Microphase separation of block copolymer solutions in a flow field

Films of polystyrene–polybutadiene–polystyrene (PS/PB/PS) triblock copolymer and polystyrene-poly(ethylene/propylene) (PS/PEP) diblock copolymer were cast from toluene solutions subjected to hydrodynamic flow at room temperature using a device based on a novel casting method we term ‘roll-casting.’ Polymer solutions were rolled between two corotating eccentric cylinders while at the same time the solvent was removed at a controlled rate. As the solvent evaporated, the block copolymers microphase separated into globally oriented structures. A discussion of the flow field that develops during roll-casting is presented and specific attention is given to the importance of the shear and elongation rates present. For the triblock and diblock, respectively, the processed structures consisted of polystyrene cylinders assembled on a hexagonal lattice in a polybutadiene matrix, and unidirectional lamellae of alternating polystyrene and polyethylene/propylene. Small-angle x-ray scattering (SAXS) and transmission electron microscopy (TEM) indicated the near single-crystal structure both types of films. SAXS also showed the styrene cylinders and the alternating lamellae to be packed closer together in roll-cast films than in simple quiescently cast films. A molecular orientation mechanism is proposed to describe both these results as well as the changes in packing and in macroscopic sample dimensions measured after complete solvent evaporation and after sample annealing. © 1993 John Wiley & Sons, Inc.     

Roll-Casting of block copolymers and of block copolymer-homopolymer blends

An improved technique for casting highly oriented films of block copolymers from solutions subjected to flow is presented. Polymer solutions were rolled between two counter-rotating adjacent cylinders while at the same time the solvent was allowed to evaporate. As the solvent evaporated, the block copolymers microphase separated into globally oriented structures. Using this method known as ‘roll-casting’ we present in this paper a study of the morphology of polystyrene-polybutadiene-polystyrene (PS/PB/PS) triblock copolymer cast with and without additional high molecular weight homopolymers. The pure copolymer films consisted of polystyrene cylinders assembled on a hexagonal lattice in a polybutadiene matrix in a near single-crystal structure. Blends of copolymer with high molecular weight polystyrene and/or polybutadiene, phase separated into ellipsoidal regions of homopolymer embedded in an oriented block copolymer matrix. Annealing the films resulted in conversion of the homopolymer regions to spheres accompanied by some misalignment of the copolymer microdomains. The morphology of these films as revealed by TEM is discussed. A brief discussion of the flow field that develops in the experimental system is also presented and its similarity to the flow field of our previous work is shown. © 1994 John Wiley & Sons, Inc.