Hole formation in thin polymer films: a two-stage process

Non-equilibrium molecular simulations of thin film rupture

The retraction of thin films, as described by the Taylor-Culick (TC) theory, is subject to widespread debate, particularly for films at the nanoscale. We use non-equilibrium molecular dynamics simulations to explore the validity of the assumptions used in continuum models by tracking the evolution of holes in a film. By deriving a new mathematical form for the surface shape and considering a locally varying surface tension at the front of the retracting film, we reconcile the original theory with our simulation to recover a corrected TC speed valid at the nanoscale.

Composition fluctuation intensity effect on the stability of polymer films

The composition fluctuation intensity dependence of the stability of a polymer film with a tiny amount of miscible component.

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.

From permeation to pore nucleation in smectic stacks

The last stage of the spreading of a stratified droplet in the odd wetting case is the evolution from a trilayer to a monolayer, that is, vanishing of the last bilayer in the stack. We studied it in the case of 8CB smectic liquid crystal on a hydrophilic surface. Receding of the last bilayer is accompanied by formation of pores in it, which appear in the outer part of it. From analysis of real-time experimental observations of this phenomenon, we demonstrate that the dislocation loops which border these pores are not located at the same height in the trilayer stack as the dislocation lines that border the bilayer. Also, careful analysis of our results using a recently developed theoretical approach of smectic liquid nanodrop spreading strongly suggests that pore nucleation is triggered by differences in chemical potential between adjacent layers, which contrasts with the classical scheme where it is attributed to lateral tension along the layers.

Stability and dewetting of metal nanoparticle filled thin polymer films: control of instability length scale and dynamics

We investigate the influence of gold nanoparticle addition on the stability, dewetting, and pattern formation in ultrathin polymer-nanoparticle (NP) composite films by examining the length and time scales of instability, morphology, and dynamics of dewetting. For these 10-50 nm thick (h) polystyrene (PS) thin films containing uncapped gold nanoparticles (diameter approximately 3-4 nm), transitions from complete dewetting to arrested dewetting to absolute stability were observed depending on the concentration of the particles. Experiments show the existence of three distinct stability regimes: regime 1, complete dewetting leading to droplet formation for nanoparticle concentration of 2% (w/w) or below; regime 2, partial dewetting leading to formation of arrested holes for NP concentrations in the range of 3-6%; and regime 3, complete inhibition of dewetting for NP concentrations of 7% and above. Major results are (a) length scale of instability, where lambdaH approximately hn remains unchanged with NP concentration in regime 1 (n approximately 2) but increases in regime 2 with a change in the scaling relation (n approximately 3-3.5); (b) dynamics of instability and dewetting becomes progressively sluggish with an increase in the NP concentration; (c) there are distinct regimes of dewetting velocity at low NP concentrations; (d) force modulation AFM, as well as micro-Raman analysis, shows phase separation and aggregation of the gold nanoparticles within each dewetted polymer droplet leading to the formation of a metal core-polymer shell morphology. The polymer shell could be removed by washing in a selective solvent, thus exposing an array of bare gold nanoparticle aggregates.

Slip effects in polymer thin films

Probing the fluid dynamics of thin films is an excellent tool for studying the solid/liquid boundary condition. There is no need for external stimulation or pumping of the liquid, due to the fact that the dewetting process, an internal mechanism, acts as a driving force for liquid flow. Viscous dissipation, within the liquid, and slippage balance interfacial forces. Thus, friction at the solid/liquid interface plays a key role towards the flow dynamics of the liquid. Probing the temporal and spatial evolution of growing holes or retracting straight fronts gives, in combination with theoretical models, information on the liquid flow field and, especially, the boundary condition at the interface. We review the basic models and experimental results obtained during the last several years with exclusive regard to polymers as ideal model liquids for fluid flow. Moreover, concepts that aim to explain slippage on the molecular scale are summarized and discussed.

Autophobic dewetting of a poly(methyl methacrylate) thin film on a silicon wafer treated in good solvent vapor

The wettability of thin poly(methyl methacrylate) (PMMA) films on a silicon wafer with a native oxide layer exposed to solvent vapors is dependent on the solvent properties. In the nonsolvent vapor, the film spread on the substrate with some protrusions generated on the film surface. In the good solvent vapor, dewetting happened. A new interface formed between the anchored PMMA chains and the swollen upper part of the film. Entropy effects caused the upper movable chains to dewet on the anchored chains. The rim instability depended on the surface tension of solvent (i.e., the finger was generated in acetone vapor (gamma(acetone) = 24 mN/m), not in dioxane vapor (gamma(dioxane) = 33 mN/m)). The spacing (lambda) that grew as an exponential function of film thickness h scaled as approximately h(1.31), whereas the mean size (D) of the resulting droplets grew linearly with h.

Dewetting dynamics of stressed viscoelastic thin polymer films

Ultrathin polymer films that are produced, e.g., by spin coating are believed to be stressed since polymers are "frozen in" into out-of-equilibrium configurations during this process. In the framework of a viscoelastic thin-film model, we study the effects of lateral residual stresses on the dewetting dynamics of the film. The temporal evolution of the height profiles and the velocity profiles inside the film as well as the dissipation mechanisms are investigated in detail. Both the shape of the profiles and the importance of frictional dissipation vs viscous dissipation inside the film are found to change in the course of dewetting. The interplay of the nonstationary profiles, the relaxing initial stress, and the changes in the dominance of the two dissipation mechanisms caused by nonlinear friction with the substrate is responsible for the rich behavior of the system. In particular, our analysis sheds a different light on the occurrence of the unexpected maximum in the rim width obtained recently in experiments on polystyrene-polydimethylsiloxane systems.

Viscoelastic thin polymer films under transient residual stresses: two-stage dewetting on soft substrates

A nonmonotonic, two-stage dewetting behavior was observed for spin coated thin viscoelastic polymer films on soft elastic substrates. At times shorter than the relaxation time of the polymer (t<tau_{rep}), dewetting generated deep trenches in the soft rubbery substrate which, in turn, almost stopped dewetting. At later stages (t>>tau_{rep}), dewetting accelerated, accompanied by an unstable rim. However, holes nucleated at t<tau_{rep} showed only this second-stage behavior. Our observations are attributed to large elastic deformations in the substrate caused by transient residual stresses within the film.

Slippage of Newtonian liquids: influence on the dynamics of dewetting thin films

Slippage of Newtonian liquids in the presence of a solid substrate is a newly found phenomenon, the origin of which is still under debate. In this article, we present a new analysis method to extract the slip length. Enhancing the slip of liquids is an important issue for microfluidic devices that demand for high throughput at low pumping power. We study the velocity of short-chained liquid polystyrene (PS) films dewetting from nonwettable solid substrates. We show how the dynamics of dewetting is influenced by slippage, and we compare the results of two types of substrates that give rise to different slip lengths. As substrates, Si wafers that have been coated with octadecyltrichlorosilane (OTS) or dodecyltrichlorosilane (DTS) were used. Our results demonstrate that the dewetting velocity for PS films on DTS is significantly larger than on OTS and that this difference originates from the different slip lengths of the liquid on top of the two surfaces. For PS films of thickness between 130 and 230 nm, we find slip lengths between 400 nm and 6 microm, depending on substrate and temperature.

Nonsolvent-induced dewetting of thin polymer films

The process of nonsolvent-induced dewetting of thin polystyrene (PS) films on hydrophilic surfaces at room temperature has been studied by using water as a nonsolvent. It is observed that the process of nonsolvent-induced dewetting is greatly different from other previous dewetting processes. The PS film is found in nonviscous state in our study. A mechanism of nonsolvent-induced dewetting is deduced in an order of penetration, replacement, and coalescent, and it is different from other previous dewetting mechanisms. The results of experiments are analyzed from thermodynamics and dynamics to support the hypothetical mechanism.

Dewetting dynamics in miscible polymer-polymer thin film mixtures

Thin polystyrene films supported by oxidized silicon (SiOx/Si) substrates may be unstable or metastable, depending on the film thickness, h, and can ultimately dewet the substrate when heated above their glass transition. In the metastable regime, holes nucleate throughout the film and subsequently grow due to capillary driving forces. Recent studies have shown that the addition of a second component, such as a copolymer or miscible polymer, can suppress the dewetting process and stabilize the film. We examined the hole growth dynamics and the hole morphology in thin film mixtures composed of polystyrene and tetramethyl bisphenol-A polycarbonate (TMPC) supported by SiOx/Si substrates. The hole growth velocity decreased with increasing TMPC content beyond that expected from changes in the bulk viscosity. The authors show that the suppression of the dewetting velocity is primarily due to reductions in the capillary driving force for dewetting and to increased friction at the substrate-polymer interface. The viscosity, as determined from the hole growth dynamics, decreases with decreasing film thickness, and is connected to a depression of the glass transition of the film.

Molecular recoiling in polymer thin film dewetting

The molecular recoiling force stemming from nonequilibrium chain conformation was found to play a very important role in the dewetting stability of polymer thin films. Correct measurements and inclusion of this molecular force into thermodynamic consideration are crucial for analyzing dewetting phenomena and nanoscale polymer chain physics. This force was measured using a simple method based on contour relaxation at the incipient dewetting holes. The recoiling stress was found to increase dramatically with molecular weight and decreasing film thickness. The corresponding forces were calculated to be in the range from 9.0 to 28.2 mN/m, too large to be neglected when compared to the dispersive forces (approximately 10 mN/m) commonly operative in thin polymer films.

Viscoelastic dewetting of a polymer film on a liquid substrate

The Dewetting of thin polymer films (60-300 nm) on a non-wettable liquid substrate has been studied in the vicinity of their glass transition temperature. In our experiment, we observe a global contraction of the film while its thickness remains uniform. We show that, in this case, the strain corresponds to simple extension, and we verify that it is linear with the stress applied by the surface tension. This allows direct measurement of the stress/strain response as a function of time, and thus permits the measurement of an effective compliance of the thin films. It is, however, difficult to obtain a complete viscoelastic characterization, as the short time response is highly dependant on the physical age of the sample. Experimental results underline the effects of residual stress and friction when dewetting is analyzed on rigid substrates.

Hole growth in freely standing polystyrene films probed using a differential pressure experiment

We have probed the whole chain mobility of polymer molecules confined to freely standing films by measuring the flow of gas through holes growing in the films at elevated temperatures using a differential pressure experiment. Freely standing polystyrene films were measured for the temperature range 92 degrees C<T<105 degrees C for films with two different molecular weights Mw=717 x 10(3) and 2240 x 10(3) , with thicknesses 51 nm<h<97 nm . This range of film thicknesses is of particular interest because large reductions in the glass transition temperature Tg have been measured previously for freely standing PS films in this thickness range. We find that hole formation and growth, and therefore substantial chain mobility, does not occur until temperatures close to the bulk value of the glass transition temperature T(bulk)g. The characteristic growth times tau for the thinnest films, which have reduced values of Tg, are not substantially less than those for thicker films, and we find that these small differences in tau can be understood in terms of the bulk phenomenon of shear thinning. We also show that the viscosity at the edge of the hole inferred from the characteristic growth times obtained in this and previous studies exhibit shear thinning with reduced shear strain rates beta that span twelve orders of magnitude.

Moving fronts in entangled polymeric films

Thin liquid films can become structurally unstable and dewet, forming holes which subsequently grow on the substrate. Considerable research has been conducted on the structural evolution and growth of holes, which invariably are shown to be circular. We show that morphologies characterized by circular holes comprise one of three possible morphological regimes. In polystyrene films, supported by silicon oxide substrates, two other regimes are observed with decreasing film thickness. In the second regime, the moving boundary of the growing hole may become unstable and form fingers. The spacing between the fingers is characterized by a well-defined wavelength lambda proportional to h(7/6) M(-1/2) , where h is the film thickness and M is the molecular weight. A dense branchlike morphology characterizes the peripheral regions of the holes in the third regime and is found only in the thinnest films.

Dewetting behavior of a block copolymer/homopolymer thin film on an immiscible homopolymer substrate

Numerous previous studies have established that the addition of a microphase-ordered AB diblock copolymer to a thin homopolymer A (hA) film can slow, if not altogether prevent, film rupture and subsequent film dewetting on a hard substrate such as silica. However, only a few reports have examined comparable phenomena when the hA/AB blend resides on a soft B-selective surface, such as homopolymer B (hB). In this work, the dewetting kinetics of thin films composed of polystyrene (PS) and a symmetric poly(styrene-b-methyl methacrylate) (SM) diblock copolymer on a poly(methyl methacrylate) substrate is investigated by hot-stage light microscopy. Without the SM copolymer, the dewetting rate of the PS layer is constant under isothermal conditions and exhibits Arrhenius behavior with an apparent activation energy of approximately 180 kJ/mol. Addition of the copolymer promotes a crossover from early- to late-stage dewetting kinetics, as evidenced by measurably different dewetting rates. Transmission electron microscopy reveals the morphological characteristics of dewetted PS/SM films as functions of film thickness and SM concentration.

Solvent-driven dewetting and rim instability

An experimental method suitable for reproducible results has been used to investigate dewetting behavior of thin films of solvent-laden polymer. This solvent-driven dewetting enables one to change spreading coefficient by an order of magnitude that is not readily realizable in thermal dewetting and to study polar interactions that have not been fully exploited experimentally. While the film instability is similar to that found in thermal dewetting, the rim instability is quite different. Two different types of the rim instability have been found. With a polar solvent, the rim instability changes from one type to another with increasing film thickness whereas the unstable rim becomes stable for an apolar solvent.

Instability, dynamics, and morphology of thin slipping films

Based on the linear stability and nonlinear simulations, we show that the surface instability, dynamics, and morphology of supported thin liquid films are profoundly altered by the presence of slippage on the substrate. A general dispersion equation for flow in slipping thin films is derived and simplified to identify three different regimes of slippage (weak, moderate, and strong) and obtain the length and time scales of instability in them. For illustration, the ubiquitous van der Waals interactions have been employed. Different regimes of slip-flow can be predicted based on a nondimensional parameter, xi, which is a function of slip length, film thickness, intermolecular potential, and interfacial tension. Two distinct transitions from weak to moderate slip and from moderate to strong slip occur at xiT1 approximately 0.01 and xiT2 approximately 500, respectively. More specifically, a decrease in film thickness causes transitions from weak to moderate to strong slip regime. Even a weak slippage causes faster breakup of a thin film, whereas slippage beyond a transition value (slip length, bT1) increases the length scale of instability and reduces the number density of holes compared to the nonslipping case. Strong slippage produces holes faster, and the holes are fewer in number and have less developed rims. The exponents for the length scale (lambdam infinity h0n; h0 is film thickness) and time scale of instability (tr infinity h0m) change nonmonotonically with slippage (for nonretarded van der Waals instability, n E (1.25, 2), m E (3, 6)). Retardation in van der Waals potential increases the exponents (n E (1.5, 2.5), m E (5, 8)). The initial stage of evolution of a slipping film, simulated based on nonlinear equations, follows the length scale and time scale of instability, close to the prediction of linear analysis. It is hoped that the present analysis will help in better interpretation of thin film experiments, in estimation of slippage, and in the determination of intermolecular forces from the length and time scales of the instability.

Dewetting near the glass transition: transition from a capillary force dominated to a dissipation dominated regime

Dynamics and corresponding morphology of dewetting of thin polystyrene films at temperatures close to the glass transition were investigated by measuring simultaneously dewetted distance and width of the rim. Comparing the opening of cylindrical holes with the retraction of a straight contact line revealed (i). a drastic influence of the geometry (planar or radial symmetry) on the dynamics at early stages, (ii). a new logarithmic dewetting regime, and (iii). transitions between four dewetting regimes clearly indicated by changes in the shape of the rim. The complete dewetting scenario can be understood as an initial dominance of capillary driving forces, which is progressively overtaken by dissipation related to the increasing size of the rim.

Spinodal-like dewetting of thermodynamically-stable thin polymer films

Energetic considerations indicate that long-range Van der Waals forces stabilize thin polystyrene (PS) films against height fluctuations on silicon substrates. Nevertheless, we report here on the amplification of capillary waves of specific wavelengths for 15 nm thick PS films on silicon, ultimately leading to dewetting in a "spinodal-like" process. However, the temporal dependence of the wavelength of the growing instability does not agree with the "classical" spinodal dewetting mechanism. Therefore, this phenomenon is ascribed to the existence of "structural" forces resulting either from the restructuring of the films or from density variations within the films during annealing, in accordance with recent theoretical treatments. The process is shown not to be limited to polystyrene films, which indicates the generality of our findings.