Vertical phase separation and liquid-liquid dewetting of thin PS/PCL blend films during spin coating

Thin films of an amorphous polymer, polystyrene (PS), and a crystalline polymer, poly(ε-caprolactone) (PCL), blend were prepared by spin coating a toluene solution. Surface chemical compositions of the blend films were measured by X-ray photoelectron spectroscopy (XPS), and the surface and interface topographical changes were followed by atomic force microscopy (AFM). By changing the PS concentration and keeping the PCL concentration of the solution at 1 wt %, a great variety of morphologies were constructed. The results show that the morphology of the blend films can be divided into three regions with increasing PS concentration. In region I, PS island domains are embedded in PCL crystals when the PS concentration is lower than 0.3 wt % and the size of the PS island increases with increasing PS concentration. In region II, holes with different sizes surrounded by a low rim are obtained when the concentration of PS is between 0.35 and 0.5 wt %. After selectively washing the PS domains, we studied the interface morphology of PS/PCL and found that the upper PS-rich layer extended into the bottom PCL layer, forming a trench surrounding the holes. In region III, an enriched two-layer structure with the PS-rich layer on top of the blend films and the PCL-rich crystal layer underneath is obtained when the concentration of PS is higher than 0.5 wt %. Last, the formation mechanism of the different surface and interface morphologies is further discussed in terms of the vertical phase separation to a layered structure, followed by liquid-liquid dewetting and crystallization processes during spin coating.     

Modelling of the High-Impact Polystyrene Morphogenesis

Summary: High-impact polystyrene (HIPS) is a hetero-phase polymer with the so-called salami morphology. Salami morphology is formed by a continuous PS phase containing micron-sized PB domains. PB domains contain submicron-sized irregular PS occlusions. In our modeling work we addressed several weak points of Cahn-Hilliard model of HIPS salami morphology evolution. The weakest point of Cahn-Hilliard model is the inherently present Ostwald ripening destabilizing or competing with graft-stabilized domains. Two mechanism of formation of HIPS morphology are supported by the model: (i) encapsulation of graft-stabilized PS-rich domains in PB particles, and (ii) polymerization of styrene dissolved in PB-rich phase and subsequent phase separation leading to PS occlusions in PB domains.     

Conductivity of Poly(methyl methacrylate)/Polystyrene/Carbon Black and Poly(ethyl methacrylate)/Polystyrene/Carbon Black Ternary Composite Films

Poly(methyl methacrylate)(PMMA)/polystyrene(PS)/carbon black(CB)and poly(ethyl methacrylate)(PEMA)/PS/CB ternary composite films were obtained using solution casting technique to investigate double percolation effect.In both PMMA/PS/CB and PEMA/PS/CB ternary composite films,the CB particles prefer to locate into PS phase based on the results of calculating wetting coefficient,which is also confirmed by SEM images.The conductivity of the films was investigated,and the percolation threshold(￠c)of both ternary composite films with different polymer blend ratios was determined by fitting the McLachlan GEM equation.Conductivity of PMMA/PS/CB ternary composite films showed a typical double percolation effect.However,due to the double emulsion structure of PEMA/PS polymer blends,the PEMA/PS/CB ternary composite films(PEMA/PS=50/50)showed a higher￠c,even CB only located in PS phase,which conflicts with the double percolation effect.A schematic diagram combined with SEM images was proposed to explain this phenomenon.     

Blends of poly(epsilon-caprolactone) and intermediate molar mass polystyrene as Langmuir films at the air/water interface

Poly(epsilon-caprolactone)/polystyrene (PCL/PS) blends, where nonamphiphilic PS is glassy in the bulk state at the experimental temperature of 22.5 degrees C, are immiscible as Langmuir films at the air/water (A/W) interface. Surface pressure-area per monomer isotherm analyses indicate that the surface concentration of amphiphilic PCL is the only factor influencing the surface pressure below the collapse transition. For PS-rich blends, Brewster angle microscopy (BAM) studies at the A/W interface and atomic force microscopy studies on Langmuir-Schaefer films reveal that PS nanoparticle aggregates formed at very low surface pressures can form networks upon further compression. The morphologies seen in PS-rich blends (networklike rings) are consistent with a recent study of a nonamphiphilic polyhedral oligomeric silsesquioxane (POSS), octaisobutyl-POSS, blended with amphiphilic poly(dimethylsiloxane), suggesting that the nonamphiphilic PS aggregates at the A/W interface produce domains with dipole densities that differ from that of pure PCL. In all composition regimes, the amphiphilic PCL phase tends to spread and form a continuous surface layer at the A/W interface, while simultaneously improving the dispersion of nonamphiphilic PS domains. During film expansion, BAM images show a gradual change in the surface morphology from highly continuous networklike structures (PS-rich blends) to broken ringlike structures (intermediate composition) to small discontinuous aggregates (PCL-rich blends). This study provides valuable information on the morphological evolution of semicrystalline PCL-based polymer blends confined in a "two-dimensional" geometry at the A/W interface and fundamental insight into the influence of microstructure (domain size, phase-separated structures, crystalline morphology, etc.) on the interfacial properties of blends as Langmuir films.     

Anomalous reinforcing effects in cellulose gel-based polymeric nanocomposites

Cellulose-synthetic polymer nanocomposite films were prepared by immersion of cellulose gel in polymer solutions followed by dry casting. The cellulose hydrogel was prepared from aqueous alkali-urea solution. As the synthetic polymer, polystyrene (PS) and poly(methyl methacrylate) (PMMA) were used. The polymer content could be changed between 10 and 80% by changing polymer concentration of immersing solution. While the mechanical properties of the cellulose-PMMA composite films showed a nearly linear dependence on PMMA content, those of cellulose-PS composites showed an anomalous behavior; both tensile strength and Young’s modulus showed prominent maxima at 15–30 wt% PS contents. This anomaly may have resulted from the specific interaction between the aromatic ring of PS and the hydrophobic plane of the glucopyranoside. Both PMMA and PS composite films showed significant improvements in dimensional thermal stability; up to 25 wt% synthetic polymer content, the coefficient of thermal expansion (CTE) was as low as ca. 30 ppm/K, about 1/3 of the pure polymers. This indicates that the regenerated cellulose network is effective in suppressing thermal expansion of the synthetic polymers.     

Preparation of micron-sized composite polymer particles containing hydrophilic 2-hydroxyethyl methacrylate and their biomedical applications

Micron-sized polystyrene or PS particles were first prepared by dispersion polymerization. Then a series of polystyrene/poly(styrene-2-hydroxyethyl methacrylate) or PS/P(S-HEMA) composite polymer particles was prepared by seeded copolymerization using different amounts of 2-hydroxyethyl methacrylate (HEMA) at the constant core/shell ratio of 1/0.5. The produced PS seed and composite polymer particles were characterized by transmission electron microscopy. Adsorption behaviors of some biologically active macromolecules were studied under similar conditions. In each case the magnitude of adsorption on composite polymer particles decreased with the increase in HEMA content in the recipe, which means that the hydrophobic interaction between the surface of the particles and biomolecules decreased. The specific activities of trypsin aqueous solution and adsorbed trypsin on PS seed and composite polymer particles prepared with different HEMA contents were also measured and compared. The activity of adsorbed trypsin on composite polymer particles improved significantly with the incorporation of hydrophilic HEMA.     

Surface aggregation structure and surface mechanical properties of binary polymer blend thin films

During preparation of very thin polymer belnd films from a solution of polymers, the phase‐separated structures which are quite different from that observed for the bulk blend film was observed. From atomic force microscopic(AFM) observation, it is concluded that the surface undulation, which reflects the phase separated morphology of the blend system, is present. In the case of (polystyrene(PS)/poly(methyl methacrylate)(PMMA)) blend system, a large influence of end‐group chemistry on the surface morphology was observed. The phase identification of the (rubbery polymer/glassy polymer) binary blend thin films was successfully achieved by scanning vioscoelasticity microsopy(SVM).     

Preparation of a unique microporous structure via two step phase separation in the course of drying a ternary polymer solution

A unique porous polymeric film was prepared by drying a ternary polymer solution: a polystyrene (PS), polyethylene glycol (PEG), and toluene solution. Highly ordered micropores, ranging from 5 to 12 mum in diameter, were formed on the film surface, and the rim of each micropore was surrounded by a ring of PEG. The effects of the weight ratio of the polymer blend and molecular weight of the polymer (PEG) on the porous structure were investigated. Based on in situ visual observation and light scattering measurements, the formation mechanism of the porous structure was speculated to be a two step phase separation: the phase separation into PEG-rich and PEG-poor (i.e., PS-rich) phases occurred first at the surface area of the ternary solutions, where polymers were condensed due to solvent evaporation. The PEG-rich phase became droplets and had an ordered structure on the surface. The PEG-poor phase became a matrix where PS and solvent coexisted as a single phase solution. Secondary phase separation then followed in the PEG droplets, which was induced by further solvent evaporation, and formed into solvent-rich and PEG-rich domains within the droplets. Solvent evaporation and secondary phase separation created a cavity structure in each PEG droplet structured on the film surface.     

Preparation of nonspherical particles via dual-seeded dispersion polymerization in the presence of saturated hydrocarbon droplets

In this study, the effect of various polymerization conditions on the shape of the particles produced by dual-seeded dispersion polymerization of a second monomer with polystyrene (PS) and poly(methyl methacrylate) (PMMA) seed particles in the presence of saturated hydrocarbon droplets in a polar media was discussed. It was observed that with changing the affinity between the hydrocarbon and PS seed particles, second monomer type, polarity, and alcohol type of the medium nonspherical particles with a variety of shapes can be produced. Furthermore, we suggested that the presence of PMMA seed particles in the medium affects the distribution of the second polymer domains on the surface of the PS seed particles in addition to the absorbed amount of the hydrocarbon by PS particles and second polymer domains and the distribution of the hydrocarbon between them. Moreover, the experimental results showed that almond shell-like PS particles can be prepared under certain conditions.     

X-ray microscopy studies of protein adsorption on a phase-segregated polystyrene/polymethyl methacrylate surface. 1. Concentration and exposure-time dependence for albumin adsorption

X-ray photoemission electron microscopy using synchrotron radiation illumination has been used to measure the spatial distributions of albumin on a phase-segregated polystyrene/poly(methyl methacrylate) (PS/PMMA) polymer thin film following adsorption from unbuffered, deionized aqueous solutions under a range of solution concentrations and exposure times. Chemical mapping of the albumin, PS, and PMMA shows that the distribution of albumin on different adsorption sites (PS, PMMA, and the interface between the PS and PMMA domains) changes depending on the concentration of the albumin solution and the exposure time. The preferred sites of absorption at low concentration and short exposure are the PS/PMMA interfaces. Albumin shows a stronger preference for the PS domains than the PMMA domains. The exposure-time dependence suggests that a dynamic equilibrium between albumin in solution and adsorbed on PS domains is established in a shorter time than is required for equilibrating albumin between the solution and the PMMA domains. The explanation of these preferences in terms of possible adsorption mechanisms is discussed.     

Effects of surfactants on the morphology of composite polymer particles produced by two‐stage seeded emulsion polymerization

Poly(methyl methacrylate) (PMMA)–polystyrene (PS) composite polymer particles were synthesized in the presence of a surfactant by two‐stage seeded emulsion polymerization. The first stage was the synthesis of PMMA particles by soapless emulsion polymerization; the second stage was the synthesis of the PMMA–PS composite polymer particles with the PMMA particles as seeds. In the second stage of the reaction, three kinds of surfactants—sodium laurate sulfate (SLS), polyoxyethylene (POE) sorbitan monolaurate (Tween 20), and sorbitan monolaurate (Span 20)—were used to synthesize the PMMA–PS composite particles. Both the properties and concentrations of the surfactants influenced the morphology of the composite particles significantly. Core–shell composite particles, with PS as the shell and PMMA as the core, were synthesized in the presence of a low concentration of the hydrophilic surfactant SLS. This result was the same as that in the absence of the surfactant. However, a low concentration of Tween 20 led to composite particles with a core/strawberry‐like shell morphology; the core region was a PS phase, and the strawberry‐like shell was a PS phase dispersed in a PMMA phase. With an increase in the concentration of SLS, the morphology of the composite particles changed from core (PMMA)–shell (PS) to core (PS)–shell (PMMA). Moreover, the effects of a high concentration of Tween 20 or Span 20 on the morphology of the PMMA–PS composite particles were investigated in this study. © 2005 Wiley Periodicals, Inc. J Polym Sci Part A: Polym Chem 43: 2224–2236, 2005     

Poly(2-acetoxyethyl methacrylate)/polystyrene latex interpenetrating polymer networks with well-defined phase-separated structure

A series of poly(2-acetoxyethyl methacrylate)/polystyrene(PAEMA/PS) latex interpenetrating polymer networks(LIPNs) were prepared by seeded soap-free emulsion polymerization of styrene on the crosslinked PAEMA seed particles using an oil-soluble initiator.These PAEMA/PS LIPNs showed a well-defined phase-separated structure with PS phase dispersing in continuous PAEMA phase.The domain size of PS phase was found to depend on the crosslinking degree of PAEMA seed particles and the amount of second-stage styrene monomer.     

Preparation of hemispherical particles by cleavage of micrometer-sized,spherical poly(methyl methacrylate)/polystyrene composite particle with Janus structure: effect of molecular weight

Micrometer-sized, hemispherical polymer particles were prepared as a result of cleavage of spherical Janus poly(methyl methacrylate) (PMMA)/polystyrene (PS) composite particle by treating particles with acetone/water solutions. The original PMMA/PS composite particles were prepared by the slow evaporation of toluene from homogeneous PMMA/PS/toluene droplets dispersed in aqueous solution of sodium dodecyl sulfate in advance. Appropriate molecular weights of PMMA and PS were necessary for occurrence of the cleavage of the Janus composite particle, resulting in PMMA and PS hemispherical particles. The cleavage depended on the composition of the acetone/water solution, which was explained by selective solvent absorption into the polymer phases. The results strongly support the cleavage mechanism of Janus composite polymer particles that had been proposed earlier.     

Effect of colloidal stabilizer on the shape of polystyrene/poly(methyl methacrylate) composite particles prepared in aqueous medium by the solvent evaporation method

Effects of the kind and concentration of stabilizers on the nonspherical shape of polystyrene (PS)/poly(methyl methacrylate) (PMMA) composite particles prepared by release of toluene from PS/PMMA/toluene droplets dispersed in stabilizer aqueous solution were examined. In the case of poly(vinyl alcohol), the surfaces of the obtained particles always had a single dimple. In the case of sodium dodecyl sulfate (SDS), the shapes of the composite particles changed from the dimple, via acorn, to spherical with increasing SDS concentration. It was clarified that the dimple and acorn shapes of the PS/PMMA composite particles were caused by contraction of the PS phase after hardening of the PMMA phase in excentered core-shell and hemisphere morphologies, respectively, which were formed by phase separation during toluene evaporation.     

The influence of nanoparticle fillers on the morphology of a spin-cast thin film polymer blend

Polymer/nanoparticle composite films are receiving growing attention thanks to their potential for application in ultra-thin electronic and optical devices. Polymer blend demixing has been shown to be a suitable technique for the structuring of polymer thin films and the patterning of nanoparticles (NP) within them. In this work we show that the morphology of thin polymer films made by spin-casting a polymer blend solution containing NP fillers on a surface depends strongly on the concentration of NP fillers. More specifically, polystyrene/polymethylmethacrylate (PS/PMMA) films formed from a toluene solution, and which demix following a nucleation and growth mechanism, were studied. It was found that both the height and the surface density of PMMA domains increased as the concentration of CoPt:Cu NPs in the film was increased. We find that similar effects are induced in a NP-free PS/PMMA demixed film upon increasing the molecular weight of the PS molecules. This suggests that under certain conditions the NPs and the polymer molecules in the blend do not behave as separate species but form aggregates.     

Interface interaction within nanopores in thin films of an amphiphilic block copolymer and CTAB

Anion exchange membranes with semi-interpenetrating polymer network (semi-IPN) were prepared based on quaternized chitosan (QCS) and polystyrene (PS). The PS was synthesized by polymerization of styrene monomers in the emulsion of the QCS in an acetic acid aqueous solution under nitrogen atmosphere at elevated temperatures. The semi-IPN system was formed by post-cross-linking of the QCS. A hydroxyl ionic conductivity of 2.80×10(-2) S cm(-1) at 80°C and a tensile stress at break of 20.0 MPa at room temperature were reached, respectively, by the semi-IPN membrane containing 21 wt.% of the PS. The durability of the semi-IPN membrane in alkaline solutions was tested by monitoring the variation of the conductivity and the mechanical strength. The degradation of the conductivity at 80°C was about 5% by immersing the membrane in a 1 mol L(-1) KOH solution at room temperature for 72 h and at 60°C for 50 h, respectively. The tensile stress at break at room temperature could maintain about 20.0 MPa for the membrane soaking in a 10 mol L(-1) KOH solution at ambient temperature for more than 70 h. The water swelling of the semi-IPN membranes was discussed based on the stress relaxation model of polymer chains, and it obeyed the Schott's second-order swelling kinetics.     

Fracture surface morphology and phase relationships of polystyrene/poly(methyl methacrylate) systems. I. Low-molecular-weight polystyrene in poly(methyl methacrylate)

Samples of low-molecular-weight polystyrene (PS) in poly(methyl methacrylate) (PMMA) were prepared by first dissolving PS in methyl methacrylate monomer and then polymerizing the monomer. Forty-three specimens of varying number-average molecular weight (2100–49,000) and composition (5–40 wt %) of PS were prepared, and the surface morphology and phase relationships studied by scanning electron microscopy. Four distinct types of phase relationships were observed: (i) a single phase consisting of PS dissolved in PMMA; (ii) PS dispersed in PMMA; (iii) PMMA dispersed in PS; and (iv) regions of PS dispersed in PMMA coexisting with regions of PMMA dispersed in PS. Values of the size and population density of the dispersed particles are reported. Finally, the size and distribution of the dispersed particles and the various types of phase relationships are discussed in terms of the ternary polystyrene/poly(methyl methacrylate)/methyl methacrylate phase diagram.     

Formation of "snowmanlike" polystyrene/poly(methyl methacrylate)/toluene droplets dispersed in an aqueous solution of a nonionic surfactant at thermodynamic equilibrium

"Snowmanlike" polystyrene (PS)/poly(methyl methacrylate) (PMMA) composite particles were prepared by evaporation of toluene from PS/PMMA/toluene droplets dispersed in an aqueous solution of polyoxyethylene nonylphenyl ether surfactant (Emulgen 911). Partitioning experiments revealed that the Emulgen 911 concentration was higher in the droplets than in the aqueous solution during toluene evaporation. As a consequence, the interfacial tensions between the polymer phases (PS and PMMA) and the aqueous phase (gammaP-T/W) were extraordinarily low (approximately 10(-1) mN/m). The interfacial tension between the PS and PMMA phases containing toluene (gammaPS-T/PMMA-T) measured by the spinning drop method was not affected by the presence of Emulgen 911. Based on minimization of the total interfacial free energy at a polymer weight fraction in the toluene droplet of 0.17, the formation of spherical droplets is expected, in agreement with experiment. The subsequent morphology change of the PS/PMMA/toluene droplets from spherical to snowmanlike during toluene evaporation under thermodynamic equilibrium is attributed to (i) the low values of gammaP-T/W, which explains the increase in the interfacial area between the droplets and the aqueous phase, and (ii) the increase in gammaPS-T/PMMA-T with increasing polymer weight fraction.     

The morphology of composite polymer particles produced by multistage soapless seeded emulsion polymerization

 Composite polymer particles which contain poly(methyl methacrylate) (PMMA) and polystyrene (PS) components (PMMA/PS composite particle) were synthesized by the method of multistage soapless seeded emulsion polymerization. In this study, the process of multistage soapless seeded emulsion polymerization included two-stage polymerization, three-stage polymerization or four-stage polymerization. The morphologies of the PMMA/PS composite particles were studied. The kinetic factor was the main force to control the morphology of the linear PMMA–PS composite particles which were synthesized by the method of two-stage reaction. Both the kinetic factor and the thermodynamic factor decide the morphology of the linear composite particles which were synthesized by the method of either three-stage or four-stage reaction. However, the thermodynamic factor cannot influence the morphology of the PMMA/PS composite particles with a cross-linked structure which were synthesized by the method of three-stage reaction. The cross-linked composite polymer particles had the morphology of a multilayer structure, which showed that the polymer layers accumulated in their order of production. Received: 9 January 2001 Accepted: 14 June 2001     

Morphology of micron-sized monodispersed composite polymer particles produced by seeded polymerization for the dispersion of highly monomer-swollen polymer particles

 Monodispersed polystyrene (PS)/poly(n-butyl methacrylate) (PBMA) composite particles having 9.4 μm in diameter were produced by seeded polymerization for the dispersion of highly n-butyl methacrylate (BMA)-swollen PS particles, and their morphologies were examined. The highly BMA-swollen PS particles (about 150 times the weight of the PS seed particles) were prepared by mixing monodispersed 1.8 μm-sized PS seed particles and 0.7 μm sized BMA droplets prepared with an ultrasonic homogenizer in ethanol/water (1/2, w/w) medium at room temperature. After NaNO₂ aqueous solution as inhibitor was added in the dispersion, the seeded polymerization was carried out at 70 °C. In an optical microscopic observation, one or two spherical high contrast regions which consisted mainly of PS were observed inside PS/PBMA composite particles. In the PS domain, there were many fine spherical PBMA domains. Such morphologies were based on the phase separation of PS and PBMA within the homogeneous swollen particles during the seeded polymerization. Received: 04 June 1997 Accepted: 27 August 1997