Melt crystallization/dewetting of ultrathin PEO films via carbon dioxide annealing: the effects of polymer adsorbed layers

Determining the Characteristics of Ultrathin Polymer Films: A Spectroscopic Ellipsometry Approach

Ellipsometry is a powerful and convenient technique that is widely used to determine the thickness and optical characteristics of polymer thin films. The determination is accomplished by modeling the measured change in the polarization of an electromagnetic wave upon interacting with the thin film. However, due to the strong statistical correlations between the fit parameters in the model, simultaneous determination of the thickness and the refractive indices of optically anisotropic ultrathin films using ellipsometry remains a challenge. Here, we propose an approach that can be used to obtain reliable values of both the thickness and the optical anisotropy of ultrathin polymer films. The approach was developed by performing spectroscopic ellipsometry measurements on thin films of hydrophobic polystyrene and hydrophilic chitosan of thickness between a few tens to a few hundred nm and whose absolute value of the birefringence differed by approximately an order of magnitude. Careful consideration of the characteristics of the root mean squared error of the fits obtained by modeling the ellipsometry data and the statistical correlations between the fit parameters formed the basis of the proposed approach.

Polymer Nanocomposite Dielectrics: Understanding the Matrix/Particle Interface

Polymer nanocomposite dielectrics possess exceptional electric properties that are absent in the pristine dielectric polymers. The matrix/particle interface in polymer nanocomposite dielectrics is suggested to play decisive roles on the bulk material performance. Herein, we present a critical overview of recent research advances and important insights in understanding the matrix/particle interfacial characteristics in polymer nanocomposite dielectrics. The primary experimental strategies and state-of-the-art characterization techniques for resolving the local property-structure correlation of the matrix/particle interface are dissected in depth, with a focus on the characterization capabilities of each strategy or technique that other approaches cannot compete with. Limitations to each of the experimental strategy are evaluated as well. In the last section of this Review, we summarize and compare the three experimental strategies from multiple aspects and point out their advantages and disadvantages, critical issues, and possible experimental schemes to be established. Finally, the authors' personal viewpoints regarding the challenges of the existing experimental strategies are presented, and potential directions for the interface study are proposed for future research.

Investigation of Interfacial Water Accumulation between Polypropylene Thin Film and Si Substrate by Neutron Reflectivity

We performed neutron reflectivity (NR) measurements of isotactic polypropylene (PP) thin films deposited on a Si substrate at the saturated vapor pressure of deuterated water to investigate interfacial water accumulation between the PP and metal surfaces in PP-based polymer/inorganic filler nanocomposites and metal/resin bonding materials. The PP thin films prepared on a Si substrate by a spin-coating technique were adequate as a model system for the PP/metal interface in these materials. A water-rich layer with a maximum water concentration of 0.5, which was considerably higher than those reported in previous studies of organic/inorganic interfaces, was observed within a width of approximately 3 nm at the interface under saturated vapor conditions. This could be attributed to the weak interaction between the PP thin film and the Si substrate. The pathway of moisture transport to the interfacial region was along the interface rather than through the PP film because the hydrophobic PP thin film does not entirely swell with water vapor.

Layered Structure in the Crystalline Adsorption Layer and the Leaching Process of Poly(vinyl alcohol) Revealed by Neutron Reflectivity

We investigated the structure of the crystalline adsorption layer of poly(vinyl alcohol) (PVA) in hot water by neutron reflectivity in two cases: when the adsorption layer is exposed on the substrate by leaching the upper bulk layer and when it is deeply embedded between a relatively thick PVA film and substrate. In both cases, the PVA adsorption layer consists of three layers on the Si substrate. The bottom layer, consisting of amorphous chains that are strongly constrained on the substrate, is not swollen even in hot water at 90 °C. The middle layer, consisting of amorphous chains that are much more mobile compared with those in the bottom layer, has no freedom to assume a crystalline form. Only the molecular chains in the top layer are crystallizable in the adsorption layer, leading to a heterogeneous layered structure in the film thickness direction. This layered structure is attributed to the crystallizable chains of PVA during the formation of the adsorption layer driven by hydrogen bonding. However, the structure and dynamics in the adsorption layer may differ in both cases because the molecular chains in the vicinity of the surface seem to be affected by surface effects even in the adsorption layer.

Dynamics and Structure Formation of Confined Polymer Thin Films Supported on Solid Substrates

The stability/instability behavior of polystyrene (PS) films with tunable thickness ranging from higher as-cast to lower residual made on Si substrates with and without native oxide layer was studied in this paper. For further extraction of residual PS thin film (hresi) and to investigate the polymer-substrate interaction, Guiselin's method was used by decomposing the polymer thin films in different solvents. The solvents for removing loosely adsorbed chains and extracting the strongly adsorbed irreversible chains were selected based on their relative desorption energy difference with polymer. The PS thin films rinsed in chloroform with higher polarity than that of toluene showed a higher decrease in the residual film thickness but exhibited earlier growth of holes and dewetting in the film. The un-annealed samples with a higher oxide film thickness showed a higher decrease in the PS residual film thickness. The effective viscosity of PS thin films spin-coated on H-Si substrates increased because of more resistance to flow dynamics due to the stronger polymer-substrate interaction as compared to that of Si-SiOx substrates. By decreasing the film thickness, the overall effective mobility of the film increased and led to the decrease in the effective viscosity, with matching results of the film morphology from atomic force microscopy (AFM). The polymer film maintained low viscosity until a certain period of time, whereupon further annealing occurred, and the formation of holes in the film grew, which ultimately dewetted the film. The residual film decrement, growth of holes in the film, and dewetting of the polymer-confined thin film showed dependence on the effective viscosity, the strength of solvent used, and various involved interactions on the surface of substrates.

Cyclic Topology Enhancing Structural Ordering and Stability of Comb-Shaped Polypeptoid Thin Films against Melt-Induced Dewetting

We investigated the effect of cyclic chain topology on the molecular ordering and thermal stability of comb-shaped polypeptoid thin films on silicon (Si) substrates. Cyclic and linear poly(N-decylglycine) (PNDG) bearing long n-decyl side chains were synthesized by ring-opening polymerization of N-decylglycine-derived N-carboxyanhydrides. When the spin-coated thin films were subjected to thermal annealing at temperatures above the melting temperature (T > T m), the cyclic PNDG films exhibited significantly enhanced stability against melt-induced dewetting than the linear counterparts (l-PNDG). When recrystallized at temperatures below the crystallization temperature (T < T c), the homogeneous c-PNDG films exhibit enhanced crystalline ordering relative to the macroscopically dewetted l-PNDG films. Both cyclic and linear PNDG molecules adopt cis-amide conformations in the crystalline film, which transition into trans-amide conformations upon melting. A top-down solvent leaching treatment of both l/c-PNDG films revealed the formation of an irreversibly physisorbed monolayer with similar thickness (ca. 3 nm) on the Si substrate. The physisorbed monolayers are more disordered relative to the respective thicker crystalline films for both cyclic and linear PNDGs. Upon heating above T m, the adsorbed c-PNDG chains adopt trans-amide backbone conformation identical with the free c-PNDG molecules in the molten film. By contrast, the backbone conformations of l-PNDG chains in the adsorbed layers are notably different from those of the free chains in the molten film. We postulate that the conformational disparity between the chains in the physically adsorbed layers versus the free chains in the molten film is an important factor to account for the difference in the thermal stability of PNDG thin films. These findings highlight the use of cyclic chain topology to suppress the melt-induced dewetting in polymer thin films.

Irreversible adsorption of polymer melts and nanoconfinement effects

For almost a decade, growing experimental evidence has revealed a strong correlation between the properties of nanoconfined polymers and the number of chains irreversibly adsorbed onto nonrepulsive interfaces, e.g. the supporting substrate of thin polymer coatings, or nanofillers dispersed in polymer melts. Based on such a correlation, it has already been possible to tailor structural and dynamics properties - such as the glass transition temperature, the crystallization rate, the thermal expansion coefficients, the viscosity and the wettability - of nanomaterials by controlling the adsorption kinetics. This evidence indicates that irreversible adsorption affects nanoconfinement effects. More recently, also the opposite phenomenon was experimentally observed: nanoconfinement alters interfacial interactions and, consequently, also the number of chains adsorbed in equilibrium conditions. In this review we discuss this intriguing interplay between irreversible adsorption and nanoconfinement effects in ultrathin polymer films. After introducing the methods currently used to prepare adsorbed layers and to measure the number of irreversibly adsorbed chains, we analyze the models employed to describe the kinetics of adsorption in polymer melts. We then discuss the structure of adsorbed polymer layers, focusing on the complex macromolecular architecture of interfacial chains and on their thermal expansion; we examine the way in which the structure of the adsorbed layer affects the thermal glass transition temperature, vitrification, and crystallization. By analyzing segmental dynamics of 1D confined systems, we describe experiments to track the changes in density during adsorption. We conclude this review with an analysis of the impact of nanoconfinement on adsorption, and a perspective on future work where we also address the key ideas of irreversibility, equilibration and long-range interactions.

Tunable Properties of MAPLE-Deposited Thin Films in the Presence of Suppressed Segmental Dynamics

Processing polymer thin films by physical vapor deposition has been a major challenge due to material degradation. This challenge has limited our understanding of morphological control by top-down approaches that can be crucial for many applications. Recently, matrix-assisted pulsed laser evaporation (MAPLE) has emerged as an alternative route to fabricate polymer thin films from near-gas phase growth conditions. In this Letter, we investigate how this approach can result in a stable two-phase film structure of semicrystalline polymers via a unique combination of MAPLE and flash calorimetry. In the case of MAPLE-deposited poly(ethylene oxide) (PEO) thin films, we find a 35 °C enhancement in the glass transition temperature relative to melt-crystallized films, which is associated with irreversible chain adsorption in the amorphous region of the film. Remarkably, by varying substrate temperature during deposition, we reveal the ability to significantly tune the crystal orientation, extent of crystallinity, and lamellar thickness of MAPLE-deposited PEO thin films.

Elucidation of a Heterogeneous Layered Structure in the Thickness Direction of Poly(vinyl alcohol) Films with Solvent Vapor-Induced Swelling

We investigated the swelling behaviors of poly(vinyl alcohol) (PVA) films deposited on Si wafers with water vapor, which is a good solvent for PVA for elucidating structural and dynamical heterogeneities in the film thickness direction. Using deuterated water vapor, structural and dynamical differences in the thickness direction can be detected easily as different degrees of swelling in the thickness direction by neutron reflectivity. Consequently, the PVA film with a degree of saponification exceeding 98 mol % exhibits a three-layered structure in the thickness direction. It is considered that an adsorption layer consisting of molecular chains that are strongly adsorbed onto the solid substrate is formed at the interface with the substrate, which is not swollen with water vapor compared with the bulk-like layer above it. The adsorption layer is considered to exhibit significantly slower dynamics than the bulk. Furthermore, a surface layer that swells excessively compared with the underneath bulk-like layer is found. This excess swelling of the surface layer may be related to a higher mobility of the molecular chains or lower crystallinity at the surface region compared to the underneath bulk-like layer. Meanwhile, for the PVA film with a much lower degree of saponification, a thin layer with a slightly lower degree of swelling than the bulk-like layer above it can be detected at the interface between the film and substrate only under a high humidity condition. This layer is considered to be the adsorption layer composed of molecular chains loosely adsorbed onto the Si substrate.

Controlling the pore size in conjugated polymer films via crystallization-driven phase separation

A wide range of possible applications in sensors and optoelectronic devices have focused considerable attention on porous membranes made of semi-conducting polymers. In this study, porous films of poly(3-hexylthiophene) (P3HT) were conveniently constructed through spin-coating of solutions of a blend of P3HT and polyethylene glycol (PEG). Pores were formed by phase separation driven simultaneously by incompatibility and crystallization. The influence of the polymer concentration (c), molecular weight (Mn) and spin-coating temperature (Tsp) on the pore size and structure was investigated. With increasing c from 0.5 to 5.0 wt%, the pore diameter (d) varied from ≈1.3 μm to ≈38 μm. Similarly, we observed a substantial increase of d with increasing Mn of PEG, while changing Mn of P3HT did not affect d. Micron- and nano-scale pores coexisted in porous P3HT films. While incompatibility of P3HT and PEG caused the formation of nano-pores, micron-scale pores resulted from crystallization in the PEG-rich domains by forcing PEG molecules to diffuse from the surrounding PEG-P3HT blend region to the crystal growth front.

The fabrication and molecular alignment of poly(ethylene oxide) grating film based on hot embossing technology

The fabrication and alignment transition of poly(ethylene oxide) grating film via hot embossing technology are demonstrated.

Self-Organization of Triblock Copolymer Melt Chains Physisorbed on Non-neutral Surfaces

We here report the self-organization process of poly(styrene-b-ethylene/butadiene-b-styrene) (SEBS) triblock copolymer chains physically adsorbed on a non-neutral surface. Spin-cast SEBS thin films were prepared on silicon (Si) substrates and then annealed at a high temperature far above the bulk glass transition temperatures of the two constituent blocks. To reveal the buried interfacial structure, we utilized solvent rinsing processes and a suite of surface-sensitive techniques including ellipsometry, X-ray reflectivity, atomic force microscopy, and grazing incidence small angle X-ray scattering. We revealed that the SEBS chains form two different chain structures on the substrate simultaneously: (i) "flattened chains" with the average height of 2.5 nm but without forming microdomain structures; (ii) "loosely adsorbed chains" with the average height of 11.0 nm and the formation of perpendicularly oriented cylindrical microdomains to the substrate surface. In addition, the kinetics to form the perpendicular-oriented cylinder was sluggish (∼200 h) and proceeded via multistep processes toward the equilibrium state. We also found that the lateral microdomain structures were distorted, and the characteristic lengths of the microdomains were slightly different from the bulk even after reaching "quasiequilibrium" state within the observed time window. Furthermore, we highlight the vital role of the adsorbed chains in the self-assembling process of the entire SEBS thin film: a long-range perturbation associated with the adsorbed chains propagates into the film interior, overwhelming the free surface effect associated with surface segregation of the lower surface tension of polystyrene blocks.

Structure-induced switching of interpolymer adhesion at a solid-polymer melt interface

Here we report a link between the interfacial structure and adhesive property of homopolymer chains physically adsorbed (i.e., via physisorption) onto solids. Polyethylene oxide (PEO) was used as a model and two different chain conformations of the adsorbed polymer were created on silicon substrates via the well-established Guiselin's approach: "flattened chains" which lie flat on the solid and are densely packed, and "loosely adsorbed polymer chains" which form bridges jointing up nearby empty sites on the solid surface and cover the flattened chains. We investigated the adhesion properties of the two different adsorbed chains using a custom-built adhesion testing device. Bilayers of a thick PEO overlayer on top of the flattened chains or loosely adsorbed chains were subjected to the adhesion test. The results revealed that the flattened chains do not show any adhesion even with the chemically identical free polymer on top, while the loosely adsorbed chains exhibit adhesion. Neutron reflectivity experiments corroborated that the difference in the interfacial adhesion is not attributed to the interfacial brodening at the free polymer-adsorbed polymer interface. Instead, coarse-grained molecular dynamics simulation results suggest that the tail parts of the loosely adsorbed chains act as "connector molecules", bridging the free chains and substrate surface and improving the interfacial adhesion. These findings not only shed light on the structure-property relationship at the interface, but also provide a novel approach for developing sticking/anti-sticking technologies through precise control of the interfacial polymer nanostructures.

Ionic transport in the amorphous phase of semicrystalline polyethylene oxide thin films

We present a detailed study on the ionic transport properties of polyethylene oxide (PEO) thin films prepared under different conditions. Using a state-of-the-art Atomic Force Microscopy (AFM) methodology, we simultaneously acquired the nanostructured topography of these semicrystalline polymer films as well as the corresponding dielectric function; in the latter case by probing the frequency-dependent tip-sample electrical interactions. By means of this AFM protocol, we studied the ionic conductivity in the PEO amorphous phase and its dependence on film preparation conditions. In general, for any preparation method, we found a distribution of conductivities ranging from 10^-14 to 10^-6 S cm^-1. Specifically, PEO thin films crystallized from the melt presented relatively high conductivity values, which decreased in the PEO films prepared from solutions at room temperature depending on solvent polarity. We discuss our results by considering the molecular arrangement of the polymer segments in the complex amorphous phase, which is strongly influenced by the PEO crystallization route.

Novel Effects of Compressed CO2 Molecules on Structural Ordering and Charge Transport in Conjugated Poly(3-hexylthiophene) Thin Films

We report the effects of compressed CO₂ molecules as a novel plasticization agent for poly(3-hexylthiophene) (P3HT)-conjugated polymer thin films. In situ neutron reflectivity experiments demonstrated the excess sorption of CO₂ molecules in the P3HT thin films (about 40 nm in thickness) at low pressure (P = 8.2 MPa) under the isothermal condition of T = 36 °C, which is far below the polymer bulk melting point. The results proved that these CO₂ molecules accelerated the crystallization process of the polymer on the basis of ex situ grazing incidence X-ray diffraction measurements after drying the films via rapid depressurization to atmospheric pressure: both the out-of-plane lamellar ordering of the backbone chains and the intraplane π-π stacking of the side chains were significantly improved, when compared with those in the control P3HT films subjected to conventional thermal annealing (at T = 170 °C). Electrical measurements elucidated that the CO₂-annealed P3HT thin films exhibited enhanced charge carrier mobility along with decreased background charge carrier concentration and trap density compared with those in the thermally annealed counterpart. This is attributed to the CO₂-induced increase in polymer chain mobility that can drive the detrapping of molecular oxygen and healing of conformational defects in the polymer thin film. Given the universality of the excess sorption of CO₂ regardless of the type of polymers, the present findings suggest that CO₂ annealing near the critical point can be useful as a robust processing strategy for improving the structural and electrical characteristics of other semiconducting conjugated polymers and related systems such as polymer:fullerene bulk heterojunction films.

Flattening Process of Polymer Chains Irreversibly Adsorbed on a Solid

We report the structural relaxation process of irreversibly adsorbed polymer chains via thermal annealing that lie flat on a solid ("flattened chains"). Amorphous polystyrene and quartz, which together constitute a weakly attractive system, was used as a model where the local chain conformations of the flattened chains were investigated by sum frequency generation spectroscopy (SFG). Two different film preparation processes (i.e., spin coating and dip coating methods) were utilized to create different initial chain conformations. The spin-coated and dip-coated PS thin films were annealed at a temperature far above the bulk glass transition temperature to reach the "quasiequilibrium" state and subsequently rinsed with chloroform to uncover the buried flattened chains. The SFG results revealed that the backbone chains (constituted of CH and CH₂ groups) of the flattened PS chains preferentially orient to the weakly interactive substrate surface via thermal annealing regardless of the initial chain conformations, while the orientation of the phenyl rings becomes randomized. We postulate that increasing the number of surface-segmental contacts (i.e., enthalpic gain) is the driving force for the flattening process of the polymer chains, even onto a weakly interactive solid to overcome the conformational entropy loss in the total free energy.

On dewetting of thin films due to crystallization (crystallization dewetting)

Drying and crystallization of a thin liquid film of an ionic or a similar solution can cause dewetting in the resulting thin solid film. This paper aims at investigating this type of dewetting, herein termed "crystallization dewetting", using PbI2 dissolved in organic solvents as the model solution. PbI2 solid films are usually used in X-ray detection and lead halide perovskite solar cells. In this work, PbI2 films are fabricated using spin coating and the effect of major parameters influencing the crystallization dewetting, including the type of the solvent, solution concentration, drying temperature, spin speed, as well as imposed vibration on the substrate are studied on dewetting, surface profile and coverage, using confocal scanning laser microscopy. Simplified hydrodynamic governing equations of crystallization in thin films are presented and using a mathematical representation of the process, it is phenomenologically demonstrated that crystallization dewetting occurs due to the absorption and consumption of the solution surrounding a growing crystal. Among the results, it is found that a low spin speed (high thickness), a high solution concentration and a low drying temperature promote crystal growth, and therefore crystallization dewetting. It is also shown that imposed vibration on the substrate can affect the crystal size and crystallization dewetting.

Nanoscale adsorbed structures as a robust approach for tailoring polymer film stability

The stability or wettability of thin polymer films on solids is of vital interest in traditional technologies as well as in new emerging nanotechnologies. We report here that nanoscale structures of polymer chains adsorbed onto a solid surface play a crucial role in the thermal stability of the film. In this study, polystyrene (PS) spin-cast films (20 nm in thickness) with eight different molecular weights prepared on silicon (Si) substrates were used as a model. When low molecular weight (Mw≤ 50 kDa) PS films were subjected to thermal annealing at temperatures far above the bulk glass transition temperature, dewetting occurred promptly, while high molecular weight (Mw≥ 123 kDa) PS films were stable for at least 6 weeks at 150 °C. We reveal a strong correlation between the film stability and the two different interfacial structures of the adsorbed polymer chains: their opposing wettability against chemically identical free polymer chains results in a wetting-dewetting transition at the adsorbed polymer-free polymer interface. This is a unique aspect of the stability of polymer thin films and may be generalizable to other polymer systems regardless of the magnitude of solid-polymer attractive interactions.

Are polymers glassier upon confinement?

Glass forming systems are characterized by a stability against crystallization upon heating and by the easiness with which their liquid phase can be transformed into a solid lacking of long-range order upon cooling (glass forming ability). Here, we report the thickness dependence of the thermal phase transition temperatures of poly(l-lactide acid) thin films supported onto solid substrates. The determination of the glass transition, cold crystallization and melting temperatures down to a thickness of 6 nm, permitted us to build up parameters describing glass stability and glass forming ability. We observed a strong influence of the film thickness on the latter, while the former is not affected by 1D confinement. Further experiments permitted us to highlight key structural morphology features giving insights to our ellipsometric results via a physical picture based on the changes in the free volume content in proximity of the supporting interfaces.

Controlled Co-Assembly of Nanoparticles and Polymer into Ultralong and Continuous One-Dimensional Nanochains

We report a robust one-dimensional (1D) nanoparticle-assembly strategy that uses the self-assembly of nanoparticles with ligand and thermal controls, polyethylene glycol (PEG) with thiol and carboxyl groups, and nanoparticle oligomer and polymer codewetting process to form ultralong and continuous 1D nanochains. The 1D nanochains were assembled with closely packed 1D nanoparticle oligomer building blocks, elongated and buttressed by dynamic 1D PEG templates formed on a hydrophobic surface via anisotropic spinodal dewetting. Using this strategy, nanoparticle-packed 1D nanochains (∼1 nm interparticle spacing) were fabricated with ∼60 nm-width and a few to >10 μm-length (nearly 20 μm in some cases) from 20 nm gold nanoparticles. Our findings offer insights and open revenues for particle assembly processes and, as given by 'universality in colloid aggregation', should be readily applicable to various nanoparticles.