Electric-field-induced patterns in soft viscoelastic films: from long waves of viscous liquids to short waves of elastic solids

Anomalously High Dielectric Strength and Capacitive Energy Density of Thin Entangled Glassy Polymer Films

The influence of high-intensity electric fields on the stability of polymeric materials is a problem of interest in the design of next-generation energy storage and electronic devices, and for understanding the limits of stability of polymer films exposed to large electric fields generally. Here, we show that the dielectric strength of entangled glassy polymer films increases as an inverse power-law of the film thickness h for "ultrathin" films below a micron in thickness. The dielectric strength enhancement in these polymer films becomes as large as ≈2 GV/m in films thinner than 100 nm, but in this thickness regime, the increase of the dielectric strength depends strongly on the polymer mass, sample aging time, and the method of film preparation. The enhancement of the dielectric breakdown strength is attributed to the mechanical instability of the elastic film subjected to sufficiently large electric fields and a large, but not generally well-understood, enhancement of effective stiffness of entangled glassy polymer films subject to large deformations, an effect that has previously been observed to become greatly enhanced when such films are made thinner. As a proof of principle regarding applications, we utilize ultrathin glassy polymer films of the type studied in our paper to fabricate polymeric nanocapacitors having ultrahigh discharge energy densities (U d max) as large as 27 J/cm3 and having efficiencies greater than 80%. These efficiency values at comparable charge densities are significantly higher than those of competing ferroelectric polymer materials, and we anticipate that our observations will inspire the creation of practical high-energy density nanocapacitor devices for advanced energy storage applications.

Influence of Initial Film Properties in UVO-Mediated Patterning of an Elastomeric Film Using a TEM Grid

Ultraviolet irradiation of a cross-linked polydimethylsiloxane (PDMS) Sylgard 184 film in the presence of atmospheric oxygen (UVO) through a bare transmission electron microscope (TEM) sample holding grid is a rather simple and widely utilized technique for creating micropatterned surfaces. The surface oxidation of a Sylgard 184 film due to UVO exposure is associated with densification and the formation of a silica-like surface layer, which under a TEM grid happens only over the exposed areas of the film, resulting in a physicochemical pattern. It is known that the depth (hD) of the features depends on the duration of UVO exposure (tE). In this article, we show for the first time that hD also depends on the initial film thickness (hF) and the cross-linker percentage (CL, ratio of part A to part B) in a Sylgard 184 thin film. We show that for a specific tE, hD progressively decreases with the reduction in hF. On the other hand, hD shows a nonmonotonic dependence with CL, resulting in patterns with maximum depth for CL ≈ 10.0%. We attribute this observation to the combined effect of resistance against the penetration of the propagation front by the rigid substrate as well as stress relaxation within the exposed parts of the film below the propagating front in films with higher CL values leading to the variation of hD. The observation reported here would allow the potential fabrication of polymer films with physicochemical patterns with feature height on demand by a one-step, facile technique.

Pattern formation in thin polymeric films via electrohydrodynamic patterning

The free surface of a thin polymeric film is often unstable and deforms into various micro-/nano-patterns under an externally applied electric field. This paper reviews a recent patterning technique, electrohydrodynamic patterning (EHDP), a straightforward, cost-effective and contactless bottom-up method. The theoretical and numerical studies of EHDP are shown. How the characteristic wavelength and the characteristic time depend on both the external conditions (such as voltage, film thickness, template-substrate spacing) and the initial polymer properties (such as rheological property, electrical property and surface tension) is theoretically and experimentally discussed. Various possible strategies for fabricating high-aspect-ratio or hierarchical patterns are theoretically and experimentally reviewed. Aligning and ordering of the anisotropic polymers by EHDP is emphasized. A perspective, including novelty and limitations of the methods, particularly in comparison to some conventional patterning techniques, and a possible future direction of research, is presented.

Non-equilibrium thermal annealing of a polymer blend in bilayer settings for complex micro/nano-patterning

Micro phase separation in a thin film of a polymer blend leads to interesting patterns on different substrates. A plethora of studies in this field discussed the effect of the surface energy of the underlying tethered polymer brush or substrate on the final morphology of the polymer blend. The conventional process toward the final morphology is rather slow. Here, aiming fast lithography, we induce the kinetically driven morphological evolution by rapid thermal annealing (RTA) of the polymer blend of polystyrene (PS) and polymethylmethacrylate (PMMA) in bilayer settings at a very high temperature. The underlying film consists of untethered constituent homopolymers or their blend or random-co-polymer (RCP). Apart from the phase inversion of the blend on the PS homopolymer, a rich morphology of the blend on the RCP underlayer is uncovered with systematic investigation of the film using sequential washing with selective solvents. The dissolution characteristics and the thermal stability of the constituent polymers corroborated the observation. Based on the understanding of the morphological evolution, fabrication of a complex shaped micro/nano-pattern with multiple length scales is demonstrated using this blend/RCP system. This study shows a novel methodology for easy fabrication of hierarchical small length scale complex structures.

Parametric scheme for rapid nanopattern replication via electrohydrodynamic instability

Electrohydrodynamic (EHD) instability patterning exhibits substantial potential for application as a next-generation lithographic technique; nevertheless, its development continues to be hindered by the lack of process parameter controllability, especially when replicating sub-microscale pattern features. In this paper, a new parametric guide is introduced. It features an expanded range of valid parameters by increasing the pattern growth velocity, thereby facilitating reproducible EHD-driven patterning for perfect nanopattern replication. Compared with conventional EHD-driven patterning, the rapid patterning approach not only shortens the patterning time but also exhibits enhanced scalability for replicating small and geometrically diverse features. Numerical analyses and simulations are performed to elucidate the interplay between the pattern growth velocity, fidelity of the replicated features, and boundary between the domains of suitable and unsuitable parametric conditions in EHD-driven patterning. The developed rapid route facilitates nanopattern replication using EHD instability with a wide range of suitable parameters and further opens up many opportunities for device applications using tailor-made nanostructures in an effective and straightforward manner.

1/τ_m-dependent electrohydrodynamic replication of a hexagonally ordered hole array nanopattern by adjusting the filling ratio. As the 1/τ_m increases, the morphology evolves into the perfectly replicated hole features with increasing filling ratio.

Electrodynamic-contact-line-lithography with nematic liquid crystals for template-less E-writing of mesopatterns on soft surfaces

We report the development of a single-step, template-less and fast pathway, namely, Electrodynamic-Contact-Line-Lithography (ECLL), to write micro to nanopatterns on the surface of a soft polymer film. As a model system, a layer of nematic liquid crystals (NLC), resting on a polymer thin film, was sandwiched between a pair of electrodes emulating the electrowetting on a dielectric (EWOD) setup. Upon the application of electric field, the Maxwell stresses thus generated at the NLC-polymer interface due to the high dielectric contrast stimulated an unprecedented fingering instability at the advancing NLC-polymer-air contact line. In the process, the advancing electrospreading front of NLC left the footprint of an array of micro to nanoscale wells on the polymer surface with a long-range ordering thus unveiling a pathway for maskless patterning of a soft elastic film. Unlike the conventional electric field induced lithography (EFL), the meso-scale morphology was found to follow the short wavelength-scales as the periodicity of the patterns (λ_c) varied linearly with the thickness of the film (h), (λ_c∝h). The high dielectric contrast at the NLC-polymer interface and the local fluctuation of the NLC directors ensured a time scale much faster than the same observed for the polymer-air systems.

Reversible morphological switching and deformation hysteresis in electric field mediated instability of thin elastic films

Reversible morphology switching in a soft elastic film sandwiched between two parallel electrodes when subject to an externally applied electric field is reported herein. In contrast to electric field mediated instability of a thin liquid film, where the instability patterns remain permanent, in the present case the patterns debond completely or partially when the electric field is switched off, depending on whether the gap spacing (dG) between the film and the top electrode is >100 nm or not. The onset of instability is marked with the appearance of isotropic columns when the applied field strength (U) exceeds a critical value (Uc). The subsequent increase in U leads to the gradual transition of the instability patterns from pillars to bi-continuous labyrinths to an array of holes. Complete conformal contact is established between the film and the top electrode at U = UF. When U is reduced, the morphology changes in a reverse sequence. There is a significant level of hysteresis between the bonding and debonding stages, including persistence of the features at much lower voltages due to pinning of the patterns to the top electrode. Complete detachment occurs at a lower voltage UD when dG > 100 nm. The holes fluctuate before complete contact between the film and the top electrode due to competition between the destabilizing electric field and restoring forces due to stretching of the crosslinked polymer matrix.

Electric field mediated elastic contact lithography of thin viscoelastic films for miniaturized and multiscale patterns

Elastic contact lithography (ECL) and electric field lithography (EFL) have both shown significant potential to develop large-area micropatterns on polymeric surfaces. Recently, the major challenges associated with these processes have been the improvement of the aspect ratio and reduction in the size and periodicity of the patterns fabricated. Herein, with the help of non-linear simulations, we show that combining these methods can be one recipe to overcome these limitations. We consider a linear viscoelastic film for the linear and non-linear analyses. In this regard, we explore the role of the moving contactor to improve the aspect ratio of the patterns. The study uncovers that (i) combined destabilizing influences originating from van der Waals and electric field forces ensure smaller timescales and length scales for the instabilities, (ii) the aid from the electric field helps to improve the minimum separation distance so that the contact instability initiates at a larger separation distance, (iii) a long-range ordering can be inflicted on the patterns on the polymer surfaces when electrodes with periodic physicochemical patterns are used and (iv) the strength of the externally applied electric field and the ratio of elastic to viscous compliance of the film play crucial roles in deciding the different modes of debonding of the film - peeling, catastrophic or coalescence. The proposed method can improve the aspect ratio of patterns by ∼9-fold during the peeling mode of debonding. Furthermore, pathways to develop technologically important biomimetic surfaces with multiscale and hierarchical structures have been shown.

Making Nonsticky Surfaces of Sticky Materials: Self-Organized Microtexturing of Viscoelastic Elastomeric Layers by Tearing

Fabrication of large area, multiscale microtextured surfaces engineered for antiadhesion properties remains a challenge. Compared to an elastic surface, viscoelastic solids show much higher surface stickiness, tack, and adhesion owing to the increased contact area and energy dissipation. Here, we show a simple, low cost, large-area and high throughput method with roll-to-roll compatibility to fabricate multiscale, rough microstructures resistant to adhesion in a viscoelastic layer by controlled tearing of viscous film. Even a high adhesive strength viscoelastic solid layer, such as partially cured PDMS, is made nonsticky simply by its controlled tearing. The torn surface shows a fracture induced, self-organized leaflike micropattern resistant to sticking. The topography and adhesion strength of these structures are readily tuned by changing the tearing speed and the film thickness. The microtexture displays a springlike recovery, low adhesive strength, and easy release properties even under the high applied loads.

Adhesion-induced fingering instability in thin elastic films under strain

In this study, thin elastic films supported on a rigid substrate are brought into contact with a spherical glass indenter. Upon contact, adhesive fingers emerge at the periphery of the contact patch with a characteristic wavelength. Elastic films are also pre-strained along one axis before the initiation of contact, causing the fingering pattern to become anisotropic and align with the axis along which the strain was applied. This transition from isotropic to anisotropic patterning is characterized quantitatively and a simple model is developed to understand the origin of the anisotropy.

Synergistic Effects of Electric-Field-Assisted Annealing and Thermal Annealing in Bulk-Heterojunction Solar Cells

We propose an optimum low-temperature-based annealing procedure for semicrystalline donor-fullerene solar cells that is well-suited for plastic and flexible substrates. This proposed alternate strategy utilizes an external electric field (EF) across the bulk heterojunction (BHJ) film during processing at a desired temperature. This processing technique is studied for different molecular weights of the donor in the BHJ blend films. The films indicate an increase in interchain interactions of the semicrystalline polymer chains and an enhancement in hole mobility with EF-assisted annealing treatment. Besides being a controlled method, this processing technique is capable of yielding solar cell devices with performance equivalent to or better than those obtained using plain thermal procedures.

Generation of Hierarchically Ordered Structures on a Polymer Film by Electrohydrodynamic Structure Formation

The extensive applications of hierarchical structures in optoelectronics, micro/nanofluidics, energy conservation, etc., have led to the development of a variety of approaches for their fabrication, which can be categorized as bottom-up or top-down strategies. Current bottom-up and top-down strategies bear a complementary relationship to each other due to their processing characteristics, i.e., the advantages of one method correspond to the disadvantages of the other, and vice versa. Here we propose a novel method based on electrohydrodynamic structure formation, aimed at combining the main advantages of the two strategies. The method allows the fabrication of a hierarchically ordered structure with well-defined geometry and high mechanical durability on a polymer film, through a simple and low-cost process also suitable for mass-production. In this approach, upon application of an electric field between a template and a substrate sandwiching an air gap and a polymer film, the polymer is pulled toward the template and further flows into the template cavities, resulting in a hierarchical structure with primary and secondary patterns determined by electrohydrodynamic instability and by the template features, respectively. In this work, the fabrication of a hierarchical structure by electrohydrodynamic structure formation is studied using numerical simulations and experimental tests. The proposed method is then employed for the one-step fabrication of a hierarchical structure exhibiting a gradual transition in the periodicity of the primary structure using a slant template and a flat polymer film, which presents an excellent performance on controllable wettability.

One-Step Fabrication of Microchannels Lined with a Metal Oxide Coating

We demonstrate a simple, single-step method for metal/metal oxide coating on interior walls of microchannels in an elastomeric material like PDMS, which is the mainstay of microfluidic devices. The fabrication process involves electrodeposition of cuprous oxide on a metallic wire or a sheet, embedding it inside a PDMS matrix along with the cross-linker, curing and then swelling the PDMS elastomer, and finally pulling out the template metal wire or the metal sheet from the PDMS matrix. Stronger attachment of the metal oxide layer to PDMS allows the transfer of the metal oxide coating originally present on the template surface (wire or sheet) to the channel wall resulting in a microchannel/microslit lined with the metal/metal oxide layer. In view of the catalytic activity associated with transition metal oxides, this simple method offers a cost-effective and versatile technique to fabricate microfluidic and lab-on-a-chip devices which can be utilized as microcatalytic reactors or chemical filters. As a proof of concept, we have successfully tested the metal oxide coated microchannels and microslits as active sites for adsorption of iodide ions.

Electrically-tunable surface deformation of a soft elastomer

The flat surface of a thin elastomer on a conducting substrate can be deformed by applying an electric field to a percolating network of metallic nanowires randomly dispersed over the surface. The magnitude of the field-induced surface undulations increases with the applied field and can locally be several times the diameter of the nanowires. Optical imaging indicates that the effect is reversible and the surface flatness is recovered when the electric field is removed. It is found that it is the field-induced changes in the surface morphology rather than the nanowires themselves that strongly scatter light. The optical effects could be exploited in functional devices including tunable privacy windows, displays, and camouflage. There is also the potential for tuning the adhesion of elastomers to other materials.

Influence of electrode types on the electrohydrodynamic instability patterning process: a comparative study

A polymer film resting on a planar substrate under the influence of a electric field. (A) A conductive patterned electrode. (B) A conductive pattern on a dielectric substrate.

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.

Miniaturized pattern formation in elastic films cast on sinusoidally patterned substrates

The various morphologies that are formed when van der Waals forces or electric field is induced between film cast on a sinusoidal substrate and in contact proximity with a contactor or electrode are studied. Remarkably smaller length scales are achieved (λc < 2.96h) than those obtained with films cast on flat substrates. With van der Waals interactions, the patterns are uniformly formed throughout the film but are not regularly ordered. When electric field is used at critical voltage, more ordered, localized patterns are formed at the zones of large local interaction strengths. When these patterns are evolved by increasing the applied voltage, coexistence of all three phases-cavities, stripes, and columns-is observed throughout the film. The localized patterns that are initially formed vary with the voltage applied and strongly dictate the phases of evolution. A patterned substrate/patterned contactor assembly can be made to operate like its unpatterned counterpart by making the interaction strength same everywhere and yet yield uniform, regularly ordered, highly miniaturized patterns. Such patterns are very useful in various applications like microfluidics; they are formed with great ease and can be morphologically tuned by tuning the externally applied electric field.

Biomimetic mushroom-shaped microfibers for dry adhesives by electrically induced polymer deformation

The studies on bioinspired dry adhesion have demonstrated the biomimetic importance of a surface arrayed with mushroom-shaped microfibers among other artificially textured surfaces. The generation of a mushroom-shaped microfiber array with a high aspect ratio and a large tip diameter remains to be investigated. In this paper we report a three-step process for producing mushroom-shaped microfibers with a well-controlled aspect ratio and tip diameter. First, a polymer film coated on an electrically conductive substrate is prestructured into a low-aspect-ratio micropillar array by hot embossing. In the second step, an electrical voltage is applied to an electrode pair composed of the substrate and another conductive planar plate, sandwiching an air clearance. The Maxwell force induced on the air-polymer interface by the electric field electrohydrodynamically pulls the preformed micropillars upward to contact the upper electrode. Finally, the micropillars spread transversely on this electrode due to the electrowetting effect, forming the mushroom tip. In this paper we have demonstrated a polymer surface arrayed with mushroom-shaped microfibers with a large tip diameter (3 times the shaft diameter) and a large aspect ratio (above 10) and provided the testing results for dry adhesion.

Intrinsic viscoelasticity in thin high-molecular-weight polymer films

The rheology of 44-75-nm-thick polystyrene films were probed by destabilization in an electric field. The non-cross-linked films showed the hallmark of viscoelasiticy; they exhibited elastic behavior at high shear rates and viscous rheology at low shear rates for stationary applied fields. These results are interpreted in terms of surface adhesion of chain segments in contact with the substrate surface, which substantially reduces reptative molecular motion of nearly all chains within the film.

Electrokinetic model for electric-field-induced interfacial instabilities

Technology based on electric-field-induced instabilities on thin polymer film surfaces has emerged as a promising candidate for soft lithography. Typically, the instability is modeled using the perfect dielectric (PD) or the leaky dielectric (LD) model. These assume the electric diffuse layer to be infinitesimally large or small, respectively. In the present work we conduct stability analysis assuming a PD-electrolyte solution interface. The concentration of ions and, hence, the diffuse layer thickness is in general assumed to be of the same order as the electrolyte film thickness. The PD-LD models are then realized as limiting cases of the ratio of the double layer thickness to the film thickness.

Creasing-wrinkling transition in elastomer films under electric fields

Creasing and wrinkling are different types of instabilities on material surfaces characterized by localized singular folds and continuously smooth undulation, respectively. While it is known that electric fields can induce both types of instabilities in elastomer films bonded on substrates, the relation and transition between the field-induced instabilities have not been analyzed or understood. We show that the surface energy, modulus, and thickness of the elastomer determine the types, critical fields, and wavelengths of the instabilities. By independently varying these parameters of elastomers under electric fields, our experiments demonstrate transitions between creases with short wavelengths and wrinkles with long wavelengths. We further develop a unified theoretical model that accounts for both creasing and wrinkling instabilities induced by electric fields and predicts their transitions. The experimental data agree well with the theoretical model.

Debonding energy of PDMS: A new analysis of a classic adhesion scenario

We investigated the debonding energy between confined layers of a soft elastic solid (PDMS) and a circular steel indenter in a flat punch geometry. PDMS is extensively used in applications, but also a widespread model system for fundamental research. Varying systematically the pulling speed and the viscoelastic properties, notably the modulus, we determined scaling laws for the debonding energy. We showed that the debonding energy is independent of the sample thickness. Applying a new approach and separating the crack initiation and the propagation part of the force curves, we analyzed the thickness dependence more precisely and we demonstrated that the energy to propagate the crack at given average speed does not only depend on the modulus, but also on the sample thickness.

Squeezing instabilities and delamination in elastic bilayers: a linear stability analysis

A linear stability analysis is presented to understand the instabilities that arise in an elastic bilayer, consisting of a very thin bottom layer (thickness < 100 nm) that acts as a wetting film and a top layer that acts as an adhesive film, when placed in contact proximity with an external rigid contactor. Depending on whichever layer is more compliant, "squeezing modes" of instability with a variety of length scales ranging from <<3h to <<3h (h: bilayer thickness) are found to be possible. The least length scales obtained are 0.1h. The squeezing instabilities are, however, accompanied by delamination of the film-film interface. The instability length scales, the strength of interactions required, and the delamination decrease as the compliance of the top film increases. Surface tension effects are found to have a stabilizing influence which increases the instability length scales and decreases the degree of delamination at the cost of high interaction penalty.

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.

Role of conductivity in the electrohydrodynamic patterning of air-liquid interfaces

The effect of electrical conductivity on the wavelength of an electrohydrodynamic instability of a leaky dielectric-perfect dielectric (LD-PD) fluid interface is investigated. For instabilities induced by dc fields, two models, namely the PD-PD model, which is independent of the conductivity, and the LD-PD model, which shows very weak dependence on the conductivity of the LD fluid, have been previously suggested. In the past, experiments have been compared with either of these two models. In the present work, experiments, analytical theory, and simulations are used to elucidate the dependence of the wavelength obtained under dc fields on the ratio of the instability time (τs=1/smax) and the charge relaxation time (τc=εε0/σ, where ε0 is the permittivity of vacuum, ε is the dielectric constant, and σ is the electrical conductivity). Sensitive dependence of the wavelength on the nondimensional conductivity S2=σ2μ2h0(2)/(ε0(2)φ0(2)δ2) (where σ2 is the electrical conductivity, μ2 is the viscosity, h0 is the thickness of the thin liquid film, φ0 is the rms value of the applied field, and δ is a small parameter) is observed and the PD-PD and the LD-PD cases are observed only as limiting behaviors at very low and very high values of S2, respectively. Under an alternating field, the frequency of the applied voltage can be altered to realize several regimes of relative magnitudes of the three time scales inherent to the system, namely τc, τs, and the time period of the applied field, τf. The wavelength in the various regimes that result from a systematic variation of these three time scales is studied. It is observed that the linear Floquet theory is invalid in most of these regimes and nonlinear analysis is used to complement it. Systematic dependence of the wavelength of the instability on the frequency of the applied field is presented and it is demonstrated that nonlinear simulations are necessary to explain the experimental results.

Dynamic electrostatic lithography: multiscale on-demand patterning on large-area curved surfaces

Dynamic electrostatic lithography is invented to dynamically generate various patterns on large-area and curved polymer surfaces under the control of electrical voltages. The shape of the pattern can be tuned from random creases and craters to aligned creases, craters and lines, and the size of the pattern from millimeters to sub-micrometers.

Creating self-organized submicrometer contact instability patterns in soft elastic bilayers with a topographically patterned stamp

The surface of a thin elastic bilayer becomes spontaneously unstable when it is brought in proximity to another rigid contactor. The instability patterns, which are random and isotropic, exhibit a dominant lateral length scale of instability λ, which linearly scales with the bilayer thickness (h) as: λ = R(F)h. It is known that for an elastic bilayer, R(F) exhibits a nonlinear dependence on the ratios of individual film thicknesses (H) and shear moduli (M) of the two constituent layers, and can have values as low as 0.5 under specific conditions. This is in contrast to a near constant value of R(F) ≈ 3 for a single layer elastic film. (1) These isotropic contact instability patterns in a bilayer can be ordered, aligned and modulated using a topographically patterned stamp. The precise morphology of the aligned structures depends on commensuration between λ and the stamp periodicity (λ(P)), and on the intersurface separation distance. A variety of patterns, like an array of circular holes, double periodic channels, etc., in addition to a positive and a negative replica of the stamp pattern, can be engineered with a simple stamp having 1D grating structure. A lower value of R(F) in a bilayer allows generating patterns with sub 500 nm lateral resolution, which is impossible to create by elastic contact lithography (ECL) of a single layer film due to strong surface tension effects in ultrathin films. Thus, control of elastic instability in a bilayer with a patterned stamp represents a flexible soft lithography tool allowing modulation of length scales, morphology, and order.

Instabilities of soft elastic microtubes filled with viscous fluids: pearls, wrinkles, and sausage strings

A linear stability analysis is presented to study the self-organized instabilities of a highly compliant elastic cylindrical shell filled with a viscous liquid and submerged in another viscous medium. The prototype closely mimics many components of micro- or nanofluidic devices and biological processes such as the budding of a string of pearls inside cells and sausage-string formation of blood vessels. The cylindrical shell is considered to be a soft linear elastic solid with small storage modulus. When the destabilizing capillary force derived from the cross-sectional curvature overcomes the stabilizing elastic and in-plane capillary forces, the microtube can spontaneously self-organize into one of several possible configurations; namely, pearling, in which the viscous fluid in the core of the elastic shell breaks up into droplets; sausage strings, in which the outer interface of the mircrotube deforms more than the inner interface; and wrinkles, in which both interfaces of the thin-walled mircrotube deform in phase with small amplitudes. This study identifies the conditions for the existence of these modes and demonstrates that the ratios of the interfacial tensions at the interfaces, the viscosities, and the thickness of the microtube play crucial roles in the mode selection and the relative amplitudes of deformations at the two interfaces. The analysis also shows asymptotically that an elastic fiber submerged in a viscous liquid is unstable for Y=γ/(G(e)R)>6 and an elastic microchannel filled with a viscous liquid should rupture to form spherical cavities (pearling) for Y>2, where γ, G(e), and R are the surface tension, elastic shear modulus, and radius, respectively, of the fiber or microchannel.

Linear stability analysis of electrohydrodynamic instabilities at fluid interfaces in the "small feature" limit

The endeavour to effectively harness interfacial electrohydrodynamic instabilities, to create small patterns, involves reducing the wavelength of the instability. This can be accomplished by decreasing the separation between the electrodes which may not always be possible. One may therefore have to reduce the surface tension or increase the applied voltage at a fixed electrode spacing. This can result in the wavelength of the pattern becoming of the same order as the electrode separation. Pease and Russel (J. Chem. Phys. 118, 3790 (2003)) were the first to argue that the commonly used Thin-Film Approximation (TFA) that involves an asymptotic expansion in the small parameter δ = (ε(0) φ(0)(2)/(γh(0)))(1/2) (where ε (0) is the permittivity of vacuum, φ (0) is the root mean square value of the applied potential, γ is the surface tension and h (0) is the thickness of the thin film) need not always be valid and γ may not be small in experiments. Higher-order corrections to the TFA might therefore be necessary. We extend the Direct Current (DC) field analysis of Pease and Russel to an Alternating Current (AC) field. AC field has been suggested as an effective way of controlling the wavelength of electrohydrodynamic instabilities at fluid-fluid interfaces. Infact, the perfect and leaky dielectric limits can be realised in the same fluid at very high and very low electric field frequencies, respectively. Recently, Roberts and Kumar (J. Fluid Mech. 631, 255 (2009)) carried out an analysis using TFA to investigate AC-field-induced instabilities at air-polymer interfaces. We propose a Generalized Model (GM), without the lubrication approximation, and carry out detailed comparison with the TFA. We consider the top fluid to be air, a perfect dielectric, and the bottom fluid to be a perfect or a leaky dielectric. The analysis is carried out for both DC and AC fields, and the deviation from TFA is expressed in terms of the parameter B = γh(0)/(ε(0) φ(0)(2) ) = δ(-2). We discuss variation of the wavelength of the fastest growing mode with frequency of the applied field for any arbitrary value of B, unlike the analysis of Roberts and Kumar which is restricted to B ≫ 1(δ ≪ 1) . We also revisit the analysis of Pease and Russel for instabilities under DC field and present the results in terms of the single parameter, B.

Creasing to cratering instability in polymers under ultrahigh electric fields

We report a new type of instability in a substrate-bonded elastic polymer subject to an ultrahigh electric field. Once the electric field reaches a critical value, the initially flat surface of the polymer locally folds against itself to form a pattern of creases. As the electric field further rises, the creases increase in size and decrease in density, and strikingly evolve into craters in the polymer. The critical field for the electrocreasing instability scales with the square root of the polymer's modulus. Linear stability analysis overestimates the critical field for the electrocreasing instability. A theoretical model has been developed to predict the critical field by comparing the potential energies in the creased and flat states. The theoretical prediction matches consistently with the experimental results.

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.

Embedded microstructures by electric-field-induced pattern formation in interacting thin layers

Electric-field-induced interfacial instabilities and pattern formation in a pair of interacting thin films are analyzed on the basis of linear stability analysis and long-wave nonlinear simulations. The films are coated onto two parallel plate electrodes and separated by an air gap between them. A linear stability analysis (LSA) is carried out for viscoelastic films to show that the ratios of material properties to films thickness control the length scale and timescale significantly and the presence of the second layer increases the overall capacitance and thus can lead to a smaller length scale as compared to the instability in a single film. Long-wave nonlinear analysis for interacting viscous layers indicates that the instabilities are always initiated by the antiphase squeezing rather than the in-phase bending mode of deformation at the interfaces. Nonlinear simulations on patterned electrodes show that this novel geometry for electric field patterning can be employed to generate intricate, embedded 3-D periodic patterns and to miniaturize patterns. Simulations are presented for e-molding of a number of periodic self-organized patterns such as pincushion structures, straight/corrugated embedded microchannels, and microbubbles. A few interesting examples are also shown where (1) the pathway of evolution changes without altering the equilibrium morphology when kinetic parameters such as viscous forces are changed and (2) the self-organized equilibrium morphology does not reproduce the underlying patterns on the electrodes.

A unified theory of instabilities in viscoelastic thin films: from wetting to confined films, from viscous to elastic films, and from short to long waves

A general unified theory of field (van der Waals, electric, etc.)-induced surface instabilities in thin viscoelastic films that accounts for a destabilizing field and stabilizing effects of elastic strain and surface energy is presented. The present theory seamlessly covers the instability and its different regimes in films ranging from elastic to viscous, from adhesive (confined) to wetting (free surface), and from short- to long-wave instabilities. The critical conditions for the onset of instability are found to be strongly dependent on elastic properties such as the shear modulus of the film, but the dominant wavelength is strikingly independent of the film rheology. Different regimes based on a nondimensional parameter (gamma/mu h) are uncovered, where gamma is the surface energy, mu is the elastic shear modulus, and h is the film thickness. A short-wave, elasticlike response with wavelength lambda approximately = 2.96 h is obtained for gamma/mu h < 0.1, whereas long waves that depend nonlinearly on the field strength and surface energy are obtained for gamma/mu h > 1. Owing to their small critical thickness, wetting films destabilized by intermolecular forces always display long-wave instability regardless of their viscoelasticity. Furthermore, our numerical simulations based on energy minimization for unstable wetting elastic films show the formation of islands for ultrathin films and a morphological phase transition to holes embedded in the film for relatively thicker films. Unlike viscous films, however, unstable elastic films do not display a unique dominant wavelength but a bimodal distribution of wavelengths.

Observation of Bessel beams from electric-field-induced patterns on polymer surfaces

We report the observation of Bessel-like beams from periodic patterns induced on viscoelastic polymer surfaces by electric field. The patterns resembling a microaxicon array originate from electrohydrodynamic instabilities in polymer films, where the feature dimensions can be easily controlled. The output beam characteristics from these patterns revealed characteristic traits of Bessel beams.