Deposition of polymer films by spin casting: A quantitative analysis

Transient nucleation driven by solvent evaporation

We theoretically investigate homogeneous crystal nucleation in a solution containing a solute and a volatile solvent. The solvent evaporates from the solution, thereby continuously increasing the concentration of the solute. We view it as an idealized model for the far-out-of-equilibrium conditions present during the liquid-state manufacturing of organic electronic devices. Our model is based on classical nucleation theory, taking the solvent to be a source of the transient conditions in which the solute drops out of the solution. Other than that, the solvent is not directly involved in the nucleation process itself. We approximately solve the kinetic master equations using a combination of Laplace transforms and singular perturbation theory, providing an analytical expression for the nucleation flux. Our results predict that (i) the nucleation flux lags slightly behind a commonly used quasi-steady-state approximation. This effect is governed by two counteracting effects originating from solvent evaporation: while a faster evaporation rate results in an increasingly larger influence of the lag time on the nucleation flux, this lag time itself is found to decrease with increasing evaporation rate. Moreover, we find that (ii) the nucleation flux and the quasi-steady-state nucleation flux are never identical, except trivially in the stationary limit, and (iii) the initial induction period of the nucleation flux, which we characterize as a generalized induction time, decreases weakly with the evaporation rate. This indicates that the relevant time scale for nucleation also decreases with an increasing evaporation rate. Our analytical theory compares favorably with results from a numerical evaluation of the governing kinetic equations.

Structure Influence of Amine-Containing Additives on the Solution State and Out-of-Plane Conductivity of PEDOT:PSS for Efficient Organic Solar Cells

Additives are extensively explored for improving PEDOT:PSS performances mainly through the removal of excess PSS and as a secondary dopant. In this work, amine-containing additives are introduced to PEDOT:PSS solutions as processing additives where the interactions to the PSS are anticipated through electrostatic interactions. Such interactions affected solution property where the increased viscosity is found to significantly increase the out-of-plane conductivity of the PEDOT:PSS thin films. Organic solar cells adopting these additive-assisted processed PEDOT:PSS layers as hole transporting layers (HTL) showed the improved device performances that resulted from the reduced series resistance provided by the PEDOT:PSS HTL. A top power conversion efficiency of 18.28% is achieved with para-phenylenediamine (PPD) additive in the PEDOT:PSS HTL, which is 3.5% higher compared to devices with neat PEDOT:PSS thin film as the HTL.

Enhancing the Potential of Polymer Composites Using Biochar as a Filler: A Review

This article discusses the scope biochar's uses; biochar is a sustainable organic material, rich in carbon, that can be synthesized from various types of biomass feedstock using thermochemical reactions such as pyrolysis or carbonization. Biochar is an eco-friendly filler material that can enhance polymer composites' mechanical, thermal, and electrical performances. In comparison to three inorganic fillers, namely carbon black, carbon nanotubes (CNT), and carbon filaments, this paper explores the optimal operating conditions for regulating biochar's physical characteristics, including pore size, macro- and microporosity, and mechanical, thermal, and electrical properties. Additionally, this article presents a comparative analysis of biochar yield from various thermochemical processes. Moreover, the review examines how the surface functionality, surface area, and particle size of biochar can influence its mechanical and electrical performance as a filler material in polymer composites at different biochar loads. The study showcases the outstanding properties of biochar and recommends optimal loads that can improve the mechanical, thermal, and electrical properties of polymer composites.

From Whispering Gallery Mode Resonators to Biochemical Sensors

Optical biosensors are frontrunners for the rapid and real-time detection of analytes, particularly for low concentrations. Among them, whispering gallery mode (WGM) resonators have recently attracted a growing focus due to their robust optomechanical features and high sensitivity, measuring down to single binding events in small volumes. In this review, we provide a broad overview of WGM sensors along with critical advice and additional "tips and tricks" to make them more accessible to both biochemical and optical communities. Their structures, fabrication methods, materials, and surface functionalization chemistries are discussed. We propose this reflection under a pedagogical approach to describe and explain these biochemical sensors with a particular focus on the most recent achievements in the field. In addition to highlighting the advantages of WGM sensors, we also discuss and suggest strategies to overcome their current limitations, leaving room for further development as practical tools in various applications. We aim to provide new insights and combine different knowledge and perspectives to advance the development of the next generation of WGM biosensors. With their unique advantages and compatibility with different sensing modalities, these biosensors have the potential to become major game changers for biomedical and environmental monitoring, among many other relevant target applications.

Effect of solvent on the emulsion and morphology of polyfluorene films: all-atom molecular dynamics approach

The morphology of conjugated polymer thin films deposited by the resonant infrared matrix-assisted pulsed laser evaporation (RIR-MAPLE) process is related to the emulsion characteristics. However, a fundamental understanding of how and why the emulsion characteristics control the film properties and device performance is yet unclear. We performed all-atom molecular dynamics simulations of emulsions containing a mixture of polyfluorene (PFO) polymer, various primary solvents, secondary solvent, and water. The emulsion properties were then examined as a function of variable primary solvent and correlated with the morphology of deposited PFO thin films. The examination of the explicit interactions between all components of the emulsion indicated that using a primary solvent with a lower solubility-in-water and a higher non-bonded interaction energy ratio, between the solvent, polymer, and water in the emulsion recipe, produced the best result with smoother and denser films. Additionally, our simulation results are consistent with the AFM experimental results, indicating that interactions driven by trichlorobenzene (TCB) primary solvent within the emulsion are responsible for high-quality, smooth, and continuous thin film surfaces. Overall, this study can support the choice of a suitable primary solvent and provides the computational framework for predictions of new recipes for polymeric emulsion systems.

Immobilization of Polymers to Surfaces by Click Reaction for Photocatalysis with Recyclability

A surface-bound photocatalyst offers advantages of reusability and recyclability with ease. While it can be immobilized by spin coating or drop-casting, a more reliable and durable method involves the formation of a self-assembled monolayer (SAM) on a suitable surface using designer molecules. In this paper, we report devising a practical, durable, and recyclable photocatalytic surface using immobilized polytriazoles of diketopyrrolopyrrole (DPP). While the SAM formation techniques were utilized for superior results, conventional coatings of polymers on surfaces were performed for comparison. Different methods confirmed efficient immobilization and high grafting density for the SAM technique. Computational models suggested favorable energy parameters for active materials. Photocatalytic studies were performed using both immobilized polymers and polymers in solution for comparison. These findings are important for understanding various physicochemical characteristics of polytriazole-functionalized surfaces.

New Insights into Spin Coating of Polymer Thin Films in Both Wetting and Nonwetting Regimes

Spin coating is a common method for fabricating polymer thin films on flat substrates. The well-established Meyerhofer relationship between film thickness (h) and spin rate (ω), h ∝ ω^-1/2, enables the preparation of thin films with desired thickness by adjusting the spin rate and other experimental parameters. The 1/2 exponent has been verified by previous studies involving organic thin films prepared on silicon wafers. In this study, 88% and >99% hydrolyzed poly(vinyl alcohol) (PVOH) polymers were adsorbed and spin-coated from an aqueous solution onto four different substrates. The substrates were prepared by covalently attaching poly(dimethylsiloxane) (PDMS) of different molecular weights onto silicon wafers (SiO₂). Atomic force microscopy images indicate that the PVOH films transitioned from stable on SiO₂, to metastable, and then to unstable as PDMS molecular weight was increased. Notably, none of the polymer-substrate systems studied here exhibited the thickness-spin rate profile predicted by the Meyerhofer model. Based on the experimental results, a more general adsorption-deposition model is proposed that decouples the total spin-coated thickness into two components─the adsorbed thickness (h₁) and the spin-deposited thickness (h₂). The former accounts for polymer-substrate interactions, and the latter depends on polymer concentration and spin rate. In unstable systems, the exponents were found to be ∼0 because slip takes place at the solution-substrate interface during spin and the spin-deposited thickness is 0. In metastable and stable systems, a universal relationship between spin-deposited thickness and spin rate emerged, independent of the substrate type and polymer concentration for each polymer examined. Our findings indicate the importance of film stability and polymer-substrate interactions in the application of spin coating.

Amphiphilic Polymer Conetwork Gel Films Based on Tetra-Poly(ethylene Glycol) and Tetra-Poly(ε-Caprolactone)

The preparation and investigation of gel films from a model amphiphilic polymer conetwork (ACN) grant a deeper control and understanding of the structure-property relationship in the bulk phase and at the interface of materials with promising applications. In order to allow the simultaneous transport of hydrophilic and hydrophobic substances, polymeric networks with finely distributed hydrophilic and hydrophobic components are very suitable. When designing new soft materials such as coatings, in addition to the structure in the bulk phase, the structure at the interface plays a critical role. In this study, two alternating tetra-arm star polymers poly(ε-caprolactone) (tetra-PCL-Ox) and amino-terminated poly(ethylene glycol) (tetra-PEG-NH2) form an amphiphilic polymer conetwork. The correlation between different synthesis strategies for gel films of this ACN model system and their resulting properties will be described. Through various spin coating techniques, control over film thickness and roughness is achievable and highlights differences to macroscopic gel samples. Atomic force microscopy (AFM) measurements reveal the effect of solvents of different polarities on the swelling ability and surface structure. This correlates with AFM investigations of the mechanical properties on ACN gel films, demonstrating a strong effect on the resulting elastic modulus E, depending on the presence or absence of a good solvent during synthesis. Furthermore, a higher E modulus is obtained in the presence of the selective solvent water, compared to the non-selective solvent toluene. This observation is explained through selective swelling of the tetra-arm star polymers displaying a different hydrophobicity.

Automated Laser-Transfer Synthesis of High-Density Microarrays for Infectious Disease Screening

Laser-induced forward transfer (LIFT) is a rapid laser-patterning technique for high-throughput combinatorial synthesis directly on glass slides. A lack of automation and precision limits LIFT applications to simple proof-of-concept syntheses of fewer than 100 compounds. Here, an automated synthesis instrument is reported that combines laser transfer and robotics for parallel synthesis in a microarray format with up to 10 000 individual reactions cm^{- 2} . An optimized pipeline for amide bond formation is the basis for preparing complex peptide microarrays with thousands of different sequences in high yield with high reproducibility. The resulting peptide arrays are of higher quality than commercial peptide arrays. More than 4800 15-residue peptides resembling the entire Ebola virus proteome on a microarray are synthesized to study the antibody response of an Ebola virus infection survivor. Known and unknown epitopes that serve now as a basis for Ebola diagnostic development are identified. The versatility and precision of the synthesizer is demonstrated by in situ synthesis of fluorescent molecules via Schiff base reaction and multi-step patterning of precisely definable amounts of fluorophores. This automated laser transfer synthesis approach opens new avenues for high-throughput chemical synthesis and biological screening.

The memory of thin polymer films generated by spin coating

We present results from isothermal and temperature-sweep creep experiments adapted to filaments which were derived from spin coated and subsequently crumpled thin polystyrene films. Due to the existence of residual stresses induced by preparation, the filaments showed significant shrinkage which we followed as a function of time at various temperatures. In addition, the influence of preparation conditions and subsequent annealing of supported thin polymer films on shrinkage and relaxation behavior was investigated. The temporal evolution of shrinkage revealed a sequence of relaxation regimes. We explored the temperature dependence of this relaxation and compared our observations with published results on drawn melt-spun fibers. This comparison revealed intriguing similarities between both systems prepared along different pathways. For instance, the magnitudes of shrinkage of melt-spun fibers and of filaments from crumpled spin coated polymer films are similar. Thus, our results suggest the existence of generic mechanisms of "forgetting", i.e., how non-equilibrated polymers lose their memory of past processing events.

Nonporous, Strong, Stretchable, and Transparent Electrospun Aromatic Polyurea Nanocomposites as Potential Anticorrosion Coating Films

This study, for the first time, focused on the fabrication of nonporous polyurea thin films (~200 microns) using the electrospinning method as a novel approach for coating applications. Multi-walled carbon nanotubes (MWCNTs) and hydrophilic-fumed nanosilica (HFNS) were added separately into electrospun polyurea films as nano-reinforcing fillers for the enhancement of properties. Neat polyurea films demonstrated a tensile strength of 14 MPa with an elongation of 360%. At a loading of 0.2% of MWCNTs, the highest tensile strength of 21 MPa and elongation of 402% were obtained, while the water contact angle remained almost unchanged (89°). Surface morphology analysis indicated that the production of polyurea fibers during electrospinning bonded together upon curing, leading to a nonporous film. Neat polyurea exhibited high thermal resistance with a degradation temperature of 380 °C. Upon reinforcement with 0.2% of MWCNTs and 0.4% of HFNS, it increased by ~7 °C. The storage modulus increased by 42 MPa with the addition of 0.2% of MWCNTs, implying a superior viscoelasticity of polyurea nanocomposite films. The results were benchmarked with anti-corrosive polymer coatings from the literature, revealing that the production of nonporous polyurea coatings with robust strength, elasticity, and thermal properties was achieved. Electrospun polyurea coatings are promising candidates as flexible anti-corrosive coatings for heat exchanges and electrical wires.

Polyelectrolytes as Building Blocks for Next-Generation Membranes with Advanced Functionalities

The global society is in a transition, where dealing with climate change and water scarcity are important challenges. More efficient separations of chemical species are essential to reduce energy consumption and to provide more reliable access to clean water. Here, membranes with advanced functionalities that go beyond standard separation properties can play a key role. This includes relevant functionalities, such as stimuli-responsiveness, fouling control, stability, specific selectivity, sustainability, and antimicrobial activity. Polyelectrolytes and their complexes are an especially promising system to provide advanced membrane functionalities. Here, we have reviewed recent work where advanced membrane properties stem directly from the material properties provided by polyelectrolytes. This work highlights the versatility of polyelectrolyte-based membrane modifications, where polyelectrolytes are not only applied as single layers, including brushes, but also as more complex polyelectrolyte multilayers on both porous membrane supports and dense membranes. Moreover, free-standing membranes can also be produced completely from aqueous polyelectrolyte solutions allowing much more sustainable approaches to membrane fabrication. The Review demonstrates the promise that polyelectrolytes and their complexes hold for next-generation membranes with advanced properties, while it also provides a clear outlook on the future of this promising field.

Water vapor induced self-assembly of islands/honeycomb structure by secondary phase separation in polystyrene solution with bimodal molecular weight distribution

The formation of complex structures in thin films is of interest in many fields. Segregation of polymer chains of different molecular weights is a well-known process. However, here, polystyrene with bimodal molecular weight distribution, but no additional chemical modification was used. It was proven that at certain conditions, the phase separation occurred between two fractions of bimodal polystyrene/methyl ethyl ketone solution. The films were prepared by spin-coating, and the segregation between polystyrene phases was investigated by force spectroscopy. Next, water vapour induced secondary phase separation was investigated. The introduction of moist airflow induced the self-assembly of the lower molecular weight into islands and the heavier fraction into a honeycomb. As a result, an easy, fast, and effective method of obtaining island/honeycomb morphologies was demonstrated. The possible mechanisms of the formation of such structures were discussed.

Solid State NMR Spectroscopy a Valuable Technique for Structural Insights of Advanced Thin Film Materials: A Review

Solid-state NMR has proven to be a versatile technique for studying the chemical structure, 3D structure and dynamics of all sorts of chemical compounds. In nanotechnology and particularly in thin films, the study of chemical modification, molecular packing, end chain motion, distance determination and solvent-matrix interactions is essential for controlling the final product properties and applications. Despite its atomic-level research capabilities and recent technical advancements, solid-state NMR is still lacking behind other spectroscopic techniques in the field of thin films due to the underestimation of NMR capabilities, availability, great variety of nuclei and pulse sequences, lack of sensitivity for quadrupole nuclei and time-consuming experiments. This article will comprehensively and critically review the work done by solid-state NMR on different types of thin films and the most advanced NMR strategies, which are beyond conventional, and the hardware design used to overcome the technical issues in thin-film research.

Solvent Effect to the Uniformity of Surfactant-Free Salmon-DNA Thin Films

Fabrication of surfactant-modified DNA thin films with high uniformity, specifically DNA-CTMA, has been well considered via drop-casting and spin-coating techniques. However, the fabrication of thin films with pure DNA has not been sufficiently studied. We characterize the uniformity of thin films from aqueous salmon DNA solutions mixed with ethanol, methanol, isopropanol, and acetone. Measurements of thickness and macroscopic uniformity are made via a focused-beam ellipsometer. We discuss important parameters for optimum uniformity and note what the effects of solvent modifications are. We find that methanol- and ethanol-added solutions provide optimal fabrication methods, which more consistently produce high degrees of uniformity with film thickness ranging from 20 to 200 nm adjusted by DNA concentration and the physical parameters of spin-coating methods.

Modeling of Poly(methylmethacrylate) Viscous Thin Films by Spin-Coating

A predictive film thickness model based on an accepted equation of state is applied to the spin-coating of sub-micron poly(methylmethacrylate) viscous thin films from toluene. Concentration effects on density and dynamic viscosity of the spin-coating solution are closely examined. The film thickness model is calibrated with a system-specific film drying rate and was observed to scale with the square root of spin speed. Process mapping is used to generate a three-dimensional design space for the control of film thickness.

Polyurethane prepolymer-modified high-content starch-PBAT films

We report a modified starch-poly(butylene adipate co-terephthalate) (PBAT) film (MSPF) prepared by extrusion blowing. Polyurethane prepolymer (PUP), was modified to the starch to enhance the compatibility. Different contents of amylose was blended with PBAT for improving mechanical strength and oxygen-barrier properties of MSPF. The microstructures, crystallinity, mechanical properties, oxygen-barrier capacity of MSPF were thoroughly evaluated. The result showed that MSPF with high starch content and excellent performances was successfully prepared with the synergy of PUP modification, amylose introduction and extrusion blowing. The crystallinity, hydrophobicity, oxygen-barrier properties and mechanical properties of MSPF increased with the increasing amylose content. The maximum tensile strength and elongation at break of MSPF reached 10.6 MPa and 805.6 %, respectively, even at the high starch content of 50 %. The result demonstrated that MSPF having excellent mechanical properties and oxygen-barrier properties could be use in the biodegradable field such as packaging materials, agricultural films and garbage bags.

Processing Induced Nonequilibrium Behavior of Polyvinylpyrrolidone Nanofilms Revealed by Dewetting

Polyvinylpyrrolidone (PVP) nanofilms prepared by spin-coating have vast applications in biological and microdevice fields. However, detailed knowledge of processing induced nonequilibrium behavior of PVP nanofilms and solutions for minimizing residual stresses toward high-quality films has still been lacking. In the present study, we first explored the rapid film formation process via statistics on nascent holes. Next, by employing dewetting as a major probe, we revealed that many processing conditions, particularly previously overlooked variables like the atmosphere, substrates, and immersion time, were correlated substantially with the degree of nonequilibrium of nanofilms. Proper aging temperature and time were demonstrated essential for releasing residual stresses and achieving more equilibrium nanofilms. This work offered abundant experimental evidence in the building relationship between the processing and nonequilibrium nature of polymer nanofilms, which were crucial for their preparation and application.

Controlled Deposition of Nanosize and Microsize Particles by Spin-Casting

The deposition of nanosize and microsize spherical particles on planar solid substrates by hydrodynamic-evaporative spin-casting is studied. The particles are dispersed in a volatile liquid, which evaporates during the process, and the particles are finally deposited on the substrate. Their coverage, Γ, depends on the processing parameters (concentration by weight, particles size, etc.). The behavior of the particles during the spin-casting process and their final Γ values are investigated. It is found that for up to particle diameters of a few micrometers, particle deposition can be described by a theoretical approach developed for the spin-casting of polymer solutions (Karpitschka, S.; Weber, C. M.; Riegler, H. Chem. Eng. Sci. 2015, 129, 243-248. Danglad-Flores, J.; Eickelmann, S.; Riegler, H. Chem. Eng. Sci. 2018, 179, 257-264). For large particles, this basic theory fails. The causes of this failure are analyzed, and a corrected, more general theoretical approach is presented. It takes into account particle size effects as well as particle sedimentation. In summary, we present new insights into the spin-cast process of particle dispersions, analyze the contributions affecting the final particle coverage, and present a theoretical approach which describes and explains the experimental findings.

Solvent-tunable dipeptide-based nanostructures with enhanced optical-to-electrical transduction

We explore a facile approach to construct solvent-tunable dipeptide-based nanostructures, which exhibit a structure-dependent and remarkably enhanced optoelectronic response.

Rupture of ultrathin solution films on planar solid substrates induced by solute crystallization

On-line optical imaging of continuously thinning planar films in a spin cast configuration reveals the rupture behavior of ultra-thin films of binary mixtures of a volatile solvent and a nonvolatile solute. The pure solvents completely wet the silica substrates whereas the solution films rupture at certain film thicknesses, h_rupture, which depend on, c₀, the initial weighing in solute concentrations. With small c₀, h_rupture increases proportional to c₀. With high c₀, all films rupture at h_rupture≈50nm, independent of c₀. The findings can be explained by the solute enrichment during the evaporative thinning. Solute crystallization at the liquid/substrate interface upon reaching solute supersaturation leads to locally different wetting properties. This induces locally the rupture of the film as soon as it is sufficiently thin. A proper data rescaling based on this scenario yields a universal rupture behavior of various different solvent/solute mixtures.

Meniscus Shape around Nanoparticles Embedded in Molecularly Thin Liquid Films

Individual nanoparticles embedded in molecularly thin films at planar substrates and the resulting film surface distortion (meniscus) adjacent to the nanoparticles are investigated by conventional optical reflection microscopy. Even for nanoparticles much smaller than the Rayleigh diffraction limit, the meniscus creates such a pronounced optical footprint that the location of the nanoparticles can be identified. This is because the decay length (lateral extension) of the meniscus exceeds the size of the nanoparticle by orders of magnitude. Therefore, for the first time, the exact shape of the meniscus of the liquid adjacent to a nanosize object could be measured and analyzed. The meniscus has a zero curvature shape (cosine hyperbolic). The liquid in the meniscus is in pressure equilibrium with the far-field planar film. The decay length decreases with the decreasing nanoparticle size. However, it is independent of the far-field film thickness. Supposedly, the decay length is determined by van der Waals interactions although it is unknown what determines its (unexpectedly large) absolute value. The presented technical approach may be used to investigate biological systems (for instance, surface distortions in supported membranes caused by proteins or protein aggregates).