Fabrication and scaling of disordered hyperuniform (dHU) materials remain hampered by the difficulties in controlling the spontaneous phenomena leading to this novel kind of exotic arrangement of objects. In this work, we demonstrate a hybrid top-down/bottom-up approach based on sol-gel dip-coating and nano-imprint lithography for the faithful reproduction of dHU metasurfaces in metal oxides (MOx). Nano- to micro-structures made of silica and titania can be directly printed over several cm2 on glass and on silicon substrates. Firstly, we describe the polymer mold fabrication starting from a hard master obtained via spontaneous solid-state dewetting. Then we address the effective dHU character of the master and of the replica and the role of the initial thickness of the sol-gel layer on the MOx replicas. Finally, these structures will be optimized towards their exploitation in many potential photonic applications like photonic devices (anti-reflection coatings, quantum emitters).
This article demonstrates that the combination of all-dielectric metal oxides sol-gel sensitive materials and metasurfaces, prepared by simple sol-gel methods (dip-coating and soft-Nano Imprint Lithography), can lead to nanocomposite systems with high sensitivity for RI variation and VOC concentration in air detection in spectral shift mode: 4500 nm / RIU ; 0.2 nm / ppm, and in direct reflectance mode: FOM* = 17 ; 0.55 10-3 R / ppm. The metasurface is composed of TiO2 high aspect ratio nano pillars array, replicated from a commercial anti-reflective polymer surface, while the sensitive materials embedding the latter are class II hybrid silica microporous materials containing various types of covalently bonded organic functions. These hybrid layers showed relative significant differences in chemical affinity with different VOCs, which can be exploited to eliminate interferences with air moisture and for qualitative analysis of gas mixtures. We also demonstrated that the presence of the TiO2 metasurface is responsible for the signal intensity increase by almost an order of magnitude in simple reflection mode. This improvement compared to simple Fabry-Perot bi-layer is due to the antenna effect, enhancing the interaction of the confined electromagnetic wave with the sensitive medium. This sol-gel nanocomposite system presents many advantages such as high throughput and low-cost elaboration of the elements, high chemical mechanical and thermal stability ensuring a high stability for detection for long period of time.
In this work, mechanically, chemically, and thermally resistant broadband and broad-angle antireflection coatings were prepared on 10 cm diameter glass substrates combining sol−gel deposition with nanoimprint lithography. The coatings are composed of water-repellent methylated silica (Si4O7Me2) and exhibit a transverse refractive index gradient created by tapered, nipple-dimple, subwavelength nanostructures, featuring a record vertical aspect ratio of ∼1.7. The structure is composed of hexagonal arrays of nanopillars (∼200 nm height, ∼120 nm width) and holes (∼50 nm depth, ∼100 nm width) with a 270 nm pitch. The corresponding effective refractive index is between 1.2 and 1.26, depending on the fabrication conditions. Total transmission for double-face nanoimprint wafers reaches 96−97% in the visible range; it is limited by specular reflection and mostly by the intrinsic diffusion of the glass substrate. The antireflective effect is effective up to an ∼60° incidence angle. We address the robustness of the inorganic-based coating in various realistic and extreme conditions, comparing them to the organic perfluoropolyether (PFPE) counterpart (master reference). The sol−gel system is extremely stable at high temperature (up to 600 °C, against 200 °C for the polymer reference). Both systems showed excellent chemical stability, except in strong alkaline conditions. The inorganic nanostructure showed an abrasion resistance of more than 2 orders of magnitude superior to the polymer one with less than 20% loss of antireflective performance after 2000 rubbing cycles under an ∼2 N cm−2 pressure. This difference springs from the large elastic modulus of the sol−gel material combined with an excellent adhesion to the substrate and to the specific nipple-dimple conformation. The presence of holes allows maintaining a refractive index gradient profile even after tearing out part of the nanopillar population. Our results are relevant to applications where transparent windows with broadband and broad-angle transmission are needed, such as protective glasses on photovoltaic cells or C-MOS cameras.
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