Drying dip-coated colloidal films

We present the results from a small-angle X-ray scattering (SAXS) study of lateral drying in thin films. The films, initially 10 μm thick, are cast by dip-coating a mica sheet in an aqueous silica dispersion (particle radius 8 nm, volume fraction ?(s) = 0.14). During evaporation, a drying front sweeps across the film. An X-ray beam is focused on a selected spot of the film, and SAXS patterns are recorded at regular time intervals. As the film evaporates, SAXS spectra measure the ordering of particles, their volume fraction, the film thickness, and the water content, and a video camera images the solid regions of the film, recognized through their scattering of light. We find that the colloidal dispersion is first concentrated to ?(s) = 0.3, where the silica particles begin to jam under the effect of their repulsive interactions. Then the particles aggregate until they form a cohesive wet solid at ?(s) = 0.68 ± 0.02. Further evaporation from the wet solid leads to evacuation of water from pores of the film but leaves a residual water fraction ?(w) = 0.16. The whole drying process is completed within 3 min. An important finding is that, in any spot (away from boundaries), the number of particles is conserved throughout this drying process, leading to the formation of a homogeneous deposit. This implies that no flow of particles occurs in our films during drying, a behavior distinct to that encountered in the iconic coffee-stain drying. It is argued that this type of evolution is associated with the formation of a transition region that propagates ahead of the drying front. In this region the gradient of osmotic pressure balances the drag force exerted on the particles by capillary flow toward the liquid-solid front.     

Effect of soluble polymer binder on particle distribution in a drying particulate coating

Soluble polymer is frequently added to inorganic particle suspensions to provide mechanical strength and adhesiveness to particulate coatings. To engineer coating microstructure, it is essential to understand how drying conditions and dispersion composition influence particle and polymer distribution in a drying coating. Here, a 1D model revealing the transient concentration profiles of particles and soluble polymer in a drying suspension is proposed. Sedimentation, evaporation and diffusion govern particle movement with the presence of soluble polymer influencing the evaporation rate and solution viscosity. Results are summarized in drying regime maps that predict particle accumulation at the free surface or near the substrate as conditions vary. Calculations and experiments based on a model system of poly(vinyl alcohol) (PVA), silica particles and water reveal that the addition of PVA slows the sedimentation and diffusion of the particles during drying such that accumulation of particles at the free surface is more likely.     

Drying of films formed by ordered poly(ethylene oxide)-poly(propylene oxide) block copolymer gels

The drying of hydrogel films formed by poly(ethylene oxide)-poly(propylene oxide) (PEO-PPO) block copolymers (Pluronic P105 and Pluronic L64) is investigated at various air relative humidity (RH) conditions in the range 11-94%. These amphiphilic block copolymers self-assemble to form a variety of ordered (lyotropic liquid crystalline) structures as the water content decreases. The amount of water lost increases linearly with the drying time initially (constant rate region, stage I). After this linear region, a falling rate is observed (stage II). The drying rate increases with decreasing RH, thus greatly shortening the drying time. A decrease of the initial film thickness or a decrease in the initial water content shortens the drying time; however, the drying mechanism remains the same. Analysis of the experimental data shows that the hydration level in the Pluronic hydrogel mainly determines the drying rate, rather than the type of ordered structure formed. Two distinct regions (liquid/gel and solid/crystalline) are observed in the drying isotherm for PEO-PPO block copolymers and homopolymer poly(ethylene glycol)s. A model for one-dimensional water diffusion is used to fit the experimental drying results at different RH, initial film thickness, and initial water content conditions. The model accounts for the shrinkage of the film during drying and for a water diffusion coefficient that is a function of the water concentration in the film. For the experimental conditions considered here, the Biot number (Bi) is less than unity and the drying is mainly limited by evaporation at the film surface. The diffusion model is used to obtain information for cases where Bi > 1.     

Heterogeneous drying of colloidal polymer films: dependence on added salt

Using magnetic resonance profiling coupled with dynamic light scattering, we have investigated the mechanisms leading to the formation of a partly coalesced surface layer, or "open skin", during film formation from waterborne polymer dispersions. We present the first use of the skewness of the distribution of free water as a model-free indicator of the spatial nonuniformity of drying. The skewness reaches a maximum at the same time at which a strong, static component, presumably originating from a skin at the film/air interface, appears in the light scattering data. Addition of salt to the dispersion increases both the skewness of the distribution of free water and the propensity for skin formation. Surprisingly, the drying is influenced not only by the concentration and valency of the ions in the salt but also by the particular ion. At intermediate particle densities, added salt strongly lowers the cooperative diffusion coefficient, Dcoop. When the particles reach close packing, Dcoop sharply increases. If the particles readily coalesce, the effects of the increased diffusivity will be counteracted, thereby inducing the formation of a skin. A modified Peclet number, Pe, using Dcoop, is proposed, so that the presence of salt is explicitly considered. This modified Pe is able to predict the nonuniformity in drying that leads to skin formation.     

Formation and drying of colloidal crystals using nanosized silica particles

Much interest has been generated in the fabrication of colloidal crystals from suspensions because of the promise of photonic band gap applications. However, since the case of small, nonsedimenting colloidal particles indeed remains rather rarely treated, spherical silica particles with diameters varying from 75 down to 20 nm have been used in the present work to fabricate colloidal crystals by drying the suspending liquid. Typical events that take place during the drying process of a particulate film, such as cracking, compaction and penetration of air into a porous network, have been evaluated using existing theories, and the maximum stress in the drying film could be approximated. Investigation on the dry film structure by scanning electron microscopy showed the arrangement of particles in a close-packed system. To interpret the formation of such crystals, the amplitudes of the interparticle and capillary forces have been estimated from existing models. The repulsive interparticle forces allow the particles to remain stable and thus rearrange up to fairly high particle concentration. These modeling results showed the dominance of the capillary contribution at the end of the drying process. Nitrogen adsorption/desorption measurements gave very coherent results regarding both pore volume and pore size of the dry particulate films when compared to the expected ordered packing arrangements.     

Thinning of drying latex films due to surfactant

Lateral non-uniformities in surfactant distribution in drying latex films induce surface tension gradients at the film surface and lead to film thinning through surfactant spreading. Here we investigate the influence of the surfactant driven to the air-water interface, during the early stages of latex film drying, on the film thinning process which could possibly lead to film rupture. A film height evolution equation is coupled with conservation equations for particles and surfactant, within the lubrication approximation, and solved numerically, to obtain the film height, particle volume fraction, and surfactant concentration profiles. Parametric analysis identifies the effect of drying rate, dispersion viscosity and initial particle volume fraction on film thinning and reveals the conditions under which films could rupture. The results from surface profilometry conform qualitatively to the model predictions.     

Facile fabrication of mechanochromic-responsive colloidal crystal films

This paper presents a simple approach to fabricate a reversible mechanochromic-responsive crystal film based on the room-temperature film-formation of monodisperse polymer latex by the aid of nanosilica particles. In this approach, when the "soft" colloidal polymer spheres were blended with colloidal silica particles and then cast on a substrate, followed by drying at room temperature for self-assembly, an elastic crystal film was directly obtained. This crystal film has not only reversible and repeatable mechanochromic-responsive property, but also tunable color and peak position covering almost entire visible spectral region, depending upon the sizes of polymer spheres and strains. This optical response is attributed to the variation of lattice spacing during deformation.     

A model for the drying process during film formation in waterborne acrylic coatings

Establishing drying mechanisms during film formation in waterborne acrylic coatings is a technologically important problem, however complex, and still poorly understood. A model for the prediction of evaporation kinetics is proposed in this paper, where films are supposed to dry normally with respect to the film surface, and a drying front separates a top dry region from a bottom wet region. The model accounts for the competition between water evaporation and particle diffusion that determines the degree of vertical homogeneity, but also for the competition between water evaporation and particle deformation that ultimately establishes the rate-determining step in film formation processes. The model was validated by performing gravimetric water-loss experiments on latexes of acrylic polymers of various composition, various particle size and stabilizing systems, under different environmental temperatures and humidity, and various initial film thicknesses in order to evaluate the effect of the different factors that can in principle influence the film formation process.     

Aqueous foam films stabilized by sodium naphthenates

Stratification of a foam liquid film drawn from aqueous solutions of sodium naphthenate at relatively high concentration is likely due to a lamellar liquid crystal-like structure within the film. Film stratification, resulting in stepwise thinning, has been observed in foam films formed from systems containing either moderate to high concentrations of surfactant or in films formed from solutions containing solid particles. At moderate surfactant concentrations, film stratification is likely due to layers of ordered spherical micelles as postulated in Wasan and Nikolov's model of film stratification. At high surfactant concentrations, stepwise thinning of the films and occurrence of domains of uniform color within the film suggest a lamellar liquid crystal-like structure within the film, potentially up to hundred or more oriented layers. The LLC-like structure inside the film can occur at concentrations below the lower limit of the LLC existence as a bulk phase.     

Cracking in drying latex films

Thin films of latex dispersions containing particles of high glass transition temperature generally crack while drying under ambient conditions. Experiments with particles of varying radii focused on conditions for which capillary stresses normal to the film deform the particles elastically and generate tensile stresses in the plane of the film. Irrespective of the particle size, the drying film contained, simultaneously, domains consisting of a fluid dispersion, a fully dried packing of deformed spheres, and a close packed array saturated with water. Interestingly, films cast from dispersions containing 95-nm sized particles developed tensile stresses and ultimately became transparent even in the absence of water, indicating that van der Waals forces can deform the particles. Employing the stress-strain relation for a drying latex film along with the well-known Griffith's energy balance concept, we calculate the critical stress at cracking and the accompanying crack spacing, in general agreement with the observed values.     

Drying dissipative structures of spindle-shaped hematite particles coated with polymer brush

Macroscopic and microscopic drying patterns were observed on a cover glass, a watch glass, and a Petri glass dish during dryness of aqueous suspensions of spindle-shaped particles of hematite coated with polymer brush (SHB). Outer and inner broad rings formed and the spoke-lines appeared especially on a watch glass at the intermediate initial concentration of SHB. Cooperative drying processes of the convection, sedimentation, and solidification were supported also for the anisotropic particles. Most of the long axes of SHB particles distributed parallel to the substrate plane. There appeared the microscopic alignment of the several ten micrometers similar-sized aggregates composed of the SHB particles. The parallel and/or flower-like (or spoke-like) arrangements of SHB particles were observed in the scanning electron microscopy. Effective shape of SHB particles including the electrical double layers during the convection flow processes are deduced to be near spherical. However, the effective shape came to be spindle-like during the sedimentary and solidification processes by the thinning of the double layers. The distorted paralleled and/or flower-like alignments of SHB particles were observed in the dried film.     

The Film Formation of Polymer Particles in Drying Thin Films of Aqueous Acrylic Latices

The aim of this study is to determine the factors that contribute to the process of film formation of binder particles in drying aqueous dispersion coatings, based on acrylic polymers. It is known that concentrated latices of uniform size show iridescent, colored light patterns. These colors are caused by interparticle interference, and they are only present when the latex particles are ordered in a regular structure. The interparticle interference can be characterized by measuring the transmission as a function of wavelength of the incident light. It appeared that the changes of the interparticle interference of a drying latex film can be related to changes in the interparticle distance and displacement. It was also found that the interparticle distance becomes "negative" upon coalescence of the latex particles. This means that from this point on, the change in interparticle interference is directly related to the indentation or deformation of the latex particles. It became clear that the coalescence process differs from deformation mechanisms accepted in the literature. It seems that the deformation of the particles follows a biaxial mechanism. This means that the particles deform only in one direction, perpendicular to the film surface. Copyright 2000 Academic Press.     

Pore-scale modelling and tomographic visualisation of drying in granular media

Spatio-temporal evolution of liquid phase clusters during drying of a granular medium (realised by random packing of cylindrical particles) has been investigated at the length-scale of individual pores. X-ray microtomography has been used to explicitly resolve the three-dimensional spatial distribution of the solid, liquid, and gas phases within the wet particle assemblies. The propagation of liquid menisci through the granular medium during drying was dynamically followed. The effect of contact angle on the degree of dispersion of the drying front has been studied by observing drying in a layer of untreated (hydrophilic) and silanised particles; the drying front was found to be sharper in the case of the silanised (less hydrophilic) particles. This observation was confirmed by direct numerical simulations of drying in a digitally encoded porous medium identical in structure to the experimental one. The simulations also revealed that the average gas-liquid interfacial area in a given porous microstructure strongly depends on the contact angle.     

The influence of sodium ethene sulphonate comonomer on the film formation process of poly(vinyl acetate) dispersions

Various latex dispersions from vinyl acetate/sodium ethene sulphonate (sodium vinyl sulphonate) copolymers, stabilised by a constant amount of Hostapal BV, a surfactant with poly(ethylene oxide) groups, were investigated by a variety of solid and liquid state nuclear magnetic resonance methods. In order to investigate the influence of sodium ethene sulphonate on the film formation process, the serum and polymer were analysed separately. The stoichiometric monomer composition of the copolymer in the aqueous phase and in the hydrophobic particles was obtained. The ionic comonomer is enriched at the particle surface via its proximity to the applied surfactant by two-dimensional exchange NMR. For investigations of the film formation process, latex dispersions were prepared and dried to form spatially homogeneous films at different defined solid contents. Depending on the chemical composition of a chosen dispersion, NMR allows the investigation of the drying process of the water. The drying process is a function of the ionic strength of the dispersion and the hydrophilicity of the polymer. It is correlated to the drying mechanism of the water within the film. A not fully dried film contains external water outside the particles, water at ionic and non-ionic groups at surfactants in the polymer water interface and, additionally, water in the swollen and mobilised polymer. The distribution of water to these environments is markedly changed by the ionic comonomer, especially close to the end of the drying process.     

Role of capillary stresses in film formation

Stresses generated during film formation were deduced from the deflection of a copper cantilever coated with a drying latex. Experiments with particles of varying radii and glass transition temperatures (Tg) focused on conditions for which capillary stresses normal to the film deform the particles to close the voids. Soft particles (low Tg) formed continuous films, but hard ones (high Tg) produced fascinating arrays of cracks. For both soft and rigid particles, the lateral stresses were tensile and scaled on the surface tension divided by the particle radius. Clearly, tensile stresses in the plane of the film responsible for cracking arise from the same capillary pressure that drives compression in the normal direction. Solving the model (Routh & Russel 1996, 1999) for lateral flow of the fluid dispersion prior to close packing and deformation of the solid beyond close packing yields volume fraction, film thickness, and stress profiles for comparison with observations for both film-forming and film-cracking cases.     

Autostratification in drying colloidal dispersions: effect of particle interactions

When particles differing in size or charge are mixed and cast, vertical segregation is an inevitable phenomenon in the produced films. Apart from the Peclet number, which is the ratio of evaporation to diffusion rates, particle interactions play a crucial role in determining the distribution of particles in the dried films. Trueman et al. (1) developed a model for vertical segregation of particles during drying. Their numerical solution assumed that the chemical potentials were determined entirely by entropy. We report the effect of particle interactions in various systems: (i) charged particles with different Peclet numbers and (ii) charged particles with the same Peclet numbers. An experimental study has also been carried out for particles with Peclet numbers straddling unity; the experimental results conform with the behavior predicted theoretically.     

Temperature and relative humidity dependency of film formation of polymeric latex dispersions

Thermogravimetric analysis and a synchrotron small-angle X-ray scattering technique were employed to characterize the structural evolution of a polymeric latex dispersion during the first three stages of film formation at different temperatures and relative humidities. Three intermediate stages were identified: (1) stage I*, (2) stage I**, and (3) stage II*. Stage I* is intermediate to the conventionally defined stages I and II, where latex particles began to crystallization. The change of drying temperature affects the location of the onset of ordering, whereas relative humidity does not. Stage I** is where the latex particles with their diffuse shell of counterions in the fcc structure are in contact with each other. The overlapping of these layers results in an acceleration of the lattice shrinkage due to a decrease of effective charges. Stage II* is where the latex particles, dried well above their T(g), are deformed and packed only partially during film formation due to incomplete evaporation of water in the latex film. This is because of a rapid deformation of the soft latex particles at the liquid/air interface so that a certain amount of water is unable to evaporate from the latex film effectively. For a latex dispersion dried at a temperature close to its minimum film formation temperature, the transition between stages II and III can be continuous because the latex particles deform at a much slower rate, providing sufficient surface area for water evaporation.     

Electrical currents resulting from reduction/oxidation processes of tested particles on “inner” and “outer” surfaces of electroactive polymer films

Heterogeneous reactions of tested particles proceeding on electroactive films with different kinds of thin pores are described formally in terms of diffusion equations complicated with an accompanying volume reaction inside the film interior. As it is shown, in polarization curves of such processes, there might appear limiting flows, which are essentially smaller than the limiting diffusion flow of tested particles in the bathing electrolyte. These flows should not depend on a film pores’ topology, but be determined by the ratio of the total surface of pores and the visible film one. The obtained results are compared with those followed for the case when tested particles actually inculcate into the film matrix and react with either oxor red-fragments of the film. Identification criteria of the compared mechanisms are discussed.     

Diffusion in mesoporous materials and polymers swelling: a transient calorimetric approach

The diffusion of water and benzene has been followed by DSC using the thermoporosimetry (TPM) approach. The diffusion of water has been observed during the drying of a water impregnated mesoporous silica gel at 40 degrees C under dry air. It was found that the confinement affects the evaporation rate of water. The diffusion of benzene has been observed during the drying and the swelling of a cross linked PDMS sample. The mesh size distributions (MSD) of the elastomer, during swelling and drying, have been calculated at various times using the TPM formalism. Extrapolating the mean mesh size of the polymeric network, it was found that the dry polymer has an average mesh of about 2.5 nm.     

Corrosion protection enhancement effect by mixed silica nanoparticles of different sizes incorporated in a sol–gel silica film

We demonstrate an enhancement of corrosion protection by sol–gel silica film including mixed silica nanoparticles of 10 and 50 nm. Low-temperature silica films were prepared by sol–gel dip-coating method, followed by a thermal annealing at 200 °C. Importantly, film with mixed particles exhibits lower corrosion current density and slower loss of film resistance during the immersion in electrolyte solution, showing an improved corrosion protection over the film with 50 nm particles. The improved corrosion protectability of the mixed particles comes from the suppressed diffusion of ionic species by a close packing of 10 nm particles.