Dipping versus spraying: exploring the deposition conditions for speeding up layer-by-layer assembly

Polyelectrolyte film fabrication by successive spraying of polycation and polyanion solutions is described and compared to classic dipping. The poly(styrenesulfonate)/poly(allylamine) system is examined in detail. The influence of various parameters such as spraying time, polyelectrolyte concentration, and effect of film drying during multilayer construction is investigated. It is found that film deposition by spraying is easily controlled and very reliable. The thickness of the multilayers grows linearly with the number of deposition cycles similarly to what is observed when dipping substrates or when polyelectrolyte solutions flow over a surface. The assembly of films is very fast and leads to films with small surface roughness as estimated by atomic force microscopy and X-ray reflectometry. Spray deposition allows achieving regular multilayer growth even under conditions for which dipping fails to produce homogeneous films (e.g., extremely short contact times). Moreover, because drainage constantly removes a certain quantity of the excess material arriving at the surface, one can even skip the rinsing step and, thus, speed up even further the whole buildup process.     

Influence of the polyelectrolyte molecular weight on exponentially growing multilayer films in the linear regime

Alternated deposition of polyanions and polycations on a charged solid substrate leads to the buildup of polyelectrolyte multilayer (PEM) films. Two types of PEM films were reported in the literature: films whose thickness increases linearly and films whose thickness increases exponentially with the number of deposition steps. However, it was recently found that, for exponentially growing films, the exponential increase of the film thickness takes place only during the initially deposited pairs of layers and is then followed by a linear increase. In this study, we investigate the growth process of hyaluronic acid/poly(L-lysine) (HA/PLL) and poly(L-glutamic acid)/poly(allylamine) (PGA/PAH) films, two films whose growth is initially exponential, when the growth process enters the linear regime. We focus, in particular, on the influence of the molecular weight (Mw) of the polyelectrolytes. For both systems, we find that the film thickness increment per polyanion/polycation deposition step in the linear growth regime is fairly independent of the molecular weights of the polyelectrolytes. We also find that when the (HA/PLL)n films are constructed with low molecular weight PLL, these chains can diffuse into the entire film during each buildup cycle, even for very thick films, whereas the PLL diffusion of high molecular weight chains is restricted to the upper part of the film. Our results lead to refinement of the buildup mechanism model, introduced previously for the exponentially growing films, which is based on the existence of three zones over the entire film thickness. The mechanism no longer needs all the "in" and "out" diffusing polyanions or polycations to be involved in the buildup process to explain the linear growth regime but merely relies on the interaction between the polyelectrolytes with an upper zone of the film. This zone is constituted of polyanion/polycation complexes which are "loosely bound" and rich in the polyelectrolyte deposited during the former deposition step.     

Formation of polyelectrolyte multilayers from polysaccharides at low ionic strength

Layer-by-layer deposition of sodium carboxymethylcellulose (NaCMC) and chitosan (CHI) was used to create polyelectrolyte multilayers on ellipsoidal beta-FeOOH particles at low ionic strength. Using electro-optics, we investigated the formation of films in dependence on the polyelectrolyte charge density by controlling pH of the dipping solutions. We found out a linear growth of the CMC/CHI films when they are constructed from highly charged CHI (at pH 4.0) and weakly charged NaCMC (at pH 4.0 and 5.5). The hydrodynamic thickness of the film constructed at pH 4.0/4.0 is unusually large for a linearly growing film (ca. 220 nm after deposition of 8 bilayers), but it strongly decreases (ca. 4 times) with increasing ionization of NaCMC (at pH 5.5). In both cases, the multilayer buildup proceeded through a series of adsorption-desorption steps. This was explained by a partial loss of CHI from the film surface on exposure to the solution of longer NaCMC molecules. The irregular film growth correlated quite well with the variations in the electrical polarizability of the polymer-coated particles. This correlation enabled us to conclude that the adsorption of both polymers occurs only on the film surface, with no diffusion in and out of the film bulk during deposition of each CMC/CHI bilayer.     

Effect of temperature on the buildup of polyelectrolyte multilayers

The effect of temperature on the buildup of polyelectrolyte multilayers consisting of poly(styrenesulfonate) (PSS), poly(diallyldimethylammonium) (PDADMA), and poly(allylamine) (PAH) was studied by using a quartz crystal microbalance. The increase of temperature in the deposition process was shown to have a considerable effect on the rate of the layer-by-layer buildup. The effect of temperature on the PDADMA/PSS deposition was found to be stronger than on the PAH/PSS deposition. The increasing temperature was found to extend the exponential buildup regime in all of the studied systems. A buildup model was created to simulate the buildup and to explain the effect of temperature. The model is based on the assumption that each deposition step leads to a quasi-equilibrium between the concentration of the polymer repeating unit in solution and the composition of the layer. According to the model, the layer-by-layer buildup is inherently exponential, becoming linear whenever diffusion is not fast enough to carry the polymer within the entire thickness of the film. This buildup model is discussed jointly with the earlier published three-zone model of the polyelectrolyte multilayers. The rate of the buildup is characterized by growth exponent beta. The temperature dependence of the growth exponent is discussed in connection with the thermodynamic parameters of the deposition.     

Layer by layer self-assembled polyelectrolyte multilayers with embedded phospholipid vesicles obtained by spraying: integrity of the vesicles

In a previous paper (Michel, M.; Vautier, D.; Voegel, J.-C.; Schaaf, P.; Ball, V. Langmuir 2004, 20, 4835), we showed that phospholipid vesicles can be incorporated into poly(glutamic-acid)/poly(allylamine) (PGA/PAH) multilayered polyelectrolyte films built by the alternated dipping of a surface in polyanion and polycation solutions. AFM imaging, quartz crystal microbalance, and ellipsometry suggested that the vesicles remain intact when adhering on the surface. In the present paper, we show that such films can also be realized by spraying both the polyelectrolyte solutions and the vesicles onto the surface. Using such vesicles filled with ferrocyanide ions, we prove by cyclic voltammetry that the sprayed vesicles remain intact when embedded in the multilayers. We show that multilayers containing two distinct layers of intact vesicles separated by several polyanion/polycation bilayers can also be constructed. Polyelectrolyte multilayers containing layers of phospholipid vesicles could act as reservoirs for drug or other biologically active molecules in controlled release bioactive coatings.     

Polypeptide multilayer films on colloidal particles: an in situ electro-optical study

The buildup of poly(L-glutamic acid) (PGA) and poly(L-lysine) (PLL) multilayers on beta-FeOOH colloidal particles was investigated by means of electro-optics and electrophoresis. The films were built at different (acidic) pH in the absence of salt. We found that the thickness of the film grows linearly when the fully charged PLL (at pH 5.5) is combined with almost fully charged PGA (at pH 6.5), with a thickness of about 2 nm per single layer. When the fully charged PLL is combined with weakly charged PGA (at pH 4.5), the film thickness increases exponentially with the number of deposited layers. The thickness of the exponentially growing film increases to 300 nm after deposition of 16 layers. The exponential film growth is attributed to the ability of the PLL to diffuse "in" and "out" of the film bulk at each deposition step. The variation in the electrical polarizability of the film-coated particles was also monitored as a function of the number of adsorbed layers. The result reveals that the PLL chains, which can diffuse into the film bulk, have no measurable contribution to the electro-optical effect of the films terminated with PLL. It is only due to the polarization of counterions of the PLL adsorbed on the film surface.     

Layer by layer buildup of polysaccharide films: physical chemistry and cellular adhesion aspects

The formation ofpolysaccharide films based on the alternate deposition of chitosan (CHI) and hyaluronan (HA) was investigated by several techniques. The multilayer buildup takes place in two stages: during the first stage, the surface is covered by isolated islets that grow and coalesce as the construction goes on. After several deposition steps, a continuous film is formed and the second stage of the buildup process takes place. The whole process is characterized by an exponential increase of the mass and thickness of the film with the number of deposition steps. This exponential growth mechanism is related to the ability of the polycation to diffuse "in" and "out" of the whole film at each deposition step. Using confocal laser microscopy and fluorescently labeled CHI, we show that such a diffusion behavior, already observed with poly(L-lysine) as a polycation, is also found with CHI, a polycation presenting a large persistence length. We also analyze the effect of the molecular weight (MW) of the diffusing polyelectrolyte (CHI) on the buildup process and observe a faster growth for low MW chitosan. The influence of the salt concentration during buildup is also investigated. Whereas the CHI/HA films grow rapidly at high salt concentration (0.15 M NaCl) with the formation of a uniform film after only a few deposition steps, it is very difficult to build the film at 10(-4) M NaCl. In this latter case, the deposited mass increases linearly with the number of deposition steps and the first deposition stage, where the surface is covered by islets, lasts at least up to 50 bilayer deposition steps. However, even at these low salt concentrations and in the islet configuration, CHI chains seem to diffuse in and out of the CHI/HA complexes. The linear mass increase of the film with the number of deposition steps despite the CHI diffusion is explained by a partial redissolution of the CHI/HA complexes forming the film during different steps of the buildup process. Finally, the uniform films built at high salt concentrations were also found to be chondrocyte resistant and, more interestingly, bacterial resistant. Therefore, the (CHI/HA) films may be used as an antimicrobial coating.     

Surface interactions during polyelectrolyte multilayer buildup. 1. Interactions and layer structure in dilute electrolyte solutions

We report the investigation of surface forces between polyelectrolyte multilayers of poly(allylamine hydrochloride) (PAH) and poly(styrenesulfonate sodium salt) (PSS) assembled on mica surfaces during film buildup using a surface force apparatus. Up to four polyelectrolyte layers were prepared on each surface ex situ, and the surface interactions were measured in 10(-4) M KBr solutions. The film thickness under high compressive loads (above 2000 microN/m) increased linearly with the number of deposited layers. In all cases, the interaction between identical surfaces at large separations (>100 A from contact) was dominated by electrostatic double-layer repulsion. By fitting DLVO theory to the experimental force curves, the apparent double-layer potential of the interacting surfaces was calculated. At shorter separations, an additional non-DLVO repulsion was present due to polyelectrolyte chains extending some distance from the surface into solution, thus generating an electrosteric type of repulsion. Forces between dissimilar multilayers (i.e., one of the multilayers terminated with PSS and the other with PAH) were attractive at large separations (30-400 A) owing to a combination of electrostatic attraction and polyelectrolyte bridging.     

Formation and dielectric properties of polyelectrolyte multilayers studied by a silicon-on-insulator based thin film resistor

The formation of polyelectrolyte multilayers (PEMs) is investigated using a silicon-on-insulator based thin film resistor which is sensitive to variations of the surface potential. The buildup of the PEMs at the silicon oxide surface of the device can be observed in real time as defined potential shifts. The influence of polymer charge density is studied using the strong polyanion poly(styrene sulfonate), PSS, combined with the statistical copolymer poly(diallyl-dimethyl-ammoniumchloride-stat-N-methyl-N-vinylacetamide), P(DADMAC-stat-NMVA), at various degrees of charge (DC). The multilayer formation stops after a few deposition steps for a DC below 75%. We show that the threshold of surface charge compensation corresponds to the threshold of multilayer formation. However, no reversion of the preceding surface charge was observed. Screening of polyelectrolyte charges by mobile ions within the polymer film leads to a decrease of the potential shifts with the number of layers deposited. This decrease is much slower for PEMs consisting of P(DADMAC-stat-NMVA) and PSS as compared to PEMs consisting of poly(allylamine-hydrochloride), PAH, and PSS. From this, significant differences in the dielectric constants of the polyelectrolyte films and in the concentration of mobile ions within the films can be derived.     

Microfluidics as A Tool to Understand the Build‐Up Mechanism of Exponential‐Like Growing Films

Microfluidics is used here for the first time to efficiently tune the growth conditions for understanding the build‐up mechanism of exponentially growing polyelectrolyte (PE) films. The velocity of PE supply and time of interaction can be successfully altered during the layer‐by‐layer assembly. Another advantage of this method is that the deposition of poly‐L ‐lysine/hyaluronic acid (PLL/HA) films in microchannels can be monitored online by fluorescence microscopy. The study demonstrates that PE mass transport to the film surface and diffusion in the film are key parameters affecting PLL/HA film build‐up. Increase of PE supply rate results in a change in the “transition” (exponential‐to‐linear growth) towards higher number of deposition steps, thus indicating a mass transport‐mediated growth mechanism.     

Multilayers of charged polypeptides as studied by in situ ellipsometry and quartz crystal microbalance with dissipation

The buildup of poly(L-glutamic acid) (PGA) and poly(L-lysine) (PLL) multilayers on silica and titanium surfaces, with and without an initial layer of polyethyleneimine (PEI), was investigated and characterized by means of in situ ellipsometry and quartz crystal microbalance with dissipation. A two-regime buildup was found in all systems, where the length of the first slow-growing regime is dependent on the structure of the initial layers. In the second fast-growing regime, the film thickness grows linearly while the mass increases more than linearly (close to exponentially) with the number of deposited layers. The film refractive indices as well as the water contents indicate that the film density changes as the multilayer film builds up. The change in film density was proposed to be due to polypeptides diffusing into the multilayer film as they attach. Furthermore, the use of PEI as the initial layer was found to induce a difference in the thickness increments for PGA and PLL.     

Assembly of poly(N-isopropylacrylamide)-co-acrylic acid microgel thin films on polyelectrolyte multilayers: Effects of polyelectrolyte layer thickness, surface charge, and microgel solution pH

Temperature- and pH-sensitive poly(N-isopropylacrylamide)?Cco-acrylic acid (pNIPAm-co-AAc) microgels were deposited on glass substrates coated with polyelectrolyte multilayers composed of the polycation poly(allylamine hydrochloride) (PAH) and the polyanion poly(sodium 4-styrenesulfonate) (PSS). The microgel density and structure of the resultant films were investigated as a function of: (1) the number of PAH/PSS layers (layer thickness); (2) the charge on the outer layer of the polyelectrolyte multilayer film; and (3) the pH of microgel deposition solution. The resultant films were studied by differential interference contrast optical microscopy, atomic force microscopy, and scanning electron microscopy. It was found that the coverage of the microgels on the surface was a complex function of the pH of the deposition solution, the charge on the outer layer of the polyelectrolyte thin film and the PAH/PSS layer thickness; although it appears that microgel charge plays the biggest role in determining the resultant surface coverage.     

Layer by layer self-assembled polyelectrolyte multilayers with embedded phospholipid vesicles

We describe a method to embed phospholipid vesicles into polyelectrolyte multilayers built up by the alternate deposition of polyanions and polycations. Before deposition, the vesicles are rigidified by polycation adsorption onto their surface avoiding their fusion once deposited on the multilayer surface. The vesicles adsorb to form a compact and "hard" monolayer as imaged by atomic force microscopy. The thickness of the adsorbed vesicle layer, of the order of 250 nm, is very close to the diameter of the vesicles in solution. This work should open the route to the buildup of multilayer films containing phospholipid vesicles that could act as "reservoirs" for drugs or enzymatic nanoreactors.     

Relationship between the growth regime of polyelectrolyte multilayers and the polyanion/polycation complexation enthalpy

The alternate deposition of polyanions and polycations leads to the formation of films called polyelectrolyte multilayer films (PEMs). Two types of growth processes are reported in the literature, leading to films that grow either linearly or exponentially with the number of deposition steps. In this article we try to establish a correlation between the nature of the growth process and the heat of complexation between the polyanions and the polycations constituting the PEM film. Isothermal titration microcalorimetry experiments performed on several polyanion/polycation systems seem to indicate that an endothermic complexation process is characteristic of an exponential film growth, whereas a strongly exothermic process corresponds to a linear growth regime. Finally, weakly exothermic processes seem to be associated with weakly exponentially growing films. These results thus show that exponentially growing processes are mainly driven by entropy. This explains why the exponential growth processes are more sensitive to temperature than the linear growing processes. This temperature sensitivity is shown on the poly-L-glutamic acid/poly(allylamine) system which grows either linearly or exponentially depending on the ionic strength of the polyelectrolyte solutions.     

Nanocomposite silica/polyamine films prepared by a reactive layer-by-layer deposition

Composite material nanofilms of controlled thickness constituted by ceramics and polymers find more and more applications to improve the properties and functionalities of material surfaces. In this paper we present a new way to deposit such composite coatings by alternated contacts of a surface with a polyamine solution (either poly(allylamine), poly(ethyleneimine), poly-l-lysine, or poly(diallydimethylammonium)chloride and silicic acid. The experiments are mainly realized by spraying of solutions onto the surface. The polyamines deposited in the first spraying step catalyze silica formation upon further spraying of a silicic acid-containing solution. The film thickness increases linearly with the number of deposition steps, the thickness increment being of the order of a few nanometers per silicic acid/polyamine layer. Infrared spectroscopy in the total attenuated reflection mode reveals spectra that are close to those of pure silica particles. The film morphology is further investigated by means of atomic force microscopy and environmental scanning electron microscopy. This reactive layer-by-layer deposition constitutes a new way to build, in an easy way, nanocomposite coatings with precise control of their thickness.     

New 2-in-1 polyelectrolyte step-by-step film buildup without solution alternation: from PEDOT-PSS to polyelectrolyte complexes

Although never emphasized and increasingly used in organic electronics, PEDOT-PSS (poly(3,4-ethylenedioxythiophene)-poly(styrene sulfonate)) layer-by-layer (lbl) film construction violates the alternation of polyanion and polycation rule stated as a prerequisit for a step-by-step film buildup. To demonstrate that this alternation is not always necessary, we studied the step-by-step construction of films using a single solution containing polycation/polyanion complexes. We investigated four different systems: PEDOT-PSS, bPEI-PSS (branched poly(ethylene imine)-poly(sodium 4-styrene sulfonate)), PDADMA-PSS (poly(diallyl dimethyl ammonium)-PSS), and PAH-PSS (poly(allylamine hydrochloride)-PSS). The film buildup obtained by spin-coating or dipping-and-drying process was monitored by ellipsometry, UV-vis-NIR spectrophotometry, and quartz-crystal microbalance. The surface morphology of the films was characterized by atomic force microscopy in tapping mode. After an initial transient regime, the different films have a linear buildup with the number of deposition steps. It appears that, when the particles composed of polyanion-polycation complex and complex aggregates in solution are more or less liquid (case of PEDOT-PSS and bPEI-PSS), our method leads to smooth films (roughness on the order of 1-2 nm). On the other hand, when these complexes are more or less solid particles (case of PDADMA-PSS and PAH-PSS), the resulting films are much rougher (typically 10 nm). Polycation/polyanion molar ratios in monomer unit of the liquid, rinsing, and drying steps are key parameters governing the film buildup process with an optimal polycation/polyanion molar ratio leading to the fastest film growth. This new and general lbl method, designated as 2-in-1 method, allows obtaining regular and controlled film buildup with a single liquid containing polyelectrolyte complexes and opens a new route for surface functionalization with polyelectrolytes.     

Anomalous thickness evolution of multilayer films made from poly-L-lysine and mixtures of hyaluronic acid and polystyrene sulfonate

Using a mixture of polyanions or polycations offers a new way to control the properties of polyelectrolyte multilayer (PEM) films. The central issue of PEM films made from blended polyelectrolyte solutions is the relation between the properties of the blended architecture and the properties of the films made from each pure component. Two situations are possible: either (i) the properties of the blended films are intermediate between those corresponding to the single components or (ii) new effects may emerge leading, for instance, to improved mechanical properties. Situation (i) is expected when the chemical natures of both polyelectrolytes from the blended mixture are close, whereas situation (ii) is more probable when the polyelectrolytes from the blend are very different. In this study, we focus on the buildup of PEM films made by the alternate spray deposition of a polyanion blend [a mixture of polystyrene-4-sulfonate (PSS) and hyaluronic acid (HA) in different mass fractions] and a polycation solution of poly-L-lysine (PLL). Whereas (HA-PLL) films exhibit a strong exponential growth with the number of deposition steps, the (PSS-PLL) system is only weakly exponential. We find that when the composition of the polyanion blend ranges from pure (HA-PLL) to pure (PSS-PLL), the films can always be constructed. However, the polyanion composition of the films is far from that of the polyanion solutions used for the buildup. One observes a strong preference for the incorporation of PSS over HA into the films. Moreover, the most striking feature is that the film thickness does not evolve monotonously with the polyanion solution composition but passes through a sharp minimum for a polyanion solution containing 90-95% HA. A possible mechanism for this peculiar finding is proposed.     

Reinvestigation on the buildup mechanism of alternate multilayers consisting of poly(L-glutamic acid) and poly(L-, D-, and DL-lysines)

The buildup mechanism of polypeptide multilayers prepared by the layer-by-layer deposition of a polyanion (poly(L-glutamic acid) (PGA)) and polycations (poly(L-lysine) (PLL), poly(D-lysine) (PDL), and copoly(DL-lysine)(PDLL)) was reinvestigated by using in situ ATR-IR spectroscopy. A difference spectral technique applied to analyze the spectra indicated that the deposition of both the PGA and PLL (PDL) layers accompanies the formation of secondary structures consisting mainly of the antiparallel pleated sheet (the beta-sheet) structure, and that the formation of the beta-sheet structure cannot always be explained in terms of polyanion/polycation complex formation or charge compensation between the polyanion and polycations, although it has been considered as a major process in the multilayer buildup process. Instead, the present paper proposes the following mechanism. During the deposition of the polyelectrolyte, a small amount of the beta-sheet structures are produced at the interface as a result of charge compensation between a polyelectrolyte and an oppositely charged polyelectrolyte in the multilayer. The beta-sheets act as nuclei from which further propagation of the structure takes place at the solution/multilayer interfaces. The driving force of the buildup process in the new mechanism is a kinetically favorable insolubilization of each polyelectrolyte in solution at the interfaces.     

Stability and structure of polyelectrolyte multilayers deposited from salt free solutions

Molecular-dynamics (MD) simulation results show that polyelectrolyte multilayers deposited from salt free solutions on charged planar surfaces are thermodynamically stable structures that form spontaneously regardless of the method of deposition. The simulation also shows that the polyelectrolyte multilayers are "fuzzy" in nature and molecules in one layer interpenetrate other layers. The influence of chain length, surface charge, and polymer charge is also investigated. Layer thickness was found to be independent of chain length. The ratio of surface to chain charge was found to influence the thickness of the first layer and the amount of polymer absorbed in the first few layers. The thickness of the subsequent layers was found to be independent of the charge ratio.     

Multicompartment films made of alternate polyelectrolyte multilayers of exponential and linear growth

The layer by layer deposition process of polyelectrolytes is used to construct films equipped with several compartments containing "free polyelectrolytes". Each compartment corresponds to a stratum of an exponentially growing polyelectrolyte multilayer film, and two consecutive compartments are separated by a stratum composed of a linearly growing multilayer that acts as a barrier preventing polyelectrolyte diffusion from one compartment to another. We use hyaluronic acid/poly(L-lysine) as the system to build the compartments and the poly(styrene sulfonate)/poly(allylamine) system for the barrier. Using confocal microscopy, it is shown that poly(L-lysine) diffuses only within the compartment in which it was initially introduced during the film construction and is thus unable to cross the barriers. Using fluorescein isothiocyanate as a pH indicator, it is also shown that although poly(styrene sulfonate)/poly(allylamine) multilayers act as a barrier for polyelectrolytes, they do not prevent proton diffusion through the film. Such films open the route for multiple functionalization of biomaterial coatings.