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.     

Effect of substrate surface on dewetting behavior and chain orientation of semicrystalline block copolymer thin films

Three symmetrical semicrystalline oxyethylene/oxybutylene block copolymers (EmBn) were spin-coated on different substrates including silicon, hydrophobically modified silicon, and mica. The effects of surface property on the dewetting behavior of EmBn thin films and the chain orientation of the crystalline block were investigated with atomic force microscopy and grazing incidence X-ray diffraction . The EmBn thin films on silicon exhibit an autophobic dewetting behavior, while ordinary dewetting occurs for the thin films on modified silicon. It was observed that the stems of the E crystals in the first half-polymer layer contacting the mica surface were parallel to the surface, in contrast to the perpendicular chain orientation of the other polymer layers and of the first half-polymer layer on silicon. This is attributed to the strong interaction between the E block and mica, verified by infrared spectra.     

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     

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.     

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.     

Slippage of Newtonian liquids: influence on the dynamics of dewetting thin films

Slippage of Newtonian liquids in the presence of a solid substrate is a newly found phenomenon, the origin of which is still under debate. In this article, we present a new analysis method to extract the slip length. Enhancing the slip of liquids is an important issue for microfluidic devices that demand for high throughput at low pumping power. We study the velocity of short-chained liquid polystyrene (PS) films dewetting from nonwettable solid substrates. We show how the dynamics of dewetting is influenced by slippage, and we compare the results of two types of substrates that give rise to different slip lengths. As substrates, Si wafers that have been coated with octadecyltrichlorosilane (OTS) or dodecyltrichlorosilane (DTS) were used. Our results demonstrate that the dewetting velocity for PS films on DTS is significantly larger than on OTS and that this difference originates from the different slip lengths of the liquid on top of the two surfaces. For PS films of thickness between 130 and 230 nm, we find slip lengths between 400 nm and 6 microm, depending on substrate and temperature.     

Influence of molecular architecture on the dewetting of thin polystyrene films

The control of dewetting for thin polymer films is a technical challenge and of significant academic interest. We have used polystyrene nanoparticles to inhibit dewetting of high molecular weight, linear polystyrene, demonstrating that molecular architecture has a unique effect on surface properties. Neutron reflectivity measurements were used to demonstrate that the nanoparticles were uniformly distributed in the thin (ca. 40 nm) film prior to high temperature annealing, yet after annealing, they were found to separate to the solid substrate, a silanized silicon wafer. Dewetting was eliminated when the nanoparticles separated to form a monolayer or above while below this surface coverage the dewetting dynamics was severely retarded. Blending linear polystyrene of similar molecular weight to the polystyrene nanoparticle with the high molecular weight polystyrene did not eliminate dewetting.     

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.     

Photoactive additives for cross-linking polymer films: Inhibition of dewetting in thin polymer films

In this report, we describe a versatile photochemical method for cross-linking polymer films and demonstrate that this method can be used to inhibit thin polymer films from dewetting. A bifunctional photoactive molecule featuring two benzophenone chromophores capable of abstracting hydrogen atoms from various donors, including C-H groups, is mixed into PS films. Upon exposure to UV light, the bis-benzophenone molecule cross-links the chains presumably by hydrogen abstraction followed by radical recombination. Photoinduced cross-linking is characterized by infrared spectroscopy and gel permeation chromatography. Optical and atomic force microscopy images show that photocrosslinked polystyrene (PS) thin films resist dewetting when heated above the glass transition temperature or exposed to solvent vapor. PS films are inhibited from dewetting on both solid and liquid substrates. The effectiveness of the method to inhibit dewetting is studied as a function of the ratio of cross-linker to macromolecule, duration of exposure to UV light, film thickness, the driving force for dewetting, and the thermodynamic nature of the substrate.     

Structure and dewetting behavior of polyhedral oligomeric silsesquioxane-filled polystyrene thin films

Polyhedral oligomeric silsesquioxane (POSS) meets increasing interest as a building unit for inorganic-organic hybrid materials. The incorporation of cyclopentyl-substituted POSS (CpPOSS) into polystyrene (PS) thin films led to an inhibition of dewetting. In this paper, the dispersion state of CpPOSS in the CpPOSS/PS hybrid films and, furthermore, the relationships between the structure and dewetting inhibition effect are discussed. Structural analysis of the hybrid films revealed that CpPOSS segregated to the film surface and crystallized. The segregation of CpPOSS to the surface changes the surface free energy and spreading coefficient of the film. Interfacial structure was also roughened by the segregation of CpPOSS, which can contribute to the inhibition of dewetting by pinning the contact line of the PS film with the substrate. The inhibition of dewetting can be attributed to the modification of the film surface and interface by the segregation of CpPOSS.     

Electrically anisotropic thin films consisting of polymeric and metallic nanolayers from self-assembled lamellae of diblock copolymers

We demonstrated the fabrication of electrically anisotropic thin films of alternating polymeric layers and metallic layers in nanometer thickness by utilizing self-assembled nanodomains of symmetric diblock copolymers. Nanometer-thick metal layers macroscopically parallel to the film plane were synthesized by electroless Ag deposition on Au nanoparticles selectively in one of the blocks. Every Ag/Au layer was completely separated by nanometer-thick polymer layers in the direction perpendicular to the film plane. Therefore, the conductivity of the film was highly anisotropic, differing by at least 8 orders of magnitude in directions parallel and perpendicular to the film plane, even though the in-plane conductivity (2.8 x10(-6) S/cm) was in the range of semiconductors. If self-assembled nanodomains of diblock copolymers were not employed, a serial layer-by-layer process for each layer would be required to fabricate such an electrically anisotropic thin film.     

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.     

Early and intermediate stages of guided dewetting in polystyrene thin films

We investigated the early and intermediate stages of the guided dewetting of polystyrene (PS) thin films on chemically patterned silicon, achieved by micro-contact printing of non-wettable self-assembling monolayers of an alkylsilane. Two different types of ordered patterns could be achieved depending on the annealing temperature and time. Study of the dynamics of hole growth revealed a deviation of the growth profile from the trend on homogeneous substrates, attributed to the pinning of the PS rims on the borders of the hydrophobic regions. The ordered patterns produced could be useful in applications that require spatially localized features of controlled surface chemistry, such as studies in proteomics, single cell studies, and biosensors.     

Atomic force microscopy studies on the dewetting of perfluorinated ionomer thin films

The surface structure and dewetting process of thin films of complex perfluorinated ion‐containing polymers have been studied with atomic force microscopy. These polymers, or ionomers, consist of hydrophilic, hydrophobic, and ionic groups, which are noncompatible with one another, and this results in the association of the polymers into supramolecular structures. These types of polymers have a broad range of technological uses, ranging from thin selective coatings to fuel cells in the form of polymer electrolyte membranes. As the technology calls for thinner films, the interfacial structure and dynamics (wetting/dewetting) of the films become critical in controlling the overall behavior of the polymers. The ionomer under consideration forms structured films consisting of bundles of micelles. These ultrathin films do not dewet above the glass‐transition temperatures of the polymers, contrary to what has been observed in thin diblock copolymers. Perturbing the system with a high‐ionic‐strength solution, however, results in a breakup of the primary aggregate and enhances the adhesion of the films and their stability. © 2002 Wiley Periodicals, Inc. J Polym Sci Part B: Polym Phys 41: 149–158, 2003     

Nonlinear evolution of thin liquid films dewetting near soft elastomeric layers

The nonlinear evolution of thin liquid films dewetting near soft elastomeric layers is examined in this work. Evolution equations are derived by applying the lubrication approximation and assuming that van der Waals forces in the liquid cause the dewetting and that the solid can be described as a linear viscoelastic material. Two cases are examined: (i) a liquid layer resting on an elastomer bounded from below by a rigid substrate, and (ii) an elastomer overlying a thin liquid film bounded from below by a rigid substrate. Linear stability analysis is carried out to obtain asymptotic relations which are then compared against solutions of the full characteristic equations. In the liquid-on-solid case, numerical solutions of the evolution equations show that van der Waals forces cause thinning of the liquid film and thickening of the elastomeric solid beneath film depressions. Inclusion of a short-range repulsive force suggests that regular patterns may form in which ridges of fluid rest on depressions in the solid. In the solid-on-liquid case, the van der Waals forces cause the solid layer to break up before the liquid film can dewet. The results presented here support the idea that the dewetting of thin liquid films might be exploited to create topographically patterned surfaces on soft polymeric solids.     

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.     

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     

Contact instability of thin elastic films on patterned substrates

The free surface of a soft elastic film becomes unstable and forms an isotropic labyrinth pattern when a rigid flat plate is brought into adhesive contact with the film. These patterns have a characteristic wavelength, lambda approximately 3H, where H is the film thickness. We show that these random structures can be ordered, modulated, and aligned by depositing the elastic film (cross-linked polydimethylsiloxane) on a patterned substrate and by bringing the free surface of the film in increasing adhesive contact with a flat stamp. Interestingly, the influence of the substrate "bleeds" through the film to its free surface. It becomes possible to generate complex two-dimensional ordered structures such as an array of femtoliter beakers even by using a simple one-dimensional stripe patterned substrate when the instability wavelength, lambda approximately 3H, nearly matches the substrate pattern periodicity. The free surface morphology is modulated in situ by merely varying the stamp-surface separation distance. The free surface structures originating from the elastic contact instability can also be made permanent by the UV-ozone induced oxidation and stiffening.     

Synthesis, post-modification and self-assembled thin films of pentafluorostyrene containing block copolymers

Block copolymers consisting of a pentafluorostyrene (PFS) block and a hydrophilic block were synthesized by RAFT polymerisation. The hydrophilic blocks consist of methacrylate derivatives, 4-hydroxystyrene or 4-vinylpyridine monomers. The block copolymers were obtained with narrow molecular weight distributions and the molecular weights were in good agreement with the theoretical values. In addition, a model thiol was reacted with the PFS moieties of the block copolymers. This polymer–analogous reaction was performed under ambient conditions in high yields resulting quantitatively in para-substitution of the pentafluorophenyl rings. Finally, thin films consisting of block copolymers that showed strong phase-segregation behaviour and ordered nanostructured surfaces consisting of both blocks were obtained.