Irreversible Adsorption Controls Crystallization in Vapor-Deposited Polymer Thin Films

Anisotropic material depletion in epitaxial polymer crystallization

The physical properties of a semicrystalline polymer thin film are intimately related to the morphology of its crystalline domains. While the mechanisms underlying crystallization of flat-on oriented polymer crystals are well known, similar mechanisms remain elusive for edge-on oriented thin films due to the propensity of substantially thin films to adopt flat-on orientations. Here, we employ an epitaxial polymer-substrate relationship to enforce edge-on crystallization in thin films. Using matrix-assisted pulsed laser evaporation (MAPLE), we deposit films in which crystal nucleation is spatially separated from subsequent epitaxial crystallization. These experiments, together with phase-field simulations, demonstrate a highly anisotropic and localized material depletion during edge-on crystallization. These results provide deeper insight into the physics of polymer crystallization under confinement and introduce a processing motif in the crystallization of ultrathin structured films.

Free Space Makes the Polymer "Dead Layer" Alive

The effect of free space on molecular motion inside the polymer "dead layer" or adsorbed nanolayers on solid surfaces is investigated. Free space is introduced into the nanolayer by choosing a polymer with a relatively big side group, poly n-butyl methacrylate (PnBMA), and polarization-resolved single-molecule fluorescence microscopy is adopted as the method. The rotational motion of the doped fluorescent probes is found to be considerably excited at moderate temperatures, attributed to the free space brought by the side group of the PnBMA. The development of the adsorbed nanolayer by the prolonged annealing of the parent film is carefully monitored, together with the evolution of the molecular motion and the glass transition temperature (T_g). The T_g values of the exposed nanolayers are considerably lower than that of the bulk system, while they become higher than those in the bulk situation when the nanolayer is covered with a polymer top layer. The experimental evidence has demonstrated that the free space made available by the side group and the air-polymer interface has considerably promoted the molecular motion inside the adsorbed nanolayers, even under the situation of overwhelming surface attraction.

Direct observation of desorption of a melt of long polymer chains

Tuning the thermodynamic state of a material has a tremendous impact on its performance. In the case of polymers placed in proximity of a solid wall, this is possible by annealing above the glass transition temperature, Tg, which induces the formation of an adsorbed layer. Whether heating to higher temperatures would result in desorption, thereby reverting the thermodynamic state of the interface, has so far remained elusive, due to the interference of degradation. Here, we employ fast scanning calorimetry, allowing to investigate the thermodynamics of the interface while heating at 104 K s-1. We show that applying such rate to adsorbed polymer layers permits avoiding degradation and, therefore, we provide clear-cut evidence of desorption of a polymer melt. We found that the enthalpy and temperature of desorption are independent of the annealing temperature, which, in analogy to crystallization/melting, indicates that adsorption/desorption is a first order thermodynamic transition.

Review and reproducibility of forming adsorbed layers from solvent washing of melt annealed films

Recent studies suggest chain adsorption in the melt may be responsible for a number of property changes in thin films by making correlations between the residual adsorbed layer thickness h_ads(t) measured after a given solvent washing procedure as a function of annealing time t of the film at an elevated temperature prior to this solvent rinse. This procedure, frequently called "Guiselin's experiment", refers to the thought experiment proposed in a 1992 theoretical treatment by Guiselin that assumed chain segments in contact with the surface are irreversibly adsorbed whereby unadsorbed chains could be washed away by solvent without disturbing the adsorbed substrate contact points in the melt. In the present work, we review this recent literature, identifying and experimentally testing a common protocol for forming adsorbed layers h_ads(t) from solvent washing melt films. We find h_ads(t) curves to be far less reproducible and reliable than implied in the literature, strongly dependent on solvent washing and substrate cleaning conditions, and annealing at elevated temperatures is unnecessary as densification of films sitting at room temperature makes the glassy film harder to wash off, leaving behind h_ads of comparable thickness. This review also summarizes literature understanding developed over several decades of study on polymer adsorption in solution, which experimentally demonstrated that polymer chains in solution are highly mobile, diffusing and exchanging on the surface even in the limit of strong adsorption, contradicting Guiselin's assumption. Preformed adsorbed layers of different thicknesses h_ads are shown to not affect the average glass transition temperature or physical aging of 30 nm thick films. In summary, a number of open questions and implications are discussed related to thin films and polymer nanocomposites.

Irreversible adsorption of polymer melts and nanoconfinement effects

For almost a decade, growing experimental evidence has revealed a strong correlation between the properties of nanoconfined polymers and the number of chains irreversibly adsorbed onto nonrepulsive interfaces, e.g. the supporting substrate of thin polymer coatings, or nanofillers dispersed in polymer melts. Based on such a correlation, it has already been possible to tailor structural and dynamics properties - such as the glass transition temperature, the crystallization rate, the thermal expansion coefficients, the viscosity and the wettability - of nanomaterials by controlling the adsorption kinetics. This evidence indicates that irreversible adsorption affects nanoconfinement effects. More recently, also the opposite phenomenon was experimentally observed: nanoconfinement alters interfacial interactions and, consequently, also the number of chains adsorbed in equilibrium conditions. In this review we discuss this intriguing interplay between irreversible adsorption and nanoconfinement effects in ultrathin polymer films. After introducing the methods currently used to prepare adsorbed layers and to measure the number of irreversibly adsorbed chains, we analyze the models employed to describe the kinetics of adsorption in polymer melts. We then discuss the structure of adsorbed polymer layers, focusing on the complex macromolecular architecture of interfacial chains and on their thermal expansion; we examine the way in which the structure of the adsorbed layer affects the thermal glass transition temperature, vitrification, and crystallization. By analyzing segmental dynamics of 1D confined systems, we describe experiments to track the changes in density during adsorption. We conclude this review with an analysis of the impact of nanoconfinement on adsorption, and a perspective on future work where we also address the key ideas of irreversibility, equilibration and long-range interactions.

Density of Obstacles Affects Diffusion in Adsorbed Polymer Layers

The translational diffusion of molecules dispersed into polymer matrices slows down tremendously when approaching a nonrepulsive interface. To unravel the origin of this phenomenon, we investigated the diffusion of molecular probes in the direction normal to an adsorbing wall. Using adsorbed polymer layers as matrices, we were able to decouple interfacial and finite size effects and determined the relation between the diffusion time and the area available at the polymer/solid interface. Based on the results of our investigation, we present a physical picture, suggesting that the reduction in diffusion rate is correlated to the degree of chain adsorption onto the substrate, that is, the density of surface obstacles encountered by tracer molecules.

Self-Assembled Copolymer Adsorption Layer-Induced Block Copolymer Nanostructures in Thin Films

In polymer thin films, the bottom polymer chains are irreversibly adsorbed onto the substrates creating an ultrathin layer. Although this thin layer (only a few nanometers thick) governs all film properties, an understanding of this adsorbed layer remains elusive, and thus, its effective control has yet to be achieved, particularly in block copolymer (BCP) thin films. Herein, we employ self-assembled copolymer adsorption layers (SCALs), transferred from the air/water interfacial self-assembly of BCPs, as an effective control of the adsorbed layer in BCP thin films. SCALs replace the natural adsorbed layer, irreversibly adsorbing onto the substrates when other BCP is additionally coated on the SCALs. We further show that SCALs guide the thin film nanostructures because they provide topological restrictions and enthalpic/entropic preferences for a BCP self-assembly. The SCAL-induced self-assembly enables unprecedented control of nanostructures, creating novel nanopatterns such as spacing-controlled hole/dot patterns, dotted-line patterns, dash-line patterns, and anisotropic cluster patterns with exceptional controllability.

Tunable Properties of MAPLE-Deposited Thin Films in the Presence of Suppressed Segmental Dynamics

Processing polymer thin films by physical vapor deposition has been a major challenge due to material degradation. This challenge has limited our understanding of morphological control by top-down approaches that can be crucial for many applications. Recently, matrix-assisted pulsed laser evaporation (MAPLE) has emerged as an alternative route to fabricate polymer thin films from near-gas phase growth conditions. In this Letter, we investigate how this approach can result in a stable two-phase film structure of semicrystalline polymers via a unique combination of MAPLE and flash calorimetry. In the case of MAPLE-deposited poly(ethylene oxide) (PEO) thin films, we find a 35 °C enhancement in the glass transition temperature relative to melt-crystallized films, which is associated with irreversible chain adsorption in the amorphous region of the film. Remarkably, by varying substrate temperature during deposition, we reveal the ability to significantly tune the crystal orientation, extent of crystallinity, and lamellar thickness of MAPLE-deposited PEO thin films.

Taming the Strength of Interfacial Interactions via Nanoconfinement

The interaction between two immiscible materials is related to the number of contacts per unit area formed by the two materials. For practical reasons, this information is often parametrized by the interfacial free energy, which is commonly derived via rather cumbersome approaches, where properties of the interface are described by combining surface parameters of the single materials. These combining rules, however, neglect any effect that geometry might have on the strength of the interfacial interaction. In this Article, we demonstrate that the number of contacts at the interface between a thin polymer coating and its supporting substrate is altered upon confinement at the nanoscale level. We show that explicitly considering the effect of nanoconfinement on the interfacial potential allows a quantitative prediction of how sample geometry affects the number of contacts formed at the interface between two materials.

Damage-free plasma etching of porous organo-silicate low-k using micro-capillary condensation above -50 °C

The micro-capillary condensation of a new high boiling point organic reagent (HBPO), is studied in a periodic mesoporous oxide (PMO) with ∼34 % porosity and k-value ∼2.3. At a partial pressure of 3 mT, the onset of micro-capillary condensation occurs around +20 °C and the low-k matrix is filled at -20 °C. The condensed phase shows high stability from -50 < T ≤-35 °C, and persists in the pores when the low-k is exposed to a SF6-based plasma discharge. The etching properties of a SF6-based 150W-biased plasma discharge, using as additive this new HBPO gas, shows that negligible damage can be achieved at -50 °C, with acceptable etch rates. The evolution of the damage depth as a function of time was studied without bias and indicates that Si-CH3 loss occurs principally through Si-C dissociation by VUV photons.

Mechanisms of Polymer Adsorption onto Solid Substrates

Controlling polymer/substrate interfaces without modifying chemistry is nowadays possible by finely tuning the formation of adsorbed layers. The complex processes leading to irreversible attachment of chains onto solid substrates are governed by two mechanisms: molecular rearrangement and potential-driven adsorption. Here we introduce an analytical method to differentiate these two mechanisms. By analyzing experiments and simulations, we investigate how changes in thermal energy and interaction potential affect equilibrium and nonequilibrium components of the adsorption kinetics. We find that the adsorption process is thermally activated, with activation energy comparable to that of local noncooperative processes. On the other hand, the final adsorbed amount depends on the interface interaction only (i.e., it is temperature independent in experiments). We identify a universal linear relation between the growth rates at short and long adsorption times, suggesting that the monomer pinning mechanism is independent of surface coverage, while the progressive limitation of free sites significantly limits the adsorption rate.

How irreversible adsorption affects interfacial properties of polymers

Growing experimental evidence shows that the behavior of polymer chains confined at the nanoscale level strongly depends on the degree of adsorption correlated to the number density of monomers pinned onto the supporting substrate. In this contribution, after introducing the physics behind the mechanisms of irreversible adsorption, we review recent experimental observations on how adsorption affects properties of polymer melts confined in 1D, focusing on those related to the thermal glass transition, maximum water uptake, viscosity and crystallization. These findings strongly support a new physical framework of confined soft matter, not trivially limited to finite size effects and interfacial interactions, but also enriched by non-equilibrium phenomena.

Irreversible Adsorption Erases the Free Surface Effect on the Tg of Supported Films of Poly(4-tert-butylstyrene)

When cooled at constant rate, a 25 nm thin film of poly(4-tert-butylstyrene) vitrifies 50 K lower than in bulk. This record sets the largest depression in thermal glass transition temperature (T_g) ever observed upon confinement at the nanoscale level. Same as for other supported polymer layers, this reduction in T_g has been attributed to the presence of a free surface, the ensemble of molecules at the interface with air remaining in the liquid state also at temperatures well below bulk T_g. Here, we verify that such tremendous shifts can be erased upon prolonged annealing in the liquid state, hinting at a metastable nature of confinement effects. We demonstrate that the recovery of bulk behavior and the manifestation of the free surface are enslaved to the kinetics of irreversible adsorption of chains on the supporting substrate.