Wrinkling-to-delamination transition in thin polymer films on compliant substrates

Coexistence and Coevolution of Wrinkle and Ridge Patterns in the Film-Substrate System by Uniaxial Compression

Homogeneous wrinkles and localized patterns are ubiquitous in nature and are useful for a wide range of practical applications. Although various strain-driven surface instability modes have been extensively investigated in the past decades, understanding the coexistence, coevolution, and interaction of wrinkles and localized patterns is still a great challenge. Here, we report on the formation and evolution of coexisting wrinkle and ridge patterns in metal films deposited on poly(dimethylsiloxane) (PDMS) substrates by uniaxial compression. It is found that the evolving surface patterns show unique features of morphological transition from stages I to III: namely, transition from localized ridges to coexisting wrinkles and ridges, and finally to sinusoidal-like structures, as the compression increases. Based on the compressive strain-driven surface instability theory and finite element numerical simulation, the morphological features, transition behaviors, and underlying mechanisms of such complex patterns are investigated in detail, and the changes of amplitude and wavelength versus the strain are consistent with our experiments. This work could promote a better understanding of the effect of strain localization and the interaction of multiple surface patterns in hard film-soft substrate systems.

Delamination-Assisted Ultrafast Wrinkle Formation in a Freestanding Film

Freestanding films provide a versatile platform for materials engineering thanks to additional structural motifs not found in films with a substrate. A ubiquitous example is wrinkles, yet little is known about how they can develop over as fast as a few picoseconds due to a lack of experimental probes to visualize their dynamics in real time on the nanoscopic scale. Here, we use time-resolved electron diffraction to directly observe light-activated wrinkling formation in freestanding La2/3Ca1/3MnO3 films. Via a "lock-in" analysis of oscillations in the diffraction peak position, intensity, and width, we quantitatively reconstructed how wrinkles develop on the time scale of lattice vibration. Contrary to the common assumption of fixed boundary conditions, we found that wrinkle development is associated with ultrafast delamination at the film boundaries. Our work provides a generic protocol to quantify wrinkling dynamics in freestanding films and highlights the importance of the film-substrate interaction in determining the properties of freestanding structures.

High-performance flexible strain sensors based on silver film wrinkles modulated by liquid PDMS substrates

Flexible strain sensors based on controllable surface microstructures in film-substrate systems can be extensively applied in high-tech fields such as human-machine interfaces, electronic skins, and soft robots. However, the rigid functional films are susceptible to structural destruction and interfacial failure under large strains or high loading speeds, limiting the stability and durability of the sensors. Here we report on a facile technique to prepare high-performance flexible strain sensors based on controllable wrinkles by depositing silver films on liquid polydimethylsiloxane (PDMS) substrates. The silver atoms can penetrate into the surface of liquid PDMS to form an interlocking layer during deposition, enhancing the interfacial adhesion greatly. After deposition, the liquid PDMS is spontaneously solidified to stabilize the film microstructures. The surface patterns are well modulated by changing film thickness, prepolymer-to-crosslinker ratio of liquid PDMS, and strain value. The flexible strain sensors based on the silver film/liquid PDMS system show high sensitivity (above 4000), wide sensing range (∼80%), quick response speed (∼80 ms), and good stability (above 6000 cycles), and have a broad application prospect in the fields of health monitoring and motion tracking.

A Solvent-Free, Thermally Curable Low-Temperature Organic Planarization Layer for Thin Film Encapsulation

Thin film encapsulation (TFE) is an essential component to ensure reliable operation of environmentally susceptible organic light-emitting diode-based display. In order to integrate defect-free TFE on display with complex surface structures, additional planarization layer is imperative to planarize the surface topography. The thickness of conventional planarization layer is as high as tens of µm, but the thickness must be reduced substantially to minimize the light leakage in smaller devices such as micro light-emitting diodes. In this study, a thin-less than 2 µm-planarization is achieved via solvent-free process, initiated chemical vapor deposition (iCVD). By adapting copolymer from two soft, but curable monomers, glycidyl acrylate (GA) and 2-(dimethylamino)ethyl methacrylate, excellent planarization performance is achieved on various nano-grating patterns. With only 1.5 µm-thick iCVD planarization layer, a 600 nm-deep trench polyurethane acrylate pattern is flattened completely. The TFE fabricated on planarized pattern exhibits excellent barrier property as fabricated on flat glass substrate, which strongly suggests that iCVD planarization layer can serve as a promising planarization layer to fabricate TFE on various types of complicated device surfaces.

Controllable Buckle Delaminations in Polymer-Supported Periodic Gradient Films by Mechanical Compression

Surface instabilities including wrinkles and buckle-delaminations are widespread in nature and can be found in a wide range of practical applications. Compared with the homogeneous wrinkle mode, the buckle-delaminations are spontaneously stress-localized, and their initiation positions and geometrical parameters are hardly precisely controlled by a simple method. Here, we report on the controllable buckle-delaminations in periodic thickness-gradient metal films on polydimethylsiloxane (PDMS) substrates by uniaxial mechanical compression. It is found that a periodic thickness-gradient film is spontaneously formed by masking a copper grid during deposition. The released mechanical strain tends to concentrate in thinner film regions, resulting in the restricted growth of buckle-delaminations. The geometrical features, evolutional behaviors, and underlying physical mechanisms of such buckle-delaminations are analyzed and discussed in detail based on the buckling model and finite element simulations. This work would provide a better understanding of the restricted buckle-delaminations in heterogeneous film-substrate systems and controllable fabrication of ordered structural arrays by copper grid masking and mechanical loading.

Developing the Nondevelopable: Creating Curved-Surface Electronics from Nonstretchable Devices

The incorporation of electronics onto curved surfaces promises to bring new levels of intelligence to the ergonomic, aesthetic, aerodynamic, and optical surfaces that are ever-present in our lives. However, since many of these surfaces have 2D (i.e., nondevelopable) curvature, they cannot be formed from the deformation of a flat, nonstretchable sheet. This means that curved electronics cannot capitalize on the rapid technological advances taking place in the field of ultrathin electronics, since ultrathin devices, though ultraflexible, are not stretchable. In this work, a shrink-based paradigm is presented to apply such thin-film electronics to nondevelopable surfaces, expanding the capabilities of current nondevelopable electronics, and linking future developments in thin-film technology to similar developments in curved devices. The wrinkling of parylene-based devices and the effects of shrinkage on common electrical components are examined, culminating in shrinkable touch sensors and organic photovoltaics, laminated to various nondevelopable surfaces without loss of performance.

Hierarchical Self-Assembly of Metal-Ion-Modulated Chitosan Tubules

Soft materials such as gels or biological tissues can develop via self-assembly under chemo-mechanical forces. Here, we report the instantaneous formation of soft tubular structures with a two-level hierarchy by injecting a mixture of inorganic salt and chitosan (CS) solution from below into a reactor filled with alkaline solution. Folding and wrinkling instabilities occur on the originally smooth surface controlled by the salt composition and concentration. Liesegang-like precipitation patterns develop on the outer surface on a μm length scale in the presence of calcium chloride, while the precipitate particles are distributed evenly in the bulk as corroborated by X-ray μ-CT. On the other hand, barium hydroxide precipitates out only in the thin outer layer of the CS tubule when barium chloride is introduced into the CS solution. Independent of the concentration of the weakly interacting salt, an electric potential gradient across the CS membrane develops, which vanishes when the pH difference between the two sides of the membrane diminishes.

Surface buckling delamination patterns of film on soft spherical substrates

This study aims to provide a fundamental understanding of the morphological transition of film buckling-delamination in an elastomeric bilayer spherical shell system. We developed an experimental system in which surface delamination buckles emerge because of biaxial compression of the elastomeric bilayer spherical shell driven by an air-pressured (pneumatic) device. A flat PDMS plate was first isotropically expanded and shaped into a hemisphere by air pressure. Subsequently, the hemisphere substrate was covered with a thin PDMS film. By releasing the air pressure, the substrate contracts and the outer film surface were subjected to biaxial compression; this resulted in various surface patterns of film buckling-delamination. It was found that the surface morphology transitions from initial delamination sites and that the buckles propagate on the entire surface of the sphere. This pattern formation is dependent on the surface strain distribution, i.e., radial strain and circumferential strain. In order to control the surface pattern, we systematically changed the material and system parameters such as film thickness, Young's modulus, and interfacial adhesion condition. In addition, finite element (FEM) computation was carried out to simulate the surface pattern and to elucidate the mechanism of buckling-delamination morphological transition.

The emergence of local wrinkling or global buckling in thin freestanding bilayer films

Periodic wrinkling of a rigid capping layer on a deformable substrate provides a useful method for templating surface topography for a variety of novel applications. Many experiments have studied wrinkle formation during the compression of a rigid film on a relatively soft pre-strained elastic substrate, and most have focused on the regime where the substrate thickness can be considered semi-infinite relative to that of the film. As the relative thickness of the substrate is decreased, the bending stiffness of the film dominates, causing the bilayer to transition to either local wrinkling or a global buckling instability. In this work optical microscopy was used to study the critical parameters that determine the emergence of local wrinkling or global buckling of freestanding bilayer films consisting of a thin rigid polymer capping layer on a pre-strained elastomeric substrate. The thickness ratio of the film and substrate as well as the pre-strain were controlled and used to create a buckling phase diagram which describes the behaviour of the system as the ratio of the thickness of the substrate is decreased. A simple force balance model was developed to understand the thickness and strain dependences of the wrinkling and buckling modes, with excellent quantitative agreement being obtained with experiments using only independently measured material parameters.

Spontaneously Micropatterned Silk/Gelatin Scaffolds with Topographical, Biological, and Electrical Stimuli for Neuronal Regulation

Effective integration of stimulation and direction in bionic scaffolds by materials and microstructure design has been the focus in the advancement of nerve regeneration. Hydrogels are the most promising biomimicked materials used in developing nerve grafts, but the highly hydrated networks limit the fabrication of hydrogel materials into complex biomedical devices. Herein, facile lithography-free and spontaneously micropatterned techniques were used to fabricate a smart protein hydrogel-based scaffold, which carried topographical, electrical, and chemical induction for neural regulation. The synthesized tissue-mimicked silk-gelatin (SG)/polylactic acid bilayer system can self-form three-dimensional ordered corrugation micropatterns with well-defined dimensions (wavelength, λ) based on the stress-induced topography. Through magnetically and topographically guided deposition of the synthesized nerve growth factor-incorporated Fe₃O₄-graphene nanoparticles (GFPNs), a biologically and electrically conductive cell passage with one-dimensional directionality was constructed to allow for a controllable constrained geometric effect on neuronal adhesion, differentiation, and neurite orientation. Particularly, the SG with corrugation patterns of λ ≈ 30 μm resulted in the optimal cell adhesion and differentiation in response to the pattern guidance. Furthermore, the additional electrical stimulation applied on GFPN-deposited SG resulted in a 1.5-fold increase in the neurite elongation by day 7, finally leading to the neuronal connection by day 21. Such a hydrogel device with synergistic effects of physical and chemical enhancement on neuronal activity provides an expectable opportunity in the development of next-generation nerve conduits.

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.

Spontaneous formation of two-dimensional wrinkles in poly(urethane-isocyanurate) rigid foam boards

Processing low density poly(urethane-isocyanurate) rigid foam boards still remains challenging, especially for high thickness panels. In particular, subsequent shrinkage of the foam panel during cooling and cross-linking of the matrix creates in-plane compressive stresses in the facing that can be relieved by buckling with a relatively uniform wavelength of a few millimeters. An extensive study in the scientific literature documents the variety of wrinkling morphologies obtained when a thin film bonded on top of a soft substrate is compressed, and we proposed to apply this model in order to explain experimental observations of wrinkling in the case of a flexible facing bonded to a poly(urethane-isocyanurate) rigid foam. The wavelength, amplitude, and pattern of the waves were found to give information about the mismatch in Young’s modulus as well as the level of compressive strain in the foam panel at the moment of wrinkling formation. A shore durometer (type 00) was systematically used to quickly probe the mechanical properties of the foam surface at various locations along the width of the insulation panel (after removal of the facing) and was found to be a valuable tool to explain the location of surface wrinkling and its evolution with time. Variations in mechanical properties of the foam surface were explained in terms of differences in cell orientation near the surface.

Harnessing the interface mechanics of hard films and soft substrates for 3D assembly by controlled buckling

Techniques for forming sophisticated, 3D mesostructures in advanced, functional materials are of rapidly growing interest, owing to their potential uses across a broad range of fundamental and applied areas of application. Recently developed approaches to 3D assembly that rely on controlled buckling mechanics serve as versatile routes to 3D mesostructures in a diverse range of high-quality materials and length scales of relevance for 3D microsystems with unusual function and/or enhanced performance. Nonlinear buckling and delamination behaviors in materials that combine both weak and strong interfaces are foundational to the assembly process, but they can be difficult to control, especially for complex geometries. This paper presents theoretical and experimental studies of the fundamental aspects of adhesion and delamination in this context. By quantifying the effects of various essential parameters on these processes, we establish general design diagrams for different material systems, taking into account 4 dominant delamination states (wrinkling, partial delamination of the weak interface, full delamination of the weak interface, and partial delamination of the strong interface). These diagrams provide guidelines for the selection of engineering parameters that avoid interface-related failure, as demonstrated by a series of examples in 3D helical mesostructures and mesostructures that are reconfigurable based on the control of loading-path trajectories. Three-dimensional micromechanical resonators with frequencies that can be selected between 2 distinct values serve as demonstrative examples.

Deformation of Single Crystals, Polycrystalline Materials, and Thin Films: A Review

With the rapid development of nano-preparation processes, nanocrystalline materials have been widely developed in the fields of mechanics, electricity, optics, and thermal physics. Compared to the case of coarse-grained or amorphous materials, plastic deformation in nanomaterials is limited by the reduction in feature size, so that they generally have high strength, but the toughness is relatively high. The "reciprocal relationship" between the strength and toughness of nanomaterials limits the large-scale application and development of nanomaterials. Therefore, the maintenance of high toughness while improving the strength of nanomaterials is an urgent problem to be solved. So far, although the relevant mechanism affecting the deformation of nanocrystalline materials has made a big breakthrough, it is still not very clear. Therefore, this paper introduces the basic deformation type, mechanism, and model of single crystals, polycrystalline materials, and thin films, and aims to provide literature support for future research.

Hierarchical wrinkles and oscillatory cracks in metal films deposited on liquid stripes

Fascinating crack and wrinkle patterns driven by stresses are ubiquitous in natural and artificial systems. It is of great interest to control the morphologies of stress-driven patterns by using facile techniques. Here we report on the spontaneous formation of hierarchical wrinkles and oscillatory cracks in metal films deposited on liquid (or soft polymer) stripes. It is found that the metal film is under a tensile stress during deposition owing to the thermal expansion of the liquid substrate. As the film thickness is beyond a critical value, oscillatory cracks with sawtoothlike shapes form on the liquid stripes. The ratio of crack oscillation period to amplitude is independent of the stripe width and film material, which can be well explained by the "brittle adhesive joints" model. After deposition, the metal film is under a compressive stress, which is relieved by formation of various wrinkle patterns. Hierarchical wrinkles with changing wavelengths form near the stripe edge while labyrinth or wavy wrinkles form at the center. Energy analysis was adopted to explain the formation and evolution of the wrinkle patterns. This study could promote better understanding of the formations of crack and wrinkle patterns in constrained film structures and controllable fabrication of stress-driven patterns by prefabricating liquid (or soft polymer) interlayer arrays.

Filiform corrosion as a pressure-driven delamination process

Filiform corrosion produces long and narrow trails on various coated metals through the detachment of the coating layer from the substrate. In this work, we present a combined experimental and theoretical analysis of this process with the aim to describe quantitatively the shape of the cross-section, perpendicular to the direction of propagation, of the filaments produced. For this purpose, we introduce a delamination model of filiform corrosion dynamics and show its compatibility with experimental data where the coating thickness has been varied systematically.

Impact of Substrate Characteristics on Stretchable Polymer Semiconductor Behavior

Stretchable conductive polymer films are required to survive not only large tensile strain but also stay functional after the reduction in applied strain. In the deformation process, the elastomer substrate that is typically employed plays a critical role in response to the polymer film. In this study, we examine the role of a polydimethylsiloxane (PDMS) elastomer substrate on the ability to achieve stretchable PDPP-4T films. In particular, we consider the adhesion and near-surface modulus of the PDMS tuned through UV/ozone (UVO) treatment on the competition between film wrinkling and plastic deformation. We also consider the role of PDMS tension on the stability of films under cyclic strain. We find that increasing the near-surface modulus of the PDMS and maintaining the PDMS in tension throughout the cyclic strain process promote plastic deformation over film wrinkling. In addition, the UVO treatment increases film adhesion to the PDMS resulting in a significantly reduced film folding and delamination. For a 20 min UVO-treated PDMS, we show that a PDPP-4T film root-mean-square roughness is consistently below 3 nm for up to 100 strain cycles with a strain range of 40%. In addition, although the film is plastically deforming, the microstructural order is largely stable as probed by grazing incidence X-ray scattering and UV-visible spectroscopy. These results highlight the importance of neighboring elastomer characteristics on the ability to achieve stretchable polymer semiconductors.

Harnessing fold-to-wrinkle transition and hierarchical wrinkling on soft material surfaces by regulating substrate stiffness and sputtering flux

Strain-induced complex surface patterns such as wrinkles, folds and hierarchical structures are quite useful in a wide range of practical applications. Although various surface patterns have been extensively investigated, precisely controlling the coexistence and transition of multimodal structures is still a challenge. In this work, we report on a facile technique to harness fold-to-wrinkle transition and hierarchical wrinkling on soft material surfaces by regulating substrate stiffness and sputtering flux. It is found that as the substrate stiffness or sputtering flux increases, the surface patterns successively evolve from networked folds to isolated folds (coexistence of folds and wrinkles) and finally to labyrinth-like wrinkles. For larger sputtering flux, two distinct wrinkling patterns (i.e., G1 wrinkling due to surface instability during sputtering and G2 wrinkling due to thermal compression after deposition) can coexist on the sample surfaces, resulting in the spontaneous formation of hierarchical wrinkles. The report in this work could promote better understanding of the sputtering effect on the spontaneous pattern formation for soft materials and controllable fabrication of multiple complex patterns by simply regulating substrate stiffness and sputtering flux.

Delamination of a thin sheet from a soft adhesive Winkler substrate

A uniaxially compressed thin elastic sheet that is resting on a soft adhesive substrate can form a blister, which is a small delaminated region, if the adhesion energy is sufficiently weak. To analyze the equilibrium behavior of this system, we model the substrate as a Winkler or fluid foundation. We develop a complete set of equations for the profile of the sheet at different applied pressures. We show that at the edge of delamination, the height of the sheet is equal to sqrt[2]ℓ_{c}, where ℓ_{c} is the capillary length. We then derive an approximate solution to these equations and utilize them for two applications. First, we determine the phase diagram of the system by analyzing possible transitions from the flat and wrinkled to delaminated states of the sheet. Second, we show that our solution for a blister on a soft foundation converges to the known solution for a blister on a rigid substrate that assumed a discontinuous bending moment at the blister edges. This continuous convergence into a discontinuous state marks the formation of a boundary layer around the point of delamination. The width of this layer relative to the extent length of the blister, ℓ, scales as w/ℓ∼(ℓ_{c}/ℓ_{ec})^{1/2}, where ℓ_{ec} is the elastocapillary length scale. Notably, our findings can provide guidelines for utilizing compression to remove thin biofilms from surfaces and thereby prevent the fouling of the system.

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.