Block copolymer (BCP) self-assembly has attracted considerable attention for many decades because it can yield ordered structures in a wide range of morphologies, including spheres, cylinders, bicontinuous structures, lamellae, vesicles, and many other complex or hierarchical assemblies. These aggregates provide potential or practical applications in many fields. The present tutorial review introduces the primary principles of BCP self-assembly in bulk and in solution, by describing experiments, theories, accessible morphologies and morphological transitions, factors affecting the morphology, thermodynamics and kinetics, among others. As one specific example at a more advanced level, BCP vesicles (polymersomes) and their potential applications are discussed in some detail.

Vesicles are microscopic sacs that enclose a volume with a molecularly thin membrane. The membranes are generally self-directed assemblies of amphiphilic molecules with a dual hydrophilic-hydrophobic character. Biological amphiphiles form vesicles central to cell function and are principally lipids of molecular weight less than 1 kilodalton. Block copolymers that mimic lipid amphiphilicity can also self-assemble into vesicles in dilute solution, but polymer molecular weights can be orders of magnitude greater than those of lipids. Structural features of vesicles, as well as properties including stability, fluidity, and intermembrane dynamics, are greatly influenced by characteristics of the polymers. Future applications of polymer vesicles will rely on exploiting unique property-performance relations, but results to date already underscore the fact that biologically derived vesicles are but a small subset of what is physically and chemically possible.

The observation by transmission electron microscopy of six different stable aggregate morphologies is reported for the same family of highly asymmetric polystyrene-poly-(acrylic acid) block copolymers prepared in a low molecular weight solvent system. Four of the morphologies consist of spheres, rods, lamellae, and vesicles in aqueous solution, whereas the fifth consists of simple reverse micelle-like aggregates. The sixth consists of up to micrometer-size spheres in aqueous solution that have hydrophilic surfaces and are filled with the reverse micelle-like aggregates. In addition, a needle-like solid, which is highly birefringent, is obtained on drying of aqueous solutions of the spherical micelles. This range of morphologies is believed to be unprecedented for a block copolymer system.

Crew-cut micelle-like aggregates of various morphologies prepared from polystyrene-b-poly(acrylic acid), PS-b-PAA, diblock copolymers under near-equilibrium conditions, were studied by transmission electron microscopy (TEM). The insoluble block (PS) contents in the copolymers ranged from 80 to 98 wt %. In spherical micelles, the micelle cores, formed by aggregation of the PS blocks, were generally monodisperse. A comparison between star and crew-cut micelles showed that the latter are distinguished by a low density of corona chains on the core surface and a low degree of stretching of the PS blocks in the cores. As the PAA content in block copolymer decreased, the morphology of the aggregates changed progressively from spheres to cylinders, to bilayers (both vesicles and lamellae), and eventually to compound micelles consisting of an assembly of inverted micelles surrounded by a hydrophilic surface. The compound micelles are believed to be a new morphology for block copolymers. The addition of homopolystyrene to the diblocks changed the morphologies from bilayers or cylinders to spheres. The present system provides the first instance in which all these multiple aggregate morphologies have been observed directly in block copolymers in a low molecular weight solvent with changing copolymer composition. It is believed that this is the only way so far to prepare stable nanosize glassy vesicles of block copolymers which form spontaneously and can be isolated in water and studied directly by electron microscopy.

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