochloric acid. Up to now, mechanical surface nano-processing of inorganic sol–gel films had only been reported in limited cases, using metal complexes with bulky ligands and assistance by photoreactive organic components.32–34 In contrast, nanoimprinting of the ceramic films was successfully achieved by applying the TE/A method. Fig. 4a–d shows the AFM images of the nanoimprinted metal oxide films prepared using polymer molds with 460 nm-pitch nanopillar or nanohole patterns. Nanohole and nanopillar arrays were formed by the structural transfer from the polymer molds. It was possible to induce curing at the desired timing by heating and atmospheric exposure of the precursor thin films composed of the metal alkoxides and the mixed catalysts, which led to nanoimprinting with good reproducibility. The heights of the patterned nanostructures are ca. 55–75% of those of the surface structures of the molds due to volume shrinkage of the frameworks. After calcination at 550 °C, further volume shrinkage of the ceramic frameworks was observed, but the nanoscale periodic patterns were retained for all the films (Fig. 4e, f and Fig. S14, ESI†), accompanied by the crystallization of each framework (Fig. 4g).35–37
Footnote |
| † Electronic supplementary information (ESI) available: Experimental section, characterization of organosilica films, properties of catalysts and supplementary data on metal oxide films. See DOI: https://doi.org/10.1039/d3qm00070b |
| This journal is © the Partner Organisations 2023 |