Patterned polymer films via reactive silane infusion-induced wrinkling

Wrinkled Interfaces: Taking Advantage of Anisotropic Wrinkling to Periodically Pattern Polymer Surfaces

Periodically patterned surfaces can cause special surface properties and are employed as functional building blocks in many devices, yet remaining challenges in fabrication. Advancements in fabricating structured polymer surfaces for obtaining periodic patterns are accomplished by adopting "top-down" strategies based on self-assembly or physico-chemical growth of atoms, molecules, or particles or "bottom-up" strategies ranging from traditional micromolding (embossing) or micro/nanoimprinting to novel laser-induced periodic surface structure, soft lithography, or direct laser interference patterning among others. Thus, technological advances directly promote higher resolution capabilities. Contrasted with the above techniques requiring highly sophisticated tools, surface instabilities taking advantage of the intrinsic properties of polymers induce surface wrinkling in order to fabricate periodically oriented wrinkled patterns. Such abundant and elaborate patterns are obtained as a result of self-organizing processes that are rather difficult if not impossible to fabricate through conventional patterning techniques. Focusing on oriented wrinkles, this review thoroughly describes the formation mechanisms and fabrication approaches for oriented wrinkles, as well as their fine-tuning in the wavelength, amplitude, and orientation control. Finally, the major applications in which oriented wrinkled interfaces are already in use or may be prospective in the near future are overviewed.

Growth-Induced Wrinkles and Dotlike Patterns of a Swollen Fluoroalkylated Thin Film by the Reaction of Surface-Attached Polymethylhydrosiloxane

The design of hydrophobic surfaces requires a material which has a low solid surface tension and a simple fabrication process for anchoring and controlling the surface morphology. A generic method for the spontaneous formation of robust instability patterns is proposed through the hydrosilylation of a fluoroalkene bearing dangling chains, R_f = C₆F₁₃(CH₂)₃-, with a soft polymethylhydrosiloxane (PMHS) spin-coated gel polymer (0.8 μm thick) using Karstedt catalyst. These patterns were easily formed by an irreversible swelling reaction due to the attachment of a layer to various substrates. The buckling instability was created by two different approaches for a gel layer bound to a rigid silicon wafer substrate (A) and to a soft nonswelling silicone elastomer foundation (B). The observations of grafted R_f-PMHS films in the swollen state by microscopy revealed two distinct permanent patterns on various substrates: dotlike of wavelength λ = 0.4-0.7 μm (A) or wrinkle of wavelength λ = 4-7 μm (B). The elastic moduli ratios of film/substrate were determined using PeakForce quantitative nanomechanical mapping. The characteristic wavelengths (λ) of the patterns for systems A and B were quantitatively estimated in relation to the thickness of the top layer. A diversity of wrinkle morphologies can be achieved by grafting different side chains on pristine PMHS films. The water contact angle (WCA) hysteresis of fluorinated chain (R_f) was enhanced upon roughening the surfaces, giving highly hydrophobic surface properties for water with static/hysteresis WCAs of 136°/74° in the resulting wrinkle (B) and 119°/41° in the dotlike of lower roughness (A). The hydrophobic properties of grafted films on A with various mixtures of hexyl/fluoroalkyl chains were characterized by static CA: WCA 104-119°, ethylene glycol CA 80-96°, and n-hexadecane CA 17-61°. A very low surface energy of 15 mN/m for R_f-PMHS was found on the smoother dotlike pattern.

Surface Wrinkling on Polymer Films

A series of gold precursor solutions are prepared by dissolving HAuCl₄ and its mixtures with K₂CO₃ of different contents in deionized (DI) water. Neat HAuCl₄ predominately forms AuCl₄^- ions in an aqueous solution. In the presence of K₂CO₃, AuCl₄^- ions hydrolyze to form [AuCl_4-x(OH)_x]^- complex ions. Increasing the content of K₂CO₃ in a gold precursor solution increases the content of [AuCl_4-x(OH)_x]^- complex ions and decreases the content of AuCl₄^- ions. Poly(4-vinyl pyridine) (P4VP) films of two different molecular weights are deposited on SiO_x/Si by spin coating, by which the thicknesses are controlled by polymer weight fractions in butanol. Those P4VP films form periodic wrinkles when immersed in aqueous solutions, followed by drying. The surface wrinkling is induced by swelling pressure that overwhelms the mechanical property of the P4VP film. The periodicity and amplitude of wrinkles grown on the P4VP films strongly correlate with initial thickness, AuCl₄^- ion content, and residual stress.

Fabrication of sub-20 nm patterns using dopamine chemistry in self-aligned double patterning

A self-aligned double patterning approach using a dopamine chemistry-inspired coating technique has been developed for the fabrication of sub-20 nm patterns. Poly(methyl methacrylate) (PMMA) films were patterned by nanoimprint lithography to form relief features. A thin layer of polydopamine (PDA) was conformally deposited on the surface of the PMMA pattern sidewalls to form a spacer layer. After etching the surface of the PDA layer from the horizontal surfaces and subsequently removing the PMMA template, free-standing PDA sidewall patterns remained that essentially doubled the original PMMA pattern density with decreased feature dimensions as compared to the initial PMMA template structures. The critical dimension of the PDA patterns can be tuned to ∼20 nm by controlling the PDA deposition conditions and further reduced to ∼13 nm by thermal carbonization of the PDA. Both simple lines and more complex rhombic ring features were fabricated by this technique to demonstrate its capacity for replicating arbitrary patterns. This work represents a simple and scalable strategy for preparing well-defined nanostructures with feature sizes usually only accessible via complex leading edge lithographic methods.

Reversible Surface Patterning by Dynamic Crosslink Gradients: Controlling Buckling in 2D

Harnessing the self-organization of soft materials to make complex, well-ordered surface patterns in a noninvasive manner is challenging. The wrinkling of thin films provides a compelling strategy to achieve this. Despite much attention, however, a simple, single-step, reversible method that gives rise to controlled, two-dimensional (2D) ordered, continuous, and discontinuous patterns has proven to be elusive. Here a novel, robust method is described to achieve this using an ultraviolet-light-sensitive anthracene-containing polymer thin film. The origin of the patterns is the local buckling of the thin film, where the control over the topology is given by laterally patterning out-of-plane gradients in the crosslink density of the film. The underlying buckling mechanics and formation of the surface features are well-described by finite element analysis. By illuminating the film with a photomask, local and long-range patterns that can be both continuous and discontinuous are able to be written. Furthermore, the patterning is fully reversible over multiple cycles. The results demonstrate a simple strategy for erasable storage of information in a surface topography that has applications in memory, anticounterfeiting, and plasmonics.

Macroscopically ordered hexagonal arrays by directed self-assembly of block copolymers with minimal topographic patterns

A simple and robust method has been developed for the generation of macroscopically ordered hexagonal arrays from the directed self-assembly (DSA) of cylinder-forming block copolymers (BCPs) based on minimal trench patterns with solvent vapor annealing. The use of minimal trench patterns allows us to probe the guided hexagonal arrays of cylindrical microdomains using grazing incidence small angle X-ray scattering (GISAXS), where the sample stage is rotated on the basis of the six-fold symmetry of a hexagonal system. It is found that the (10) planes of hexagonal arrays of cylindrical microdomains are oriented parallel to the underlying trench direction over macroscopic length scales (∼1 × 1 cm²). However, there are misorientations of the hexagonal arrays with short-range ordering. GISAXS patterns show that the hexagonal arrays on the minimal trench pattern are distorted, deviating from a perfect hexagonal lattice. This distortion has been attributed to the absence of topographic constraints in the unconfined direction on the 1-D minimal trench pattern. Also, the frustration of BCP microdomains, arising from the incommensurability between the trench pitch and natural period of the BCP at the base of the trench, influences the distortion of the hexagonal arrays.

Formation of a Crack-Free, Hybrid Skin Layer with Tunable Surface Topography and Improved Gas Permeation Selectivity on Elastomers Using Gel-Liquid Infiltration Polymerization

Surface modifications of elastomers and gels are crucial for emerging applications such as soft robotics and flexible electronics, in large part because they provide a platform to control wettability, adhesion, and permeability. Current surface modification methods via ultraviolet-ozone (UVO) and/or O₂ plasma, atomic layer deposition (ALD), plasmas deposition, and chemical treatment impart a dense polymer or inorganic layer on the surface that is brittle and easy to fracture at low strain levels. This paper presents a new method, based on gel-liquid infiltration polymerization, to form hybrid skin layers atop elastomers. The method is unique in that it allows for control of the skin layer topography, with tunable feature sizes and aspect ratios as high as 1.8 without fracture. Unlike previous techniques, the skin layer formed here dramatically improves the barrier properties of the elastomer, while preserving skin layer flexibility. Moreover, the method is versatile and likely applicable to most interfacial polymerization systems and network polymers on flat and patterned surfaces.

Hydrogels with Lotus Leaf Topography: Investigating Surface Properties and Cell Adhesion

The interactions of cells with the surface of materials is known to be influenced by a range of factors that include chemistry and roughness; however, it is often difficult to probe these factors individually without also changing the others. Here we investigate the role of roughness on cell adhesion while maintaining the same underlying chemistry. This was achieved by using a polymerization in mold technique to prepare poly(hydroxymethyl methacrylate) hydrogels with either a flat topography or a topography that replicated the microscale features of lotus leaves. These materials were then assessed for cell adhesion, and atomic force microscopy and contact angle analysis were then used to probe the physical reasons for the differing behavior in relation to cell adhesion.

Controlling film topography to form highly hydrophobic waterborne coatings

Coatings have a tremendous impact on economy as they reduce corrosion that has an estimated cost of 3% of the world's GDP. Hydrophobic coatings are particularly efficient for this purpose and the challenge is to produce cost effective and environmentally friendly, highly hydrophobic, cohesive and non-porous coatings applicable to large and irregular surfaces. This work shows that this goal can be achieved by forming wrinkles on the surface of waterborne coatings through fine-tuning of the film forming conditions. The proof of concept was demonstrated by using waterborne dispersions of copolymers of 1H,1H,2H,2H-perfluorodecyl acrylate and 2-ethylhexyl acrylate, and using the temperature and hardness of the copolymer as control variables during film formation. This allowed the formation of transparent films with a wrinkled surface that had a contact angle of 133°, which represents an increase of 20° with respect to the film cast under standard conditions.

Mechanically Tunable Slippery Behavior on Soft Poly(dimethylsiloxane)-Based Anisotropic Wrinkles Infused with Lubricating Fluid

We demonstrate a novel technique to fabricate mechanically tunable slippery surfaces using one-dimensional (anisotropic) elastic wrinkles. Such wrinkles show tunable topography (amplitude) on the application of mechanical strain. Following Nepenthes pitcher plants, lubricating fluid infused solid surfaces show excellent slippery behavior for test liquid drops. Therefore, combining the above two, that is, infusing suitable lubricating fluid on elastic wrinkles, would enable us to fabricate mechanically tunable slippery surfaces. Completely stretched (flat) wrinkles have uniform coating of lubricating fluid, whereas completely relaxed (full amplitude) wrinkles have most of the lubricating oil in the wrinkle grooves. Therefore, water drops on completely stretched surface show excellent slippery behavior, whereas on completely relaxed surface they show reduced slippery behavior. Therefore, continuous variation of wrinkle stretching provides reversibly tunable slippery behavior on such a system. Because the wrinkles are one-dimensional, they show anisotropic tunability of slippery behavior depending upon whether test liquid drops slip parallel or perpendicular to the wrinkles.

Bio-based Wrinkled Surfaces Harnessed from Biological Design Principles of Wood and Peroxidase Activity

A new and simple approach for surface wrinkling inspired by polymer assemblies in wood fibers is introduced. A hard skin is synthesized on a linear polysaccharide support that resembles the structural units of the cell wall. This skin, a wood mimetic layer, is produced through immersion in a solution containing phenolic precursor and subsequent surface reaction by horseradish peroxidase. A patterned surface with micron-scale wrinkles is formed upon drying and as a result of inhomogeneous shrinkage. We demonstrate that the design of the wrinkled surfaces can be controlled by the molecular structure of the phenolic precursor, temperature, and drying stress. It is noteworthy that this is a totally bio-based system involving green materials and processes.

Scaling Up Nature: Large Area Flexible Biomimetic Surfaces

The fabrication and advanced function of large area biomimetic superhydrophobic surfaces (SHS) and slippery lubricant-infused porous surfaces (SLIPS) are reported. The use of roll-to-roll nanoimprinting techniques enabled the continuous fabrication of SHS and SLIPS based on hierarchically wrinkled surfaces. Perfluoropolyether hybrid molds were used as flexible molds for roll-to-roll imprinting into a newly designed thiol-ene based photopolymer resin coated on flexible polyethylene terephthalate films. The patterned surfaces exhibit feasible superhydrophobicity with a water contact angle around 160° without any further surface modification. The SHS can be easily converted into SLIPS by roll-to-roll coating of a fluorinated lubricant, and these surfaces have outstanding repellence to a variety of liquids. Furthermore, both SHS and SLIPS display antibiofouling properties when challenged with Escherichia coli K12 MG1655. The current article describes the transformation of artificial biomimetic structures from small, lab-scale coupons to low-cost, large area platforms.

Kinetic study of a swelling-induced network of folds in a cross-linked PS-PDMS film

Constructing a network of folds in a cross-linked PS-PDMS film through combining mesostructural organization of PS-PDMS and solvent-induced mechanical instability.

High aspect ratio wrinkles via substrate prestretch

A non-fractured, high aspect ratio wrinkled surface is successfully fabricated. Building upon recently developed models of the localization transition and the current knowledge of surface failures, the wrinkling mode is stabilized at high strain, doubling the accessible wrinkling aspect ratio to the currently reported value. This high aspect ratio surface provides significant promise for future wrinkle-based applications.

Superhydrophobic surfaces from hierarchically structured wrinkled polymers

This work reports the creation of superhydrophobic wrinkled surfaces with hierarchical structures at both the nanoscale and microscale. A nanoscale structure with 500 nm line gratings was first fabricated on poly(hydroxyethyl methacrylate) films by nanoimprint lithography while a secondary micro-scale structure was created by spontaneous wrinkling. Compared with random wrinkles whose patterns show no specific orientation, the hierarchical wrinkles exhibit interesting orientation due to confinement effects of pre-imprinted line patterns. The hierarchically wrinkled surfaces have significantly higher water contact angles than random wrinkled surfaces, exhibiting superhydrophobicity with water contact angles higher than 160° and water sliding angle lower than 5°. The hierarchically structured wrinkled surfaces exhibit tunable wettability from hydrophobic to superhydrophobic and there is an observed transition from anisotropic to isotropic wetting behavior achievable by adjusting the initial film thickness.