Deformation Hysteresis of Electrohydrodynamic Patterning on a Thin Polymer Film

Tackling Multi-Physics Nano-Scale Phenomena in Capillary Force Lithography with Small Data by Hybrid Intelligence

The scientific community has been looking for novel approaches to develop nanostructures inspired by nature. However, due to the complicated processes involved, controlling the height of these nanostructures is challenging. Nanoscale capillary force lithography (CFL) is one way to use a photopolymer and alter its properties by exposing it to ultraviolet radiation. Nonetheless, the working mechanism of CFL is not fully understood due to a lack of enough information and first principles. One of these obscure behaviors is the sudden jump phenomenon-the sudden change in the height of the photopolymer depending on the UV exposure time and height of nano-grating (based on experimental data). This paper uses known physical principles alongside artificial intelligence to uncover the unknown physical principles responsible for the sudden jump phenomenon. The results showed promising results in identifying air diffusivity, dynamic viscosity, surface tension, and electric potential as the previously unknown physical principles that collectively explain the sudden jump phenomenon.

Pattern formation in thin polymeric films via electrohydrodynamic patterning

The free surface of a thin polymeric film is often unstable and deforms into various micro-/nano-patterns under an externally applied electric field. This paper reviews a recent patterning technique, electrohydrodynamic patterning (EHDP), a straightforward, cost-effective and contactless bottom-up method. The theoretical and numerical studies of EHDP are shown. How the characteristic wavelength and the characteristic time depend on both the external conditions (such as voltage, film thickness, template-substrate spacing) and the initial polymer properties (such as rheological property, electrical property and surface tension) is theoretically and experimentally discussed. Various possible strategies for fabricating high-aspect-ratio or hierarchical patterns are theoretically and experimentally reviewed. Aligning and ordering of the anisotropic polymers by EHDP is emphasized. A perspective, including novelty and limitations of the methods, particularly in comparison to some conventional patterning techniques, and a possible future direction of research, is presented.

Loading a High-Viscous Droplet via the Cone-Shaped Liquid Bridge Induced by an Electrostatic Force

In transfer printing, the loaded droplet on the probe has a significant influence on the dispensing resolution. A suitable loading approach for a high-viscous liquid is highly required. Herein, a novel electrostatic loading method is presented, in which the main aim is to control precisely the formation and breaking of a cone-shaped liquid bridge. An experimental device is developed. The influence of electrical and geometric parameters on the feature size of the liquid bridge is investigated in detail. In the formation of the liquid bridge, the increase of voltage or the decrease of the air gap can enhance the electric field intensity, thus reducing the formation period and increasing the initial cone tip diameter of the liquid cone. After the liquid bridge is formed, both the circuit current implying the liquid wetted area on the probe surface and the lifting velocity of the probe are utilized to further regulate the volume of the loaded droplet. Loaded droplets ranging from 60 to 600 pL are obtained via the method with a standard deviation of 4 to 30 pL. Moreover, a dot array is transferred with different loaded droplets. The minimum diameter of the printed dots is about 140 μm with a variation less than 5%. The advantages include the reduced risk of contamination, the droplet-size independent of the size of the probe, and the low cost of the device.

Odd-viscosity-induced instability of a falling thin film with an external electric field

The influence of odd viscosity of Newtonian fluid on the instability of thin film flowing along an inclined plane under a normal electric field is studied. By odd viscosity, we mean apart from the well-known coefficient of shear viscosity, a classical liquid with broken time-reversal symmetry is endowed with a second viscosity coefficient in biological, colloidal, and granular systems. Under the long wave approximation, a nonlinear evolution equation of the free surface is derived by the method of systematic asymptotic expansion. The effects of the odd viscosity and external electric field are considered in this evolution equation and an analytical expression of critical Reynolds number is obtained. It is interesting to find that, by linear stability analysis, the critical Reynolds number increases with odd viscosity and decreases with external strength of electric field. In other words, odd viscosity has a stable effect and electric field has a destabilized effect on flowing of thin film. In addition, through nonlinear analysis, we obtain a Ginsburg-Landau equation and find that the film has not only the supercritical stability zone and the subcritical instability zone but also the unconditional stability zone and the explosive zone. The variations of each zone with related parameters, such as the strength of electric field, odd viscosity, and Reynolds number, etc., are investigated. The results are conducive to the further development of related experiments.

Parametric scheme for rapid nanopattern replication via electrohydrodynamic instability

Electrohydrodynamic (EHD) instability patterning exhibits substantial potential for application as a next-generation lithographic technique; nevertheless, its development continues to be hindered by the lack of process parameter controllability, especially when replicating sub-microscale pattern features. In this paper, a new parametric guide is introduced. It features an expanded range of valid parameters by increasing the pattern growth velocity, thereby facilitating reproducible EHD-driven patterning for perfect nanopattern replication. Compared with conventional EHD-driven patterning, the rapid patterning approach not only shortens the patterning time but also exhibits enhanced scalability for replicating small and geometrically diverse features. Numerical analyses and simulations are performed to elucidate the interplay between the pattern growth velocity, fidelity of the replicated features, and boundary between the domains of suitable and unsuitable parametric conditions in EHD-driven patterning. The developed rapid route facilitates nanopattern replication using EHD instability with a wide range of suitable parameters and further opens up many opportunities for device applications using tailor-made nanostructures in an effective and straightforward manner.

1/τ_m-dependent electrohydrodynamic replication of a hexagonally ordered hole array nanopattern by adjusting the filling ratio. As the 1/τ_m increases, the morphology evolves into the perfectly replicated hole features with increasing filling ratio.

Polyvinyl chloride gels microlens array with a well-controlled curvature obtained by solvent evaporation under DC electric fields

In this paper, polyvinyl chloride (PVC) gels microlens arrays (MLAs) with controllable curvatures were prepared by evaporation of the solvent under DC electric fields. In order to obtain these arrays, the PVC gel solution was first injected into the cofferdam of a ring array patterned electrode substrate. Upon polarization under DC electric field, the electric charge injected from the cathode was carried by the plasticizers towards the anode to accumulate on its surface. After complete evaporation of the solvent, the PVC gels formed stable MLAs. The focal length of the formed MLAs obtained after evaporation of the 100 µL PVC gel solvent under 30 V DC field was 8.68 mm. The focal length of the as-obtained PVC gel-based MLAs can be well-controlled by merely tuning the strength of the electric field or by changing the volume of the PVC gel solution. Thus, it can be concluded that the proposed methodology looks very promising for future fabrication of MLAs with uniform size in larger areas.

Deformation hysteresis of a water nano-droplet in an electric field

Electric field is an effective method to manipulate droplets in micro/nano-scale, and various physical phenomena have been found due to the interaction of electric field and fluid flow. In this study, we developed a molecular dynamic model to investigate the deforming behavior of a nano-droplet in a uniform electric field. The nano-droplet was initially confined between two plates and then wetted on the lower plate (i.e., substrate) until an equilibrium state, after that a uniform electric field in vertical direction was imposed to the system. Due to the electrical force, the droplet started to deform until achieving a new equilibrium state and the dynamic process is recorded. By comparing the equilibrium state under different electric field strength, we found a deformation hysteresis phenomenon, i.e., different deformations were obtained when increasing and decreasing the electric field. To be specific, a large electric field (E = 0.57 V ·nm^-1) is needed to stretch the nano-droplet to touch the upper plate, while a relatively lower field (E = 0.40 V ·nm^-1) is adequate to keep it contacting with the plate. Accompanied by the deformation hysteresis, a distribution hysteresis of the average dipole orientations of water molecules in the nano-droplet is also found. Such a hysteresis phenomenon is caused by the electrohydrodynamic interactions between droplet and plates, and the findings of this study could enhance our understanding of droplet deformation in an electric field.

Reversible morphological switching and deformation hysteresis in electric field mediated instability of thin elastic films

Reversible morphology switching in a soft elastic film sandwiched between two parallel electrodes when subject to an externally applied electric field is reported herein. In contrast to electric field mediated instability of a thin liquid film, where the instability patterns remain permanent, in the present case the patterns debond completely or partially when the electric field is switched off, depending on whether the gap spacing (dG) between the film and the top electrode is >100 nm or not. The onset of instability is marked with the appearance of isotropic columns when the applied field strength (U) exceeds a critical value (Uc). The subsequent increase in U leads to the gradual transition of the instability patterns from pillars to bi-continuous labyrinths to an array of holes. Complete conformal contact is established between the film and the top electrode at U = UF. When U is reduced, the morphology changes in a reverse sequence. There is a significant level of hysteresis between the bonding and debonding stages, including persistence of the features at much lower voltages due to pinning of the patterns to the top electrode. Complete detachment occurs at a lower voltage UD when dG > 100 nm. The holes fluctuate before complete contact between the film and the top electrode due to competition between the destabilizing electric field and restoring forces due to stretching of the crosslinked polymer matrix.

Ordered high aspect ratio nanopillar formation based on electrical and thermal reflowing of prepatterned thin films

Creating well-ordered, submicron-sized pillars have been stated as main limitation for electrically induced patterning of nanofilms (thickness <100 nm) [1]. In our previous works, it was shown that the aspect ratio of formed nanopillars was increased to about 0.35 when thermocapillary induced instabilities (Thermally Induced Patterning, TIP) is combined with electrodynamics instabilities (Electrically Induced Patterning, EIP). However, further reduction of pillar size resulted in a coarse and randomly distributed pillars [2,3]. Here, the reflowing of initially prepatterned nanofilms are examined in the EIP and combined EIP-TIP process to create a well-ordered and high aspect ratio nanopillar arrays without sacrificing the fidelity of the final structure. The long-wave approximation is used to simplify the governing equations and boundary conditions leading to a fourth order nonlinear partial differential equation called thin film equation that describes the spatio-temporal evolution of the interface. The mechanism of pattern reflowing is discussed for both linear (initial) and nonlinear (long-term) deformations in EIP and EIP-TIP process. The optimum initial pattern width, height and the center-to-center distance is found based on the characteristic wavelength for growth of instabilities predicted by linear stability analysis and nonlinear simulation results.

Pattern-Directed Ordering of Spin-Dewetted Liquid Crystal Micro- or Nanodroplets as Pixelated Light Reflectors and Locomotives

Chemical pattern directed spin-dewetting of a macroscopic droplet composed of a dilute organic solution of liquid crystal (LC) formed an ordered array of micro- and nanoscale LC droplets. Controlled evaporation of the spin-dewetted droplets through vacuum drying could further miniaturize the size to the level of ∼90 nm. The size, periodicity, and spacing of these mesoscale droplets could be tuned with the variations in the initial loading of LC in the organic solution, the strength of the centripetal force on the droplet, and the duration of the evaporation. A simple theoretical model was developed to predict the spacing between the spin-dewetted droplets. The patterned LC droplets showed a reversible phase transition from nematic to isotropic and vice versa with the periodic exposure of a solvent vapor and its removal. A similar phase transition behavior was also observed with the periodic increase or reduction of temperature, suggesting their usefulness as vapor or temperature sensors. Interestingly, when the spin-dewetted droplets were confined between a pair of electrodes and an external electric field was applied, the droplets situated at the hydrophobic patches showed light-reflecting properties under the polarization microscopy highlighting their importance in the development of micro- or nanoscale LC displays. The digitized LC droplets, which were stationary otherwise, showed dielectrophoretic locomotion under the guidance of the external electric field beyond a threshold intensity of the field. Remarkably, the motion of these droplets could be restricted to the hydrophilic zones, which were confined between the hydrophobic patches of the chemically patterned surface. The findings could significantly contribute in the development of futuristic vapor or temperature sensors, light reflectors, and self-propellers using the micro- or nanoscale digitized LC droplets.