Cubosomes and hexosomes are recent solution morphologies with an ordered porous structure and are observed for lipids and amphiphilic block copolymers (BCPs) with high hydrophobic fractions. Whereas lipid hexosomes typically exhibit a prismatic shape, BCP hexosomes have so far only been observed as closed microspheres where inner channels are not connected to the surrounding medium. Here, we describe the formation of flat, prismatic BCP hexosomes with pronounced faceting and a highly ordered lattice of hexagonally packed channels. We assemble polystyrene-block-poly(4-vinylpyridine) (PS-b-P4VP or SV) into the hexosome framework using polystyrene-block-poly(4-vinylpyridine)-block-poly(tert-butyl methacrylate) (PS-b-P4VP-b-PT or SVT) as a macromolecular surfactant in low-χ solvents. During solvent exchange, SV-rich domains form through liquid-liquid phase separation, followed by solidification and confined assembly within these domains. Since the final solvent (acetone) has a very low χ parameter toward PS and P4VP (equaling low interfacial tension), solidification of the hexosome occurs under confinement conditions that we term "supersoft". The low interfacial tension allows the stabilization of the hexagonal-prismatic shape, which originates from the hexagonal lattice of channels. Increasing the interfacial tension with polar cosolvents at some point dominates the particle shape, resulting in deformation of prismatic BCP hexosomes into spinning-top structures. The use of low-χ solvents for confined assembly of BCPs may allow the formation of unusual particle shapes simply by tuning the polymer-solvent interaction.
Keywords: block copolymers; electron tomography; hexosomes; self-assembly; supersoft confinement.