Surface-induced structure formation of polymer blends on patterned substrates

Three-dimensional nanofabrication with elastomeric phase masks

This Feature Article reviews recent work on an optical technique for fabricating, in a single exposure step, three-dimensional (3D) nanostructures with diverse structural layouts. The approach, which we refer to as proximity field nanopatterning, uses conformable, elastomeric phase masks to pattern thick layers of transparent, photosensitive materials in a conformal contact mode geometry. Aspects of the optics, the materials, and the physical chemistry associated with this method are outlined. A range of 3D structures illustrate its capabilities, and several application examples demonstrate possible areas of use in technologies ranging from microfluidics to photonic materials to density gradient structures for chemical release and high-energy density science.

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.

Combinatorial generation and replication-directed assembly of complex and varied geometries with thin films of diblock copolymers

Directed assembly of fine-scale, very complex patterns with a variety of features, including terminations, jogs, disclinations, acute and obtuse bends, and sharp radii of curvature, was achieved with a symmetric poly(styrene-block-methylmethacrylate) (PS-b-PMMA) copolymer. The complex pattern was generated spontaneously by spin coating and annealing a thin film of a lamellae-forming block copolymer on a chemically neutral surface. The resulting "fingerprint" pattern had a domain spacing of 47.5 nm. Oxygen plasma treatment of the block copolymer converted it into an insoluble chemical nanopattern that was quantified by XPS, goniometry, and the wetting behavior of the block copolymer. Spin coating a second thin film of the block copolymer and annealing resulted in directed assembly that replicated the fingerprint pattern, including the most complicated defect structures. A computer vision algorithm was developed and implemented to compare the patterns quantitatively, taking into account inherent differences in image contrast, scale, rotation, and translation.

Phase separation of polymer-dispersed liquid crystals on a chemically patterned substrate

The surface-induced structure formation of polymer-dispersed liquid crystals (PDLCs) on a chemically patterned substrate was studied for the first time. The patterns on the substrate were successfully transferred to the PDLC film, resulting in alternating LC-rich and polymer-rich phases. This simple approach offers a new means of organizing micrometer-sized LC domains into well-ordered structures in a polymer matrix of PDLCs.

Laser-induced structures in a polymer blend in the vicinity of the phase boundary

We have determined the diffusion, thermal diffusion, and Soret coefficients of a poly(dimethyl siloxane)/poly(ethyl-methyl siloxane) (PDMS/PEMS) polymer blend as a function of composition and temperature within the homogeneous phase. The critical slowing down of the diffusion and the corresponding critical divergence of the Soret coefficient are described within the pseudospinodal concept both for critical and off-critical compositions. These data are used to model in detail the channel-like structures that form due to the Soret effect when a focused laser beam is scanned across a polymer film of 100microm thickness. A moderate vertical asymmetry is attributed to solutal convection. Although heat rapidly diffuses away from the laser focus, the composition distribution in the early stage resembles the sharp profile of the laser beam. PDMS accumulates within the center of the structures, whereas a thin PEMS-rich layer is formed that isolates the central core from the windows. Experimentally, the structures are analyzed by means of phase contrast microscopy. Possible applications as rewritable optical waveguides or tunable phase plates are briefly discussed.

Wetting-layer formation mechanisms of surface-directed phase separation under different quench depths with off-critical compositions in polymer binary mixture

Focusing on the off-critical condition, the quench depth dependence of surface-directed phase separation in the polymer binary mixture is numerically investigated by combination of the Cahn-Hilliard-Cook theory and the Flory-Huggins-de Gennes theory. Two distinct situations, i.e., for the wetting, the minority component is preferred by the surface and the majority component is preferred by the surface, are discussed in detail. The simulated results show that the formation mechanism of the wetting layer is affected by both the quench depth and the off-critical extent. Moreover, a diagram, illustrating the formation mechanisms of the wetting layer with various quench depths and compositions, is obtained on the basis of the simulated results. It is found that, when the minority component is preferred by the surface, the growth of the wetting layer can exhibit pure diffusion limited growth law, logarithmic growth law, and Lifshitz-Slyozov growth law. However, when the majority component is preferred by the surface, the wetting layer always grows logarithmically, regardless of the quench depth and the off-critical extent. It is interesting that the surface-induced nucleation can be observed in this case. The simulated results demonstrate that the surface-induced nucleation only occurs below a certain value of the quench depth, and a detailed range about it is calculated and indicated. Furthermore, the formation mechanisms of the wetting layer are theoretically analyzed in depth by the chemical potential gradient.

Polymer phase separation on lattice patterned surfaces

We demonstrate the self-organization of phase-separated polymer microstructures on two-dimensionally chemically patterned surfaces. Pattern replication is expected when both the blend composition ratio matches the surface patterning area ratio, and the pattern periodicity matches the natural phase separation length scale. By varying film thickness and blend composition, we show that ordered morphologies also result for contrary situations, resulting in the formation of a rich variety of hierarchically-ordered microstructures. This hierarchy suggests that non-equilibrium structures generated by incomplete phase separation of blend components are locked in by rapid solvent quenching during casting.

Effect of sequential layer-by-layer surface modifications on the surface energy of plasma-modified poly(dimethylsiloxane)

Surface-initiated grafting of N,N-dimethylacrylamide, styrenesulfonate (SS), and (ar-vinylbenzyl)trimethylammonium chloride (VBTAC) from microwave plasma carboxylated, initiator-functionalized poly(dimethylsiloxane) (PDMS) surfaces was accomplished utilizing reversible addition-fragmentation chain transfer (RAFT) polymerization. Surface spectroscopic attenuated total reflectance (ATR) FT-IR analysis and atomic force microscopy (AFM) measurements were utilized to determine surface grafting and morphological surface features. The VBTAC-grafted PDMS provided a smooth, hydrophilic cationic surface for creating layer-by-layer (LBL) surfaces via alternating deposition of well-defined poly(SS) and poly(VBTAC), also prepared via aqueous RAFT. Comparisons of the ATR FT-IR spectra of the LBL assemblies and those of respective anionic poly(SS) and cationic poly(VBTAC) components confirmed strong electrostatic complexation of a fraction of the sulfonate and quarternary ammonium species in the layers as well as the existence of noncomplexed species. AFM images of surface topology indicated the presence of domains, likely phase-separated segments of the respective homopolymers, as well as interlayer mixing. The employed LBL methodology results in formation of stable, highly hydrophilic surfaces on a PDMS substrate. To our knowledge, this is the first study that illustrates surface functionalization of PDMS using microwave plasma and RAFT polymerization, followed by LBL deposition of polyelectrolytes.

From a two-dimensional chemical pattern to a three-dimensional topology through selective inversion of a liquid-liquid bilayer

Soft organic surfaces with more and more complex topologies are required daily to engineer appropriate microstructures for many different applications such as DNA array technology, biological optics for advanced photonic systems and microfluidics. Complementarily to conventional lithographic processes, several pioneering methods have been developed recently, by controlling phase separation of polymer blends, spinodal decomposition of homopolymers or by using the action of additional external forces driving diverse instabilities. Here we present a method that not only provides original concepts towards the three-dimensional (3D) structuring of liquids, on the basis of the synergistic effects of molecular diffusion and confined nucleation, but also suggests original solutions for the transport, mixing and filtering of small volumes of liquid. Through the intrinsic destabilization of a liquid-liquid bilayer, the 2D pattern of a chemically structured surface with 'hydrophilic' and 'hydrophobic' domains is transferred to a solid/liquid interface as a 3D topography with either 'positive' or 'negative' replication. This easy-to-use process has potential applications in various technological realms requiring a specific topography at interfaces such as microfluidics or biosensors.

Creating patterned poly(dimethylsiloxane) surfaces with amoxicillin and poly(ethylene glycol)

This paper reports a simple microwave plasma patterning of poly(dimethylsiloxane) (PDMS) surfaces, which is accomplished by allowing selective surface areas to microwave plasma exposure in the presence of gaseous monomer. When maleic anhydride is used for microwave plasma reaction in the presence of physical barrier on the PDMS substrate, the resulting patterned surfaces with chemically bonded maleic anhydride and carboxylic acid groups are generated. In this particular study we attached amoxicillin via ammonolysis under weak base conditions in the presence of a catalyst as well as poly(ethyleneglycol) (PEG). A combination of internal reflection IR imaging (IRIRI) and atomic force microscopy (AFM) revealed that amoxicillin and PEG can be readily reacted on the microwave plasma patterned PDMS surfaces. Surface areas directly exposed to microwave plasmons exhibit the highest reactivity due to higher content of functional groups. These studies also show that molecular weight of PEG has also significant effect on kinetics of surface reactions.

Nucleating Pattern Formation in Spin-Coated Polymer Blend Films with Nanoscale Surface Templates

We use Dip-Pen Nanolithography (DPN) to generate monolayer surface templates for guiding pattern formation in spin-coated polymer blend films. We study template-directed pattern formation in blends of polystyrene/poly(2-vinylpyridine) (PS/P2VP) as well as blends of PS and the semiconducting conjugated polymer poly(3-hexylthiophene) (P3HT). We show that acid-terminated monolayers can be used to template pattern formation in PS/P3HT blends, while hydrophobic monolayers can be used to template pattern formation in PS/P2VP blends. In both blends, the polymer patterns comprise laterally-phase separated regions surrounded by vertically separated bilayers. We hypothesize that the observed patterns are formed by template-induced dewetting of the bottom layer of a polymer bilayer during the spin-coating process. We compare the effects of template feature size and spacing on the resulting polymer patterns with predictions from published models of template-directed dewetting in thin films and find the data in good agreement. For both blends we observe that a minimum feature size is required to nucleate dewetting/phase separation. We find this minimum template diameter to be approximately 180 nm in 50/50 PS/P2VP blends, and approximately 100 nm in 50/50 PS/P3HT blends. For larger template diameters, PS/P2VP blends show evidence for pattern formation beginning at the template boundaries, while PS/P3HT blends rupture randomly across the template features.

Phase behavior of symmetric ternary block copolymer-homopolymer blends in thin films and on chemically patterned surfaces

The phase diagram of symmetric ternary blends of diblock copolymers and homopolymers in thin films was determined as a function of increasing volume fraction of homopolymer (phi(H)) and was similar to that for these materials in the bulk. Blends with compositions in the lamellar region of the diagram (phi(H)< or =0.4) could be directed to assemble into ordered lamellar arrays on chemically striped surfaces if the characteristic blend dimension (L(B)) and the period of the stripes (L(S)) were commensurate such that L(S)=L(B)+/-0.10L(B). Blends with compositions in the microemulsion region of the diagram (phi(H) approximately 0.6) assembled into defect-free lamellar phases on patterned surfaces with L(S)> or =L(B), but formed coexisting lamellar (with period L(S)) and homopolymer-rich phases when L(S)<L(B).

Formation of parallel strips in thin films of polystyrene/poly(vinyl pyrrolidone) blends via spin coating on unpatterned substrates

Patterns of parallel strips, consisting of alternating polystyrene (PS) and poly(vinyl pyrrolidone) (PVP) regions, were observed in thin films spin cast from a PS/PVP/chloroform solution on unpatterned substrates. The formation of anisotropic patterns, manifested not only in thickness variation but also in composition variation, was found to be driven by Marangoni instability, with the PS and PVP streams flowing toward the preferred regions as the phase separation induced by solvent evaporation proceeded. The initial viscosity of the polymer solution and the thickness of the spin-cast films were lumped into one single parameter to study the phase morphology development at various initial polymer solution concentrations. Interestingly, the ratio of the square of the film thickness to the viscosity, a parameter loosely related to the Marangoni number, was found to reach a maximum value at the concentration where the strip patterns were most well-developed.

Simulated annealing study of asymmetric diblock copolymer thin films

We report a simulated annealing study of the morphology of asymmetric diblock copolymer thin films confined between two homogeneous and identical surfaces. We have focused on copolymers that form a gyroidal morphology in the bulk. The morphological dependence of the confined films on the film thickness and the surface-polymer interaction has been systematically investigated. From the simulations it is found that much richer morphologies can form for the gyroid-forming asymmetric diblock copolymer thin films, in contrast to the lamella-forming symmetric and cylinder-forming asymmetric diblock copolymer films. Multiple morphological transitions induced by changing the film thickness and polymer-surface interactions are observed.

Forces between chemically structured substrates mediated by critical fluids

We consider binary liquid mixtures close to their critical points confined by two parallel, geometrically flat, and chemically structured substrates. Universal order parameter profiles are calculated within mean field theory for periodic patterns of stripes with alternating preferences for the two species of the mixture and with different relative positions of the two substrates. From the order parameter profiles the effective forces between the two plates are derived. The tuning of Casimir amplitudes is discussed.

Ferroelectric phase transition in individual single-crystalline BaTiO3 nanowires

We report scanned probe characterizations of the ferroelectric phase transition in individual barium titanate (BaTiO3) nanowires. Variable-temperature electrostatic force microscopy is used to manipulate, image, and evaluate the diameter-dependent stability of ferroelectric polarizations. These measurements show that the ferroelectric phase transition temperature (TC) is depressed as the nanowire diameter (dnw) decreases, following a 1/dnw scaling. The diameter at which TC falls below room temperature is determined to be approximately 3 nm, and extrapolation of the data indicates that nanowires with dnw as small as 0.8 nm can support ferroelectricity at lower temperatures. We also present density functional theory (DFT) calculations of bare and molecule-covered BaTiO3 surfaces. These calculations indicate that ferroelectricity in nanowires is stabilized by molecular adsorbates such as OH and carboxylates. These adsorbates are found to passivate polarization charge more effectively than metallic electrodes, explaining the observed stability of ferroelectricity in small-diameter BaTiO3 nanowires.

Geometry-induced pulse instability in microdesigned catalysts: the effect of boundary curvature

We explore the effect of boundary curvature on the instability of reactive pulses in the catalytic oxidation of on microdesigned Pt catalysts. Using ring-shaped domains of various radii, we find that the pulses disappear (decollate from the inert boundary) at a turning point bifurcation, and we trace this boundary in both physical and geometrical parameter space. These computations corroborate experimental observations of pulse decollation.

Cellulose—model films and the fundamental approach

This critical review describes the recent arrival of ultrathin films of cellulose. The methodology of preparation as well as the applications of the films for fundamental research is fully covered. The review places cellulose in a wider scientific context where cellulose research is no longer a field of interest for specialised scientists only. Cellulose and cellulosic materials should interest communities such as biochemists, physical chemists, surface chemists, organic chemists, polymer chemists and also physicists working close the disciplines mentioned. (149 references.).

Honeycomb pattern formation via polystyrene/poly(2-vinylpyridine) phase separation

The surface morphologies and properties of polystyrene (PS)/poly(2-vinylpyridine) (PVP) blend films cast on the mica substrate from ethylbenzene solution were investigated upon controlling different weight ratios and solvent evaporation rates. A near-honeycomblike surface morphology of the PS/PVP blend film formed under controlling the solvent evaporation rate due to the effect of Marangoni-Benard convection. The results of static water contact angles, X-ray photoelectron spectroscopy, solvent selective etching, and treatment by water illustrated that the near-honeycomblike structures on the surface of PS/PVP blend films were different for different weight ratios of PS and PVP. After treatment with water for several minutes, PVP islands-like structure emerged in the holes of the film for a PS/PVP weight ratio of 4/1, and a quasihexagonal arrangement of alternate big and small PVP droplets emerged on the top layer of the film for a PS/PVP weight ratio of 7/1. The formation mechanisms of different surface structures and their response behaviors to water were discussed.

Wetting-driven structure ordering of a copolymer/homopolymer/nanoparticle mixture in the presence of a modulated potential

We investigate pattern formation on a solid substrate of a diblock copolymer-homopolymer mixture containing doping wettable nanoparticles with a preferential attraction for one component of the copolymers, using a three-order-parameter model. The presence of doping nanoparticles under the surface-interaction modulation breaks the isotropy in the process of microphase-separation and macrophase-separation. This leads to the formation of orientational microphase and macrophase structures due to the interplay between the phase separation and wetting particle ordering under a modulated potential at the late stage. Simulations suggest that the microphase morphology and macrophase morphology can be changed through adjustment of the wetting strength, the amplitude as well as the period of the modulated potential. It provides some important insights for changing microphase and macrophase structures in polymer blends by wetting-driven spinodal decomposition.

An interfacial instability in a transient wetting layer leads to lateral phase separation in thin spin-cast polymer-blend films

Spin-coating is a very widely used technique for making uniform thin polymer films. For example, the active layers in most experimental semiconducting polymer-based devices, such as light-emitting diodes and photovoltaics, are made this way. The efficiency of such devices can be improved by using blends of polymers; these phase separate during the spin-coating process, creating the complex morphology that leads to performance improvements. We have used time-resolved small-angle light scattering and light reflectivity during the spin-coating process to study the development of structure directly. Our results provide evidence that a blend of two polymers first undergoes vertical stratification; the interface between the stratified layers then becomes unstable, leading to the final phase-separated thin film. This has given us the basis for establishing a full mechanistic understanding of the development of morphology in thin mixed polymer films, allowing a route to the rational design of processing conditions so as to achieve desirable morphologies by self-assembly.