Large-scale colloidal self-assembly by doctor blade coating.

This article reports a simple, roll-to-roll compatible coating technology for producing 3D highly ordered colloidal crystal-polymer nanocomposites, colloidal crystals, and macroporous polymer membranes. A vertically beveled doctor blade is utilized to shear align silica microsphere-monomer suspensions to form large-area nanocomposites in a single step. The polymer matrix and the silica microspheres can be selectively removed to create colloidal crystals and self-standing macroporous polymer membranes. The thickness of the shear-aligned crystal is correlated with the viscosity of the colloidal suspension, and the coating speed and the correlations can be qualitatively explained by adapting the mechanisms developed for conventional doctor blade coating. We further demonstrate that the doctor blade coating speed can be significantly increased by using a dual-blade setup. The optical properties of the self-assembled structures are evaluated by normal-incidence reflection measurements, and the experimental results agree well with the theoretical predictions using Bragg's law and a scalar wave approximation model. We have also demonstrated that the templated macroporous polymers with interconnected voids and uniform interconnecting nanopores can be directly used as filtration membranes to achieve size-exclusive separation of particles.