Embedded microstructures by electric-field-induced pattern formation in interacting thin layers

Generation of Hierarchically Ordered Structures on a Polymer Film by Electrohydrodynamic Structure Formation

The extensive applications of hierarchical structures in optoelectronics, micro/nanofluidics, energy conservation, etc., have led to the development of a variety of approaches for their fabrication, which can be categorized as bottom-up or top-down strategies. Current bottom-up and top-down strategies bear a complementary relationship to each other due to their processing characteristics, i.e., the advantages of one method correspond to the disadvantages of the other, and vice versa. Here we propose a novel method based on electrohydrodynamic structure formation, aimed at combining the main advantages of the two strategies. The method allows the fabrication of a hierarchically ordered structure with well-defined geometry and high mechanical durability on a polymer film, through a simple and low-cost process also suitable for mass-production. In this approach, upon application of an electric field between a template and a substrate sandwiching an air gap and a polymer film, the polymer is pulled toward the template and further flows into the template cavities, resulting in a hierarchical structure with primary and secondary patterns determined by electrohydrodynamic instability and by the template features, respectively. In this work, the fabrication of a hierarchical structure by electrohydrodynamic structure formation is studied using numerical simulations and experimental tests. The proposed method is then employed for the one-step fabrication of a hierarchical structure exhibiting a gradual transition in the periodicity of the primary structure using a slant template and a flat polymer film, which presents an excellent performance on controllable wettability.

Coupled self-organization: thermal interaction between two liquid films undergoing long-wavelength instabilities

The effects of thermal coupling between two thin liquid layers separated by a gas layer are discussed. The liquid layers undergo long-wavelength instabilities driven by gravitational and thermocapillary stresses. To study the dynamics, both a linear stability analysis and a full numerical solution of the thin-film equations are performed. The results demonstrate that the stability properties of the combined system differs substantially from the case where both layers evolve independently from each other. Most prominently, oscillatory instabilities, not present in single-liquid layer configurations, may occur.

Electric-field-induced interfacial instabilities of a soft elastic membrane confined between viscous layers

We explore the electric-field-induced interfacial instabilities of a trilayer composed of a thin elastic film confined between two viscous layers. A linear stability analysis (LSA) is performed to uncover the growth rate and length scale of the different unstable modes. Application of a normal external electric field on such a configuration can deform the two coupled elastic-viscous interfaces either by an in-phase bending or an antiphase squeezing mode. The bending mode has a long-wave nature, and is present even at a vanishingly small destabilizing field. In contrast, the squeezing mode has finite wave-number characteristics and originates only beyond a threshold strength of the electric field. This is in contrast to the instabilities of the viscous films with multiple interfaces where both modes are found to possess long-wave characteristics. The elastic film is unstable by bending mode when the stabilizing forces due to the in-plane curvature and the elastic stiffness are strong and the destabilizing electric field is relatively weak. In comparison, as the electric field increases, a subdominant squeezing mode can also appear beyond a threshold destabilizing field. A dominant squeezing mode is observed when the destabilizing field is significantly strong and the elastic films are relatively softer with lower elastic modulus. In the absence of liquid layers, a free elastic film is also found to be unstable by long-wave bending and finite wave-number squeezing modes. The LSA asymptotically recovers the results obtained by the previous formulations where the membrane bending elasticity is approximately incorporated as a correction term in the normal stress boundary condition. Interestingly, the presence of a very weak stabilizing influence due to a smaller interfacial tension at the elastic-viscous interfaces opens up the possibility of fabricating submicron patterns exploiting the instabilities of a trilayer.

Ultrafast large-area micropattern generation in nonabsorbing polymer thin films by pulsed laser diffraction

An ultrafast, parallel, and beyond-the-master micropatterning technique for ultrathin (30-400 nm) nonabsorbing polymer films by diffraction of laser light through a 2D periodic aperture is reported. The redistribution of laser energy absorbed by the substrate causes self-organization of polymer thin films in the form of wrinklelike surface relief structures caused by localized melting and freezing of the thin film. Unlike conventional laser ablation and laser writing processes, low laser fluence is employed to only passively swell the polymer as a pre-ablative process without loss of material, and without absorption/reaction with incident radiation. Self-organization in the thin polymer film, aided by the diffraction pattern, produces microstructures made up of thin raised lines. These regular microstructures have far more complex morphologies than the mask geometry and very narrow line widths that can be an order of magnitude smaller than the openings in the mask. The microstructure morphology is easily modulated by changing the film thickness, aperture size, and geometry, and by changing the diffraction pattern.