Molecular weight effects on the phase morphology of PS/P4VP blend films on homogeneous SAM and heterogeneous SAM/Au substrates

Fabrication of PCDTBT Conductive Network via Phase Separation

Poly[N-9'-hepta-decanyl-2,7-carbazole-alt-5-5-(4',7'-di-2-thienyl-2',1',3'-benzothiadiazole)] (PCDTBT) is a stable semiconducting polymer with high rigidity in its molecular chains, which makes it difficult to organize into an ordered structure and affects the device performance. Here, a PCDTBT network consisting of aggregates and nanofibers in thin films was fabricated through the phase separation of mixed PCDTBT and polyethylene glycol (PEG). Using atomic force microscopy (AFM), the effect of the blending conditions (weight ratio, solution concentration, and molecular weight) and processing conditions (substrate temperature and solvent) on the resulting phase-separated morphologies of the blend films after a selective washing procedure was studied. It was found that the phase-separated structure's transition from an island to a continuous structure occurred when the weight ratio of PCDTBT/PEG changed from 2:8 to 7:3. Increasing the solution concentration from 0.1 to 3.0 wt% led to an increase in both the height of the PCDTBT aggregate and the width of the nanofiber. When the molecular weight of the PEG was increased, the film exhibited a larger PCDTBT aggregate size. Meanwhile, denser nanofibers were found in films prepared using PCDTBT with higher molecular weight. Furthermore, the electrical characteristics of the PCDTBT network were measured using conductive AFM. Our findings suggest that phase separation plays an important role in improving the molecular chain diffusion rate and fabricating the PCDTBT network.

Structure evolution during phase separation in spin-coated ethylcellulose/hydroxypropylcellulose films

Porous phase-separated films made of ethylcellulose (EC) and hydroxypropylcellulose (HPC) are commonly used for controlled drug release. The structure of these thin films is controlling the drug transport from the core to the surrounding liquids in the stomach or intestine. However, detailed understanding of the time evolution of these porous structures as they are formed remains elusive. In this work, spin-coating, a widely applied technique for making thin uniform polymer films, was used to mimic the industrial manufacturing process. The focus of this work was on understanding the structure evolution of phase-separated spin-coated EC/HPC films. The structure evolution was determined using confocal laser scanning microscopy (CLSM) and image analysis. In particular, we determined the influence of spin-coating parameters and EC : HPC ratio on the final phase-separated structure and the film thickness. The film thickness was determined by profilometry and it influences the ethanol solvent evaporation rate and thereby the phase separation kinetics. The spin speed was varied between 1000 and 10 000 rpm and the ratio of EC : HPC in the polymer blend was varied between 78 : 22 wt% and 40 : 60 wt%. The obtained CLSM micrographs showed phase separated structures, typical for the spinodal decomposition phase separation mechanism. By using confocal laser scanning microscopy combined with Fourier image analysis, we could extract the characteristic length scale of the phase-separated final structure. Varying spin speed and EC : HPC ratio gave us precise control over the characteristic length scale and the thickness of the film. The results showed that the characteristic length scale increases with decreasing spin speed and with increasing HPC ratio. The thickness of the spin-coated film decreases with increasing spin speed. It was found that the relation between film thickness and spin speed followed the Meyerhofer equation with an exponent close to 0.5. Furthermore, good correlations between thickness and spin speed were found for the compositions 22 wt% HPC, 30 wt% HPC and 45 wt% HPC. These findings give a good basis for understanding the mechanisms responsible for the morphology development and increase the possibilities to tailor thin EC/HPC film structures.

Controlling the pore size in conjugated polymer films via crystallization-driven phase separation

A wide range of possible applications in sensors and optoelectronic devices have focused considerable attention on porous membranes made of semi-conducting polymers. In this study, porous films of poly(3-hexylthiophene) (P3HT) were conveniently constructed through spin-coating of solutions of a blend of P3HT and polyethylene glycol (PEG). Pores were formed by phase separation driven simultaneously by incompatibility and crystallization. The influence of the polymer concentration (c), molecular weight (Mn) and spin-coating temperature (Tsp) on the pore size and structure was investigated. With increasing c from 0.5 to 5.0 wt%, the pore diameter (d) varied from ≈1.3 μm to ≈38 μm. Similarly, we observed a substantial increase of d with increasing Mn of PEG, while changing Mn of P3HT did not affect d. Micron- and nano-scale pores coexisted in porous P3HT films. While incompatibility of P3HT and PEG caused the formation of nano-pores, micron-scale pores resulted from crystallization in the PEG-rich domains by forcing PEG molecules to diffuse from the surrounding PEG-P3HT blend region to the crystal growth front.

Directed ordering of phase separated domains and dewetting of thin polymer blend films on a topographically patterned substrate

Substrate pattern guided self-organization of ultrathin and confined polymeric films on a topographically patterned substrate is a useful approach for obtaining ordered meso and nano structures over large areas, particularly if the ordering is achieved during film preparation itself, eliminating any post-processing such as thermal or solvent vapor annealing. By casting a dilute solution of two immiscible polymers, polystyrene (PS) and polymethylmethacrylate (PMMA), from a common solvent (toluene) on a topographically patterned substrate with a grating geometry, we show the formation of self-organized meso patterns with various degrees of ordering. The morphology depends on both the concentration of the dispensed solution (C_n) and the blend composition (R_B). Depending on the extent of dewetting during spin coating, the final morphologies can be classified into three distinct categories. At a very low C_n the solution dewets fully, resulting in isolated polymer droplets aligned along substrate grooves (Type 1). Type 2 structures comprising isolated threads with aligned phase separated domains along each substrate groove are observed at intermediate C_n. A continuous film (Type 3) is obtained above a critical concentration (C_n*) that depends on R_B. While the extent of ordering of the domains gradually diminishes with an increase in film thickness for Type 3 patterns, the size of the domains remains much smaller than that on a flat substrate, resulting in significant downsizing of the features due to the lateral confinement imposed on the phase separation process by the topographic patterns. Finally, we show that some of these structures exhibit excellent broadband anti-reflection (AR) properties.

In situ imaging and height reconstruction of phase separation processes in polymer blends during spin coating

Spin coating polymer blend thin films provides a method to produce multiphase functional layers of high uniformity covering large surface areas. Applications for such layers include photovoltaics and light-emitting diodes where performance relies upon the nanoscale phase separation morphology of the spun film. Furthermore, at micrometer scales, phase separation provides a route to produce self-organized structures for templating applications. Understanding the factors that determine the final phase-separated morphology in these systems is consequently an important goal. However, it has to date proved problematic to fully test theoretical models for phase separation during spin coating, due to the high spin speeds, which has limited the spatial resolution of experimental data obtained during the coating process. Without this fundamental understanding, production of optimized micro- and nanoscale structures is hampered. Here, we have employed synchronized stroboscopic illumination together with the high light gathering sensitivity of an electron-multiplying charge-coupled device camera to optically observe structure evolution in such blends during spin coating. Furthermore the use of monochromatic illumination has allowed interference reconstruction of three-dimensional topographies of the spin-coated film as it dries and phase separates with nanometer precision. We have used this new method to directly observe the phase separation process during spinning for a polymer blend (PS-PI) for the first time, providing new insights into the spin-coating process and opening up a route to understand and control phase separation structures.

Interplay between dewetting and layer inversion in poly(4-vinylpyridine)/polystyrene bilayers

We investigated the morphology and dynamics of the dewetting of metastable poly(4-vinylpyridine) (P4VP) thin films situated on top of polystyrene (PS) thin films as a function of the molecular weight and thickness of both films. We focused on the competition between the dewetting process, occurring as a result of unfavorable intermolecular interactions at the P4VP/PS interface, and layer inversion due to the lower surface energy of PS. By means of optical and atomic force microscopy (AFM), we observed how both the dynamics of the instability and the morphology of the emerging patterns depend on the ratio of the molecular weights of the polymer films. When the bottom PS layer was less viscous than the top P4VP layer (liquid-liquid dewetting), nucleated holes in the P4VP film typically stopped growing at long annealing times because of a combination of viscous dissipation in the bottom layer and partial layer inversion. Full layer inversion was achieved when the viscosity of the top P4VP layer was significantly greater (>10⁴) than the viscosity of the PS layer underneath, which is attributed to strongly different mobilities of the two layers. The density of holes produced by nucleation dewetting was observed for the first time to depend on the thickness of the top film as well as the polymer molecular weight. The final (completely dewetted) morphology of isolated droplets could be achieved only if the time frame of layer inversion was significantly slower than that of dewetting, which was characteristic of high-viscosity PS underlayers that allowed dewetting to fall into a liquid-solid regime. Assuming a simple reptation model for layer inversion occurring at the dewetting front, the observed surface morphologies could be predicted on the basis of the relative rates of dewetting and layer inversion.

Phase-separated thin film structures for efficient polymer blend light-emitting diodes

We report laterally and vertically phase-separated thin film structures in conjugated polymer blends created by polymer molecular weight variation. We find that micrometer-scale lateral phase separation is critical in achieving high initial device efficiency of light-emitting diodes, whereas improved balance of charge carrier mobilities and film thickness uniformity are important in maintaining high efficiency at high voltages. The optoelectronic properties of these blend thin films and devices are strongly influenced by the polymer chain order/disorder and the interface state formed at polymer/polymer heterojunctions.

Periodic porous stripe patterning in a polymer blend film induced by phase separation during spin-casting

A periodic striping pattern with microscale pore size is observed on the surface of thin films prepared by spin-casting from a polystyrene (PS) and polyethylene glycol (PEG) blend solution. The pattern is created by the convection generated by thermal gradients in the solution between the substrate and film solution during solvent evaporation, the radial flow of the spin-coated solution, and the primary and secondary phase separation of the PS and PEG solutions. The formation mechanism of the periodic porous stripe pattern is discussed, wherein the effects of the polymer blend weight ratio, polymer concentration, and drying rate on the formation of the periodic porous striping pattern are investigated using scanning electron and atomic force microscopy.

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.

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.

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.