Patterning molecularly thin films of polymers—new methods for photolithographic structuring of surfaces

Three novel photolithographic processes for patterning of molecularly thin polymer films are described. The polymer monolayers are prepared by immobilization of initiator molecules to surfaces of solid substrates followed by thermally or photochemically activated radical chain polymerization. Thus polymer chains which are covalently linked to the surfaces of the substrates are obtained. The films can be patterned using appropriate masks and deep or near UV irradiation before, during or after polymer formation. The procedures described in this paper allow the chemical tailoring of surfaces with high spatial resolution. Step-and-repeat procedures, which take advantage of the covalent linking of the polymers to the surfaces, permit the preparation of multifunctional polymer patterns.     

喷墨打印图案化高分子薄膜及其在有机电子器件加工中的应用

喷墨打印技术由于在图案化加工方面的高效、低成本、非接触形式及柔性的加工过程等特点而被应用于有机电子器件的加工中.通过打印功能性高分子溶液,喷墨打印实现了功能高分子薄膜的沉积和图案化,并实现了有机发光二极管、有机薄膜晶体管及其集成器件的加工.对喷墨打印在有机电子器件加工中取得的成果进行了总结,同时综述了高分子溶液喷墨打印过程中存在的基本科学问题和研究现状.     

Control of doctor‐blade coated poly (3,4‐ethylenedioxythiophene)/poly(styrenesulfonate) electrodes shape on prepatterned substrates via microflow control in a drying droplet

We demonstrated a simple patterning method for the deposition of polymer electrodes such as poly(3,4‐ethylenedioxythiophene)/poly(styrenesulfonate) (PEDOT/PSS). We made use of the difference in wettability between hydrophobic surfaces and hydrophilic surfaces to make the patterns. However, the patterns made with our patterning method created undesirable ring‐like stains, which were caused by the outward flow of the solute within the PEDOT/PSS solution drop. To achieve homogenous device performance, we proposed a simple process for removing this ring‐like stain by making the surface tension gradient with dual solvent system in the PEDOT/PSS solution drop. Because this surface tension gradient causes the inward flow of the solute within the PEDOT/PSS solution drop, the ring‐like stain is removed. Finally, we confirmed the potential of our patterning method for polymer electrodes such as the PEDOT/PSS by fabricating pentacene thin‐film transistors (TFTs) and measuring the electrical properties of the pentacene TFTs. © 2011 Wiley Periodicals, Inc. J Polym Sci Part B: Polym Phys 49: 1590–1596, 2011     

Surface energy gradient driven convection for generating nanoscale and microscale patterned polymer films using photosensitizers

The Marangoni effect describes how fluid flows in response to gradients in surface energy. This phenomenon could be broadly harnessed to pattern the surface topography of polymer films if generalizable techniques for programming surface energy gradients existed. Here, a near UV–visible light (NUV–vis) photosensitizer, 9,10‐dibromo‐anthracene (DBA), was doped into thin films of a model polymer, poly(isobutyl methacrylate). After exposure to light through a photomask and heating above the glass transition, thermolysis of photo‐oxidized DBA and grafting to the polymer promoted flow of the film material into the exposed regions. This mechanism did not significantly alter the molecular weight of PiBMA or the film's glass transition temperature, but resulted in an increase in film surface energy as indicated by a decrease in water contact angle. Film height variations of 580 nm were produced using a mask with 12.5 μm features; a mask with 800 nm features was also employed to generate topographic features of corresponding width without expensive contacting equipment. Due to the broad absorbance spectra of DBA, highly accessible and/or unconventional light sources may be employed in this process; this advantage was demonstrated by patterning with sunlight. The nonspecific radical‐mediated nature of the DBA grafting reaction makes this a promising approach for many classes of polymers. © 2014 Wiley Periodicals, Inc. J. Polym. Sci., Part B: Polym. Phys. 2014 , 52, 1195–1202     

Malonic Acid Diazoesters for C−H Insertion Crosslinking (CHic) Reactions: A Versatile Method for the Generation of Tailor‐Made Surfaces

A simple and versatile method for the modification of a broad spectrum of surfaces with thin polymer films through the thermally or photochemically induced generation of surface‐attached polymer networks is reported. The system is based on copolymers containing diazomalonate groups, which can be activated by heat or light. To this end, the copolymers are deposited from solution onto solid substrates by standard techniques of thin‐film deposition (spin coating, dip coating). Upon activation the diazomalonate group decomposes and forms a carbene, which induces C−H insertion crosslinking (CHic) reactions. In the course of this process network formation and covalent surface attachment occur at the same time. The crosslinking process proceeds very rapidly, especially when the carbenes generated in the activation process cannot undergo Wolff‐rearrangement. The presented system can be used for the generation of a wide range of polymer layers and microstructures on a broad spectrum of surfaces.     

Control of wettability of molecularly thin liquid films by nanostructures

The patterning of liquid thin films on solid surfaces is very important in various fields of science and engineering related to surfaces and interfaces. A method of nanometer-scale patterning of a molecularly thin liquid film on a silicon substrate using the lyophobicity of the oxide nanostructures has recently been reported (Fukuzawa, K.; Deguchi, T.; Kawamura, J.; Mitsuya, Y.; Muramatsu, T.; Zhang, H. Appl. Phys. Lett. 2005, 87, 203108). However, the origin of the lyophobicity of the nanostructure with a height of around 1 nm, which was fabricated by probe oxidation, has not yet been clarified. In the present study, the change in thickness of the liquid film on mesa-shaped nanostructures and the wettability for the various combinations of the thickness of the liquid films and the height of ridge-shaped nanostructures were investigated. These revealed that lyophobicity is caused by a lowering of the intermolecular interaction between the liquid and silicon surfaces by the nanostructure and enables the patterning of a liquid film along it. The tendency of the wettability for a given liquid film and nanostructure size can be predicted by estimating the contributions of the intermolecular interaction and capillary pressure. In this method, the height of the nanostructure can control the wettability. These results can provide a novel method of nanoscale patterning of liquid thin films, which will be very useful in creating new functional surfaces.     

Focused laser-induced marangoni dewetting for patterning polymer thin films

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

Patterned immobilization of biomolecules by using ion irradiation‐induced graft polymerization

A new method for biomolecular patterning based on ion irradiation‐induced graft polymerization was demonstrated in this study. Ion irradiation on a polymer surface resulted in the formation of active species, which was further used for surface‐initiated graft polymerization of acrylic acid. The results of the grafting study revealed that the surface graft polymerization using 20 vol % of acrylic acid on the poly(tetrafluoroethylene) (PTFE) film irradiated at the fluence of 1 × 10¹⁵ ions/cm² for 12 h was the optimum graft polymerization condition to achieve the maximum grafting degree. The results of the fluorescence microscopy also revealed that the optimum fluence to achieve the maximum fluorescence intensity was 1 × 10¹⁵ ions/cm². The grafting of acrylic acid on the PTFE surfaces was confirmed by a fluorescence labeling method. The grafted PTFE films were used for the immobilization of amine‐functionalized p‐DNA, followed by hybridization with fluorescently tagged c‐DNA. Biotin‐amine was also immobilized on the acrylic acid grafted PTFE surfaces. Successful biotin‐specific binding of streptavidin further confirmed the potential of this strategy for patterning of various biomolecules. © 2009 Wiley Periodicals, Inc. J Polym Sci Part A: Polym Chem 47: 6124–6134, 2009     

Microdomain morphology of lamella‐forming diblock copolymer confined in a thin film

We report the self‐consistent field theory (SCFT) of the morphology of lamella‐forming diblock copolymer thin films confined in two horizontal symmetrical/asymmetrical surfaces. The morphological dependences of thin films on the polymer‐surface interactions and confinement, such as film thickness and confinement spatial structure, have been systematically investigated. Mechanisms of the morphological transitions can be understood mainly through the polymer‐surface interactions and confinement entropy, in which the plat confinement surface provides a surface‐induced effect. The confinement is expressed in the form of the ratio D/L₀, here D is film thickness, and L₀ is the period of bulk lamellar‐structure. Much richer morphologies and multiple surface‐induced morphological transitions for the lamella‐forming diblock copolymer thin films are observed, which have not been reported before. © 2008 Wiley Periodicals, Inc. J Polym Sci Part B: Polym Phys 47: 1–10, 2009     

Relaxation of polymer thin films in isothermal temperature‐jump measurements

The dynamic behavior of thin polymer films is of interest in the fabrication of microelectronics and optoelectronics and in the coatings industry. It is known that polymer relaxation is affected by film thickness and the particular substrate/polymer pair. We previously used a spectroscopic ellipsometer to investigate the glass transition in thin films. In addition to information on the modification of thermal transitions such as the glass‐transition temperature, the speed of data acquisition in an automated, spectroscopic ellipsometer, operated at a single wavelength of 780 nm, allows for the direct observation of the isothermal dimensions of a thin polymer film as a function of time after a rapid temperature change. In this article, we discuss recent results from the observation of the time dependence of film‐normal thickness and normalized, in‐plane, lateral dimension as well as simple fits to this relaxation behavior in terms of a normalized viscosity and relaxation time. The results support a highly asymmetric initial thermal expansion normal to the film followed by close to isotropic relaxation and anisotropic “flow” (the flow in response to the vanishingly small shears of thermal expansion). These features may clarify issues involving the observation of chain confinement in thin polymer films in terms of potential differences between equilibrium and dynamic measurements. © 2000 John Wiley & Sons, Inc. J Polym Sci B: Polym Phys 38: 2929–2936, 2000     

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     

Honeycomb micropatterning of proteins on polymer films through the inverse microemulsion approach

Here we report the rapid and convenient patterning of proteins on porous polymer film using the inverse microemulsion approach. Following this method, proteins, which were dissolved in water, were transferred into dichloromethane solution of polymers through the formation of inverse microemulsion by mixing the two solutions. The protein-containing microemulsion droplets accumulated automatically into large and stable ones on the surface of organic solution casting on solid substrates, and formed tightly packed microemulsion droplet arrays driven by surface tension. With the evaporation of organic solvent and water, the microemulsion droplet arrays, which act as the template, turn to honeycomb patterned pores bearing proteins in them. The formed protein patterns can be locally applied for the detection of other proteins through specific recognition. The generality and reproducibility for the formation of BSA/PS microporous film and protein patterning by using different polymers and solvents were demonstrated by investigating surfactant addition, polymer and solvent types, and casting volume on the morphology of the microporous films. A preliminary mechanism for the protein patterning is discussed based on the analysis of the experimental results.     

Local dynamic mechanical properties in model free-standing polymer thin films

High-frequency sinusoidal oscillations of a coarse-grained polymer model are used to calculate the local dynamic mechanical properties (DMPs) of free-standing polymer thin films. The storage modulus G(') and loss modulus G(") are examined as a function of position normal to the free surfaces. It is found that mechanically soft layers arise near the free surfaces of glassy thin films, and that their thickness becomes comparable to the entire film thickness as the temperature approaches the glass transition T(g). As a result, the overall stiffness of glassy thin films decreases with film thickness. It is also shown that two regions coexist in thin films just at the bulk T(g); a melt-like region (G(')G(")) in the middle of the film. Our findings on the existence of a heterogeneous distribution of DMPs in free-standing polymer thin films provide insights into recent experimental measurements of the mechanical properties of glassy polymer thin films.     

Polyelectrolyte multilayers prepared on hydrogel surfaces

Poly(vinyl alcohol) hydrogels were alternately immersed in aqueous solutions of oppositely charged polymers. The adsorption of the cationic dye methylene blue to the immersed hydrogels suggested the presence of a coating on the hydrogel surfaces. Static contact angles with an air bubble in water showed layer‐by‐layer growth of the films. The films could be transferred onto solid substrates for mechanical strength after the hydrogels were placed on the solid substrates, and this resulted in an estimation of the film thickness. The number of assembly steps could regulate the film thickness. We present here coatings of hydrogels with thin polymer films prepared by layer‐by‐layer assembly. © 2005 Wiley Periodicals, Inc. J Polym Sci Part A: Polym Chem 43: 1062–1067, 2005     

Photochromism and electrochemistry of a dithienylcyclopentene electroactive polymer

A bifunctional substituted dithienylcyclopentene photochromic switch bearing electropolymerisable methoxystyryl units, which enable immobilization of the photochromic unit on conducting substrates, is reported. The spectroscopic, electrochemical, and photochemical properties of a monomer in solution are compared with those of the polymer formed through oxidative electropolymerization. The electroactive polymer films prepared on gold, platinum, glassy carbon, and indium titanium oxide (ITO) electrodes were characterized by cyclic voltammetry, X-ray photoelectron spectroscopy (XPS), and atomic force microscopy (AFM). The thickness of the films formed is found to be limited to several monolayer equivalents. The photochromic properties and stability of the polymer films have been investigated by UV/vis spectroscopy, electrochemistry, and XPS. Although the films are electrochemically and photochemically stable, their mechanical stability with respect to adhesion to the electrode was found to be sensitive to both the solvent and the electrode material employed, with more apolar solvents, glassy carbon, and ITO electrodes providing good adhesion of the polymer film. The polymer film is formed consistently as a thin film and can be switched both optically and electrochemically between the open and closed state of the photochromic dithienylethene moiety.     

Patterning of spontaneous rolling thin polymer films for versatile microcapillaries

We investigate the spontaneous rolling of polydimethylsiloxane (PDMS) thin films and demonstrate the fabrication of capillaries with topographical and chemical patterns on the inner wall. Thin films of PDMS are either coated by a layer of hard material or have their surface hardened by plasma oxidation. They are then driven out of equilibrium by selective solvent swelling in vapor phase resulting in a tubular rolled‐up system. The inner diameter of those is measured as a function of layer thickness for different solvents and capping types. Those results are shown to be in good agreement with Timoshenko theory. Before rolling, the future inner surface can be characterized and functionalized. We demonstrate topographical and chemical patterning, respectively by embossing and microcontact printing. These methods are very simple and can easily produce cylindrical capillaries with inner diameter between 20 and some hundreds of microns with fully functionalized inner surface, overcoming many difficulties encountered in conventional soft lithography techniques. © 2017 Wiley Periodicals, Inc. J. Polym. Sci., Part B: Polym. Phys. 2017 , 55, 721–728     

Experimental evidence and theoretical analysis of physical aging in thin and thick amorphous glassy polymer films

Through time‐dependent gas transport properties, we have investigated the physical aging process of amorphous glassy polymer films made from a polynorbornene. By combining the concepts of free volume and the kinetic theory of glass stabilization, it was found that the time dependence of the gas permeability could be rationalized through the thickness dependence of the glass transition temperature. A mathematical relationship was developed that directly relates polymer physical aging (tracked by the gas permeability decay) and sample thickness. It was confirmed by permeation measurements with nitrogen and helium that the aging process is accelerated for thin glassy polymer films (about 8000 Å). The theoretical results show that accelerated aging for thin films compared to thick films can be qualitatively predicted, based on the decrease in the glass transition temperature when the film thickness decreases. © 1999 John Wiley & Sons, Inc. J Polym Sci B: Polym Phys 37: 2239–2251, 1999     

Crystalline morphology evolution in PCL thin films

The transition of crystalline morphology is revealed in poly(?‐caprolactone) (PCL) thin films as the polymer film thickness changes from hundreds of nanometers to several nanometers. The PCL can crystallize into spherulites, dense‐branching morphology (DBM), or dendrites, depending on the polymer film thickness. It was found that when the polymer film thickness approaches 2Rg (radius of gyration of polymer), there is a remarkable change in crystalline morphology. Under this condition, the polymer crystallization is a diffusion‐controlled process. When the value of polymer film thickness closes to Rg, PCL cannot crystallize, and a dewetting phenomenon will take place. Moreover, polymer morphology can be controlled by varying supercooling. The effect of molecular weight on polymer morphology has been investigated. The main factors that affected pattern formation in nonequilibrium crystallization are also discussed. © 2005 Wiley Periodicals, Inc. J Polym Sci Part B: Polym Phys 43: 1303–1309, 2005     

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     

Surface engineering of styrene/PEGylated‐fluoroalkyl styrene block copolymer thin films

A series of diblock copolymers prepared from styrenic monomers was synthesized using atom transfer radical polymerization. One block was derived from styrene, whereas the second block was prepared from a styrene modified with an amphiphilic PEGylated‐fluoroalkyl side chain. The surface properties of the resulting polymer films were carefully characterized using dynamic contact angle, XPS, and NEXAFS measurements. The polymer morphology was investigated using atomic force microscope and GISAXS studies. The block copolymers possess surfaces dominated by the fluorinated unit in the dry state and a distinct phase separated microstructure in the thin film. The microstructure of these polymers is strongly influenced by the thin film structure in which it is investigated. © 2008 Wiley Periodicals, Inc. J Polym Sci Part A: Polym Chem 47: 267–284, 2009