Nanosheet Particles with Defect‐Free Block Copolymer Structures Driven by Emulsions Containing Crystallizable Surfactants

Abstract Highly anisotropic‐shaped particles with well‐ordered internal nanostructures have received significant attention due to their unique shape‐dependent photonic, rheological, and electronic properties and packing structures. In this work, nanosheet particles with cylindrical block copolymer (BCP) arrays are achieved by utilizing collapsed emulsions as a scaffold for BCP self‐assembly. Highly elongated structures with large surface areas are formed by employing crystallizable surfactants that significantly reduce the interfacial tension of BCP emulsions. Subsequently, the stabilized elongated emulsion structures lead to the formation of BCP nanosheets. Specifically, when polystyrene‐block‐polydimethylsiloxane (PS‐b‐PDMS) and 1‐octadecanol (C18‐OH) are co‐assembled within an emulsion, C18‐OH penetrates the surfactant layer at the emulsion interface, lowering the interfacial tension (i.e., below 1 mN m⁻¹) and causing emulsion deformation. In addition, C18‐OH crystallization allows for kinetic arrest of the collapsed emulsion shape during solvent evaporation. Consequently, PS‐b‐PDMS BCPs self‐assemble into defect‐free structures within nanosheet particles, exhibiting an exceptionally high aspect ratio of over 50. The particle formation mechanism is further investigated by controlling the alkyl chain length of the fatty alcohol. Finally, the coating behavior of nanosheet particles is investigated, revealing that the deposition pattern on a substrate is strongly influenced by the particle's shape anisotropy, thus highlighting their potential for advanced coating applications.