Templating of thin films induced by dewetting on patterned surfaces

Wimpled thin films via multiple motions of a bubble decorated with surface-active molecules

HYPOTHESIS

Thin liquid films play a crucial role in various systems and applications. Understanding the mechanisms that regulate their morphology is a scientific challenge with obvious implications for application optimization. Thin liquid films trapped between bubbles and air-liquid interface can show various configurations influenced by their deformation history and system characteristics.

EXPERIMENTS

The morphology of thin liquid films formed in the presence of surface-active molecules is here studied with interferometric techniques. Three different systems with varying interfacial properties are investigated to understand their influence on film morphology. Specific deformation histories are applied to the films to generate complex film structures.

FINDINGS

We achieve the creation of a rather stable wimple by implementing controlled bubble motions against the air-liquid interface. We provide a criterion for wimple formation based on lubrication theory. The long-term stability of the wimple is also investigated, and more complex multi-wimple structures are experimentally produced building upon the achieved wimple stability.

Physicochemical defect guided dewetting of ultrathin films to fabricate nanoscale patterns

Pathways to fabricate self-organized nanostructures have been identified exploiting the instabilities of ultrathin (<100 nm) polystyrene (PS) film on the polydimethylsiloxane (PDMS) substrates loaded with discrete and closely packed gold nanoparticles (AuNPs). The AuNPs were deposited on the PDMS substrates by chemical treatment, and the size and periodicity of the AuNPs were varied before coating the PS films. The study unveils that the physicochemical heterogeneity created by the AuNPs on the PDMS surface could guide the hole-formation, influence the average spacing between the holes formed at the initial dewetting stage, and affects the spacing and periodicity of the droplets formed at the end of the dewetting phase. The size and spacing of the holes and the droplets could be tuned by varying the nanoparticle loading on the PDMS substrate. Interestingly, as compared to the dewetting of PS films on the homogeneous PDMS surfaces, the AuNP guided dewetted patterns show ten-fold miniaturization, leading to the formation of the micro-holes and nanodroplets. The spacing between the droplets could also see a ten-fold reduction resulting in high-density random patterns on the PDMS substrate. Further, the use of a physicochemical substrate with varying density of physicochemical heterogeneities could impose a long-range order to the dewetted patterns to develop a gradient surface. The reported results can be of significance in the fabrication of high-density nanostructures exploiting the self-organized instabilities of thin polymers films.

Polymer dewetting in solvent-non-solvent environment- new insights on dynamics and lithography-free patterning

HYPOTHESIS

We show that one may employ polymer dewetting in solvent-non-solvent environment to obtain lithography-free fabrication of well-defined nano- to micro- scale polymer droplets arrays from pre-patterned polymer films. The polymer droplet pattern may be converted to a series of hybrid organic-inorganic and inorganic well-defined nano-patterns by using sequential infiltration synthesis (SIS). In particular, we scrutinize the physical parameters which govern the dewetting of flat and striped polymer thin films, which is the key to obtaining our objective of lithography-free ordered nano-patterns.

EXPERIMENTS

We immerse polystyrene (PS) and polymethyl methacrylate (PMMA) thin films in water in the presence of chloroform vapors. We study the ensuing polymer dewetting dynamics and the pattern formation of nanospheres by employing in-situ light microscopy and scanning electron microscopy. We then investigate pattern formation by dewetting of polymer stripes, fabricated by directed solvent evaporation, and SIS of AlO_x from vapor phase precursors, trimethyl aluminum (TMA) and H₂O, within the nanosphere patterns.

FINDINGS

We find that solvent- non-solvent environments render film dewetting rates, which are an order of magnitude faster than solvent vapor dewetting, and supports the formation of small solid polymer droplets, down to sub-100 nm droplet size, of large contact angles with the solid substrate. Pre-patterned polymer film stripes support the formation of highly ordered structures of polymer droplets, which are easily transformed to hybrid polymer-AlO_x nanosphere patterns and templated AlO_x nanosphere via SIS.

Lithographically Defined Cross-Linkable Top Coats for Nanomanufacturing with High-χ Block Copolymers

The directed self-assembly (DSA) of block copolymers (BCPs) is a powerful method for the manufacture of high-resolution features. Critical issues remain to be addressed for successful implementation of DSA, such as dewetting and controlled orientation of BCP domains through physicochemical manipulations at the BCP interfaces, and the spatial positioning and registration of the BCP features. Here, we introduce novel top-coat (TC) materials designed to undergo cross-linking reactions triggered by thermal or photoactivation processes. The cross-linked TC layer with adjusted composition induces a mechanical confinement of the BCP layer, suppressing its dewetting while promoting perpendicular orientation of BCP domains. The selection of areas of interest with perpendicular features is performed directly on the patternable TC layer via a lithography step and leverages attractive integration pathways for the generation of locally controlled BCP patterns and nanostructured BCP multilayers.

Tear-film breakup: The role of membrane-associated mucin polymers

Mucin polymers in the tear film protect the corneal surface from pathogens and modulate the tear-film flow characteristics. Recent studies have suggested a relationship between the loss of membrane-associated mucins and premature rupture of the tear film in various eye diseases. This work aims to elucidate the hydrodynamic mechanisms by which loss of membrane-associated mucins causes premature tear-film rupture. We model the bulk of the tear film as a Newtonian fluid in a two-dimensional periodic domain, and the lipid layer at the air-tear interface as insoluble surfactants. Gradual loss of membrane-associated mucins produces growing areas of exposed cornea in direct contact with the tear fluid. We represent the hydrodynamic consequences of this morphological change through two mechanisms: an increased van der Waals attraction due to loss of wettability on the exposed area, and a change of boundary condition from an effective negative slip on the mucin-covered areas to the no-slip condition on exposed cornea. Finite-element computations, with an arbitrary Lagrangian-Eulerian scheme to handle the moving interface, demonstrate a strong effect of the elevated van der Waals attraction on precipitating tear-film breakup. The change in boundary condition on the cornea has a relatively minor role. Using realistic parameters, our heterogeneous mucin model is able to predict quantitatively the shortening of tear-film breakup time observed in diseased eyes.

Formation of High-Density Brush of Liquid Crystalline Polymer Block Associated with Dewetting Process on Amorphous Polymer Film

The understanding of polymer dewetting on solid surfaces is significant in both fundamental polymer physics and practical film technologies. When liquid crystalline (LC) polymers are dewetted, LC ordering is involved in the dewetting process. Here, we report on the characteristic dewetting processes of a diblock copolymer composed of a cyanobiphenyl side chain liquid crystalline polymer (SCLCP) block connected with polystyrene (PS) taking place on a PS base film. Thin films of the block copolymer were prepared by the water-floating method onto the PS film, and the dewetting process is observed in a softened state above the glass transition temperature of the PS. At the smectic A phase temperature of the SCLCP block, the dewetted surface layer generated a flat unique fingering pattern leading to a monolayered (two-dimensional) high-density LC polymer brush through the LC ordering. The important role of the anchoring PS block on the base PS film surface is suggested for the formation of highly stretched LC polymer brush. Above the isotropization temperature, in contrast, ordinary three-dimensional droplet morphologies with smooth round edges were observed. By photo-cross-linking the base PS film, the lateral diffusion rate was significantly reduced. This can be applied to an entropy-driven morphology patterning via dewetting. The polymer brush formation and its spatial controls are expected to provide new opportunities for the modification strategies of polymer surfaces.

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

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

Rupture of ultrathin solution films on planar solid substrates induced by solute crystallization

On-line optical imaging of continuously thinning planar films in a spin cast configuration reveals the rupture behavior of ultra-thin films of binary mixtures of a volatile solvent and a nonvolatile solute. The pure solvents completely wet the silica substrates whereas the solution films rupture at certain film thicknesses, h_rupture, which depend on, c₀, the initial weighing in solute concentrations. With small c₀, h_rupture increases proportional to c₀. With high c₀, all films rupture at h_rupture≈50nm, independent of c₀. The findings can be explained by the solute enrichment during the evaporative thinning. Solute crystallization at the liquid/substrate interface upon reaching solute supersaturation leads to locally different wetting properties. This induces locally the rupture of the film as soon as it is sufficiently thin. A proper data rescaling based on this scenario yields a universal rupture behavior of various different solvent/solute mixtures.

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

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

Assembly of PCBM and tn-ZnPc Molecular Domains and Phase Separation of Molecular Mixtures from Liquid Solution on Si(111)

We present the results of investigations aimed at understanding the mechanisms by which small, mutually immiscible organic molecules self-assemble into domains during phase separation from liquid solutions in the presence of a solid substrate. As an example system, we investigated molecular mixtures of tetranitro zinc-phthalocyanine (tn-ZnPc), an electron donor, and [6,6]-phenyl-C₆₁-butyric acid methyl ester (PCBM), an electron acceptor, in chloroform solution, deposited onto native oxide-covered Si(111) substrates. We found qualitatively different behavior in the formation of domains of the two types of molecules, seemingly because of a large difference in their solubilities in the solvent. The morphology of PCBM molecule domains varies widely depending on the solvent evaporation rate, the presence/absence of tn-ZnPc molecules in the solution, solvent annealing conditions, and seemingly the presence/absence of trace impurities. By contrast, we find evidence that the shape of the tn-ZnPc domains is insensitive to evaporation; these form while in liquid suspension, and the assembly of domains into clusters varies according to the rate and mode of solvent evaporation.

Directed ordering of phase separated domains and dewetting of thin polymer blend films on a topographically patterned substrate

Substrate pattern guided self-organization of ultrathin and confined polymeric films on a topographically patterned substrate is a useful approach for obtaining ordered meso and nano structures over large areas, particularly if the ordering is achieved during film preparation itself, eliminating any post-processing such as thermal or solvent vapor annealing. By casting a dilute solution of two immiscible polymers, polystyrene (PS) and polymethylmethacrylate (PMMA), from a common solvent (toluene) on a topographically patterned substrate with a grating geometry, we show the formation of self-organized meso patterns with various degrees of ordering. The morphology depends on both the concentration of the dispensed solution (C_n) and the blend composition (R_B). Depending on the extent of dewetting during spin coating, the final morphologies can be classified into three distinct categories. At a very low C_n the solution dewets fully, resulting in isolated polymer droplets aligned along substrate grooves (Type 1). Type 2 structures comprising isolated threads with aligned phase separated domains along each substrate groove are observed at intermediate C_n. A continuous film (Type 3) is obtained above a critical concentration (C_n*) that depends on R_B. While the extent of ordering of the domains gradually diminishes with an increase in film thickness for Type 3 patterns, the size of the domains remains much smaller than that on a flat substrate, resulting in significant downsizing of the features due to the lateral confinement imposed on the phase separation process by the topographic patterns. Finally, we show that some of these structures exhibit excellent broadband anti-reflection (AR) properties.

Dual Imprinted Polymer Thin Films via Pattern Directed Self-Organization

Synthetic topographically patterned films and coatings are typically contoured on one side, yet many of nature's surfaces have distinct textures on different surfaces of the same object. Common examples are the top and bottom sides of the butterfly wing or lotus leaf, onion shells, and the inside versus outside of the stem of a flower. Inspired by nature, we create dual (top and bottom) channel patterned polymer films. To this end, we first develop a novel fabrication method to create ceramic line channel relief structures by converting the oligomeric residue of stamped poly(dimethylsiloxane) (PDMS) nanopatterns on silicon substrates to glass (SiOx, silica) by ultraviolet-ozone (UVO) exposure. These silica patterned substrates are flow coated with polystyrene (PS) films and confined within an identically patterned top confining soft PDMS elastomer film. Annealing of the sandwich structures drives the PS to rapidly mold fill the top PDMS pattern in conjunction with a dewetting tendency of the PS on the silica pattern. Varying the film thickness h, from less than to greater than the pattern height, and varying the relative angle between the top-down and bottom-up patterned confinement surfaces create interesting uniform and nonuniform digitized defects in PS channel patterns, as also a defect-free channel regime. Our dual patterned polymer channels provide a novel fabrication route to topographically imprinted Moiré patterns (whose applications range from security encrypting holograms to sensitive strain gauges), and their basic laser light diffractions properties are illustrated and compared to graphical simulations and 2D-FFT of real-space AFM channel patterns. While traditional "geometrical" and "fringe" Moiré patterns function by superposition of two misaligned optical patterned transmittance gratings, our topographic pattern gratings are quite distinct and may allow for more unique holographic optical characteristics with further development.

Kinetics of sub-spinodal dewetting of thin films of thickness dependent viscosity

An alternative explanation of the time varying and very low growth exponents in dewetting of polymer films like polystyrene films is presented based on non-linear simulations. The kinetics of these films is explored within the framework of experimentally observed thickness dependent viscosity. These films exhibit sub-spinodal dewetting via formation of satellite holes in between primary dewetted holes under favorable conditions of excess intermolecular forces and film thicknesses. We find that conditions responsible for sub-spinodal dewetting concurrently lead to remarkable changes in the kinetics of dewetting of even primary holes. For example, the radius of the hole grows in time with a power-law growth exponent sequence of [Formula: see text], in contrast to the usual  ∼4/5. This is due to the cumulative effect of reduced rim mobility due to thickness dependent viscosity and hindrance created by satellite holes.

Rhodamine-doped nanoporous polymer films as high-performance anti-reflection coatings and optical filters

We demonstrate a simple and robust procedure for the fabrication of rhodamine-doped nanoporous poly(methyl methacrylate) (PMMA) films, whose optical properties, such as anti-reflection, fluorescence and absorption can be tailored to specific applications. By exploiting phase separation of a binary polymer blend (PMMA and polystyrene), we fabricated foam-like nanoporous films that could be easily and cost-effectively integrated into the fabrication process of optical components. We link film morphology, studied by multifrequency atomic force microscopy (AFM), to the effective refractive index of the films for use as anti-reflection coatings. The film's morphology leads to superior broadband anti-reflection performance compared with homogeneous films. For applications involving optical filters and spectral conversion layers (e.g., for photovoltaic applications), we doped the films with the fluorescent molecule rhodamine, whereby simple variations in the fabrication process enabled us to prepare rhodamine-doped nanoporous PMMA with tunable fluorescence and absorption, without losing the anti-reflective properties. The above combination of optical properties makes the films attractive for a wide range of applications.

Nanostructure Formation by controlled dewetting on patterned substrates: A combined theoretical, modeling and experimental study

We perform systematic two-dimensional energetic analysis to study the stability of various nanostructures formed by dewetting solid films deposited on patterned substrates. Our analytical results show that by controlling system parameters such as the substrate surface pattern, film thickness and wetting angle, a variety of equilibrium nanostructures can be obtained. Phase diagrams are presented to show the complex relations between these system parameters and various nanostructure morphologies. We further carry out both phase field simulations and dewetting experiments to validate the analytically derived phase diagrams. Good agreements between the results from our energetic analyses and those from our phase field simulations and experiments verify our analysis. Hence, the phase diagrams presented here provide guidelines for using solid-state dewetting as a tool to achieve various nanostructures.

Stability and break-up of thin liquid films on patterned and structured surfaces

Solid surfaces with chemical patterning or topographical structure have attracted attention due to many potential applications such as manufacture of flexible electronics, microfluidic devices, microscale cooling systems, as well as development of self-cleaning, antifogging, and antimicrobial surfaces. In many configurations involving patterned or structured surfaces, liquid films are in contact with such solid surfaces and the issue of film stability becomes important. Studies of stability in this context have been largely focused on specific applications and often not connected to each other. The purpose of the present review is to provide a unified view of the topic of stability and rupture of liquid films on patterned and structured surfaces, with particular focus on common mathematical methods, such as lubrication approximation for the liquid flow, bifurcation analysis, and Floquet theory, which can be used for a wide variety of problems. The physical mechanisms of the instability discussed include disjoining pressure, thermocapillarity, and classical hydrodynamic instability of gravity-driven flows. Motion of a contact line formed after the film rupture is also discussed, with emphasis on how the receding contact angle is expected to depend on the small-scale properties of the substrate.

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

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

Instability, self-organization and pattern formation in thin soft films

The free surface of a thin soft polymer film is often found to become unstable and self-organizes into various meso-scale structures. In this article we classify the instability of a thin polymer film into three broad categories, which are: category 1: instability of an ultra-thin (<100 nm) viscous film engendered by amplification of thermally excited surface capillary waves due to interfacial dispersive van der Waals forces; category 2: instability arising from the attractive inter-surface interactions between the free surface of a soft film exhibiting room temperature elasticity and another rigid surface in its contact proximity; and category 3: instability caused by an externally applied field such as an electric field or a thermal gradient, observed in both viscous and elastic films. We review the salient features of each instability class and highlight how characteristic length scales, feature morphologies, evolution pathways, etc. depend on initial properties such as film thickness, visco-elasticity (rheology), residual stress, and film preparation conditions. We emphasize various possible strategies for aligning and ordering of the otherwise isotropic structures by combining the essential concepts of bottom-up and top-down approaches. A perspective, including a possible future direction of research, novelty and limitations of the methods, particularly in comparison to the existing patterning techniques, is also presented for each setting.

Stable Freestanding Thin Films of Copolymer Melts Far from the Glass Transition

Thin polymer films have attracted attention because of both their broad range of applications and of the fundamental questions they raise regarding the dynamic response of confined polymers. These films are unstable if the temperature is above their glass transition temperature T_g. Here, we describe freestanding thin films of centimetric dimensions made of a comb copolymer melt far from its glass transition that are stable for more than a day. These long lifetimes allowed us to characterize the drainage dynamics and the thickness profile of the films. Stratified regions appear as the film drains. We have evidence that the stability, thinning dynamics, and thickness profile of the films result from structural forces in the melt. Understanding the key mechanisms behind our observations may lead to new developments in polymeric thin films, foams, and emulsions without the use of stabilizing agents.

Instabilities of Layers of Deposited Molecules on Chemically Stripe Patterned Substrates: Ridges versus Drops

A mesoscopic continuum model is employed to analyze the transport mechanisms and structure formation during the redistribution stage of deposition experiments where organic molecules are deposited on a solid substrate with periodic stripe-like wettability patterns. Transversally invariant ridges located on the more wettable stripes are identified as very important transient states and their linear stability is analyzed accompanied by direct numerical simulations of the fully nonlinear evolution equation for two-dimensional substrates. It is found that there exist two different instability modes that lead to different nonlinear evolutions that result (i) at large ridge volume in the formation of bulges that spill from the more wettable stripes onto the less wettable bare substrate and (ii) at small ridge volume in the formation of small droplets located on the more wettable stripes. In addition, the influence of different transport mechanisms during redistribution is investigated focusing on the cases of convective transport with no-slip at the substrate, transport via diffusion in the film bulk and via diffusion at the film surface. In particular, it is shown that the transport process does neither influence the linear stability thresholds nor the sequence of morphologies observed in the time simulation, but only the ratio of the time scales of the different process phases.

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

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

Solvent vapour mediated spontaneous healing of self-organized defects of liquid crystal films

Ultrathin liquid crystal films showed a nematic to isotropic transition when exposed to solvent vapour for a short duration while a reverse isotropic to nematic transition was observed when the film was isolated from the solvent exposure. The phase transitions were associated with the appearance and fading of surface patterns as the solvent molecules diffused into and out of the film matrix, resulting in the destruction or restoration of the orientational order. A long-time solvent vapour exposure caused the dewetting of the film on the surface, which was demonstrated by the formation of holes and their growth in size with the progress of time. Even at this stage, withdrawal of the solvent exposure produced an array of nematic fingers, which nearly self-healed the dewetted holes. The change in contact angle due to the phase transition coupled with the imbalance of osmotic pressure across the contact line due to the differential rate of solvent evaporation from the film and the hole helped the fingers to grow towards the centre of the hole. The appearance of the fingers upon withdrawal of the solvent exposure and their disappearance upon exposure to solvent were also found to be a nearly reversible process. These findings could significantly contribute to the development of vapour sensors and self-healing surfaces using liquid crystal thin films.

Ordered alternating binary polymer nanodroplet array by sequential spin dewetting

We report a facile technique for fabricating an ordered array of nearly equal-sized mesoscale polymer droplets of two constituent polymers (polystyrene, PS and poly(methyl methacrylate), PMMA) arranged in an alternating manner on a topographically patterned substrate. The self-organized array of binary polymers is realized by sequential spin dewetting. First, a dilute solution of PMMA is spin-dewetted on a patterned substrate, resulting in an array of isolated PMMA droplets arranged along the substrate grooves due to self-organization during spin coating itself. The sample is then silanized with octadecyltrichlorosilane (OTS), and subsequently, a dilute solution of PS is spin-coated on to it, which also undergoes spin dewetting. The spin-dewetted PS drops having a size nearly equal to the pre-existing PMMA droplets position themselves between two adjacent PMMA drops under appropriate conditions, forming an alternating binary polymer droplet array. The alternating array formation takes place for a narrow range of solution concentration for both the polymers and depends on the geometry of the substrate. The size of the droplets depends on the extent of confinement, and droplets as small as 100 nm can be obtained by this method, on a suitable template. The findings open up the possibility of creating novel surfaces having ordered multimaterial domains with a potential multifunctional capability.

Mechanically modulated dewetting by atomic force microscope for micro- and nano- droplet array fabrication

Organizing a material into well-defined patterns during the dewetting process provides an attractive micro-/nano-fabrication method without using a conventional lithographic process, and hence, offers potential applications in organic electronics, optics systems, and memory devices. We report here how the mechanical modification of polymer surface by an Atomic Force Microscope (AFM) can be used to guide thin film dewetting evolution and break the intrinsic spatial correlation of spontaneous instability. An AFM is used to implement the mechanical modification of progressively narrow grids to investigate the influence of pattern size on the modulation of ultrathin polystyrene films dewetting evolution. For films with different initial thicknesses, when grid size is close to or below the characteristic wavelength of instability, the spinodal dewetting is suppressed, and film rupture is restricted to the cutting trench. We will show in this paper it is possible to generate only one droplet per gridded area on a thin film subsequent to nucleation dominated dewetting on a non-patterned substrate. Furthermore, when the grid periodicity exceeds the spinodal length, the number of droplets in predefined areas gradually approaches that associated with unconfined dewetting.

Charge-induced local dewetting on polymer electrets studied by atomic force microscopy

Polymer electrets are one of the most important series of electrets, which are widely used both in academic research and industrial applications. The effect of trapped charges on dielectric properties of the polymer electret is critical for more intelligent utilization of these materials. Herein we report the charge-induced polymer relaxation reflected by the local dewetting of the polymer electrets with charge patterns. Because the difference in charge-induced relaxation results in selective dewetting of thin polymer films, polymers in the charged areas are preferentially dewetted from the substrate compared with the neutral areas under heating or solvent annealing, leading to the appearance of hole arrays. Therefore, the effect of trapped charges on relaxation was also studied via monitoring the relaxation behaviours of homo-polymer and block copolymer films as well as measuring the mechanical properties of homo-polymers with charge patterns. These results demonstrate that the charge trapped in polymer electrets could accelerate relaxation and drive the dewetting process of thin polymer films.

Stability of thin liquid films and sessile droplets under confinement

The stability of nonvolatile thin liquid films and of sessile droplets is strongly affected by finite size effects. We analyze their stability within the framework of density functional theory using the sharp kink approximation, i.e., on the basis of an effective interface Hamiltonian. We show that finite size effects suppress spinodal dewetting of films because it is driven by a long-wavelength instability. Therefore nonvolatile films are stable if the substrate area is too small. Similarly, nonvolatile droplets connected to a wetting film become unstable if the substrate area is too large. This instability of a nonvolatile sessile droplet turns out to be equivalent to the instability of a volatile drop which can attain chemical equilibrium with its vapor.

Capillary wave confinement-induced stabilization of polymer films

We show that temporary confinement of polystyrene thin films by an elastomeric capping layer possessing nanoimprinted subcapillary wavelength (λ << λcap (20 μm)) line channels (amplitude A ≈ 120 nm) can suppress film dewetting on thermodynamically unfavorable substrates by arresting the amplitude growth and in-plane propagation of the destabilizing surface capillary waves. Confinement by either a smooth elastomer capping layer (A ≈ 1 nm) or with pattern features above the threshold dimension only retards dewetting but does not prevent it. The nanoimprint pattern is therefore essential to preventing dewetting, illustrating that only the penalty of elastomer deformation and interfacial tension reduction is insufficient.

Directed assembly of P3HT:PCBM blend films using a chemical template with sub-300 nm features

Surface energy has been demonstrated as a means to direct interfacial-layer composition in polymer:fullerene blends utilized as active layers in organic photovoltaic devices. Combined with recent materials advances in the preparation of nanoscale chemical patterns, surface energy control of nanophase separation presents an opportunity to employ patterned surface energy templates to control the 3D blend morphology of polymer:fullerene blends. This report details the directed assembly of poly(3-hexylthiophene):phenyl-C61-butyric acid methyl ester (P3HT:PCBM) blends atop linear grating patterns with domains of alternating high and low surface energy of 50 to 600 nm in width prepared by nanoscale oxidative lithography of alkyl-terminated self-assembled monolayers on SiO2 and SiH surfaces. Tapping-, contact-, and current-sensing AFM studies demonstrated that chemical patterns were effective at directing the 3D morphology of P3HT:PCBM blends at dimensions of >200 nm. As the dimensionality of domains approached 100 nm, the chemical patterns were no longer able to direct phase segregation, evidence that a directed spinodal decomposition mechanism was responsible for the observed morphology. Surprisingly, the low surface energy component (P3HT) was found to be atop the high surface energy domains of the template, in conflict with current understanding of the role of surface energy directed assembly in polymer blends. These results suggest that the directed spinodal decomposition mechanism applies to conjugated polymer:fullerene blends, but that additional parameters unique to these types of systems will require refinement of the theory to adequately describe and predict the behavior of these scientifically and industrially interesting materials.

Self-organized pathways to nanopatterns exploiting the instabilities of ultrathin confined bilayers

Self-organized interfacial instabilities of an ultrathin bilayer confined between a pair of rigid surfaces is explored. The bilayers are classified based on the macroscopic dewetting behaviors of the liquid films sandwiched between a pair of confining surfaces having surface energy higher or lower than the liquid films. Linear and nonlinear analyses employing the governing equations originating from the continuum description together with molecular dynamics (MD) simulations unveil the salient spatiotemporal features of the dewetting process. The study uncovers that, under the destabilizing influence of the intermolecular interactions, the interface of a confined bilayer can deform into interesting embedded and encapsulated patterns with nanoscale periodicity. The continuum and MD simulations collectively show the detailed route to dewetting starting from the formation of holes in the early stage, their growth to achieve equilibrium contact angle at the intermediate phase, and then to evolve into the equilibrium morphologies at the later stage. Examples are shown where the length and the time scales of the simulated nanostructures from both the continuum and MD approaches are found to agree with the same obtained from the linear stability analysis. We also highlight the deviations that are observed in the continuum and MD approaches. The study confirms that the reduced stabilizing interfacial tension at the liquid-liquid interface together with enhanced intermolecular interaction because of the thinness of the layers can be an alternative strategy for pattern miniaturization exploiting the instabilities of a thin confined bilayer. Further, the study shows that use of topographical patterns on the bounding surfaces can impose periodic order to the holes, droplets, columns, and channels, which can find important applications in the diverse areas of nanotechnology.

Coarsening dynamics of nanodroplets on topographically structured substrates

Employing a biharmonic boundary integral method with linear elements, coarsening dynamics of nanodroplets on topographical step heterogeneity is investigated. It is shown that the step height and droplet configuration have an influential effect on the dynamics. Increasing the step height slows down the process while locating the droplets close to the step boosts the coarsening rate. Considering a slip boundary condition enhances the dynamics and reveals a transition in the droplet migration direction. Our results reveal that increasing the surface wettability weakens the dynamics. Various types of the disjoining pressure over the step are also considered and their effects on the coarsening are investigated.

Ordered to isotropic morphology transition in pattern-directed dewetting of polymer thin films on substrates with different feature heights

Controlled dewetting of a thin polymer film on a topographically patterned substrate is an interesting approach for aligning isotropic dewetted structures. In this article, we investigate the influence of substrate feature height (H(S)) on the dewetting pathway and final pattern morphology by studying the dewetting of polystyrene (PS) thin films on grating substrates with identical periodicity (λ(P) = 1.5 μm), but H(S) varying between 10 nm and 120 nm. We identify four distinct categories of final dewetted morphology, with different extent of ordering: (1) array of aligned droplets (H(S) ≈ 120 nm); (2) aligned undulating ribbons (H(S) ≈ 70-100 nm); (3) multilength scale structures with coexisting large droplets uncorrelated to the substrate and smaller droplets/ribbons aligned along the stripes (H(S) ≈ 40-60 nm); and (4) large droplets completely uncorrelated to the substrate (H(S) < 25 nm). The distinct morphologies across the categories are attributed to two major factors: (a) whether the as-cast film is continuous (H(S)≤ 80 nm) or discontinuous (H(S)≥ 100 nm) and (b) in case of a continuous film, whether the film ruptures along each substrate stripe (H(S)≥ 70 nm) or with nucleation of random holes that are not correlated to the substrate features (H(S)≤ 60 nm). While the ranges of H(S) values indicated in the parentheses are valid for PS films with an equivalent thickness (h(E)) ≈ 50.3 nm on a flat substrate, a change in h(E) merely alters the cut-off values of H(S), as the final dewetted morphologies and transition across categories remain generically unaltered. We finally show that the structures obtained by dewetting on different H(S) substrates exhibits different levels of hydrophobicity because of combined spatial variation of chemical and topographic contrast along the surface. Thus, the work reported in this article can find potential application in fabricating surfaces with controlled wettability.

Stability of thin wetting films on chemically nanostructured surfaces

The morphology and stability of thin volatile wetting films on model chemically patterned surfaces composed of periodic arrays of alternating completely and partially wettable nanostripes are investigated. The equilibrium film morphology is recorded as a function of undersaturation using noncontact atomic force microscopy. Films spanning the entire pattern are found to be stable only for thicknesses in excess of a critical value, h(c), whereas thinner films spontaneously dewet the partially wettable regions of the substrate. The critical thickness h(c) increases linearly with the width of the partially wettable stripes in good agreement with an interface displacement model derived from microscopic density functional theory. These results provide detailed insights into the dewetting of thin films driven by competing intermolecular forces.

Electric-field-induced interfacial instabilities of a soft elastic membrane confined between viscous layers

We explore the electric-field-induced interfacial instabilities of a trilayer composed of a thin elastic film confined between two viscous layers. A linear stability analysis (LSA) is performed to uncover the growth rate and length scale of the different unstable modes. Application of a normal external electric field on such a configuration can deform the two coupled elastic-viscous interfaces either by an in-phase bending or an antiphase squeezing mode. The bending mode has a long-wave nature, and is present even at a vanishingly small destabilizing field. In contrast, the squeezing mode has finite wave-number characteristics and originates only beyond a threshold strength of the electric field. This is in contrast to the instabilities of the viscous films with multiple interfaces where both modes are found to possess long-wave characteristics. The elastic film is unstable by bending mode when the stabilizing forces due to the in-plane curvature and the elastic stiffness are strong and the destabilizing electric field is relatively weak. In comparison, as the electric field increases, a subdominant squeezing mode can also appear beyond a threshold destabilizing field. A dominant squeezing mode is observed when the destabilizing field is significantly strong and the elastic films are relatively softer with lower elastic modulus. In the absence of liquid layers, a free elastic film is also found to be unstable by long-wave bending and finite wave-number squeezing modes. The LSA asymptotically recovers the results obtained by the previous formulations where the membrane bending elasticity is approximately incorporated as a correction term in the normal stress boundary condition. Interestingly, the presence of a very weak stabilizing influence due to a smaller interfacial tension at the elastic-viscous interfaces opens up the possibility of fabricating submicron patterns exploiting the instabilities of a trilayer.

Self-assembled three-dimensional nanocrown array

Although an ordered nanoplasmonic probe array will have a huge impact on light harvesting, selective frequency response (i.e., nanoantenna), and quantitative molecular/cellular imaging, the realization of such an array is still limited by conventional techniques due to the serial processing or resolution limit by light diffraction. Here, we demonstrate a thermodynamically driven, self-assembled three-dimensional nanocrown array that consists of a core and six satellite gold nanoparticles (GNPs). Our ordered nanoprobe array is fabricated over a large area by thermal dewetting of thin gold film on hexagonally ordered porous anodic alumina (PAA). During thermal dewetting, the structural order of the PAA template dictates the periodic arrangement of gold nanoparticles, rendering the array of gold nanocrown. Because of its tunable size (i.e., 50 nm core and 20 nm satellite GNPs), arrangement, and periodicity, the nanocrown array shows multiple optical resonance frequencies at visible wavelengths as well as angle-dependent optical properties.

Block copolymer films with free interfaces: ordering by nanopatterned substrates

We study block copolymers (BCPs) on patterned substrates, where the top polymer film surface is not constrained but is free and can adapt its shape self-consistently. In particular, we investigate the combined effect of free interface undulations with wetting of the BCP film as induced by nanopatterned substrates. Under wetting conditions and for a finite volume of BCP material, we find equilibrium droplets composed of coexisting perpendicular and parallel lamellar domains. The self-assembly of BCPs on topographic patterned substrates is also investigated and it is found that the free interface induces mixed morphologies of parallel and perpendicular domains coupled with a nonflat free interface. Our study has some interesting consequences for experimental setups of graphoepitaxy and nanoimprint lithography.

Polymer blend lithography: A versatile method to fabricate nanopatterned self-assembled monolayers

A rapid and cost-effective lithographic method, polymer blend lithography (PBL), is reported to produce patterned self-assembled monolayers (SAM) on solid substrates featuring two or three different chemical functionalities. For the pattern generation we use the phase separation of two immiscible polymers in a blend solution during a spin-coating process. By controlling the spin-coating parameters and conditions, including the ambient atmosphere (humidity), the molar mass of the polystyrene (PS) and poly(methyl methacrylate) (PMMA), and the mass ratio between the two polymers in the blend solution, the formation of a purely lateral morphology (PS islands standing on the substrate while isolated in the PMMA matrix) can be reproducibly induced. Either of the formed phases (PS or PMMA) can be selectively dissolved afterwards, and the remaining phase can be used as a lift-off mask for the formation of a nanopatterned functional silane monolayer. This "monolayer copy" of the polymer phase morphology has a topographic contrast of about 1.3 nm. A demonstration of tuning of the PS island diameter is given by changing the molar mass of PS. Moreover, polymer blend lithography can provide the possibility of fabricating a surface with three different chemical components: This is demonstrated by inducing breath figures (evaporated condensed entity) at higher humidity during the spin-coating process. Here we demonstrate the formation of a lateral pattern consisting of regions covered with 1H,1H,2H,2H-perfluorodecyltrichlorosilane (FDTS) and (3-aminopropyl)triethoxysilane (APTES), and at the same time featuring regions of bare SiO(x). The patterning process could be applied even on meter-sized substrates with various functional SAM molecules, making this process suitable for the rapid preparation of quasi two-dimensional nanopatterned functional substrates, e.g., for the template-controlled growth of ZnO nanostructures [1].