Relaxing nonequilibrated polymers in thin films at temperatures slightly above the glass transition

We have studied the dewetting process of thin polystyrene films on nonwettable substrates in the viscoelastic regime slightly above the glass transition temperature. The evolution of the shape of the dewetting rim for varying film thickness, molecular weights and dewetting temperatures allowed us to determine the relaxation rates of residual stresses, which originated from nonequilibrated polymer chain conformations formed during film preparation by spin‐coating. For long chain polymers, we found rates notably faster than the longest bulk relaxation processes, highly independent of molecular weight and temperature. Our study demonstrates that dewetting is a powerful tool for sensitive characterization of nonequilibrium properties of thin polymer films. © 2017 Wiley Periodicals, Inc. J. Polym. Sci., Part B: Polym. Phys. 2017 , 55, 515–523     

Hole‐growth instability in the dewetting of evaporating polymer solution films

We investigate the dewetting of aqueous, evaporating polymer [poly(acrylic acid)] solutions cast on glassy hydrophobic (polystyrene) substrates. As in ordinary dewetting, the evaporating films initially break up through the nucleation of holes that perforate the film, but the rapidly growing holes become unstable and form nonequilibrium patterns resembling fingering patterns that arise when injecting air into a liquid between two closely spaced plates (Hele–Shaw patterns). This is natural because the formation of holes in thin films is similar to air injection into a polymer film where the thermodynamic driving force of dewetting is the analogue of the applied pressure in the flow measurement. The patterns formed in the rapidly dewetting and evaporating polymer films become frozen into a stable glassy state after most of the solvent (water) has evaporated, leaving stationary patterns that can be examined by atomic force microscopy and optical microscopy. Similar patterns have been observed in water films evaporating from mica substrates, block copolymer films, and modest hole fingering has also been found in the dewetting of dry polymer films. From these varied observations, we expect this dewetting‐induced fingering instability to occur generally when the dewetting rate and film viscosity are sufficiently large. © 2002 Wiley Periodicals, Inc. J Polym Sci Part B: Polym Phys 40: 2825–2832, 2002     

Influence of progressive cross-linking on dewetting of polystyrene thin films

We present dewetting experiments on thin polymer films as a function of cross-linking density. Covalent cross-links were obtained in the glassy state on the basis of azide photochemistry of linear random copolymers of styrene and p-(azidomethyl)styrene, i.e., 106 and 2500 kg/mol with 7% and 1% azide functionality among the polymer backbone, respectively. Upon ultraviolet radiation, azides generate highly unstable nitrene radicals which react with the surrounding polymer backbone, yielding covalent cross-links. We determined the probability for film rupture, defined by the number of holes formed per unit area, and the relaxation time (tauw) of residual stresses which resulted from the film preparation process. For the lower molar mass polymer studied and for azide conversion rates lower than 60%, only partial cross-linking occurred. The effective molar mass of the polymer increased, and consequently, an increase in tauw was observed. The increase in tauw was accompanied by a decrease in hole density, indicating that the still present residual stresses in the films were not able anymore to rupture the films at the high probability of un-cross-linked polymers. For high conversion (>60%), cross-linking was significant enough to lead to the formation of a three-dimensional rubbery network which, in turn, generated an elastic force that counteracted the driving forces. This elastic force eventually inhibited dewetting and the relaxation of residual stresses. Thus, at high conversions, the relaxation time tauw grew exponentially and the number of holes tended toward zero. For the higher molar mass polymer, no changes in the relaxation time tauw were observed for low conversion (<30%). However, at a higher conversion rate, tauw increased drastically, suggesting an almost infinitely long relaxation time at 100% conversion. Consequently, to successfully stabilize thin polymer films by cross-linking, it is preferable to use long polymer chains.     

Viscoelastic properties of ultrathin polycarbonate films by liquid dewetting

A liquid dewetting method for the determination of the viscoelastic properties of ultrathin polymer films has been extended to study thickness effects on the properties of ultrathin polycarbonate (PC) films. PC films with film thicknesses ranging from 4 to 299 nm were placed on glycerol at temperatures from below the macroscopic glass transition temperature (T_g) to above it with the dewetting responses being monitored. It is found that the isothermal creep results for films of the same thickness, but dewetted at different temperatures can be superposed into one master curve, which is consistent with the fact of PC being a thermorheologically simple material. Furthermore, the results show that the T_g of PC thin films is thickness dependent, but the dependence is weaker than the results for freely standing films and similar to literature data for PC films supported on rigid substrates. It was also found that the rubbery plateau region for the PC films stiffens dramatically, but still less than what has been observed for freely standing polycarbonate films. The rubbery stiffening is discussed in terms of a recently reported model that relates macroscopic segmental dynamics with the stiffening. © 2015 Wiley Periodicals, Inc. J. Polym. Sci., Part B: Polym. Phys. 2015 , 53, 1559–1566     

Interfacial structure in thin water layers formed by forced dewetting on self-assembled monolayers of omega-terminated alkanethiols on Ag

A method for the spectroscopic characterization of interfacial fluid molecular structure near solid substrates is reported. The thickness and interfacial molecular structure of residual ultrathin D20 films remaining after forced dewetting on alkanethiolate self-assembled monolayers (SAMs) of 11 1-mercaptoundecanoic acid (11-MUA), 11-mercaptoundecanol (11-MUD), and undecanethiol (UDT) on Ag are investigated using ellipsometry and surface Raman spectroscopy. The residual film thickness left after withdrawal is greater on hydrophilic SAMs than on hydrophobic SAMs. This behavior is rationalized on the basis of differing degrees of fluid slip within the interfacial region due to different interfacial molecular structure. The v(O-D) regions of surface Raman spectra clearly indicate unique interfacial molecular properties within these films that differ from bulk D20. Although the residual films are created by shear forces and Marangoni flow at the three-phase line during the forced dewetting process, the nature of the films sampled optically must also be considered from the standpoint of thin film stability after dewetting. Thus, the resulting D20 films exist in vastly different morphologies depending on the nature of the water-SAM interactions. Residual D20 is proposed to exist as small nanodroplets on UDT surfaces due tospontaneous rupture of the film after dewetting. In contrast, on 11-MUD and 11-MUA surfaces, these films exist in a metastable state that retains their conformal nature on the underlying modified surface. Analysis of the peak intensity ratios of the so-called "ice-like" to "liquid-like" v(O-D) modes suggests more ice-like D20 character near 11-MUD surfaces, but more liquid-like character near 11-MUA and UDT surfaces. The creation of residual ultrathin films by forced dewetting is thus demonstrated to be a powerful method for characterizing interfacial molecular structure of fluids near a solid substrate under ambient conditions of temperature and pressure.     

Partial dewetting of polyethylene thin films on rough silicon dioxide surfaces

The effect of roughness on the dewetting behavior of polyethylene thin films on silicon dioxide substrates is presented. Smooth and rough silicon dioxide substrates of 0.3 and 3.2-3.9 nm root-mean-square roughness were prepared by thermal oxidation of silicon wafers and plasma-enhanced chemical vapor deposition on silicon wafers, respectively. Polymer thin films of approximately 80 nm thickness were deposited by spin-coating on these substrates. Subsequent dewetting and crystallization of the polyethylene were observed by hot-stage optical microscopy in reflection mode. During heating, the polymer films melt and dewet on both substrates. Further observations after cooling indicate that, whereas complete dewetting occurs on the smooth substrate surface, partial dewetting occurs for the polymer film on the rough surface. The average thickness of the residual film on the rough surface was determined by ellipsometry to be a few nanometers, and the spatial distribution of the polymer in the cavities of the rough surface could be obtained by X-ray reflectometry. The residual film originates from the impregnation of the porous surface by the polymer fluid, leading to the observed partial dewetting behavior. This new type of partial dewetting should have important practical consequences, as most real surfaces exhibit significant roughness.     

Multiscale dewetting of triblock copolymer thin film induced by solvent vapor

Multiscale dewetting of poly(styrene‐b‐ethylene/butylenes‐b‐styrene) (SEBS) triblock copolymer thin films induced by volatile solvent vapor treatment were observed in this study. Film rupture occurred at first and produced macroscopic holes. Near‐regular droplets (which represented a compromise between complete disorder and perfect order) could be formed at the last stage. The mechanism of solvent‐driven dewetting was discussed by comparing with that of thermal‐induced dewetting. Similar to thermal‐induced dewetting, the block copolymer thin films initially break up through the nucleation of holes that perforated the films. The rapid growing holes became unstable and formed nonequilibrium fingering patterns. The films exhibit autophobic or autodewetting phenomena. The velocity of the holes growth was nearly a constant (3.3 μm/min). The stages of the dewetting were quite similar to that found for homopolymer and block copolymer thin films dewetting on solid or liquid substrates under thermal treatment. © 2005 Wiley Periodicals, Inc. J Polym Sci Part B: Polym Phys 43: 2874–2884, 2005     

Competition between dewetting and cross-linking in poly(N-vinylpyrrolidone)/polystyrene bilayer films

We investigated the dewetting of metastable poly(N-vinylpyrrolidone) (PNVP) thin films (45 nm) on top of polystyrene (PS) thin films (58 nm) as a function of annealing temperature and molecular weight of PS (96 and 6850 kg/mol). We focused on the competition between dewetting, occurring as a result of unfavorable intermolecular interactions at the PNVP/PS interface, and spontaneous cross-linking of PNVP, occurring during thermal annealing, as we recently reported (Telford, A. M.; James, M.; Meagher, L.; Neto, C. ACS Appl. Mater. Interfaces 2010, 2, 2399-2408). Using optical microscopy, we studied how the dewetting morphology and dynamics at different temperatures depended on the relative viscosity of the top PNVP film, which increased with cross-linking time, and of the bottom PS film. In the PNVP/PS96K system, cross-linking dominated over dewetting at temperatures below 180 °C, reducing drastically nucleated hole density and their maximum size, while above 180 °C the two processes reversed, with complete dewetting occurring at 200 °C. On the other hand, the PNVP/PS6850K system never achieved advanced dewetting stages as the dewetting was slower than cross-linking in the investigated temperature range. In both systems, dewetting of the PNVP films could be avoided altogether by thermally annealing the bilayers at temperatures where cross-linking dominated. The cross-linking was characterized quantitatively using neutron reflectometry, which indicated shrinkage and densification of the PNVP film, and qualitatively through selective removal of the bottom PS film. A simple model accounting for progressive cross-linking during the dewetting process predicted well the observed hole growth profiles and produced estimates of the PNVP cross-linking rate coefficients and of the activation energy of the process, in good agreement with literature values for similar systems.     

Focused laser-induced marangoni dewetting for patterning polymer thin films

Highly-localized focused laser spike (FLaSk) heating of polymer thin films is a resist- and developer-free alternative to two-dimensional (2D) laser direct write for creating patterns on the single micron or, by exploiting overlap effects, submicron scale. The massive temporal and spatial thermal gradients and resulting thermal Marangoni stresses generated by FLaSk are an effective means for the directed dewetting and patterning of such films. Here, the general applicability of this technique to glassy amorphous polymer thin film systems is investigated through systematic investigation of film thickness, glass transition temperature, and polymer mobility. The results reveal that the important parameters are the film thickness (coupled to the optical heating effects through anti-reflection coating effects) and the high-temperature polymer melt mobility, allowing for generation of single features with linewidths of down to ∼1 μm. Further, the introduction of spatial mobility variations by using polymer brushes, bilayers, and microphase separated block copolymers leads to additional profile manipulation effects (i.e. spontaneous 2D pattern generation and flattened top profiles). © 2015 Wiley Periodicals, Inc. J. Polym. Sci., Part B: Polym. Phys. 2016, 54, 225–236     

Nonsolvent-induced dewetting of thin polymer films

The process of nonsolvent-induced dewetting of thin polystyrene (PS) films on hydrophilic surfaces at room temperature has been studied by using water as a nonsolvent. It is observed that the process of nonsolvent-induced dewetting is greatly different from other previous dewetting processes. The PS film is found in nonviscous state in our study. A mechanism of nonsolvent-induced dewetting is deduced in an order of penetration, replacement, and coalescent, and it is different from other previous dewetting mechanisms. The results of experiments are analyzed from thermodynamics and dynamics to support the hypothetical mechanism.     

Dewetting Kinetics of Thin Polymer Films with Different Architectures: Effect of Polymer Adsorption

We have investigated the influence of the adsorption process on the dewetting behavior of the linear polystyrene film(LPS),the 3-arm star polystyrene film(3 SPS) and the ring polystyrene film(RPS) on the silanized Si substrate.Results show that the adsorption process greatly influences the dewetting behavior of the thin polymer films.On the silanized Si substrate,the 3 SPS chains exhibit stronger adsorption compared with the LPS chains and RPS chains; as a result,the wetting layer forms more easily.For LPS films,with the decrease of annealing temperature,the kinetics of polymer film changes from exponential behavior to slip dewetting.As a comparison,the stability of 3 SPS and RPS films switches from slip dewetting to unusual dewetting kinetic behavior.The adsorbed nanodroplets on the solid substrate play an important role in the dewetting kinetics by reducing the driving force of dewetting and increase the resistant force of dewetting.Additionally,Brownian dynamics(BD) simulation shows that the absolute values of adsorption energy(ε) gradually increase from linear polymer(-0.3896) to ring polymer(-0.4033) and to star polymer(-0.4264),which is consistent with the results of our adsorption experiments.     

Selective solvent annealing induced phase separation and dewetting in PMMA/SAN blend ultrathin films

Phase behaviors induced by solvent annealing in poly(methyl methacrylate) (PMMA) and poly(styrene‐ran‐acrylonitrile) (SAN) blend ultrathin films have been investigated by atomic force microscopy and grazing incidence small‐angle X‐ray scattering. Our results indicate that both the phase separation within the blend and the dewetting of the film induced by composition fluctuation take place upon the selective solvent annealing, producing complex structures containing upper droplets (of one phase) and mimic‐films (of the other rich‐phase). The use of acetic acid (the selective solvent for PMMA) generates PMMA mimic‐film and SAN droplets, while the introduction of DMF (exhibiting better solubility for SAN) vapor results in the formation of SAN mimic‐film and PMMA droplets. Essentially, the interaction at polymer/substrate interface, resultant wettability of selected component, solubility of PMMA and SAN in adopted solvent dominate not only the phase separation and the dewetting of the whole film but also the synergism of them. © 2014 Wiley Periodicals, Inc. J. Polym. Sci., Part B: Polym. Phys. 2014 , 52, 1243–1251     

Surface and interface morphology of polystyrene/poly(methyl methacrylate) thin‐film blends and bilayers

The surface and interface morphologies of polystyrene (PS)/poly(methyl methacrylate) (PMMA) thin‐film blends and bilayers were investigated by means of atomic force microscopy (AFM) and X‐ray photoelectron spectroscopy. Spin‐coating a drop of a PS solution directly onto a PMMA bottom layer from a common solvent for both polymers yielded lateral domains that exhibited a well‐defined topographical structure. Two common solvents were used in this study. The structure of the films changed progressively as the concentration of the PS solution was varied. The formation of the blend morphology could be explained by the difference in the solubility of the two polymers in the solvent and the dewetting of PS‐rich domains from the PMMA‐rich phase. Films of the PS/PMMA blend and bilayer were annealed at temperatures above their glass‐transition temperatures for up to 70 h. All samples investigated with AFM were covered with PS droplets of various size distributions. Moreover, we investigated the evolution of the annealed PS/PMMA thin‐film blend and bilayer and gave a proper explanation for the formation of a relatively complicated interface inside a larger PS droplet. © 2005 Wiley Periodicals, Inc. J Polym Sci Part B: Polym Phys 44: 9–21, 2006     

A novel temperature‐step method to determine the glass transition temperature of ultrathin polymer films by liquid dewetting

A novel temperature‐step experimental method that extends the Bodiguel‐Fretigny liquid dewetting method of investigating polymer thin films is described and results presented from an investigation of thickness effects on the glass transition temperature (T_g) of ultrathin polystyrene (PS) films. Unlike most other methods of thin film investigation, this procedure promises a rapid screening tool to determine the overall profile of T_g versus film thickness for ultrathin polymer films using a limited number of samples. Similar to our prior observations and other literature data, with this new method obvious T_g depression was observed for PS thin films dewetting on both glycerol and an ionic liquid. The results for PS dewetting on the two different liquids are similar indicating only modest effects of the substrate on the T_g‐film thickness relationship. In both instances, the T_g depression is somewhat less than for similar PSs supported on silicon substrates reported in the literature. © 2013 Wiley Periodicals, Inc. J. Polym. Sci., Part B: Polym. Phys. 2013 , 51, 1343–1349     

Dynamics of dewetting at the nanoscale using molecular dynamics

Large-scale molecular dynamics simulations are used to model the dewetting of solid surfaces by partially wetting thin liquid films. Two levels of solid-liquid interaction are considered that give rise to large equilibrium contact angles. The initial length and thickness of the films are varied over a wide range at the nanoscale. Spontaneous dewetting is initiated by removing a band of molecules either from each end of the film or from its center. As observed experimentally and in previous simulations, the films recede at an initially constant speed, creating a growing rim of liquid with a constant receding dynamic contact angle. Consistent with the current understanding of wetting dynamics, film recession is faster on the more poorly wetted surface to an extent that cannot be explained solely by the increase in the surface tension driving force. In addition, the rates of recession of the thinnest films are found to increase with decreasing film thickness. These new results imply not only that the mobility of the liquid molecules adjacent to the solid increases with decreasing solid-liquid interactions, but also that the mobility adjacent to the free surface of the film is higher than in the bulk, so that the effective viscosity of the film decreases with thickness.     

The brittle–ductile transition induced by thermal ageing of toluene cast poly(2,6‐dimethyl‐1,4‐phenylene oxide) as observed by interfacial friction

The interfacial shear stress of toluene cast poly(2,6‐dimethyl‐1,4‐phenylene oxide) films has been studied as a function of annealing temperature. The surface topography of these films was studied by scanning probe microscopy following a single sliding pass. Casting from toluene results in a semicrystalline film with a rigid amorphous phase and containing a small amount of residual solvent that exhibits a higher interfacial shear stress than a high temperature annealed solvent‐free amorphous film. Films containing small amounts of toluene exhibit a wear pattern consisting of ripples oriented perpendicular to the sliding direction following a single sliding pass. These results support the notion that the interfacial shear stress is a function of the shear yield stress, and, that during sliding friction tensile stresses must form at the polymer surface. © 2009 Wiley Periodicals, Inc. J Polym Sci Part B: Polym Phys 47: 1637–1643, 2009     

RUPTURING OF POLYMER FILMS WITH RUBBING-INDUCED SURFACE DEFECTS

It has been a long-standing question whether dewetting of polymer film from non-wettable substrate surfaceswherein the bicontinuous morphology never forms in the dewetting film is due to spinodal instability or heterogeneousnucleation. In this experiment, we use a simple method to make the distinction through introduction of topographical defectsof the films by rubbing the sample surface with a rayon cloth. Spinodal dewetting is identified for those films that dewet by acharateristic wavevector, q, independent of the density of rubbing-induced defects. Heterogeneous nucleation, on the otherhand, is identified for those with q increasing with increasing density of defects. Our result shows that PS films on oxidecoated silicon with thickness less than ≈ 13 nm are dominated by spinodal dewetting, but the thicker films are dominated bynucleation dewetting. We also confirm that spinodal dewetting does not necessarily lead to a bicontinuous morphology in thedewetting film, contrary to the classic theory of Cahn.     

High thermal conductivity of polymerizable liquid‐crystal acrylic film having a twisted molecular orientation

The aligned films, the homogeneous film, the 90°‐twisted film and the 180°‐twisted film, have been prepared by immobilizing the polymerizable liquid crystals under the UV irradiation. The relation between the thermal conductivity and the aligned molecular direction of the films was investigated. It is indicated that the additional thermal transmission effect, which the increase of the thermal conductivity may be induced, would exist in the twisted films. © 2006 Wiley Periodicals, Inc. J Polym Sci Part B: Polym Phys 44: 1419–1425, 2006     

Dewetting dynamics in miscible polymer-polymer thin film mixtures

Thin polystyrene films supported by oxidized silicon (SiOx/Si) substrates may be unstable or metastable, depending on the film thickness, h, and can ultimately dewet the substrate when heated above their glass transition. In the metastable regime, holes nucleate throughout the film and subsequently grow due to capillary driving forces. Recent studies have shown that the addition of a second component, such as a copolymer or miscible polymer, can suppress the dewetting process and stabilize the film. We examined the hole growth dynamics and the hole morphology in thin film mixtures composed of polystyrene and tetramethyl bisphenol-A polycarbonate (TMPC) supported by SiOx/Si substrates. The hole growth velocity decreased with increasing TMPC content beyond that expected from changes in the bulk viscosity. The authors show that the suppression of the dewetting velocity is primarily due to reductions in the capillary driving force for dewetting and to increased friction at the substrate-polymer interface. The viscosity, as determined from the hole growth dynamics, decreases with decreasing film thickness, and is connected to a depression of the glass transition of the film.     

Submicron films prepared from aqueous dispersions of nanoscale polymer crystals

Thin and ultrathin films of polyethylene of variable thickness are obtained from aqueous dispersions of prefabricated nanoscale crystals by spin‐coating. Continuous films with a thickness of only 15 nm, up to 220 nm, homogeneous over hundreds of μm, or assembled discontinuous monolayers of flat‐on lamella particles were prepared, depending on the solids content of the dispersion employed, as revealed by AFM and TEM. The morphology of melt‐recrystallized films was not affected by the surfactant present. Homogeneous continuous films without undesirable dewetting were retained upon melting and recrystallization of the films upon cooling, composed of polygonal spherulites for a thicker film (220 nm), randomly grown edge‐on lamella for a 40 nm film, and dominant flat‐on lamella for a 15 nm thick film. Annealing below T_m resulted in lamella thickening, without changes of crystal orientation or structure of the particle assemblies for discontinuous monolayers. Surfactant adsorbed to the nanocrystals in the aqueous dispersion desorbs at least partially during formation of the nascent films, and upon annealing below the melting point surfactant migrates to the film‐air interface to form aggregates, which can be removed by rinsing, during which the film stays intact and structurally unaltered as revealed, amongst others, by water contact angles. © 2009 Wiley Periodicals, Inc. J Polym Sci Part A: Polym Chem 47: 6420–6432, 2009