Creation of ordered patterns by dewetting of thin films on homogeneous and heterogeneous substrates

Spontaneous formation of locally ordered patterns during dewetting of thin films on homogeneous and heterogeneous substrates is investigated based on the 3-D nonlinear equation of motion. Physicochemical heterogeneities engender the rapid formation of the primary holes that serve as "seeds" for the formation of locally ordered structures. The secondary multiring structure surrounding the primary hole evolves by one of the following two different pathways depending on the film thickness vis-à-vis the location of the minimum in the spinodal curve: (A) Thick films evolve by the formation of secondary satellite holes that originate from a ring-like depression behind the rim of the primary hole. The process of ordering is repeated until the true spinodal holes appear on the remaining substrate. (B) Ordering in a relatively thin film occurs by the formation of droplets caused by the disintegration of the elevated rim that surrounds the primary hole. The radial distance between the successive ordered layers is close to the spinodal length scale, lambda(m). Droplets within the same layer are separated by a distance slightly greater than lambda(m), whereas holes within the same layer are separated by a distance slightly less than lambda(m). The number density of holes or droplets in the ordered pattern is of the same order as the predictions of the spinodal theory. The number of ordered layers and the size of the locally ordered domain depend significantly on the relative magnitudes of the time scales for the following events: (1) formation of the primary hole, (2) growth of holes (inverse of hole-growth velocity), (3) formation of a secondary feature (hole or droplet) adjacent to the primary hole, (4) true spinodal rupture far from the primary hole. The morphology of an ordered structure can therefore be tailored by modulation of the film thickness and the short- and long-range intermolecular interactions (substrate surface properties), since these affect the time scales 1 to 4 in different ways.     

Polymer crystallization of ultrathin films on solid substrates

Recently, polymer crystallization in ultrathin films (thickness less than 100 nm) on solid substrates has attracted increased attention. As it can be considered to be a quasi-two-dimensional (2D) system with one-dimensional (1D) confinement along the substrate normal, ultrathin polymer film offers unique possibilities for testing the theories of crystallization and for studying the effects of confinement and interface which may invoke new mechanisms other than those applied in bulk crystallization of polymers. In this article, we will summarize the important results of ultrathin film crystallization of polymers obtained in the past decades. The morphologies, the crystallization kinetics, and the transformation between monolayer crystals with various metastabilities are reviewed in depth, with an attempt at discussing the ultrathin polymer film crystallization in the general framework of thermodynamics and kinetics of crystallization.     

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     

Thickness-dependent autophobic dewetting of thin polymer films on coated substrates

We demonstrate that the wetting behavior of a thin liquid film, poly(4-bromostyrene) (PBrS), on top of a solid substrate may be effectively controlled with the insertion of a secondary liquid film, poly(4-vinyl pyridine) (P4VP), underneath the primary film. This secondary film remains stable under all conditions, and can be viewed as an extension of the substrate itself. On the basis of results from X-ray standing waves generated via total external reflection from an X-ray mirror, time-of-flight secondary ion mass spectroscopy, optical microscopy, and atomic force microscopy, we construct the full Helmholtz free energy versus PBrS thickness curve using existing theories that account for both long- and short-range interactions. The form of the free energy curve, which contains an inflection point and an absolute minimum at a nonzero PBrS thickness, accurately reflects our observation that thick PBrS films undergo autophobic dewetting on top of the stable P4VP, while sufficiently thin PBrS films remain stable. The thickness of the autophobic wetting layer is controlled by the range of the repulsive interaction between the film and the substrate, and is found to be ～4 nm for the PBrS/P4VP interface.     

A criterion for dewetting initiation from surface disturbances on ultrathin polymer films

Nanoindentation-induced defects on ultrathin (h = 17 nm) polystyrene (PS) films that are spin cast on silicon (Si) substrates, with residual depths of penetration lower than the film thickness (<17 nm), can either grow to initiate dewetting or level, which results in a flat polymer surface, upon heating above the glass-transition temperature (T(g)). The excess surface energy (DeltaF(gamma)) of the system, which is added to the initially flat coating with the formation of an indent, provides a critical value, DeltaF(gamma,crit) = 6.1 x 10(-16) J, which determines indent evolution upon annealing. An indent grows when DeltaF(gamma) > DeltaF(gamma,crit) and levels when DeltaF(gamma) < DeltaF(gamma,crit). This conclusion is in agreement with previous reports, which used DeltaF(gamma) to distinguish the two (dewetting/leveling) opposing processes (1) in the case of indents deeper than the film thickness and (2) in the case of built-in ordered surface disturbances by capillary force lithography.     

Apparent dewetting of ultrathin multilayered polyelectrolyte films incubated in aqueous environments

We have investigated and characterized changes in film morphology and surface structure that occur when ultrathin multilayered polyelectrolyte films fabricated from linear poly(ethylene imine) (LPEI), sodium poly(styrene sulfonate) (SPS), and two hydrolytically degradable polyamines (polymers 1 and 2) are incubated in physiologically relevant environments. Characterization of the physical erosion profiles of films having the structure (LPEI/SPS)10(1/SPS)4(2/SPS)4 (approximately 80 nm thick) by atomic force microscopy (AFM), reflective optical microscopy, and scanning electron microscopy (SEM) demonstrated that these materials undergo large-scale changes in surface structure and morphology upon incubation in phosphate-buffered saline (PBS) at 37 degrees C. The patterns and structures generated during this transformation (e.g., nucleation and growth of holes, coalescence of holes, formation of cell-type structures, and the subsequent breakup of these features into droplets) are similar in many ways to those observed for the dewetting of thin films of conventional polymers, such as polystyrene, on nonwetting surfaces. The processes reported here are sufficiently slow (they occur over approximately 100 h) and occur under sufficiently mild conditions (e.g., incubation in PBS at 37 degrees C) to permit characterization and quantification of the structures and features that arise during the course of these transformations. The apparent dewetting of these ultrathin films upon exposure to aqueous environments creates future opportunities to investigate and characterize processes of mass transport in this class of ionically cross-linked assemblies.     

Coupling of microphase separation and dewetting in weakly segregated diblock co-polymer ultrathin films

We have studied the coupling behavior of microphase separation and autophobic dewetting in weakly segregated poly(ε-caprolactone)-block-poly(L-lactide) (PCL-b-PLLA) diblock co-polymer ultrathin films on carbon-coated mica substrates. At temperatures higher than the melting point of the PLLA block, the co-polymer forms a lamellar structure in bulk with a long period of L ～ 20 nm, as determined using small-angle X-ray scattering. The relaxation procedure of ultrathin films with an initial film thickness of h = 10 nm during annealing has been followed by atomic force microscopy (AFM). In the experimental temperature range (100-140 °C), the co-polymer dewets to an ultrathin film of itself at about 5 nm because of the strong attraction of both blocks with the substrate. Moreover, the dewetting velocity increases with decreasing annealing temperatures. This novel dewetting kinetics can be explained by a competition effect of the composition fluctuation driven by the microphase separation with the dominated dewetting process during the early stage of the annealing process. While dewetting dominates the relaxation procedure and leads to the rupture of the ultrathin films, the composition fluctuation induced by the microphase separation attempts to stabilize them because of the matching of h to the long period (h ～ 1/2L). The temperature dependence of these two processes leads to this novel relaxation kinetics of co-polymer thin films.     

Growth modes of ultrathin metal films on dissimilar metal substrates

This paper outlines some of the outstanding problems associated with the experimental determination of the growth modes of thin metal films on dissimilar metal substrates, and suggests approaches for overcoming them. Specifically, it discusses ways to differentiate between Stranski-Krastanov and alloy growth, the quantitative fitting of “Auger signaltime” plots, and the determination of the stoichiometry of surface alloys. A comparison of the observed growth modes with those predicted by the Macroscopic Atom Method shows that the results predicted by this method must be treated with extreme caution.     

Epitaxial recrystallization of HDPE-quenched ultrathin films on oriented iPP substrates

The recrystallization behavior of high-density polyethylene (HDPE) on the highly oriented isotactic polypropylene (iPP) substrates at temperatures below the melting temperature of HDPE has been investigated by means of transmission electron microscopy. The results obtained by the bright-field observation and the electron diffraction show that upon annealing the HDPE-quenched films on the oriented iPP substrates at temperatures below 125°C, only a small amount of HDPE recrystallizes on the iPP substrate with [001]_HDPE//[001]_iPP, while annealing the HDPE-quenched films at temperatures above 125°C, all of the HDPE crystallites recrystallize epitaxially on the iPP substrate with [001]_HDPE//[101]_iPP. © 1997 John Wiley & Sons, Inc. J Polym Sci B: 35 : 1415–1421, 1997     

Direct visualization of dewetting of molecularly thin liquid films on solid surfaces

The effect of the surface energy gamma, disjoining pressure, Pi, and roughness on the dewetting of molecularly thin liquid lubricant films on magnetic disks, which have sub-nanometer surface topography, has been investigated by visualizing the dewetting process directly using ellipsometric microscopy. The dewetting process of thin liquids on the rough surface is determined not only by the well-known instability of films, which is determined by the sign of dPi/dh, but also by the sign of Pi and the surface topography of the substrate even if its roughness is of the sub-nanometer order. The dewetting film formed small droplets, which were not along the surface topography of the substrate, when Pi < 0. On the other hand, it formed grooves along the surface topography with a sub-nanometer roughness when Pi > 0. Moreover, the sub-nanometer roughness initiated the dewetting of the metastable liquid thin films.     

Static contact angle hysteresis on smooth, homogeneous solid substrates

A theory of contact angle hysteresis on smooth, homogeneous solid substrates is developed in terms of shape of disjoining/conjoining pressure isotherm and quasi-equilibrium phenomena. It is shown that all contact angles, θ, in the range θ _r?<?θ?<?θ _a, which are different from the unique equilibrium contact angle θ?≠?θ _e, correspond to the state of slow “microscopic” advancing or receding motion of the liquid if θ _e ?<?θ?<?θ _a or θ _r?<?θ?<?θ _e, respectively. This “microscopic” motion almost abruptly becomes fast “macroscopic” advancing or receding motion after the contact angle reaches the critical values θ?=?θ _a or θ _r?=?θ, correspondingly. The values of the static receding, θ _r, and static advancing, θ _a, contact angles in cylindrical capillaries were calculated earlier, based on the shape of disjoining pressure isotherm. It is shown that an advancing contact angle of a droplet on a solid substrate depends on the drop volume and is not a unique characteristic of the liquid–solid system. The suggested mechanism of contact angle hysteresis has direct experimental confirmation.     

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     

Electrodeposition for obtaining homogeneous or heterogeneous cobalt-copper films

Direct electrodeposition of heterogeneous deposits may be an alternative method for preparing cobalt-copper coatings with magnetoresistive properties. Co-Cu electrodeposition was obtained in sulfate baths containing different citrate concentrations in order to prepare either homogeneous or heterogeneous Co-Cu deposits. X-ray diffraction (XRD) and voltammetric stripping analysis were used to study the kind of deposits formed. Citrate-free baths produced heterogeneous films, although dendritic growth was observed, thus increasing the deposit's thickness. Increasing the Cu(II)/Co(II) ratio in solution enabled the formation of smoother deposits. The presence of citrate at up to twice the total metallic concentration in the bath improved the morphological aspects of the deposits, their structural heterogeneity being maintained. Higher citrate concentrations induced the loss of heterogeneity, and both electrochemical and diffraction peaks tended towards single peaks. Homogeneous Co-Cu deposits, formed by a solid solution structure, were obtained in highly complexed citrate baths.     

Phase behavior and dewetting for polymer blend films studied by in situ AFM and XPS: from thin to ultrathin films

In this work, the film thickness (l0) effect on the phase and dewetting behaviors of the blend film of poly(methyl methacrylate)/poly(styrene-ran-acrylonitrile) (PMMA/SAN) has been studied by in situ atomic force microscopy (AFM) and X-ray photoelectron spectroscopy (XPS). The thinner film shows the more compatibility of the blend, and the phase separation of the film occurs at l0>5Rg (radius of gyration). An initially time-independent q*, the characteristic wavenumber of the phase image, which is in good agreement of Cahn's linearized theory for the early stage of spinodal decomposition, has been obtained in real space and discussed in detail. For 5Rg>l0>3Rg, a "pseudo-dewetting/(phase separation+wetting)" behavior occurs, where the pseudo-wetting is driven by the concentration fluctuation mechanism. For l0<3Rg, a "real dewetting/(phase separation+wetting)" behavior occurs.     

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.     

Viscoelastic dewetting of constrained polymer thin films

Thin films of fluids are playing a leading role in countless natural and industrial processes. Here we study the stability and dewetting dynamics of viscoelastic polymer thin films. The dewetting of polystyrene close to the glass transition reveals unexpected features: asymmetric rims collecting the dewetted liquid and logarithmic growth laws that we explain by considering the nonlinear velocity dependence of friction at the fluid/solid interface and by evoking residual stresses within the film. Systematically varying the time so that films were stored below the glass-transition temperature, we studied simultaneously the probability for film rupture and the dewetting dynamics at early stages. Both approaches proved independently the significance of residual stresses arising from the fast solvent evaporation associated with the spin-coating process. © 2006 Wiley Periodicals, Inc. J Polym Sci Part B: Polym Phys 44: 3022–3030, 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     

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.     

Kinetics of fluid spreading on viscoelastic substrates

The spontaneous spreading of non‐film‐forming fluids on the surfaces of aqueous solutions of poly(2‐acrylamido‐2‐methyl‐propanesulfonic acid) and its chemically crosslinked gels was studied. The experiments were performed in the same concentration range for the solutions and gels, far above the overlap concentration of the polymer solutions. The leading edge (R) of the spreading liquid showed a power‐law behavior with time t: R = K(t + c)^α, where α is the spreading exponent and K is the spreading prefactor. α and K were significantly different for the polymer solutions and gels. Here c was a constant that depended on the initial conditions of the spreading liquids. Depending on the polymer concentration, α of the polymer solutions varied between the upper (3/4) and lower (1/10) theoretical limits for viscose liquids and solids, respectively. This indicates that no universal scaling law exists for the spreading process on viscoelastic surfaces. On the polymer gels, which were elastic substrates, universal values of α could be observed and could be expressed as R ∝ (t + c)^0.45 and R ∝ (t + c)^0.3 for miscible and nonmiscible spreading liquids, respectively; they showed no dependence on the polymer concentration or network mesh size. This shows that on an elastic gel surface, spreading is more or less similar to that on a solid surface. © 2005 Wiley Periodicals, Inc. J Polym Sci Part B: Polym Phys 43: 562–572, 2005     

Solvation in homogeneous and heterogeneous media

A short account on solvation of solute in Homogeneous and Heterogeneous Media has been presented. Basic concepts of specific and nonspecific interactions with some specific examples are discussed based on Koppel and Palm (KP) and Abaham, Kamlet and Taft (AKT) approaches. List of AKT parameters describing specific and non-specific solvation parameters for homogeneous media (pure solvents) and heterogeneous media (micelles) has been presented in tables.