Swelling-induced morphology in ultrathin supported films of poly(d,l-lactide)

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.

Swelling induced debonding of thin hydrogel films grafted on silicon substrates

We report on the delamination of thin (≈μm) hydrogel films grafted to silicon substrates under the action of swelling stresses. Poly(dimetylacrylamide) (PDMA) films are synthesized by simultaneously cross-linking and grafting preformed polymer chains onto the silicon substrate using a thiol-ene reaction. The grafting density at the film/substrate interface is tuned by varying the surface density of reactive thiol-silane groups on the silicon substrate. Delamination of the films from well controlled line defects with low adhesion is monitored under a humid water vapor flow ensuring full saturation of the polymer network. A propagating delamination of the film is observed under the action of differential swelling stresses at the debonding front. A threshold thickness for the onset of this delamination is evidenced which is increasing with grafting density while the debonding velocity is also observed to decrease with an increase in grafting density. These observations are discussed within the framework of a nonlinear fracture mechanics model which assumes that the driving force for crack propagation is the difference between the swelling state of the bonded and delaminated parts of the film. Using this model, the threshold energy for crack initiation was determined from the measured threshold thickness and discussed in relation to the surface density of reactive thiol groups on the substrate.

Swelling-Activated, Soft Mechanochemistry in Polymer Materials

Swelling in polymer materials is a ubiquitous phenomenon. At a molecular level, swelling is dictated by solvent-polymer interactions, and has been thoroughly studied both theoretically and experimentally. Favorable solvent-polymer interactions result in the solvation of polymer chains. For polymers in confined geometries, such as those that are tethered to surfaces, or for polymer networks, solvation can lead to swelling-induced tensions. These tensions act on polymer chains and can lead to stretching, bending, or deformation of the material both at the micro- and macroscopic scale. This Invited Feature Article sheds light on such swelling-induced mechanochemical phenomena in polymer materials across dimensions, and discusses approaches to visualize and characterize these effects.

Processive Pathways to Metastability in Block Copolymer Thin Films

Block copolymers (BCPs) self-assemble into intricate nanostructures that enhance a multitude of advanced applications in semiconductor processing, membrane science, nanopatterned coatings, nanocomposites, and battery research. Kinetics and thermodynamics of self-assembly are crucial considerations in controlling the nanostructure of BCP thin films. The equilibrium structure is governed by a molecular architecture and the chemistry of its repeat units. An enormous library of materials has been synthesized and they naturally produce a rich equilibrium phase diagram. Non-equilibrium phases could potentially broaden the structural diversity of BCPs and relax the synthetic burden of creating new molecules. Furthermore, the reliance on synthesis could be complicated by the scalability and the materials compatibility. Non-equilibrium phases in BCPs, however, are less explored, likely due to the challenges in stabilizing the metastable structures. Over the past few decades, a variety of processing techniques were introduced that influence the phase transformation of BCPs to achieve a wide range of morphologies. Nonetheless, there is a knowledge gap on how different processive pathways can induce and control the non-equilibrium phases in BCP thin films. In this review, we focus on different solvent-induced and thermally induced processive pathways, and their potential to control the non-equilibrium phases with regards to their unique aspects and advantages. Furthermore, we elucidate the limitations of these pathways and discuss the potential avenues for future investigations.

Film Instability Induced by Swelling and Drying

Poly(2-vinyl pyridine), P2VP, films display a surface pattern of craters in a dried state after being immersed in aqueous solutions containing HAuCl₄ and its mixtures with low contents of K₂CO₃. The morphologies of craters indicate that the formation of craters involves three stages through film blistering and drying: (i) the permeability of water and solutes to swell P2VP films, (ii) partial wetting of liquid droplets near the substrate interface in the presence of the P2VP film, and (iii) evaporation-driven flows. The three stages produce the swelling pressure, Laplace pressure, and interplays among capillary flows, Marangoni flows, and pinning effects, respectively, by which craters of different dimensions and morphologies are obtained. The first stage softens the P2VP films and produces swelling pressure. This stage relies on interactions between AuCl₄^- ions, water, and protonated P2VP chains. The second stage produces liquid droplets inside the film and near the substrate interface. The surface tensions of those liquid droplets at contact lines deform swollen P2VP films. Changing film thicknesses or substrate types alters craters' lateral dimension and depth. The results indicate that film thicknesses and substrate interface energies influence the shape and dimension of liquid droplets on the substrate interface. The third stage determines morphologies of craters through interplays among capillary flows, Marangoni flows, and pinning/depinning events.

Defining Swelling Kinetics in Block Copolymer Thin Films: The Critical Role of Temperature and Vapour Pressure Ramp

We studied the kinetics of swelling in high-χ lamellar-forming poly(styrene)-block- poly(lactic acid) (PS-b-PLA) block copolymer (BCP) by varying the heating rate and monitoring the solvent vapour pressure and the substrate temperature in situ during solvo-thermal vapour annealing (STVA) in an oven, and analysing the resulting morphology. Our results demonstrate that there is not only a solvent vapour pressure threshold (120 kPa), but also that the rate of reaching this pressure threshold has a significant effect on the microphase separation and the resulting morphologies. To study the heating rate effect, identical films were annealed in a tetrahydrofuran (THF) vapour environment under three different ramp regimes, low (rT<1 °C/min), medium (24 °C/min), for 60, 90 and 120 min, respectively, while the solvent vapour pressure and the substrate temperature were measured in real time. The translational order improved significantly with increasing the heating rate. The solvent mass uptake calculated for the different ramp regimes during annealing is linearly proportional to time, indicating that the swelling kinetics followed Case II diffusion. Two stages of the swelling behaviour were observed: (i) diffusion at the initial stages of swelling and (ii) stress relaxation, controlled at later stages. Films with a faster rate of increase in vapour pressure (rP>2 kPa/min) reached the pressure threshold value at an early stage of the swelling and attained a good phase separation. According to our results, highly ordered patterns are only obtained when the volume fraction of the solvent exceeds the polymer volume fraction, i.e., (φs≥φp), during the swelling process, and below this threshold value (φs=0.5), the films did not obtain a good structural order, even at longer annealing times.

Water-induced blister formation in a thin film polymer

A failure mechanism of thin film polymers immersed in water is presented: the formation of blisters. The growth of blisters is counterintuitive as the substrates were noncorroding and the polymer does not swell in water. We identify osmosis as the driving force behind the blister formation. The dynamics of the blister formation is studied experimentally as well as theoretically, and a quantitative model describing the blister growth is developed, which accurately describes the temporal evolution of the blisters.

Solvent-assisted patterning of polyelectrolyte multilayers and selective deposition of virus assemblies

We introduce a simple method to pattern electrostatic assemblies of viruses onto a polyelectrolyte multilayer. The increased mobility of weak polycation chains in the multilayer above a given thickness ensures the surface mobility of viruses required for spontaneous ordering of densely packed viruses atop polymeric patterns. To pattern the polyelectrolyte multilayer film, we employ a nonconventional patterning method known as solvent-assisted capillary molding for the first time on multilayer films, and demonstrate micrometer-scaled dense patterns of viruses, where the accessible feature size can be correlated by the length scale of virus and swelling property of underlying patterned polyelectrolyte multilayer. We further examine the ability to modify the top surfaces of these assemblies with biological ligands, which extends the applicability of patterned viruses to biological detection purposes. We expect that the present method described here can be generally applied to the patterning of other polyelectrolyte multilayers and combined with the ordered assembly of anisotropic nanomaterials such as polymeric nanotubes or inorganic nanowires for a broad range of applications.

Wetting-induced formation of quasiperiodical wrinkling patterns in alginate-based coatings

We present the results of systematic model experimental investigations on wrinkling instabilities which develop on alginate-based coatings when they are wetted by swelling electrolyte drops. The wrinkles first appear randomly within the wet spot, before they selectively protrude out around the periphery in a quasiperiodical wrinkle pattern. We discuss the critical parameters that drive the emergence (ionic strength and swelling rate) and spatial feature (size and periodicity) of these swelling-induced structures on such complex functional coatings. Beyond their relative aesthetics and their fundamental interest related to morphological instabilities, these reconstruction structures which are invisible to the naked eye can develop in a variety of technological processes (inkjet printing for instance), affecting irreversibly the quality of the products.

The influence of the metal grain size on polymer/metal bilayer wrinkling

We report on the observation of wrinkling processes in very thin polymer/metal bilayer structures prepared spin casting and sputter preparation, respectively. The study utilizes a viscoelastic conjugated polymer typically used in optoelectronic devices with a film thickness of 100 nm. After careful thermal annealing of the polymer films thin gold layers were deposited ranging from 20 nm to 45 nm which induces a slow wrinkling process without the influence of an external stimulus. The resulting wrinkling patterns were characterized by means of atomic force microscopy and compared to calculations based on a novel model for such bilayer systems recently proposed in literature. In particular, the experiments could confirm experimentally the predicted decoupling of the characteristic wrinkling wavelength and amplitude. Moreover, it is found that the grain size of the metal layer plays an essential role in the final appearance of wrinkling patterns for the lower range of metal thickness.

Highly oriented tunable wrinkling in polymer bilayer films confined with a soft mold induced by water vapor

The authors report the formation of highly oriented wrinkling on the surface of the bilayer [polystyrene (PS)/poly(vinyl pyrrolidone) (PVP)] confined by a polydimethylsiloxane (PDMS) mold in a water vapor environment. When PVP is subjected to water vapor, the polymer loses its mechanical rigidity and changes to a viscous state, which leads to a dramatic change in Young's modulus. This change generates the amount of strain in the bilayer to induce the wrinkling. With a shape-controlled mold, they can get the ordered wrinkles perfectly perpendicular or leaned 45 degrees to the channel orientation of the mold because the orientation of the resultant force changes with the process of water diffusion which drives the surface to form the wrinkling. Additionally, they can get much smaller wrinkles than the stripe spacing of PDMS mold about one order. The wrinkle period changes with the power index of about 0.5 for various values of the multiplication product of the film thicknesses of the two layers, namely, lambda approximately (h(PS)h(PVP))(1/2).

Mechanically driven wrinkling instability in thin film polymer bilayers

Optical microscopy and atomic force microscopy were used to study a mechanically induced wrinkling instability in thin film poly(caprolactone)/polystyrene and poly(ethylene oxide)/poly(methyl methacrylate) bilayers. The instability in these samples was shown to be driven by changes in the interfacial area between a semicrystalline polymer underlayer and a glassy polymer capping layer that occurred when the underlayers were melted. The wrinkling instability resulted in the formation of one-dimensional corrugations at the surface of the bilayer samples that had a well-defined wavelength on the micrometer length scale. A linear stability analysis was used to derive a simple model of the wrinkling process in these samples. This model considered the flow and deformation of material in the molten underlayer as well as the balance of stresses in the glassy polymer capping layers. Rheological data were also obtained from polymers similar to those used to form the bilayers. These data were used to show that the model is capable of quantitatively predicting the capping layer and underlayer thickness dependencies of the characteristic wrinkling wavelengths, if the mechanical properties of the two layers and the strain in the capping layers can be determined.

Tuneable micro- and nano-periodic structures in a free-standing flexible urethane/urea elastomer film

We have studied the control and manipulation of tuneable equilibrium structures in a free-standing urethane/urea elastomer film by means of atomic force microscopy, small-angle light scattering and polarising optical microscopy. The urethane/urea elastomer was prepared by reacting a poly(propyleneoxide)-based triisocyanate-terminated prepolymer (PU) with poly(butadienediol) (PBDO), with a weight ratio of 60% PU/40% PBDO. An elastomer film was shear-cast onto a glass plate and allowed to cure, first in an oven, then in air. Latent micro- and nano-periodic patterns are induced by ultra-violet (UV) irradiation of the film and can be "developed" by applying a plane uniaxial stress or by immersing the elastomer in an appropriate solvent and then drying it. For this elastomer we describe six pattern states, how they are related and how they can be manipulated. The morphological features of the UV-exposed film surface can be tuned, reproducibly and reversibly, by switching the direction of the applied mechanical field. Elastomers extracted in toluene exhibit different surface patterns depending upon the state in which they were developed. Stress-strain data collected for the films before and after UV irradiation reveal anisotropy induced by the shear-casting conditions and enhanced by the mechanical field. We have interpreted our results by assuming the film to consist of a thin, stiff surface layer ("skin") lying atop a thicker, softer substrate ("bulk"). The skin's higher stiffness is hypothesised to be due to the more extensive cross-linking of chains located near the surface by the UV radiation. Patterns would thus arise as a competition between the effects of bending the skin and stretching/compressing the bulk, as in the work of Cerda and Mahadevan (Phys. Rev. Lett. 90, 074302 (2003)). We present some preliminary results of a simulation of this model using the Finite Element package ABAQUS.

Buckling of swelling gels

The patterns arising from the differential swelling of gels are investigated experimentally and theoretically as a model for the differential growth of living tissues. Two geometries are considered: a thin strip of soft gel clamped to a stiff gel, and a thin corona of soft gel clamped to a disk of stiff gel. When the structure is immersed in water, the soft gel swells and bends out of plane leading to a wavy periodic pattern whose wavelength is measured. The linear stability of the flat state is studied in the framework of linear elasticity using the equations for thin plates. The flat state is shown to become unstable to oscillations above a critical swelling rate and the computed wavelengths are in quantitative agreement with the experiment.

Spinodal wrinkling in thin-film poly(ethylene oxide)/polystyrene bilayers

Optical microscopy and atomic force microscopy were used to study a novel roughness-induced wrinkling instability in thin-film bilayers of poly(ethylene oxide) (PEO) and polystyrene (PS). The observed wrinkling morphology is manifested as a periodic undulation at the surface of the samples and occurs when the bilayers are heated above the melting temperature of the semi crystalline PEO (T(m) = 63 Celsius) layer. During the wrinkling of the glassy PS capping layers the system selects a characteristic wavelength that has the largest amplitude growth rate. This initial wavelength is shown to increase monotonically with increasing thickness of the PEO layer. We also show that for a given PEO film thickness, the wavelength can be varied independently by changing the thickness of the PS capping layers. A model based upon a simple linear stability analysis was developed to analyse the data collected for the PS and PEO film thickness dependences of the fastest growing wavelength in the system. The predictions of this theory are that the strain induced in the PS layer caused by changes in the area of the PEO/PS interface during the melting of the PEO are sufficient to drive the wrinkling instability. A consideration of the mechanical response of the PEO and PS layers to the deformations caused by wrinkling then allows us to use this simple theory to predict the fastest growing wavelength in the system.

Morphological dynamics of swelling-induced surface patterns in metal-capped polymer bilayer

We report on the morphological dynamics of surface patterns induced by swelling of metal-capped polymer bilayer on a substrate. When the bilayer is subject to solvent vapor, the strain is generated in the polymer layer that is confined by the substrate and the metal capping layer. An increase in the strain induces the development of the stress in the bilayer to deform the lower polymer layer perpendicularly to the surface of the bilayer. Isotropic surface wave patterns results from the stress relaxation, the wave number of the patterns shows a characteristic temporal dependency on the swelling time, such that km(t) approximately t(-1/8). This temporal evolution accompanied by the morphological dynamics gives smaller value of the growth rate of the characteristic wavelength than that of the case of swelling of gel.

Wrinkling of a sol-gel-derived thin film

We report on the wrinkle formation in a thin film produced by the sol-gel method. Through the relaxation of stress, which results from the removal of the solvent during the drying process, an isotropic wavy pattern is generated in the form of skeletal branches. The patterns have a dominant wavelength satisfying a relationship of three-fourths order of thickness. Densification of the gelated film is enhanced by an increase in the volumetric strain caused by the evaporation of the remaining solvent from the film. The number of skeletal branches and surface roughness increases as the annealing time progresses, without any change in the skeletal wavelength.