Quantifying residual stress in nanoscale thin polymer films via surface wrinkling

Advancements in Novel Mechano-Rheological Probes for Studying Glassy Dynamics in Nanoconfined Thin Polymer Films

The nanoconfinement effects of glassy polymer thin films on their thermal and mechanical properties have been investigated thoroughly, especially with an emphasis on its altered glass transition behavior compared to bulk polymer, which has been known for almost three decades. While research in this direction is still evolving, reaching new heights to unravel the underlying physics of phenomena observed in confined thin polymer films, we have a much clearer picture now. This, in turn, has promoted their application in miniaturized and functional applications. To extract the full potential of such confined films, starting from their fabrication, function, and various applications, we must realize the necessity to have an understanding and availability of robust characterization protocols that specifically target thin film thermo-mechanical stability. Being nanometer-sized in thickness, often atop a solid substrate, direct mechanical testing on such films becomes extremely challenging and often encounters serious complexity from the dominating effect of the substrate. In this review, we have compiled together a few important novel and promising techniques for mechano-rheological characterization of glassy polymer thin films. The conceptual background involved in each technique, constitutive equations, methodology, and current status of research are touched upon following a pedagogical tutorial approach. Further, we discussed each technique's success and limitations, carefully covering the puzzling or contradicting observations reported within the broad nexus of glass transition temperature-viscosity-modulus-molecular mobility (including diffusion and relaxation).

Fabrication of Self-Wrinkling Polymer Films with Tunable Patterns through an Interfacial-Fuming-Induced Surface Instability Process

Inspired by the superglue fuming method for fingerprint collection, this study developed a novel interfacial-fuming-induced surface instability process to generate wrinkled patterns on polymeric substrates. High-electronegativity groups are introduced on the substrate surface to initiate the polymerization of monomer vapors, such as ethyl cyanoacrylate, which results in the formation of a stiff poly(ethyl cyanoacrylate) capping layer. Moreover, interfacial polymerization resulted in the covalent bonding of the substrate, which led to the volumetric shrinkage of the composite and the accumulation of compressive strain. This process ultimately resulted in the development and stabilization of wrinkled surface morphologies. The authors systematically examined parameters such as the modulus of the epoxy substrate, prestrain, the flow rate of fuming, and operating temperature. The aforementioned technique can be easily applied to architectures with complex outer morphologies and inner surfaces, thereby enabling the construction of surface patterns under ambient conditions without vacuum limitations or precise process control. This study is the first to combine fuming-induced interfacial polymerization with surface instability to create robust wrinkles. The proposed method enables the fabrication of intricate microwrinkled patterns and has considerable potential for use in various practical applications, including microfluidics, optical components, bioinspired adhesive devices, and interfacial engineering.

Network of Inorganic Nanocrystals Can Swell: Study of Swelling-Induced Surface Instability

A unique organic-inorganic hybrid network composed of inorganic nanocores (ranging from semiconductors to metallic ones) interconnected through organic molecules can be produced by crosslinking the organic ligands of colloidal inorganic nanocrystals in assemblies. This work reports that this network, which is conventionally considered an inorganic film, can swell when exposed to a solvent because of the interaction between the solvent and the organic linkage within the network. Intriguingly, this work discovers that drying the solvent of the swollen organic-inorganic hybrid network can significantly affect the morphology owing to the swelling-induced compress stress, which is widely observed in various organic network systems. This work studies the surface instability of crosslinked organic-inorganic hybrid networks swollen by various organic solvents, which led to buckling delamination. Specifically, this work investigates the effects of the i) solvent-network interaction, ii) crosslinking density of the network, and iii) thickness of the film on the delamination behavior of the crosslinked network.

An entropy generation approach to the molecular recoiling stress relaxation in thin nonequilibrated polymer films

In polymers, the equilibrium state is achieved when the chains have access to the maximum number of conformational states, which allows them to explore a larger conformational space, leading to an increase in the entropy of the system. Preparation of thin polymer films using the spin-coating technique results in polymer chains being locked in a nonequilibrium state with lower entropy due to possible stretching of chains during the process. Allowing enough time for recovery results in the relaxation of the spin-coating-induced molecular recoiling stress. Annealing such a film generates entropy due to its inherent irreversibility. We employed the dewetting technique to determine the molecular recoiling stress relaxation time in poly-(tertbutyl styrene) thin films. Furthermore, we qualitatively differentiated the metastable states achieved by the polymer film using entropy generation in a relaxing polymer film as an effect of thermal entropy and associated it with the conformational entropy of polymer chains utilizing the molecular recoiling stress relaxation time. This enabled us to explain molecular recoiling stress relaxation using a rather simplistic approach involving segmental level molecular rearrangements in polymer chains by attaining transient metastable states through an entropically activated process driving toward equilibrium.

Hierarchical Surface Instability in Polymer Films

This study demonstrates hierarchical instabilities in thin films. The hierarchical instabilities display three morphological characteristics: (1) windmill-like patterns at the macroscale, (2) Bénard cells and striations at the microscale, and (3) holes at the mesoscale. Such hierarchical instabilities occurred when spin coating was performed on high-volatile solutions under a high relative humidity (RH) but were suppressed when spin coating was performed on low-volatile solutions regardless of the RH. The high-volatile solutions comprise poly(4-vinylpyridine) (P4VP) in methanol or ethanol. The low-volatility solutions comprise P4VP in propanol or butanol. P4VP molecular weights, P4VP concentrations, spin rates, and film thicknesses are not vital factors in forming hierarchical instability in spin-coated P4VP films. Instead, the formation of hierarchical instabilities depends on the RH and solvent types. Namely, the hierarchical instabilities are driven by Bénard-Marangoni convection, water vapor condensation, and disturbance of spin-up and spin-off stages during spin coating of highly volatile solutions under high RH. Mechanisms of hierarchical instabilities are interpreted in detail.

Morphological Diagram of Dynamic-Interfacial-Release-Induced Surface Instability

In this study, a morphological diagram was constructed for quantitatively predicting various modes of surface instabilities caused by the dynamic interfacial release of strain in initially flat bilayer composites comprising an elastomer and a capping layer. Theory, experiment, and simulation were combined to produce the diagram, which enables systematic generation of the following instability patterns: wrinkle, fold, period-double, delamination, and coexisting patterns. The pattern that forms is most strongly affected by three experimental parameters: the elastic modulus of the elastomer, the elastic modulus of the capping layer, and the thickness of the capping layer. The morphological diagram offers understanding of the formation of complex patterns and development of their applications. Critically, the wrinkle alignment can be well controlled by changing the direction of the interfacial release to enable the creation of centimeter-sized and highly ordered lamellar wrinkled patterns with a single orientation on a soft elastomer without the need for costly high-vacuum instruments or complex fabrication processes. The method and diagram have great potential for broad use in many practical applications ranging from flexible electronic devices to smart windows.

Tough and Conductive Nacre-inspired MXene/Epoxy Layered Bulk Nanocomposites

A long-standing quest in materials science has been the development of tough epoxy resin nanocomposites for use in numerous applications. Inspired by nacre, here we report tough and conductive MXene/epoxy layered bulk nanocomposites. The orientation of MXene lamellar scaffolds is enhanced by annealing treatment. The improved interfacial interactions between MXene lamellar scaffold and epoxy through surface chemical modification resulted in a synergistic effect. Tailoring the interlayer spacing of MXene nanosheets to a critical distance resulted in a fracture toughness about eight times higher than that of pure epoxy, surpassing other epoxy nanocomposites. Our nacre-inspired MXene/epoxy layered bulk nanocomposites also show high electrical conductivity that provides self-monitoring capability for structural integrity and exhibits an excellent electromagnetic interference shielding efficiency. Our proposed strategy provides an avenue for fabricating high-performance epoxy nanocomposites.

Hierarchical Organization of Structurally Colored Cholesteric Phases of Cellulose via 3D Printing

Structural color-a widespread phenomenon observed throughout nature is caused by light interference from ordered phases of matter. While state-of-the-art nanofabrication techniques can produce structural organization in small areas, cost-effective and scalable techniques are still lacking to generate tunable color at sub-micron length scales. In this work, structurally colored hydroxypropyl cellulose filaments are produced with a suppressed angular color response by 3D printing. The systematic study of the morphology of the filaments reveals the key stages in the induction of a two-degree hierarchical order through 3D printing. The first degree of order originated from the changing of the cholesteric pitch at a few hundred nm scale via chemical modification and tuning of the solid content of the lyotropic phase. Upon 3D printing, the secondary hierarchical order of periodic wrinkling is introduced through the Helfrich-Hurault deformation of the shear-aligned cholesteric phases. In single-layered filaments, four morphological zones with varying orders of wrinkles are identified. Detailed morphological characterization is carried out using SEM to shed light on the mechanism of the wrinkling behavior. Through this work, the possibility of modifying the wrinkling behavior is demonstrated and thus the angle dependence of the color response by changing the printing conditions.

Mechanochemistry of Spiropyran under Internal Stresses of a Glassy Polymer

Mechanophores are powerful molecular tools used to track bond rupture and characterize mechanical damage in polymers. The majority of mechanophores are known to respond to external stresses, and we report in this study the first precedent of a mechanochemical response to internal, residual stresses that accumulate during polymer vitrification. While internal stress is intrinsic to polymers that can form solids, we demonstrate that it can dramatically affect the mechanochemistry of spiropyran probes and alter their intramolecular isomerization barriers by up to 70 kJ mol^-1. This new behavior of spiropyrans (SPs) enables their application for analysis of internal stresses distribution and their mechanochemical characterization on the molecular level. Spectroscopy and imaging based on SP mechanochemistry showed high topological sensitivity and allowed us to discern different levels of internal stress impacting various locations along the polymer chain. The nature of the developed technique allows for wide-field imaging of stress heterogeneities in polymer samples of irregular shapes and dimensions, making it feasible to directly observe molecular-level manifestations of mechanical stresses that accompany the formation of a vast number of solid polymers.

The memory of thin polymer films generated by spin coating

We present results from isothermal and temperature-sweep creep experiments adapted to filaments which were derived from spin coated and subsequently crumpled thin polystyrene films. Due to the existence of residual stresses induced by preparation, the filaments showed significant shrinkage which we followed as a function of time at various temperatures. In addition, the influence of preparation conditions and subsequent annealing of supported thin polymer films on shrinkage and relaxation behavior was investigated. The temporal evolution of shrinkage revealed a sequence of relaxation regimes. We explored the temperature dependence of this relaxation and compared our observations with published results on drawn melt-spun fibers. This comparison revealed intriguing similarities between both systems prepared along different pathways. For instance, the magnitudes of shrinkage of melt-spun fibers and of filaments from crumpled spin coated polymer films are similar. Thus, our results suggest the existence of generic mechanisms of "forgetting", i.e., how non-equilibrated polymers lose their memory of past processing events.

Effective Antifogging Coating from Hydrophilic/Hydrophobic Polymer Heteronetwork

Fogging on optical devices may severely impair vision, resulting in unacceptable adverse consequences. Hydrophilic coatings can prevent surface fogging by instantly facilitating pseudo-film water condensation but suffer from short antifogging duration due to water film thickening with further condensation. Here, an innovative strategy is reported to achieve longer antifogging duration via thickening the robust bonded hydrophilic/hydrophobic polymer heteronetwork coating to enhance its water absorption capacity. The combination of strong interfacial adhesion and hydrophilic/hydrophobic heteronetwork structure is key to this approach, which avoids interfacial failure and swelling-induced wrinkles under typical fogging conditions. The developed antifogging coating exhibits prolonged antifogging durations over a wide temperature range for repetitious usages. Eyeglasses coated with this coating successfully maintained fog-free vision in two typical scenarios. Besides, the coating recipes developed in this study also have potential as underwater glues as they demonstrate strong adhesions to both glass and polymer substrates in wet conditions.

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.

Molecular motion activated by residual stress in a glassy polymer thin film

The activation, by residual stress, of the fast portion of rotational motion of single fluorescent probe molecules inside a polymer thin film near its glass transition temperature is studied at a single molecular level. Spin-casted poly n-butyl methacrylate thin films without thermal annealing are chosen as the model system and single molecule fluorescence defocused microscopy is adopted as the method. The rotational motion of the probes under residual stress is found to be more activated than that under mere thermal activation, and the kinetic energy exhibits a monotonic increase with the stress strength. A rough linear dependence of rotational kinetic energy at low stress is found, yielding the value of characteristic volume for the residual stress to activate the motion of the probes. The values of the volume are close to the van der Waals volume of the probes, indicating that the activation of the fast dynamics by residual stress is localized. The activation effect is weakened and vanishes at or above the glass transition temperature due to stress relaxation. The effect is also absent at temperatures far below T_g due to the frozen molecular motion with a much higher activation energy.

Evolution of Surface Morphology of Spin-Coated Poly(methyl methacrylate) Thin Films

The morphology of sub-micron poly(methyl methacrylate) films coated to glass supports by spin coating from toluene is examined using surface profilometry. Wrinkled surfaces with local quasi-sinusoidal periodicity were seen on the surfaces of films with thicknesses of larger than 75 nm. The surface wrinkles had large aspect ratios with wavelengths in the tens of microns and amplitudes in the tens of nanometers. Wrinkles that formed during spin-coating are attributed to surface perturbations caused by Rayleigh-Bénard-Marangoni convective instabilities. The effects of film thickness, coating solution concentration, and drying rate on the thin film surface morphology are investigated. The results can be used to prepare surfaces with controlled morphology, either smooth or with periodic wrinkles.

Intelligent Shape-Morphing Micromachines

Intelligent machines are capable of switching shape configurations to adapt to changes in dynamic environments and thus have offered the potentials in many applications such as precision medicine, lab on a chip, and bioengineering. Even though the developments of smart materials and advanced micro/nanomanufacturing are flouring, how to achieve intelligent shape-morphing machines at micro/nanoscales is still significantly challenging due to the lack of design methods and strategies especially for small-scale shape transformations. This review is aimed at summarizing the principles and methods for the construction of intelligent shape-morphing micromachines by introducing the dimensions, modes, realization methods, and applications of shape-morphing micromachines. Meanwhile, this review highlights the advantages and challenges in shape transformations by comparing micromachines with the macroscale counterparts and presents the future outlines for the next generation of intelligent shape-morphing micromachines.

Photo-Oxidation-Controlled Surface Pattern with Responsive Wrinkled Topography and Fluorescence

Wrinkles and photo-oxidation reactions are widely found in soft materials, which are intimately associated with the failure of materials and structures. It is expected that the photo-oxidation process could also have a positive effect on the material and its surface. Here, we report the photo-oxidation of 2-(4-dietheylaminophenyl)-4,5-bis(4-methoxyphenyl) imidazole (DEA-TAI) into a wrinkled bilayer system to control surface wrinkle and fluorescent patterns, in which a supramolecular polymer network composed of carboxylic acid-containing copolymer (PS-BA-AA; PS=poly(styrene), BA=butyl acrylate; AA=acrylic acid) and DEA-TAI were used as the skin layer. Ultraviolet (UV) irradiation can induce photo-oxidation of the imidazole ring of DEA-TAI to weaken the intermolecular hydrogen bonding between PS-BA-AA and DEA-TAI, resulting in the release of stress in the bilayer system. The wrinkled morphology and fluorescence of the surface can be simultaneously regulated by photo-oxidation of DEA-TAI under UV light, and the resulting wrinkles are extremely sensitive to the pH value, which can be quickly and reversibly erased by NH₃ gas. Smart surfaces with specific hierarchical wrinkles and fluorescence can be achieved by selective irradiation with photomasks, which may find potential applications in smart displays and multi-code information storage.

Light-Associated Surface Wrinkling-Based Metrology for the Photosoftening Characterization in Azobenzene-Polymer Supramolecular Complexes

As an intriguing characteristic of azobenzene-containing materials (azo-materials), photoinduced changes in mechanical properties (e.g., photosoftening) have stimulated many efforts both theoretically and experimentally. Here a simple yet powerful tool (i.e., a light-associated surface wrinkling-based method) to study the photosoftening effect in azobenzene-polymer (azo-polymer) supramolecular complexes is reported. The photo-induced modulus decrease of supramolecular complex films is deduced by analyzing the change of critical wrinkle wavelength of strain-induced surface wrinkling, in the case of varying experiment parameters. In particular, thanks to the facile modular tunability of the supramolecular system, the photosoftening effect has been systematically investigated as a function of azo-moiety content and the molecular weight of the host polymer. Notably, a photosoftening coefficient that is related to the chemical composition/structure of azo-polymers is introduced, and a simple formula that can quantify the connection of the photosoftening with external irradiation conditions and internal chemical factors of azo-polymers is derived for the first time. The obtained results are of great importance not only to enhance understanding of the photosoftening mechanism, but also to thoroughly apply it in diverse smart fields.

Stress-Actuated Spiral Microelectrode for High-Performance Lithium-Ion Microbatteries

Miniaturization of batteries lags behind the success of modern electronic devices. Neither the device volume nor the energy density of microbatteries meets the requirement of microscale electronic devices. The main limitation for pushing the energy density of microbatteries arises from the low mass loading of active materials. However, merely pushing the mass loading through increased electrode thickness is accompanied by the long charge transfer pathway and inferior mechanical properties for long-term operation. Here, a new spiral microelectrode upon stress-actuation accomplishes high mass loading but short charge transfer pathways. At a small footprint area of around 1 mm² , a 21-fold increase of the mass loading is achieved while featuring fast charge transfer at the nanoscale. The spiral microelectrode delivers a maximum area capacity of 1053 µAh cm^-2 with a retention of 67% over 50 cycles. Moreover, the energy density of the cylinder microbattery using the spiral microelectrode as the anode reaches 12.6 mWh cm^-3 at an ultrasmall volume of 3 mm³ . In terms of the device volume and energy density, the cylinder microbattery outperforms most of the current microbattery technologies, and hence provides a new strategy to develop high-performance microbatteries that can be integrated with miniaturized electronic devices.

Symmetrical Wrinkles in Single-Component Elastomers with Fingerprint-Inspired Robust Isotropic Dry Adhesive Capabilities

Robust and inexpensive dry adhesives have a great potential in multitudinous industrial applications. However, to date, the fabrication of dry adhesives, prepared using high aspect ratio structures in general, requires specific equipment and time-consuming processes, which limit their practicable utilization. Inspired from human fingerprints, in this study, we created durable single-component elastomer surfaces with symmetric and multiple concentric-shaped wrinkled patterns that exhibit isotropic dry adhesion capabilities. The dynamic interfacial release-induced surface wrinkling property of a rigid degradable polymeric capping layer [i.e., poly(l-lactide) (PLLA)] was exploited on a soft elastomer substrate [i.e., polydimethylsiloxane (PDMS)] to spontaneously form wrinkled PLLA/PDMS bilayer composites. After conducting a two-step thermal curing process on the composite and hydrolysis of the PLLA capping layer, a single-component microwrinkled PDMS surface with a large area and symmetric patterns could be generated. The patterns show flexible, durable, and isotropic dry adhesion capabilities that could be controlled by tuning their geometrical parameters (wrinkle wavelengths and amplitudes) and elastic modulus. In particular, the formation of symmetrically wrinkled patterns without using expensive lithography for patterning and costly material precursors is an advantage and could be extended to other industrial applications, such as damage-free transportation, biomimetic climbing robots, and biocompatible medical patches.

Tailoring the molecular structure of crosslinked polymers for pervaporation desalination

Polymer crosslinking imbues chemical stability to thin films at the expense of lower molecular transportation rates. Here in this work we deployed molecular dynamics simulations to optimise the selection of crosslinking compounds that overcome this trade-off relationship. We validated these simulations using a series of experiments and exploited this finding to underpin the development of a pervaporation (PV) desalination thin-film composite membrane with water fluxes reaching 234.9 ± 8.1 kg m-2 h-1 and salt rejection of 99.7 ± 0.2 %, outperforming existing membranes for pervaporation and membrane distillation. Key to achieving this state-of-the-art desalination performance is the spray coating of 0.73 μm thick crosslinked dense, hydrophilic polymers on to electrospun nanofiber mats. The desalination performances of our polymer nanocomposites are harnessed here in this work to produce freshwater from brackish water, seawater and brine solutions, addressing the key environmental issue of freshwater scarcity.

Functional Micro–Nano Structure with Variable Colour: Applications for Anti-Counterfeiting

Colour patterns based on micro-nano structure have attracted enormous research interests due to unique optical switches and smart surface applications in photonic crystal, superhydrophobic surface modification, controlled adhesion, inkjet printing, biological detection, supramolecular self-assembly, anti-counterfeiting, optical device and other fields. In traditional methods, many patterns of micro-nano structure are derived from changes of refractive index or lattice parameters. Generally, the refractive index and lattice parameters of photonic crystals are processed by common solvents, salts or reactive monomers under specific electric, magnetic and stress conditions. This review focuses on the recent developments in the fabrication of micro-nano structures for patterns including styles, materials, methods and characteristics. It summarized the advantages and disadvantages of inkjet printing, angle-independent photonic crystal, self-assembled photonic crystals by magnetic field force, gravity, electric field, inverse opal photonic crystal, electron beam etching, ion beam etching, laser holographic lithography, imprinting technology and surface wrinkle technology, etc. This review will provide a summary on designing micro-nano patterns and details on patterns composed of photonic crystals by surface wrinkles technology and plasmonic micro-nano technology. In addition, colour patterns as switches are fabricated with good stability and reproducibility in anti-counterfeiting application. Finally, there will be a conclusion and an outlook on future perspectives.

Polymer thin film adhesion utilizing the transition from surface wrinkling to delamination

Understanding the adhesion of rigid thin films to compliant substrates is critical for the development and implementation of flexible electronic devices and wearable sensor technologies. Quantifying the strength of a film-substrate interface can be challenging due to the brittleness of glassy films which can greatly complicate sample preparation, handling, and testing. Here, a method for measuring the adhesion of glassy thin films to soft elastomeric substrates is explored that exploits an understanding of surface buckling instabilities, specifically the transition from wrinkling to delamination. The adhesion (given by the critical strain energy release rate (G_c)) for two model materials' interfaces is quantified by determining the critical delamination strain for thin glassy polymer films (polystyrene (PS) and poly(methyl methacrylate) (PMMA)) from an elastomeric substrate (poly(dimethyl siloxane) (PDMS)). By accounting for edge defects that greatly reduce the critical strain for delamination, reasonable adjusted G_c values of 21.0 ± 5.1 mJ m^-2 and 32.2 ± 4.9 mJ m^-2 are found for PS-PDMS and PMMA-PDMS interfaces, respectively. The utilization of this method to characterize film modulus and adhesion could be used as a facile measurement technique for more applied polymer thin film systems.

Shell Architecture Strongly Influences the Glass Transition, Surface Mobility, and Elasticity of Polymer Core-Shell Nanoparticles

Despite the growing application of nanostructured polymeric materials, there still remains a large gap in our understanding of polymer mechanics and thermal stability under confinement and near polymer-polymer interfaces. In particular, the knowledge of polymer nanoparticle thermal stability and mechanics is of great importance for their application in drug delivery, phononics, and photonics. Here, we quantified the effects of a polymer shell layer on the modulus and glass-transition temperature (T g) of polymer core-shell nanoparticles via Brillouin light spectroscopy and modulated differential scanning calorimetry, respectively. Nanoparticles consisting of a polystyrene (PS) core and shell layers of poly(n-butyl methacrylate) (PBMA) were characterized as model systems. We found that the high T g of the PS core was largely unaffected by the presence of an outer polymer shell, whereas the lower T g of the PBMA shell layer decreased with increasing PBMA thickness. The surface mobility was revealed at a temperature about 15 K lower than the T g of the PBMA shell layer. Overall, the modulus of the core-shell nanoparticles decreased with increasing PBMA shell layer thickness. These results suggest that the nanoparticle modulus and T g can be tuned independently through the control of nanoparticle composition and architecture.

Macroscopic Geometry-Dominated Orientation of Symmetric Microwrinkle Patterns

Orientated wrinkle patterns with controlled microarchitectures are highly attractive because of their potential and broad application in technologies ranging from flexible electronic devices to smart windows. Here, we demonstrate a macroscopic, geometry-dominated strategy to fabricate symmetric microwrinkles with precisely controllable pattern dimensions and orientations through a dynamic interfacial release process. The release-induced approach is based on the release of multilayer elastomer composites from polymeric sacrificial layers in solutions combined with crosslinking-induced contraction of the elastomer substrates. Crosslinking-induced contraction provides the driving force for developing and stabilizing surface wrinkle formation, whereas the polymeric sacrificial layer provides a mild and simultaneous release process to form orientated wrinkles through kinetic control of local strain development. The macroscopic shape of the composite controls release kinetics, hence strain history, leading to the generation of photonic reflective surfaces. Moreover, stable wrinkles fabricated from various materials including metals, ceramics, and carbons can be achieved. This versatile, mold-free, and cost-effective platform technology demonstrates how global strain distributions can be harnessed through kinetics to drive local pattern development.

Photocontrollable Wrinkle Morphology Evolution on Azo-Based Multilayers for Hierarchical Surface Micropatterns Fabrication

Inspired by nature, comprehensive understanding and ingenious utilization of the self-organized wrinkling behaviors of the sandwiched multilayer bonded on substrates are important for engineering and/or functional laminated devices design. Herein, we report a facile and effective strategy to regulate the wrinkles morphology evolution and the resultant hierarchical surface micropatterns on azobenzene-based laminated multilayers by visible-light irradiation. Revealed by systematic experiments, the photocontrolled dynamic wrinkle evolutions are triggered by the reversible photoisomerization of azobenzene in the top azopolymer film and are strongly dependent on the intermediate photoinert layers (e.g., polystyrene and oxygen plasma-induced SiO _x layer) with the wrinkle-reinforcing effect or the stress relaxation acceleration effect. Interestingly, large-area well-defined hierarchical surface wrinkle patterns could be fabricated on the multilayers upon selective exposure. In the unexposed region, the wrinkles evolved into highly oriented patterns, whereas in the exposed region, they were fully erased or evolved into smaller-wavelength wrinkles. This study not only sheds light on the morphological evolution of the wrinkling laminated composites in engineering and nature but also paves a new avenue to conveniently and controllably realize the hierarchical stimulus-responsive surface patterns.

Effect of Adjacent Hydrophilic Polymer Thin Films on Physical Aging and Residual Stress in Thin Films of Poly(butylnorbornene-ran-hydroxyhexafluoroisopropyl norbornene)

The properties of thin supported polymer films can be dramatically impacted by the substrate upon which it resides. A simple way to alter the properties of the substrate (chemistry, rigidity, dynamics) is by coating it with an immiscible polymer. Here we describe how ultrathin (ca. 2 nm) hydrophilic polymer layers of poly(acrylic acid), PAA, and poly(styrenesulfonate), PSS, impact the aging behavior and the residual stress in thin films of poly(butylnorbornene-ran-hydroxyhexafluoroisopropyl norbornene), BuNB-r-HFANB. The aging rate decreases as the film thickness (h) is decreased, but the extent of this change depends on the adjacent layer. Even for the thickest films (h>500 nm), there is a decrease in the aging rate at 100 °C when BuNB-r-HFANB is in contact with PSS. In an effort to understand the origins of these differences in the aging behavior, the elastic modulus and residual stress (σR) in the films were determined by wrinkling as a function of aging time. The change in the elastic modulus during aging does not appear to be directly correlated with the densification or expansion of the films, but the aging rates appear to roughly scale as hσR 1/3. These results illustrate that the physical aging of thin polymer films can be altered by adjacent polymers.

Direct Observation of Conformational Relaxation of Polymer Chains at Surfaces

Sum-frequency generation spectroscopy was employed to follow the conformation evolution of polystyrene chains at the surface of a spin-coated film in a temperature-ramping mode as well as under isothermal annealing. The conformation of surface chains in an as-cast film was observed to be in a nonequilibrium state, in accordance with reported results for polymer chains in thin spin-coated films. While the relaxation of surface nonequilibrium chains was induced by the enhanced surface mobility, the whole chain motion such as reptation might be a key factor in determining the time scale for equilibrating the surface chain conformation.

Competing polymer-substrate interactions mitigate random copolymer adsorption

Annealing a supported polymer film in the melt state, a common practice to relieve residual stresses and erase thermal history, can result in the development of an irreversibly adsorbed nanolayer. This layer of polymer chains physically adsorbed to the substrate interface has been shown to influence thin film properties such as viscosity and glass transition temperature. Its growth is attributed to many simultaneous interactions between individual monomer units and the substrate stabilizing chains against desorption. A better understanding of how these specific polymer-substrate interactions influence the growth of the adsorbed layer is needed, particularly given how strongly the properties of geometrically-confined polymeric systems are impacted by interfaces. Here, we use homopolymers and random copolymers of styrene and methyl methacrylate to form adsorbed layers and examine the influence of chemical composition and the resulting polymer-substrate interactions on adsorbed layer growth and structure. Ellipsometric measurements reveal a non-monotonic trend between composition and thickness of the adsorbed layers that is inconsistent with the behavior normally exhibited by random copolymers, being intermediate to their respective homopolymers. We examine this trend in terms of plateau thickness and growth kinetics at two different annealing temperatures and propose a mechanism for how different polymer-substrate interactions combine to influence adsorption when copolymer films are annealed. By introducing compositional heterogeneity, this mechanism extends the study of irreversible adsorption to complex chemistries and provides for a more general understanding of how annealing should be accounted for in the proper selection and processing of polymer thin films for applications in nanotechnology.

Arcuate wrinkling on stiff film/compliant substrate induced by thrust force with a controllable micro-probe

Wrinkling patterns are widely observed in nature and can be used in many high-tech applications such as microfluidic channel, self-assembly ordered microstructures and improved adhesives. In order to use the wrinkling patterns for these applications, it is necessary to precisely control the formation and geometry of the wrinkles. In this paper, we investigate the localized wrinkling of a stiff film/compliant substrate system subjected to a thrust force with a controllable micro-probe. A thin Au film is deposited onto a thick PDMS substrate attached to a glass to form the stiff film/compliant substrate system. And a micro-probe is controlled by a piezoelectric microrobotic system to exert a point force onto the stiff film/compliant substrate to demonstrate the evolution of the localized wrinkles. The experiments show that the film will wrinkle into orthoradial morphology spontaneously when it is deformed in the vertical direction, and then it will wrinkle into arcuate morphology with deformation in the horizontal direction. Since the compressive stress and tensile stress of the film are generated simultaneously, the evolution of the arcuate wrinkles is always accompanied by some radial cracks. The morphological characteristic, formation mechanism and dynamic evolution of the arcuate wrinkles are demonstrated and discussed in detail.

A wrinkling-based method for investigating glassy polymer film relaxation as a function of film thickness and temperature

We investigate the relaxation dynamics of thin polymer films at temperatures below the bulk glass transition T_g by first compressing polystyrene films supported on a polydimethylsiloxane substrate to create wrinkling patterns and then observing the slow relaxation of the wrinkled films back to their final equilibrium flat state by small angle light scattering. As with recent relaxation measurements on thin glassy films reported by Fakhraai and co-workers, we find the relaxation time of our wrinkled films to be strongly dependent on film thickness below an onset thickness on the order of 100 nm. By varying the temperature between room temperature and T_g (≈100 °C), we find that the relaxation time follows an Arrhenius-type temperature dependence to a good approximation at all film thicknesses investigated, where both the activation energy and the relaxation time pre-factor depend appreciably on film thickness. The wrinkling relaxation curves tend to cross at a common temperature somewhat below T_g, indicating an entropy-enthalpy compensation relation between the activation free energy parameters. This compensation effect has also been observed recently in simulated supported polymer films in the high temperature Arrhenius relaxation regime rather than the glassy state. In addition, we find that the film stress relaxation function, as well as the height of the wrinkle ridges, follows a stretched exponential time dependence and the short-time effective Young's modulus derived from our modeling decreases sigmoidally with increasing temperature-both characteristic features of glassy materials. The relatively facile nature of the wrinkling-based measurements in comparison to other film relaxation measurements makes our method attractive for practical materials development, as well as fundamental studies of glass formation.

Tuning relaxation dynamics and mechanical properties of polymer films of identical thickness

Using dewetting as a characterization tool, we demonstrate that physical properties of thin polymer films can be regulated and tuned by employing variable processing conditions. For different molecular weights, the variable behavior of polystyrene films of identical thickness, prepared along systematically altered pathways, became predictable through a single parameter P, defined as the ratio of time required over time available for the equilibration of polymers. In particular, preparation-induced residual stresses, the corresponding relaxation times as well as the rupture probability of such films (of identical thickness) varied by orders of magnitude following scaling relations with P. Our experimental findings suggest that we can predictably enhance properties and hence maximize the performance of thin polymer films via appropriately chosen processing conditions.

Writing Wrinkles on Poly(dimethylsiloxane) (PDMS) by Surface Oxidation with a CO2 Laser Engraver

Surface wrinkles formed by the buckling of a strained stiff layer attached to a soft elastomer foundation have been widely used in a variety of applications. Micropatterning of wrinkled topographies is, however, limited by process/system complexities. In this article, we report an approach to write surface wrinkles with desired pattern geometries on poly(dimethylsiloxane) (PDMS) elastomers using a commercial infrared laser engraver with a spot size of 127 μm. Wrinkled micropatterns with wavelength from <50 to >300 μm were obtained in minutes without using special facilities or atmospheres. The minimal achievable pattern sizes of one-dimensional and two-dimensional patterns and the change of the minimal achievable pattern size with wrinkle orientation were investigated under a given set of operating parameters. Sub-spot size patterning was also demonstrated. To reduce surface cracking, a typical problem in large-area wrinkle patterning, a patterning scheme that separates neighboring laser exposure areas by nonexposure gaps was developed. In addition, micropatterns with gradient wrinkles were created on the surface. This is the first report that patterns microscale surface wrinkles on elastomer surfaces using infrared laser irradiation. The simple and versatile approach is expected to provide a fast yet controllable way to create wrinkled micropatterns at low cost to facilitate a broad array of studies in surface engineering, cellular biomechanics, and optics.

Time Allowed for Equilibration Quantifies the Preparation Induced Nonequilibrium Behavior of Polymer Films

Performance and properties of materials may strongly depend on processing conditions. This is particularly so for polymers, which often have relaxation times much longer than the processing times and therefore may adopt preparation dependent nonequilibrated molecular conformations that potentially cause novel properties. However, so far it was not possible to predictably and quantitatively relate processing steps and resulting properties of polymer films. Here, we demonstrate that the behavior of polymer films, probed through dewetting, can be tuned by controlling preparation pathways, defined through a dimensionless parameter [Formula: see text], which is the appropriate preparation time normalized with the characteristic relaxation time of the polymer. We revealed scaling relations between [Formula: see text] and the amount of preparation-induced residual stresses, the corresponding relaxation time, and the probability of film rupture. Intriguingly, films of the same thickness exhibited hole nucleation densities and subsequent dewetting kinetics differing by up to an order of magnitude, indicating possibilities to adjust the desired properties of polymer films by preparing them in appropriate ways.

Light-Modulated Surface Micropatterns with Multifunctional Surface Properties on Photodegradable Polymer Films

Photodegradable polymers constitute an emerging class of materials that are expected to possess advances in the areas of micro/nano- and biotechnology. Herein, we report a green and effective strategy to fabricate light-responsive surface micropatterns by taking advantage of photodegradation chemistry. Thanks to the molecular chain breakage during the photolysis process, the stress field of photodegradable polymer-based wrinkling systems undergoes continuous disturbance, leading to the release/reorganization of the internal stress. Revealed by systematic experiments, the light-induced stress release mechanism enables the dynamic adaption of not only thermal-induced labyrinth wrinkles, but uniaxially oriented wrinkle microstructures induced by mechanical straining. This method paves the way for their diverse applications, for example, in optical information display and storage, and the smart fabrication of multifunctional surfaces as demonstrated here.