Effect of Molecular Weight on Packing during Latex Film Formation

A UV-visible technique is used to study the evolution of transparency during film formation from latex particles. Latex particles with high and low molecular weight (HM and LM) polymethyl methacrylate (PMMA) are used to prepare films. Two sets of films with different latex content were prepared from HM and LM particles separately, by annealing PMMA particles above the glass transition temperature. Transmitted photon intensity, I(tr), from HM and LM films increased as the annealing temperature was increased. The increase in the transmitted photon intensity is attributed to the latex content (film thickness) for the annealed film samples. It is suggested that as the latex particles are packed (film thickness is increased) fewer voids or cracks are formed in the films. Positive and negative absorption coefficients are measured below and above 210 and 180 degrees C annealing temperatures for the HM and LM films. Packing coefficients are obtained for films in various latex contents. It is observed that LM particles are packed much easier than HM particles. Copyright 2001 Academic Press.     

Ceramic encapsulated latex composites

This work reports the encapsulation of latex particles in Al2O3-polystyrene (PS) composite films. These films were prepared from PS particles in Al2O3 dispersion at room temperature in various latex contents. Composite films were annealed at elevated temperatures in 10 min time interval above the glass transition temperature (Tg) of polystyrene. Transmitted photon intensities, I(tr) were monitored after each annealing step. AFM micrographs were also used to observe the physical changes of the composite films during annealing. It was observed that latex particles are encapsulated above a critical Al2O3 content of 33 wt% which corresponds to the critical occupation probability of p(c) = 0.33 at which the film obey the site-percolation model with a critical exponent of 0.45. Below p(c), it was seen that complete latex film formation process took place, where transparency of the film was increased by annealing.     

Kinetics of latex formation of PBMA latex in the presence of alkali soluble resin using atomic force microscopy

 The effect of alkali-soluble resin (ASR), poly(ethylene-co-acrylic acid), EAA, postadded to emulsifier-free monodisperse poly(butyl methacrylate) (PBMA) latexes on the kinetics of film formation was investigated using atomic force microscopy (AFM). Corrugation height of latex particles in films was monitored at various annealing temperatures as a function of annealing time. Enhanced polymer diffusion was found in a latex film containing ASR regardless of anneal-ing temperature. With increasing annealing temperature, a much higher rate of polymer diffusion was found in latex films containing ASR. These results can be interpreted that the low molecular weight and low Tg EAA resin adsorbed at the particle surface is more susceptible to diffusion than that of the PBMA in the film formation stage, thus it enhances the mobility of PBMA polymer. Received: 30 October 1997 Accepted: 20 March 1998     

Latex film formation studied with the atomic force microscope: Influence of aging and annealing

The surface structure of latex dispersion films was examined with an atomic force microscope. All measurements were done in air on latex films having a minimum film formation temperature of 12°C and a glass transition temperature of 18°C. One aim of this study was to follow structural changes during film formation. Three minutes after spreading the film, its surface layer dried. Afterwards, the structure of the film did not change anymore. Only after 4 months could structural changes be observed: Though individual latex particles could be identified, the particles partly melted into one another.After annealing films at 50° or 60°C for 4 h, the latex particles partly melted into one another, but individual particles could still be identified. When annealing at or above 80°C, no individual latex particles were visible anymore. With increasing temperature the film roughness decreased from 3 nm without annealing to 0.8 nm at 100°C annealing temperature. In addition, islands of 2–4 nm thickness appeared on the film surface. These islands could be scraped off the film by increasing the force between tip and sample, indicating that they are composed of surfactant which was squeezed out of the film.     

Non-affine structural evolution of soft colloidal crystalline latex films under stretching as observed via synchrotron X-ray scattering

A polymer dispersion consisting of soft latex spheres with a diameter of 135 nm was used to produce a crystalline film with face-centered cubic (fcc) packing of the spheres. Different from conventional small-molecule and hard-sphere colloidal crystals, the crystalline latex film in the present case is soft (i.e., easily deformable). The structural evolution of this soft colloidal latex film under stretching was investigated by in-situ synchrotron ultra-small-angle X-ray scattering. The film exhibits polycrystalline scattering behavior corresponding to fcc structure. Stretching results not only in a large deformation of the crystallographic structure but also in considerable nonaffine deformation at high draw ratios. The unexpected nonaffine deformation was attributed to slippage between rows of particles and crystalline grain boundaries. The crystalline structure remains intact even at high deformation, suggesting that directional anisotropic colloidal crystallites can be easily produced.     

Deformation and fracture behavior of poly(vinylidene fluoride‐trifluorethylene) ferroelectric copolymer films under uniaxial tension

The deformation and fracture behavior under uniaxial tension was characterized for P(VDF‐TrFE) 68/32 mol % copolymer films prepared under two different processing conditions. It was found that the copolymer films prepared by solution casting and then annealing show a typical polymeric brittle fracture feature. For the copolymer films prepared by stretching the solution‐cast films and then annealing process, a typical linearly strengthening stage occurs in the stress–strain curve after yielding, and the polymer film samples fracture at a much larger maximum strain and a higher tensile strength than those prepared by the former process. SEM observation and XRD analysis were carried out to examine the morphology and microstructure change during uniaxial tension. The results show that for the stretched film samples, the polymer chains undergo slipping or further reorientation during uniaxial tension, causing the increase of the peak intensity in the X‐ray diffraction pattern. For the directly annealed ones, no yielding phenomenon is observed and there is no apparent X‐ray diffraction intensity change. It was suggested that the highly‐oriented fibril structure of the stretched film samples contributes to the linearly strengthening stage after yielding in the stress–strain curve. © 2005 Wiley Periodicals, Inc. J Polym Sci Part B: Polym Phys 43: 3255–3260, 2005     

The Film Formation of Polymer Particles in Drying Thin Films of Aqueous Acrylic Latices

The aim of this study is to determine the factors that contribute to the process of film formation of binder particles in drying aqueous dispersion coatings, based on acrylic polymers. It is known that concentrated latices of uniform size show iridescent, colored light patterns. These colors are caused by interparticle interference, and they are only present when the latex particles are ordered in a regular structure. The interparticle interference can be characterized by measuring the transmission as a function of wavelength of the incident light. It appeared that the changes of the interparticle interference of a drying latex film can be related to changes in the interparticle distance and displacement. It was also found that the interparticle distance becomes "negative" upon coalescence of the latex particles. This means that from this point on, the change in interparticle interference is directly related to the indentation or deformation of the latex particles. It became clear that the coalescence process differs from deformation mechanisms accepted in the literature. It seems that the deformation of the particles follows a biaxial mechanism. This means that the particles deform only in one direction, perpendicular to the film surface. Copyright 2000 Academic Press.     

Fast transient fluorescence technique (FTRF) for studying vapor-induced latex film formation

A fast transient fluorescence (FTRF) technique was used to study latex film formation induced by organic solvent vapor. Seven different films with the same latex content were prepared separately from poly(methyl methacrylate) (PMMA) particles and exposed to vapor of various chloroform-heptane mixtures in seven different experiments. Latex films were prepared from pyrene (Py)-labeled latex particles and fluorescence lifetimes of Py were monitored during vapor-induced film formation. It was observed that pyrene lifetimes decreased as vapor exposure time increased. A Stern-Volmer kinetic analysis was used for low quenching efficiencies to interpret the decrease in pyrene lifetimes. A Prager-Tirrel model was employed to obtain back-and-forth frequencies, nu, of the reptating PMMA chains during latex film formation induced by solvent vapor. nu values were found to be correlated with chloroform content in vapor mixture. It was observed that polymer interdiffusion obeyed a t(1/2) law during film formation. The results of optical transmission experiments were found to support these findings.     

GIUSAXS and AFM studies on surface reconstruction of latex thin films during thermal treatment

The structural evolution of a single-layer latex film during annealing was studied via grazing incidence ultrasmall-angle X-ray scattering (GIUSAXS) and atomic force microscopy (AFM). The latex particles were composed of a low-Tg (-54 degrees C) core (n-butylacrylate, 30 wt %) and a high-Tg (41 degrees C) shell (t-butylacrylate, 70 wt %) and had an overall diameter of about 500 nm. GIUSAXS data indicate that the q(y) scan at q(z) = 0.27 nm(-1) (out-of-plane scan) contains information about both the structure factor and the form factor. The GIUSAXS data on latex films annealed at various temperatures ranging from room temperature to 140 degrees C indicate that the structure of the latex thin film beneath the surface changed significantly. The evolution of the out-of-plane scan plot reveals the surface reconstruction of the film. Furthermore, we also followed the time-dependent behavior of structural evolution when the latex film was annealed at a relatively low temperature (60 degrees C) where restructuring within the film can be followed that cannot be detected by AFM, which detects only surface morphology. Moreover, compared to AFM studies GIUSAXS provides averaged information covering larger areas.     

Swelling of interpenetrating networklike particles in a soft polymer matrix

Fast transient fluorescence technique was used to monitor swelling of hard latex particles in a soft polymer matrix. Various film samples were prepared from pyrene (P) and/or naphthalene (N)-labeled poly(methyl methacrylate) (PMMA) particles in a low-molecular-weight poly(isobutylene) (PIB) matrix. These PMMA particles contain interpenetrating PIB channels. Film samples were annealed at elevated temperatures to promote particle swelling. Fluorescence lifetimes, tau, were measured for each film sample. It was observed that tau values decrease as the PIB content in the matrix is increased. The decrease in tau was explained by the increase in quenching of excited P and N molecules by low-molecular-weight PIB penetrating into the PIB channels in the PMMA particles. A drastic decrease in tau above a certain temperature was attributed to the effect of particle size on the swelling of the latex particles in the PIB matrix. It was observed that small particles (P-labeled) swell at much lower annealing temperatures than large (N-labeled) particles.     

Film formation from pure and mixed latices; transient fluorescence study

A fast transient fluorescence technique was used to study latex film formation induced by organic solvent vapor. Mixtures of pyrene (P)- and naphthalene (N)-labeled and/or pure naphthalene-labeled latex films were prepared separately from poly(methyl methacrylate) (PMMA) particles. Then these pure and mixed latex films were exposed to vapor of various chloroform-heptane mixtures in seven different experiments. In both films, fluorescence lifetimes from N were monitored during vapor-induced film formation. It was observed that N lifetimes decreased as the vapor exposure time is increased. A Stern-Volmer kinetic analysis was used for low quenching efficiencies to interpret the decrease in N lifetimes. A Prager-Tirrell model was employed to obtain back-and-forth frequencies, nu, of reptating PMMA chains during latex film formation induced by solvent vapor. In both pure and mixed latex films, nu values were found to be correlated with the chloroform content in the vapor mixture. It was observed that polymer interdiffusion obeyed a t1/2 law during film formation.     

Achieving structural control with thin polystyrene-b-polydimethylsiloxane block copolymer films: The complex relationship of interface chemistry,annealing methodology and process conditions

The structure of thin microphase-separated polystyrene-block-polydimethylsiloxane (PS–PDMS) films has been studied using state-of-the-art top-down and cross-sectional electron microscopy. This is the first time that the profile of PS–PDMS films has been measured in situ and these measurements allowed us to image the shape of the PDMS domains within the film as well as examine the wetting behavior of the block copolymer film on a variety of substrates. It was found that for each polymer, substrate chemistry and annealing method combination examined, there was a small range of film thicknesses whereby the films exhibited the optimal characteristics of high levels of ordering without dewetting or multilayering. Specifically, the optimum thickness for films treated by thermal annealing was greater than that for the equivalent solvent annealed film; a change that was correlated with morphology variations related to solvent swelling of the solvent annealed films. The surface chemistry also induced changes in the optimum film thickness. Selective surfaces were shown to control whether a PDMS wetting layer was formed or not, leading to either thicker or thinner wetting optimum film thicknesses; while undulating morphologies were observed for less selective surfaces. Concomitant changes in the periodicity were then hypothesized to occur as a result of confinement effects and the selectivity of the surface.     

Site percolation model for latex film formation in soft polymer matrix

The UV-visible (UVV) technique was used to monitor latex film formation in a soft polymer matrix. Various film samples were prepared by increasing the amount of poly(methyl methacrylate) (PMMA) particles in a poly(isobutylene) (PIB) matrix. These samples were then annealed above the glass transition temperature to promote latex film formation. Transmitted photon intensities, Itr, were measured for each film. It is observed that Itr decrease as the latex content is increased, which was explained by the increase in scattered light intensity, Isc. The drastic increase in Isc above a certain latex content is attributed to the site percolation of latex particles in the PIB matrix. The percolation threshold and the critical exponent were measured and found to be 0.3 and 0.4, respectively. The increase in Itr by annealing of film samples above Tg was explained with the void closure process below 0.8 occupation probability. When the film is occupied completely with the latex particles, interdiffusion of polymer chains was observed. Viscous flow and chain diffusion activation energies were determined and found to be 8 and 51 kcal/mol, respectively.     

Healing and photon diffusion during sintering of high-T latex particles

A steady-state fluorescence technique was used to examine the annealing of films formed from high-T latex particles above the glass transition temperature. The films were prepared by sintering pyrene-labeled poly(methyl methacrylate) latex particles. During the annealing processes, the transparency of the film changed considerably. Direct fluorescence emission from excited pyrene was monitored as a function of annealing temperature to detect these changes. Scanning electron microscopy in conjunction with Monte Carlo simulations of photon diffusion in latex film were used to interpret the fluorescence results. Healing temperature and time were measured at the point where the fluorescence emission intensity becomes maximum. This was associated with the longest optical path of a photon in latex film during healing of particle(SINGLEBOND)particle boundaries. Healing activation energy was measured and found to be 10 kcal/mol. © 1996 John Wiley & Sons, Inc.     

Morphologies in solvent-annealed thin films of symmetric diblock copolymer

We have systematically studied the thin film morphologies of symmetric poly(styrene)-block-poly(methyl methacrylate) (PS-b-PMMA) diblock copolymer after annealing to solvents with varying selectivity. Upon neutral solvent vapor annealing, terraced morphology is observed without any lateral structures on the surfaces. When using PS-selective solvent annealing, the film exhibits macroscopically flat with a disordered micellar structure. While PMMA-selective solvent annealing leads to the dewetting of the film with fractal-like holes, with highly ordered nanoscale depressions in the region of undewetted films. In addition, when decreasing the swelling degree of the film in the case of PMMA-selective solvent annealing, hills and valleys are observed with the coexistence of highly ordered nanoscale spheres and stripes on the surface, in contrast to the case of higher swelling degree. The differences are explained qualitatively on the basis of polymer-solvent interaction parameters of the different components.     

Solvent vapor annealing of block copolymer thin films: removal of processing history

The ordering processes of PS-b-P2VP block copolymer thin films with different processing histories were studied during solvent vapor annealing by in situ grazing incidence small-angle X-ray scattering (GISAXS). We compared cylinder-forming PS-b-P2VP thin films with 34 kg/mol molecular weight that were prepared in three different ways: spin coating, spin coating and subsequent solvent vapor annealing where the solvent vapor was removed instantaneously, and spin coating and subsequent solvent vapor annealing where the solvent vapor was removed slowly. Block copolymer thin films retained the morphology resulting from the different “processing histories” at smaller swelling ratios. This processing history was erased when the samples reached a higher swelling ratio (~1.4). After the solvent was slowly removed from the swollen film, the surface morphology was characterized by ex situ AFM. All samples showed the same morphology after solvent annealing regardless of the initial morphology, indicating the morphology of solvent annealed samples is determined by the polymer concentration in the swollen film and the solvent vapor removal rate, but not the processing history.     

Wetting behavior of lightly sulfonated polystyrene ionomers on silica surfaces

The wetting/dewetting behavior of thin films of lightly sulfonated low molecular weight polystyrene (SPS) ionomers spin-coated onto silica surfaces were studied using atomic force microscopy (AFM), contact angle measurements, and electron microscopy. The effects of the sulfonation level, the choice of the cation, the solvent used to spin-coat the films, and the molecular weight of the ionomer were investigated. Small angle X-ray scattering was used to determine the bulk microstructure of the films. The addition of the sulfonate groups suppressed the dewetting behavior of the PS above its glass transition temperature, e.g. no dewetting occurred even after 240 h of annealing at 120 degrees C. Increasing the sulfonation level led to more homogeneous and smoother surfaces. The choice of the cation used affected the wetting properties, but not in a predictable manner. When tetrahydrofuran (THF) or a THF/methanol mixed solvent was used for spin-casting, a submicron-textured surface morphology was produced, which may be a consequence of spinodal decomposition of the film surface during casting. Upon annealing for long times, the particles coalesced into a coherent, nonwetted film.     

Temperature and relative humidity dependency of film formation of polymeric latex dispersions

Thermogravimetric analysis and a synchrotron small-angle X-ray scattering technique were employed to characterize the structural evolution of a polymeric latex dispersion during the first three stages of film formation at different temperatures and relative humidities. Three intermediate stages were identified: (1) stage I*, (2) stage I**, and (3) stage II*. Stage I* is intermediate to the conventionally defined stages I and II, where latex particles began to crystallization. The change of drying temperature affects the location of the onset of ordering, whereas relative humidity does not. Stage I** is where the latex particles with their diffuse shell of counterions in the fcc structure are in contact with each other. The overlapping of these layers results in an acceleration of the lattice shrinkage due to a decrease of effective charges. Stage II* is where the latex particles, dried well above their T(g), are deformed and packed only partially during film formation due to incomplete evaporation of water in the latex film. This is because of a rapid deformation of the soft latex particles at the liquid/air interface so that a certain amount of water is unable to evaporate from the latex film effectively. For a latex dispersion dried at a temperature close to its minimum film formation temperature, the transition between stages II and III can be continuous because the latex particles deform at a much slower rate, providing sufficient surface area for water evaporation.     

Glass transition and film formation of VeoVa/vinyl acetate latices; role of water and co-solvents

The physical forces causing deformation of latex particles during the film formation process have been witley studied. However, the forces resisting particle deformation are still poorly characterized. It is clear that the extent of particle deformation is dependent on the viscoelastic nature of the polymer. In an emulsion, the latex particles will normally contain water, surfactants and “free” monomers which lead to plasticization of the polymer. Although this effect has been recognized, so far it has been studied only on films that had been dried and then partially or completely swollen by water. In this work, plasticization of the emulsion polymers by water and co-solvent has been quantified via differential scanning calorimetry investigation directly on the aqueous latex dispersions. More specifically, the plasticizing effect of water on VeoVa/vinyl acetate copolymer latices and its influence on minimum film-forming temperature (MFFT) has been studied. A linear correlation has been found between T_g and MFFT for the wet latices. This new direct method should help to improve our understanding of the forces resisting latex film formation. Additionally, the homogeneous distribution of the hydrophobic and hydrophilic monomers (VeoVa and vinyl acetate respectively) in the latex particles was verified via a ¹³C-NMR (nuclear magnetic resonance) study performed directly on the latices. This study confirmed that no significant core/shell type of morphology had influenced latex film formation.     

Void closure and interdiffusion processes during latex film formation from surfactant-free polystyrene particles: a fluorescence study

This study reports a steady state fluorescence (SSF) technique for studying film formation from surfactant-free polystyrene (PS) latex particles. The latex films were prepared from pyrene (P)-labeled PS particles at room temperature and annealed at elevated temperatures for 5-, 10-, 20-, and 30-min time intervals above the glass transition (T(g)) temperature of polystyrene. During the annealing processes, the transparency of the film changed considerably. Scattered light (I(sc)) and fluorescence intensity (I(0P)) from P were measured after each annealing step to monitor the stages of film formation. Evolution of transparency of latex films were monitored using photon transmission intensity, I(tr). Scanning electron microscopy (SEM) was used to detect variation in the physical structure of annealed films. Onset temperature for film formation, T(0), void closure, T(v), and healing temperatures, T(h), were determined and corresponding activation energies were measured. Void closure and interdiffusion stages were modeled and related activation energies were determined.