Interplay of Substrate Surface Energy and Nanoparticle Concentration in Suppressing Polymer Thin Film Dewetting

Harnessing Polar Interactions Tunes the Stability of Ultrathin Polymer Solution Films

The stability of ultrathin (<100 nm) polymer films is essential in applications like protective coatings. On the contrary, their instability may actually be desirable for the emergence of self-assembled nanoscale patterns utilized in the fabrication of functional devices. Polymer solution films exhibit two distinct kinds of instabilities, viz., dewetting (long-wave) and decomposition (short-wave). Dewetting refers to the rupture of the continuous film to form isolated domains, while decomposition leads to phase separation within the polymer solution. The focus of this work is on leveraging polar interactions between the solute and solvent molecules to tune the stability of the film. A gradient dynamics-based thin film model is developed to investigate pattern formation in a thin polar polymer solution film. The Flory-Huggins theory is suitably modified by introducing a polar interaction parameter that depends upon the concentration of the polymer and the dipole moments of monomer (μ1) and solvent molecules (μ0). A linear stability analysis is performed to determine the characteristic length scale and growth rate of the instabilities. It is shown that the range of concentration space for the occurrence of the decomposition mode is directly affected by the Flory interaction parameter (χ0), μ0, and μ1, thereby serving as control parameters to tune the width of the concentration range. It is further shown that ignoring polar interactions may lead to incorrect predictions of the instability mode, including a complete loss of the decomposition mode. In addition, the long-wave dewetting length scale is found to decrease due to bulk dipolar interactions at higher polymer concentrations. Finally, numerical simulations are carried out to track the nonlinear evolution of the interface and concentration field for both the decomposition and dewetting modes of instability.

Accessing Thin Film Wetting Regimes during Polymer Growth by Initiated Chemical Vapor Deposition

We investigate the growth of a fluorinated polymer via initiated chemical vapor deposition onto a suite of isotropic and mesogenic liquids with a range of refractive indices. The polymer morphology at fluid interfaces was found to deviate from conformal films predicted by the positive spreading coefficient, and the resulting morphology is attributed to long-range van der Waals interactions during the deposition process. Experiments systematically vary the deposition conditions and compare the liquid phase (isotropic or nematic) to evaluate the effect of kinetic factors and the liquid substrate phase on the interfacial polymer morphology and spatial organization.

Coarse-grained molecular simulation of the effects of carbon nanotube dispersion on the mechanics of semicrystalline polymer nanocomposites

With the incorporation of carbon nanotubes (CNTs), CNT/polypropylene (PP) nanocomposites are found to possess enhanced mechanical properties, but the reinforcing effect is reduced at large added CNT weight percentages due to CNT aggregation. Optimizing the properties of a nanocomposite requires a fundamental understanding of the effects of CNT dispersion on the nanocomposite. In this work, coarse-grained molecular models of CNT/PP nanocomposites are constructed, which consist of randomly dispersed or aggregated CNT bundles. Our simulation results reveal that with randomly dispersed CNT bundles, the nanocomposite shows properties that continuously improve with increasing CNT contents due to the effective CNT/PP interface and the reinforcing effect of CNTs. By comparison, the nanocomposite with aggregated CNT clusters exhibits a decline in yield strength at CNT contents over 3 wt%, which results from a reduced CNT load-carrying capacity due to the formation of structural voids in the interfacial region. This study achieves anin situobservation of the structural void evolution of loaded nanocomposites, provides valuable insights into the effects of CNT dispersion on the mechanics of CNT/PP nanocomposites, and paves the way for optimizing the design of nanocomposites with superior mechanical properties by designing the CNT dispersion in the structure.

Observation of General Entropy-Enthalpy Compensation Effect in the Relaxation of Wrinkled Polymer Nanocomposite Films

Surface-textured polymer nanocomposite (PNC) films are utilized in many device applications, and therefore understanding the relaxation behavior of such films is important. By extending an in situ wrinkle relaxation method, we observed that the thermal stability of wrinkled PNC films, both above and below the glass transition temperature (T_g), is proportional to a film's nanoparticle (polymer grafted and bare) concentration, with a slope that changes sign at a compensation temperature (T_comp) that is determined to be in the vicinity of the film's T_g. This provides unambiguous confirmation of entropy-enthalpy compensation (EEC) as a general feature of PNC films, implying that the stability of PNC films changes from being enhanced to becoming diminished by simply passing through this characteristic temperature, a phenomenon having evident practical ramifications. We suggest EEC will also arise in films where residual stresses are associated with the film fabrication process, which is relevant to nanotech device applications.

Nanoparticle Induced Morphology Modulation in Spin Coated PS/PMMA Blend Thin Films

The influence of adding nanoparticles on the ascast morphology of spin coated immiscible polystyrene/poly(methyl methacrylate) (PS/PMMA) thin films of different thickness (h_E) and composition (R_B, volume ratio of PS to PMMA) has been explored in this article. To understand the precise effect of nanoparticle addition, the morphology of PS/PMMA thin blend films spin cast from toluene on a native oxide covered silicon wafer substrate was first investigated. It is seen that in particle free films, the generic morphology of the films remains nearly unaltered with increase in h_E, for R_B = 3:1 and 1:3. In contrast, strong h_E dependent morphology transformation is observed in films with R_B = 1:1. Subsequently, thiol-capped gold nanoparticles (AuNP) containing films with different particle concentrations (C_NP) were cast from the same solvent along with the polymer mixture. We observe that addition of AuNPs barely alters the generic morphology of the films with R_B = 3:1. In contrast, the presence of the particles significantly influences the morphology of the films with R_B = 1:1 and 1:3, particularly at higher C_NP (≈10.0%). X-ray photoelectron spectroscopy and X-ray reflectivity of some samples reveal that the AuNPs tend to migrate to the free surface through the PS phase, thereby stabilizing this layer partially or fully (depending on C_NP) against dewetting over a surface of adsorbed PMMA layer and influencing the ascast morphology as a function of C_NP. The work is fundamentally important in understanding largely overlooked implications of nanoparticle addition on the morphology of PS/PMMA blend thin films which forms the fundamental basis for future interesting studies involving dynamics of nanoparticles within the blend thin films.

Massively Parallel Nanoparticle Synthesis in Anisotropic Nanoreactors

This work reports a massively parallel approach for synthesizing inorganic nanoparticles (Au, Ag, Se, and mixed oxides of Cu, Co, Ni, Ge, and Ta) based upon lithographically generated arrays of square pyramidal nanoholes, which serve as nanoreactors. Particle precursor-containing polymers are spin-coated onto the nanoreactors, which upon dewetting generate a morphology of isolated polymer droplets in each nanoreactor. This dewetting process yields a well-defined and precisely controlled volume of polymer and therefore particle precursor in each nanoreactor. Subsequent stepwise annealing (first at 150 °C and then at 500 °C) yields arrays of monodisperse, site-isolated particles with sub-5 nm position control. By varying the precursor loading of the polymer, particle size can be systematically controlled in the 7-30 nm range. This work not only introduces the concept of merging block copolymer inks with nanohole arrays in the synthesis of nanoparticles but also underscores the value of the nanoreactor shape in controlling resulting particle position.

A simulation study on the glass transition behavior and relevant segmental dynamics in free-standing polymer nanocomposite films

In polymer/nanoparticle composite (PNC) thin films, polymer chains experience strong confinement effects not only at the free surface area but also from nanoparticles (NPs). In this work, the influence of NP-polymer interaction and NP distribution on the polymer segmental dynamics and the glass transition behavior of PNC free-standing films are investigated through molecular dynamics simulations. We demonstrate that NPs will migrate to the film surface area and form an NP-concentrated layer when NP-polymer interactions are weak, while NPs are well dispersed in the bulk region when NP-polymer interactions are strong. In both cases, we find increases in the glass transition temperature Tg compared with the pure film without NPs, although with a different degree. The weakly interacting system has the same Tg as the pure bulk system without NPs. The NP layer formed at the surface area reduces both the mobility of the surface polymer beads and the mobility gradient in the film normal direction (MGFND), therefore resulting in an increase in the Tg which highlights the vital role of the mobile surface layer. In contrast, the NPs in the bulk region enlarge the MGFND. NPs have opposite influences on the polymer bead dynamic anisotropy when they interact weakly or strongly with polymers, weakened for the former and enhanced for the latter. These findings offer a clear picture of the segmental dynamics and glass transition behavior in free-standing PNC films with different NP-polymer interaction strengths. We hope these results will be helpful for the property design of related materials.

Phase transition and dewetting of a 5CB liquid crystal thin film on a topographically patterned substrate

Thermally induced nematic to isotropic (N–I) phase transition and dewetting of 5CB liquid crystal thin films on flat and topographically patterned substrates.

Tuning the Relaxation of Nanopatterned Polymer Films with Polymer-Grafted Nanoparticles: Observation of Entropy-Enthalpy Compensation

Polymer films provide a versatile platform in which complex functional relief patterns can be thermally imprinted with a resolution down to few nanometers. However, a practical limitation of this method is the tendency for the imprinted patterns to relax ("slump"), leading to loss of pattern fidelity over time. While increasing temperature above glass transition temperature ( Tg) accelerates the slumping kinetics of neat films, we find that the addition of polymer-grafted nanoparticles (PGNP) can greatly enhance the thermal stability of these patterns. Specifically, increasing the concentration of poly(methyl methacrylate) (PMMA) grafted titanium dioxide (TiO2) nanoparticles in the composite films slows down film relaxation dynamics, leading to enhanced pattern stability for the temperature range that we investigated. Interestingly, slumping relaxation time is found to obey an entropy-enthalpy compensation (EEC) relationship with varying PGNP concentration, similar to recently observed relaxation of strain-induced wrinkling in glassy polymer films having variable film thickness. The compensation temperature,  Tcomp was found to be in the vicintity of the bulk  Tg of PMMA. Our results suggest a common origin of EEC relaxation in patterned polymer thin films and  nanocomposites.

Self-healing and dewetting dynamics of a polymer nanofilm on a smooth substrate: strategies for dewetting suppression

The self-healing and dewetting dynamics of a polymer nanofilm on a smooth, partial wetting surface are explored by many-body dissipative particle dynamics. Three types of dewetting phenomena are identified, (i) spinodal decomposition, (ii) nucleation and growth, and (iii) metastable self-healing. The outcome depends on the surface wettability (θY), the polymer film thickness (h0), and the radius of the dry hole (R0). The phase diagram of the dewetting mechanism as a function of θY and h0 is obtained for a specified R0. As the surface wettability decreases (increasing θY), the critical film thickness associated with the nucleation/self-healing crossover (hc) grows so that the metastability of the film can be retained by the self-healing process. In addition to θY and R0, hc depends on the polymer length (N) as well. It is found that a longer polymer requires a thicker nanofilm to avoid dewetting by nucleation. Two strategies for dewetting suppression are proposed. The metastability of a film of polymers with a large molecular weight can be promoted either by the addition of short polymers or by employing compact polymers such as star polymers. In the latter approach, the increment of the arm number enhances the nanofilm stability.

Hierarchical Order in Dewetted Block Copolymer Thin Films on Chemically Patterned Surfaces

We investigated the dewetting process on flat and chemically patterned surfaces of ultrathin films (thickness between 2 and 15 nm) of a cylinder forming polystyrene- block-poly(methyl methacrylate) (PS- b-PMMA) spin coated on poly(styrene- r-methyl methacrylate) random copolymers (RCPs). When the PS- b-PMMA film dewets on a 2 nm-thick RCP layer, the ordering of the hexagonally packed PMMA cylinders in the dewetted structures extends over distances far exceeding the correlation length obtained in continuous block copolymer (BCP) films. As a result, micrometer-sized circular droplets featuring defectless single grains of self-assembled PS- b-PMMA with PMMA cylinders perpendicularly oriented with respect to the substrate are generated and randomly distributed on the substrate. Additionally, alignment of the droplets along micrometric lines was achieved by performing the dewetting process on large-scale chemically patterned stripes of 2 nm thick RCP films by laser lithography. By properly adjusting the periodicity of the chemical pattern, it was possible to tune and select the geometrical characteristics of the dewetted droplets in terms of maximum thickness, contact angle and diameter while maintaining the defectless single grain perpendicular cylinder morphology of the circular droplets.

In Situ and Real-Time Studies, via Synchrotron X-ray Scattering, of the Orientational Order of Cellulose Nanocrystals during Solution Shearing

In this manuscript, we report on the ordering of the cellulose nanocrystals (CNCs) as they experience shear forces during the casting process. To achieve these measurements, in situ and in real time, we used synchrotron-based grazing incidence wide-angle X-ray scattering (GIWAX). We believe that the GIWAX technique, although not commonly used to probe these types of phenomena, can open new avenues to gain deeper insights into film formation processes and surface-driven phenomena. In particular, we investigated the influence of solution concentration, shear-cast velocity, and drying temperature on the ordering of cellulose nanocrystals (CNCs) using GIWAXS. The films were prepared from aqueous suspensions of cellulose nanocrystals at two concentration values (7 and 9 wt %). As the films were cast, the X-ray beam was focused on a fixed position and GIWAXS patterns were recorded at regular time intervals. Structural characterization of the dry films was carried out via polarized optical microscopy and scanning electron microscopy. In addition, a rheological study of the CNC suspensions was performed. Our results show that the morphology of the CNC films was significantly influenced by shear velocity, concentration of the precursor suspension, and evaporation temperature. In contrast, we observed that the orientation parameter of the films was not significantly affected. The scattering intensity of the peak (200) was analyzed as a function of time, following a sigmoidal profile, hence indicating short- and long-range interactions within the anisotropic domains as they reached their final orientation state. A model capable of describing the resulting film morphologies is also proposed. The results and analysis presented in this manuscript provide new insights into the controlled alignment of cellulose nanocrystals under shear. This controlled alignment has significant implications in the development of advanced coatings and films currently used in a myriad of applications, such as catalysis, optics, electronics, and biomedicine.

Transition from Spin Dewetting to continuous film in spin coating of Liquid Crystal 5CB

Spin dewetting refers to spontaneous rupture of the dispensed solution layer during spin coating, resulting in isolated but periodic, regular sized domains of the solute and is pre-dominant when the solute concentration (C_n) is very low. In this article we report how the morphology of liquid crystal (LC) 5CB thin films coated on flat and patterned PMMA substrate transform from spin dewetted droplets to continuous films with increase in C_n. We further show that within the spin dewetted regime, with gradual increase in the solute concentration, periodicity of the isotropic droplets (λ_D) as well as their mean diameter (d_D), gradually decreases, till the film becomes continuous at a critical concentration (C_n*). Interestingly, the trend that λ_D reduces with increase in C_n is exact opposite to what is observed in thermal/solvent vapor induced dewetting of a thin film. The spin dewetted droplets exhibit transient Radial texture, in contrast to Schlieren texture observed in elongated threads and continuous films of 5CB, which remains in the Nematic phase at room temperature. Finally we show that by casting the film on a grating patterned substrate it becomes possible to align the spin dewetted droplets along the contours substrate patterns.

Capillary Force Lithography Pattern-Directed Self-Assembly (CFL-PDSA) of Phase-Separating Polymer Blend Thin Films

We report capillary force lithography pattern-directed self-assembly (CFL-PDSA), a facile technique for patterning immiscible polymer blend films of polystyrene (PS)/poly(methyl methacrylate) (PMMA), resulting in a highly ordered phase-separated morphology. The pattern replication is achieved by capillary force lithography (CFL), by annealing the film beyond the glass transition temperature of both the constituent polymers, while confining it between a patterned cross-linked poly(dimethyl siloxane) (PDMS) stamp and the silicon substrate. As the pattern replication takes place because of rise of the polymer meniscus along the confining stamp walls, higher affinity of PMMA toward the oxide-coated silicon substrate and of PS toward cross-linked PDMS leads to well-controlled vertically patterned phase separation of the two constituent polymers during thermal annealing. Although a perfect negative replica of the stamp pattern is obtained in all cases, the phase-separated morphology of the films under pattern confinement is strongly influenced by the blend composition and annealing time. The phase-separated domains coarsen with time because of migration of the two components into specific areas, PS into an elevated mesa region and PMMA toward the substrate, because of preferential wetting. We show that a well-controlled, phase-separated morphology is achieved when the blend ratio matches the volume ratio of the elevated region to the base region in the patterned films. The proposed top-down imprint patterning of blends can be easily made roll-to-roll-compatible for industrial adoption.

Preventing Thin Film Dewetting via Graphene Capping

A monolayer 2D capping layer with high Young's modulus is shown to be able to effectively suppress the dewetting of underlying thin films of small organic semiconductor molecule, polymer, and polycrystalline metal, respectively. To verify the universality of this capping layer approach, the dewetting experiments are performed for single-layer graphene transferred onto polystyrene (PS), semiconducting thienoazacoronene (EH-TAC), gold, and also MoS₂ on PS. Thermodynamic modeling indicates that the exceptionally high Young's modulus and surface conformity of 2D capping layers such as graphene and MoS₂ substantially suppress surface fluctuations and thus dewetting. As long as the uncovered area is smaller than the fluctuation wavelength of the thin film in a dewetting process via spinodal decomposition, the dewetting should be suppressed. The 2D monolayer-capping approach opens up exciting new possibilities to enhance the thermal stability and expands the processing parameters for thin film materials without significantly altering their physical properties.

The influence of polymer architectures on the dewetting behavior of thin polymer films: from linear chains to ring chains

The dewetting behavior of ring polystyrene (RPS) film and linear polystyrene (LPS) film on silanized Si substrates with different grafting densities and PDMS substrate was investigated. Results showed that polymer architectures greatly influenced the dewetting behavior of the thin polymer film. On the silanized Si substrate with 69% grafting density, RPS chains exhibited stronger adsorption compared with LPS chains, and as a result the wetting layer formed more easily. For LPS films, with a decreased annealing temperature, the stability of the polymer film changed from non-slip dewetting via apparent slip dewetting to apparently stable. However, for RPS films, the polymer film stability switched from apparent slip dewetting to apparently stable. On the silanized Si substrate with 94% grafting density, the chain adsorption became weaker and the dewetting processes were faster than that on the substrate with 69% grafting density at the same experimental temperature for both the LPS and RPS films. Moreover, on the PDMS substrate, LPS films always showed non-slip dewetting, while the dewetting kinetics of RPS films switched from non-slip dewetting to slip dewetting behaviour. Forming the wetting layer strongly influenced the stability and dewetting behavior of the thin polymer films.

Surface Segregation and Bulk Aggregation in an Athermal Thin Film of Polymer-Nanoparticle Blends: Strategies of Controlling Phase Behavior

The phase behavior of an athermal film of a polymer-nanoparticle blend (PNB) driven by depletion attraction is investigated by dissipative particle dynamics for nanospheres and nanocubes. Surface segregation is observed at low nanoparticle concentrations, while bulk aggregation is seen at high concentrations. Surface excess and the aggregation number can be controlled by tuning the nanoparticle concentration. As surface-roughened or polymer-grafted nanoparticles are used, uniform PNBs are acquired due to the lack of depletion. Thus, addition of surface-roughened nanoparticles into PNBs of smooth nanoparticles can be employed to tune the phase characteristics. It is found that bulk aggregation is suppressed for both polymer-nanosphere and polymer-nanocube blends. However, surface segregation is impeded for polymer-nanosphere blend but enhanced for polymer-nanocube blend owing to the distinct influence of the nanoparticle shape on depletion.

RMS roughness-independent tuning of surface wettability by tailoring silver nanoparticles with a fluorocarbon plasma polymer

A layer of 14 nm-sized Ag nanoparticles undergoes complex transformation when overcoated by thin films of a fluorocarbon plasma polymer. Two regimes of surface evolution are identified, both with invariable RMS roughness. In the early regime, the plasma polymer penetrates between and beneath the nanoparticles, raising them above the substrate and maintaining the multivalued character of the surface roughness. The growth (β) and the dynamic (1/z) exponents are close to zero and the interface bears the features of self-affinity. The presence of inter-particle voids leads to heterogeneous wetting with an apparent water contact angle θ_a = 135°. The multivalued nanotopography results in two possible positions for the water droplet meniscus, yet strong water adhesion indicates that the meniscus is located at the lower part of the spherical nanofeatures. In the late regime, the inter-particle voids become filled and the interface acquires a single valued character. The plasma polymer proceeds to grow on the thus-roughened surface whereas the nanoparticles keep emerging away from the substrate. The RMS roughness remains invariable and lateral correlations propagate with 1/z = 0.27. The surface features multiaffinity which is given by different evolution of length scales associated with the nanoparticles and with the plasma polymer. The wettability turns to the homogeneous wetting state.

Synergism of Dewetting and Self-Wrinkling To Create Two-Dimensional Ordered Arrays of Functional Microspheres

Here we report a simple, novel, yet robust nonlithographic method for the controlled fabrication of two-dimensional (2-D) ordered arrays of polyethylene glycol (PEG) microspheres. It is based on the synergistic combination of two bottom-up processes enabling periodic structure formation for the first time: dewetting and the mechanical wrinkle formation. The deterministic dewetting results from the hydrophilic polymer PEG on an incompatible polystyrene (PS) film bound to a polydimethylsiloxane (PDMS) substrate, which is directed both by a wrinkled template and by the template-directed in-situ self-wrinkling PS/PDMS substrate. Two strategies have been introduced to achieve synergism to enhance the 2-D ordering, i.e., employing 2-D in-situ self-wrinkling substrates and boundary conditions. As a result, we achieve highly ordered 2-D arrays of PEG microspheres with desired self-organized microstructures, such as the array location (e.g., selectively on the crest/in the valley of the wrinkles), diameter, spacing of the microspheres, and array direction. Additionally, the coordination of PEG with HAuCl4 is utilized to fabricate 2-D ordered arrays of functional PEG-HAuCl4 composite microspheres, which are further converted into different Au nanoparticle arrays. This simple versatile combined strategy could be extended to fabricate highly ordered 2-D arrays of other functional materials and achieve desirable properties and functionalities.

Influence of film structure on the dewetting kinetics of thin polymer films in the solvent annealing process

On a non-wetting solid substrate, the solvent annealing process of a thin polymer film includes the swelling process and the dewetting process. Owing to difficulties in the in situ analysis of the two processes simultaneously, a quantitative study on the solvent annealing process of thin polymer films on the non-wetting solid substrate is extremely rare. In this paper, we design an experimental method by combining spectroscopic ellipsometry with optical microscopy to achieve the simultaneous in situ study. Using this method, we investigate the influence of the structure of swollen film on its dewetting kinetics during the solvent annealing process. The results show that for a thin PS film with low Mw (Mw = 4.1 kg mol(-1)), acetone molecules can form an ultrathin enriched layer between the PS film and the solid substrate during the swelling process. The presence of the acetone enriched layer accounts for the exponential kinetic behavior in the case of a thin PS film with low Mw. However, the acetone enriched layer is not observed in the case of a thin PS film with high Mw (Mw = 400 kg mol(-1)) and the slippage effect of polymer chains is valid during the dewetting process.

Magnetic nanoparticle film reconstruction modulated by immersion within DMSA aqueous solution

The process of reconstruction of pre-fabricated films comprising maghemite nanoparticles deposited onto flat glass substrates triggered by immersion into aqueous solutions of meso-2,3-dimercaptosuccinic acid (DMSA) at increasing concentration (0.025, 0.050, and 0.100 mol/L) is herein reported. The evolution of this process was assessed by measuring the time (t) dependence of the particle analysis histogram width (W) extracted from atomic force microscopy images. Furthermore, a physical picture to model the film reconstruction which provides reconstruction time constants associated to single particles (τ1) and small agglomerates (τn), the key units associated to the process, ranging from τ1 = 2.9 and τn = 3.4 hour (0.025 mol/L) to τ1 = 5.1 and τn = 4.6 hour (0.100 mol/L) is proposed. The nanoparticle-based film reconstruction triggered by an exogenous stimulus, the use of the W versus t data to describe the process and the model picture accounting for the recorded data have not been previously reported.

Confinement induced ordering in dewetting of ultra-thin polymer bilayers on nanopatterned substrates

We report the dewetting of a thin bilayer of polystyrene (PS) and poly(methylmethacrylate) (PMMA) on a topographically patterned nonwettable substrate comprising an array of pillars, arranged in a square lattice. With a gradual increase in the concentration of the PMMA solution (Cn-PMMA), the morphology of the bottom layer changes to: (1) an aligned array of spin dewetted droplets arranged along substrate grooves at very low Cn-PMMA; (2) an interconnected network of threads surrounding each pillar at intermediate Cn-PMMA; and (3) a continuous bottom layer at higher Cn-PMMA. On the other hand the morphology of the PS top layer depends largely on the nature of the pre-existing bottom layer, in addition to Cn-PS. An ordered array of PMMA core-PS shell droplets forms right after spin coating when both Cn-PMMA and Cn-PS are very low. Bilayers with all other initial configurations evolve during thermal annealing, resulting in a variety of ordered structures. Unique morphologies realized include laterally coexisting structures of the two polymers confined within the substrate grooves due to initial rupture of the bottom layer on the substrate followed by a squeezing flow of the top layer; an array of core-shell and single polymer droplets arranged in an alternating order etc., to highlight a few. Such structures cannot be fabricated by any stand-alone lithography technique. On the other hand, in some cases the partially dewetted bottom layer imparts stability to an intact top PS layer against dewetting. Apart from ordering, under certain specific conditions significant miniaturization and downsizing of dewetted feature periodicity and dimension as compared to dewetting of a single layer on a flat substrate is observed. With the help of a morphology phase diagram we show that ordering is achieved over a wide combination of Cn-PMMA and Cn-PS, though the morphology and dewetting pathway differs significantly with variation in the thickness of the individual layers.

Film-Stabilizing Attributes of Polymeric Core-Shell Nanoparticles

Self-organization of nanoparticles into stable, molecularly thin films provides an insightful paradigm for manipulating the manner in which materials interact at nanoscale dimensions to generate unique material assemblies at macroscopic length scales. While prior studies in this vein have focused largely on examining the performance of inorganic or organic/inorganic hybrid nanoparticles (NPs), the present work examines the stabilizing attributes of fully organic core-shell microgel (CSMG) NPs composed of a cross-linked poly(ethylene glycol dimethacrylate) (PEGDMA) core and a shell of densely grafted, but relatively short-chain, polystyrene (PS) arms. Although PS homopolymer thin films measuring from a few to many nanometers in thickness, depending on the molecular weight, typically dewet rapidly from silica supports at elevated temperatures, spin-coated CSMG NP films measuring as thin as 10 nm remain stable under identical conditions for at least 72 h. Through the use of self-assembled monolayers (SAMs) to alter the surface of a flat silica-based support, we demonstrate that such stabilization is not attributable to hydrogen bonding between the acrylic core and silica. We also document that thin NP films consisting of three or less layers (10 nm) and deposited onto SAMs can be fully dissolved even after extensive thermal treatment, whereas slightly thicker films (40 nm) on Si wafer become only partially soluble during solvent rinsing with and without sonication. Taken together, these observations indicate that the present CSMG NP films are stabilized primarily by multidirectional penetration of relatively short, unentangled NP arms caused by NP layering, rather than by chain entanglement as in linear homopolymer thin films. This nanoscale "velcro"-like mechanism permits such NP films, unlike their homopolymer counterparts of comparable chain length and thickness, to remain intact as stable, free-floating sheets on water, and thus provides a viable alternative to ultrathin organic coating strategies.

Mapping the intriguing transient morphologies and the demixing behavior in PS/PVME blends in the presence of rod-like nanoparticles

The demixing behavior, transient morphologies and mechanism of phase separation in PS/PVME blends were greatly altered in the presence of a very low concentration of rod-like particles (multiwall carbon nanotubes, MWNTs). This phenomenon is due to the specific interaction of one of the phases (PVME) with the anisotropic MWNTs, which creates a heterogeneous environment in the blend. This specific interaction alters the chain dynamics in the interfacial region as against the bulk. A comprehensive analysis using isochronal temperature sweep was performed to understand the demixing temperature in the blends. The evolution of phase morphology as a function of time and temperature was assessed by polarizing optical microscopy (POM), atomic force microscopy (AFM) and scanning electron microscopy (SEM). The addition of MWNTs increased the rheological demixing temperature and the spinodal temperature in almost all the compositions. The intriguing transient morphologies were mapped, which varied from nucleation and growth to coalescence-induced viscoelastic phase separation (C-VPS) in PVME-rich blends, to spinodal decomposition in the near-critical compositions, to transient gel-induced VPS (T-VPS) in the PS-rich compositions. Mapping of the morphology development displayed two types of fracture mechanisms: ductile fracture for near-critical compositions and brittle fracture for off-critical composition. The change in the phase separation mechanism in the presence of MWNTs was due to the variation in dynamic asymmetry brought about by these anisotropic particles. All these observations were correlated by POM, SEM and AFM studies. The length of the cooperatively rearranging region (CRR), as evaluated using modulated differential scanning calorimetry (MDSC) measurements, was found to be composition-independent. The observed variation of effective glass transition of PVME (low Tg component) on blending with PS (high Tg component) and by the addition of MWNTs accounts for the dynamic heterogeneity introduced by MWNTs in the system.

Polymer fullerene solution phase behaviour and film formation pathways

We report the phase behaviour of polymer/fullerene/solvent ternary mixtures and its consequence for the morphology of the resulting composite thin films. We focus particularly on solutions of polystyrene (PS), C60 fullerene and toluene, which are examined by static and dynamic light scattering, and films obtained from various solution ages and thermal annealing conditions, using atomic force and light microscopy. Unexpectedly, the solution phase behaviour below the polymer overlap concentration, c*, is found to be described by a simple excluded volume argument (occupied by the polymer chains) and the neat C60/solvent miscibility. Scaling consistent with full exclusion is found when the miscibility of the fullerene in the solvent is much lower than that of the polymer, giving way to partial exclusion with more soluble fullerenes (phenyl-C61-butyric acid methyl ester, PCBM) and a less asymmetric solvent (chlorobenzene), employed in photovoltaic devices. Spun cast and drop cast films were prepared from PS/C60/toluene solutions across the phase diagram to yield an identical PS/C60 composition and film thickness, resulting in qualitatively different morphologies in agreement with our measured solution phase boundaries. Our findings are relevant to the solution processing of polymer/fullerene composites (including organic photovoltaic devices), which generally require effective solubilisation of fullerene derivatives and polymer pairs in this concentration range, and the design of well-defined thin film morphologies.

Solvent-vapor-assisted dewetting of prepatterned thin polymer films: control of morphology, order, and pattern miniaturization

Ultrathin (<100 nm) unstable polymer films exposed to a solvent vapor dewet by the growth of surface instability, the wavelength (λ) of which depends on the film thickness (h(f)). While the dewetting of a flat polymer thin film results in random structures, we show that the dewetting of a prepatterned film results in myriad ordered mesoscale morphologies under specific conditions. Such a film undergoes rupture over the thinnest parts when the initial local thickness of these zones (h(rm)) is lower than a limiting thickness h(lim) ≈ 10 nm. Additionally, the width of the pattern grooves (l(s)) must be wider than λ(s) corresponding to a flat film having a thickness of h(rm) for pattern-directed dewetting to take place over surface-tension-induced flattening. We first present an experimentally obtained morphology phase diagram that captures the conditions where a transition from surface-tension-induced flattening to pattern-directed-rupture takes place. Subsequently, we show the versatility of this technique in achieving a variety of aligned mesopatterns starting from a prepatterned film with simple grating geometry. The morphology of the evolving patterns depends on several parameters such as the initial film thickness (h(f)), prepattern amplitude (h(st)), duration of solvent vapor exposure (SVE), and wettability of the stamp used for patterning. Periodic rupture of the film at regular intervals imposes directionality on the evolving patterns, resulting in isolated long threads/cylindrical ridges of polymers, which subsequently disintegrate into an aligned array of droplets due to Rayleigh-Plateau instability under specific conditions. Other patterns such as a double periodic array of droplets and an array of holes are also possible to obtain. The evolution can be interrupted at any intermediate stage by terminating the solvent vapor annealing, allowing the creation of pattern morphology on demand. The created patterns are significantly miniaturized in size as compared to features obtained from dewetting a flat film with the same hf.