Surface instabilities in ultrathin, cross-linked poly(N-isopropylacrylamide) coatings

Swelling-Activated, Soft Mechanochemistry in Polymer Materials

Swelling in polymer materials is a ubiquitous phenomenon. At a molecular level, swelling is dictated by solvent-polymer interactions, and has been thoroughly studied both theoretically and experimentally. Favorable solvent-polymer interactions result in the solvation of polymer chains. For polymers in confined geometries, such as those that are tethered to surfaces, or for polymer networks, solvation can lead to swelling-induced tensions. These tensions act on polymer chains and can lead to stretching, bending, or deformation of the material both at the micro- and macroscopic scale. This Invited Feature Article sheds light on such swelling-induced mechanochemical phenomena in polymer materials across dimensions, and discusses approaches to visualize and characterize these effects.

Diels-Alder Cross-Linked, Washing-Free Hydrogel Films with Ordered Wrinkling Patterns for Multicellular Spheroid Generation

Three-dimensional (3D) multicellular spheroids are a new generation in vitro cell model, however, their applications are severely limited by difficulties in their generation. Here patterned poly(2-hydroxyethyl methacrylate) (PHEMA) hydrogel films were synthesized for their generation. Instead of polymerization of HEMA monomers in the presence of a cross-linker, here the PHEMA films were synthesized by cross-linking furan-functionalized linear PHEMA, PHEMA-furan, and maleimide-functionalized linear PHEMA, PHEMA-mal, via Diels-Alder (DA) reaction between furan and maleimide groups. A thermal treatment temperature of 75 °C was chosen for the cross-linking reaction. The occurrence of DA reaction was confirmed by IR spectra. Using this method, cross-linked PHEMA films with smooth surface were successfully synthesized in situ in the well of cell culture plates. The films were then patterned by simply adding water to swell them. Highly ordered, honeycomb-like wrinkling patterns were successfully obtained by adjusting the furan and maleimide contents in the precursor linear polymers. The patterned hydrogel films were used to generate multicellular spheroids. Guided by the patterns, 3D spheroids with narrow size distribution, tunable size, and high cell viability were successfully obtained. The patterned PHEMA films reported here exhibited a lot of advantages. The patterning method was quite simple and required no template or special equipment. They were synthesized in situ in commercial cell culture plates. Particularly, thanks to the clean nature of the DA reaction, no low molecular weight monomer, cross-linker, initiator, or catalyst, which were potentially cytotoxic, was involved in the film synthesis, and no byproduct was produced and left in the film. The resulting films presented a high biocompatibility, allowing the avoidance of the tedious washing step. The films synthesized here were expected to have high potential for massive production of well-defined multicellular spheroids.

Drop Spreading and Confinement in Swelling-Driven Folding of Thin Films

Surface instabilities are a versatile method for generating three-dimensional (3D) surface microstructure. When an elastomeric film weakly bonded to a substrate is swollen with solvent, buckle delamination and subsequent sliding of the film on the substrate lead to the formation of tall, self-contacting, and permanent folds. This paper explores the mechanics of fold development when such folding is induced by placing a drop on the surface of the film. We show that capillary effects can induce a strong coupling between folding and drop spreading: as folds develop, they wick the solvent toward the periphery of the drop, further propagating radially aligned folds. Accordingly, a solvent drop spreads far more on films that are weakly adhered to the substrate. As drop size reduces and folding becomes increasingly confined, debonding propagates along the perimeter of the wetted region, thus leading to corral-shaped fold patterns. On the other hand, as drop size increases and confinement effects weaken, isotropically oriented folds appear at a spacing that reduces as swelling increases. The spacing between the folds and the size of the corrals are both determined by the extent to which a single fold relieves compressive stress in its vicinity by sliding. We develop a model for folding which explicitly accounts for the fact that folds must initiate with near-zero volume under the buckle. The model shows that folds can appear even at very low swelling if there are large pre-existing debonded regions at the film-substrate interface.

Rucks and folds: delamination from a flat rigid substrate under uniaxial compression

We revisit the delamination of a solid adhesive sheet under uniaxial compression from a flat, rigid substrate. Using energetic considerations and scaling arguments, we show that the phenomenology is governed by three dimensionless groups, which characterize the level of confinement imposed on the sheet, as well as its extensibility and bendability. Recognizing that delamination emerges through a subcritical bifurcation from a planar, uniformly compressed state, we predict that the dependence of the threshold confinement level on the extensibility and bendability of the sheet, as well as the delaminated shape at threshold, varies markedly between two asymptotic regimes of these parameters. For sheets whose bendability is sufficiently high, the delaminated shape is a large-slope "fold," where the amplitude is proportional to the imposed confinement. In contrast, for lower values of the bendability parameter, the delaminated shape is a small-slope "ruck," whose amplitude increases more moderately upon increasing confinement. Realizing that the instability of the fully laminated state requires a finite extensibility of the sheet, we introduce a simple model that allows us to construct a bifurcation diagram that governs the delamination process.

PHEMA hydrogel films crosslinked with dynamic disulfide bonds: synthesis, swelling-induced mechanical instability and self-healing

Undesired swelling-induced instability patterns on substrate-attached hydrogel films can be self-healed by the introduction of dynamic covalent bonds.

Buckling Instabilities in Polymer Brush Surfaces via Postpolymerization Modification

We report a simple route to engineer ultrathin polymer brush surfaces with wrinkled morphologies using post-polymerization modification (PPM), where the length scale of the buckled features can be tuned from hundreds of nanometers to one micrometer using PPM reaction time. We show that partial crosslinking of the outer layer of the polymer brush under poor solvent conditions is critical to obtain wrinkled morphologies upon swelling. Characterization of the PPM kinetics and swelling behavior via ellipsometry and the through-thickness composition profile via time-of-flight secondary ion mass spectroscopy (ToF-SIMS) provided keys insight into parameters influencing the buckling behavior.

Experimental and theoretical studies on the morphogenesis of bacterial biofilms

Biofilm morphogenesis not only reflects the physiological state of bacteria but also serves as a strategy to sustain bacterial survival. In this paper, we take the Bacillus subtilis colony as a model system to explore the morphomechanics of growing biofilms confined in a defined geometry. We find that the growth-induced stresses may drive the occurrence of both surface wrinkling and interface delamination in the biofilm, leading to the formation of a labyrinthine network on its surface. The wrinkles are perpendicular to the boundary of the constraint region. The variation in the surface undulations is attributed to the spatial stress field, which is isotropic in the inner regime but anisotropic in the vicinity of the boundary. Our experiments show that the directional surface wrinkles can confer biofilms with anisotropic wetting properties. This study not only highlights the role of mechanics in sculpturing organisms within the morphogenetic context but also suggests a promising route toward desired surfaces at the interface between synthetic biology and materials sciences.

Functionalized, biocompatible, and impermeable nanoscale coatings for PEEK

Biologically compatible coatings that provide hermetic seal could resolve a major technological hurdle in the attempt to replace metals with polymers for biochips and active medical implants. The use of amorphous carbon/diamond like carbon (a-C:H) coatings to hermetically seal and biologically enhance polyether-ether-ketone (PEEK) for biomedical device integration in the human body was investigated. The PEEK coating functionality (sp3/sp2 ratio), hardness and thickness (70-200nm) were controlled, by varying H₂ and N₂ concentration during the plasma operation with CH₄. a-C:H coatings having the highest indentation modulus of 13.5GPa, originate out of a CH₄ (90%) rich composition. Even in a mixture of 70/30 H₂/CH₄ the hardness is 4.76GPa, corresponding to hard and dense coatings. In all tested conditions of deposition coatings hardens was sufficient for the purpose of PEEK implants modification. The synthesized (a-C:H) nanoscale coatings were not water permeable as measured by the hydrolysis test, resolving the traditional challenge of swelling in wet environment. The hardness of the coatings showed strong correlations with the thickness, surprisingly however, with no correlations with the sp3/sp2 ratio. Selected non water permeable nanoscale coating on PEEK showed strong bioactivity by being viable for human osteoblast (hFOB) and human fibroblast (hGF) cells without toxicity issues. No correlation was observed between the coatings sp3/sp2 ratio and biological performance.

Surface-Anchored Poly(N-isopropylacrylamide) Orthogonal Gradient Networks

We present a versatile synthetic route leading toward generating surface-attached polyacrylamide gels, in which the cross-link density varies continuously and gradually across the substrate in two orthogonal directions. We employ free radical polymerization to synthesize random copolymers comprising ~5% of photoactive methacrylyloxybenzophenone (MABP), ~5% of thermally active styrene sulfonyl azide (SSAz), and ~90% of N-isopropylacrylamide (NIPAAm) units. The presence of MABP and SSAz in the copolymer facilitates control over the cross-link density of the gel in an orthogonal manner using photoactivated and thermally activated cross-linking chemistries, respectively. Spectroscopic ellipsometry is employed to determine the degree of swelling of the gel in water and methanol as a function of position on the substrate. Network swelling varies continuously and gradually across the substrate and is high in regions of low gel fractions and low in regions of high gel fractions.

Spontaneous wettability patterning via creasing instability

Surfaces with patterned wettability contrast are important in industrial applications such as heat transfer, water collection, and particle separation. Traditional methods of fabricating such surfaces rely on microfabrication technologies, which are only applicable to certain substrates and are difficult to scale up and implement on curved surfaces. By taking advantage of a mechanical instability on a polyurethane elastomer film, we show that wettability patterns on both flat and curved surfaces can be generated spontaneously via a simple dip coating process. Variations in dipping time, sample prestress, and chemical treatment enable independent control of domain size (from about 100 to 500 μm), morphology, and wettability contrast, respectively. We characterize the wettability contrast using local surface energy measurements via the sessile droplet technique and tensiometry.

Microphase-Separated PE/PEO Thin Films Prepared by Plasma-Assisted Vapor Phase Deposition

Immiscible polymer blends tend to undergo phase separation with the formation of nanoscale architecture which can be used in a variety of applications. Different wet-chemistry techniques already exist to fix the resultant polymeric structure in predictable manner. In this work, an all-dry and plasma-based strategy is proposed to fabricate thin films of microphase-separated polyolefin/polyether blends. This is achieved by directing (-CH2-)100 and (-CH2-CH2-O-)25 oligomer fluxes produced by vacuum thermal decomposition of poly(ethylene) and poly(ethylene oxide) onto silicon substrates through the zone of the glow discharge. The strategy enables mixing of thermodynamically incompatible macromolecules at the molecular level, whereas electron-impact-initiated radicals serve as cross-linkers to arrest the subsequent phase separation at the nanoscale. The mechanism of the phase separation as well as the morphology of the films is found to depend on the ratio between the oligomeric fluxes. For polyolefin-rich mixtures, polyether molecules self-organize by nucleation and growth into spherical domains with average height of 22 nm and average diameter of 170 nm. For equinumerous fluxes and for mixtures with the prevalence of polyethers, spinodal decomposition is detected that results in the formation of bicontinuous structures with the characteristic domain size and spacing ranging between 5 × 10(1) -7 × 10(1) nm and 3 × 10(2)-4 × 10(2) nm, respectively. The method is shown to produce films with tunable wettability and biologically nonfouling properties.

Nanoscale Surface Creasing Induced by Post-polymerization Modification

Creasing in soft polymeric films is a result of substantial compressive stresses that trigger instability beyond a critical strain and have been directly related to failure mechanisms in different materials. However, it has been shown that programming these instabilities into soft materials can lead to new applications, such as particle sorting, deformable capillaries, and stimuli-responsive interfaces. In this work, we present a method for fabricating reproducible nanoscale surface instabilities using reactive microcontacting printing (μCP) on activated ester polymer brush layers of poly(pentafluorophenyl acrylate). The sizes and structures of the nanoscale creases can be modulated by varying the grafting density of the brush substrate and pressure applied during μCP. Stress is generated in the film under confinement due to the molecular weight increase of the side chains during post-polymerization modification, which results in substantial in-plane growth in the film and leads to the observed nanoscale creases.

Submicrometric Films of Surface-Attached Polymer Network with Temperature-Responsive Properties

Temperature-responsive properties of surface-attached poly(N-isopropylacrylamide) (PNIPAM) network films with well-controlled chemistry are investigated. The synthesis consists of cross-linking and grafting preformed ene-reactive polymer chains through thiol-ene click chemistry. The formation of surface-attached and cross-linked polymer films has the advantage of being well-controlled without any caution of no-oxygen atmosphere or addition of initiators. PNIPAM hydrogel films with same cross-link density are synthesized on a wide range of thickness, from nanometers to micrometers. The swelling-collapse transition with temperature is studied by using ellipsometry, neutron reflectivity, and atomic force microscopy as complementary surface-probing techniques. Sharp and high amplitude temperature-induced phase transition is observed for all submicrometric PNIPAM hydrogel films. For temperature above LCST, surface-attached PNIPAM hydrogels collapse similarly but without complete expulsion of water. For temperature below LCST, the swelling of PNIPAM hydrogels depends on the film thickness. It is shown that the swelling is strongly affected by the surface attachment for ultrathin films below ∼150 nm. For thicker films above 150 nm (to micrometers), surface-attached polymer networks with the same cross-link density swell equally. The density profile of the hydrogel films in the direction normal to the substrate is confronted with in-plane topography of the free surface. It results that the free interface width is much larger than the roughness of the hydrogel film, suggesting pendant chains at the free surface.

Swelling-induced surface instability patterns guided by pre-introduced structures

Swelling-induced, spontaneously generated surface instability patterns in substrate-attached hydrogel films can be harnessed for advanced applications, however, methods to control their formation and morphology are missing. Here we propose that their generation may be guided by intentionally pre-introduced line structures. While uniform gel films produce irregular polygonal instability patterns, instability patterns generated in pre-patterned films with hexagonal line structures are regular hexagons with long-range order. The pre-introduced line structures act as defects in the generation of the surface instability patterns, which determine the position of the creases, regulate their rearrangement and determine their final morphology. The contrast between the pre-introduced structures and the surrounding area should be high enough for the pre-introduced structures to act as defects. Only when the characteristic wavelength of the pre-introduced pattern matches with the one of the gel film, perfect hexagonal patterns can be obtained. The gel films with uniform topographic features may find various advanced applications.

Complex dynamic substrate control: dual-tone hydrogel photoresists allow double-dissociation of topography and modulus

Complex substrate control is demonstrated with a dual-tone hydrogel photoresist. By exposing a photodegradable hydrogel to UV light through a photomask, both swollen and eroded micropatterns with a decreased modulus can be created on the surface under different exposure conditions. This provides an important tool for investigating the synergistic effects of spatially heterogeneous mechanical and topological cues on cell behavior.

Folding and birefringence behavior of poly(vinyl alcohol) hydrogel film induced by freezing and thawing

A band-like folding structure with high aspect ratio, parallel or perpendicular to the flat film, and birefringence behavior was observed for an in situ formed thin PVA hydrogel film, the folding structure being formed via freezing–thawing treatment of PVA aqueous solution coated on glass.

Roughness and salt annealing in a polyelectrolyte multilayer

The surface roughness of polyelectrolyte multilayers made from poly(diallyldimethylammonium chloride), PDADMAC, and poly(styrene sulfonate), PSS, was measured as a function of film deposition conditions. For dry multilayers, the significant roughness which builds up for thicker films is much more apparent for multilayers terminated with PSS. Corresponding roughness for PDADMA-capped multilayers may be seen by imaging in situ under electrolyte. Roughness may be substantially reduced, but not eliminated, by annealing in salt. Annealing does not lead to loss of polyelectrolyte from the film, even under conditions where the salt concentration is high enough to place the film properties beyond the glass transition. Roughness does not correlate with the molecular weight of the polyelectrolyte and is thus not caused by solution or film polymer chain conformations. The wavelength of the roughness features is approximately proportional to film thickness, which supports a mechanism whereby roughness is generated by anisotropic swelling due to water and polyelectrolyte addition in a manner similar to water uptake in hydrogels. Roughness is preserved by the glassy PSS layer and probably incorporated within the film as it grows.

Surface energy as a barrier to creasing of elastomer films: an elastic analogy to classical nucleation

In a soft elastic film compressed on a stiff substrate, creases nucleate at preexisting defects and grow across the surface of the film like channels. Both nucleation and growth are resisted by the surface energy, which we demonstrate by studying creases for elastomers immersed in several environments--air, water, and an aqueous surfactant solution. Measurement of the position where crease channeling is arrested on a gradient thickness film provides a uniquely characterized strain that quantitatively reveals the influence of surface energy, unlike the strain for nucleation, which is highly variable due to the sensitivity to defects. We find that these experimental data agree well with the prediction of a scaling analysis.

Swelling-induced delamination causes folding of surface-tethered polymer gels

When a polymer film that is weakly attached to a rigid substrate is exposed to solvent, swelling-induced compressive stress nucleates buckle delamination of the film from the substrate. Surprisingly, the buckles do not have a sinusoidal profile, instead, the film near the delamination buckles slides toward the buckles causing growth of sharp folds of high aspect ratio. These folds do not result from a wrinkle-to-fold transition; instead, the film goes directly from a flat state to a folded state. The folds persist even after the solvent evaporates. We propose that patterned delamination and folding may be exploited to realize high-aspect ratio topological features on surfaces through control of a set of boundary constraints arising from the interrelation of film-surface adhesion, film thickness and degree of swellabilty.