Meniscus instability in a thin elastic film

Real-Time Visualization of Single Polymer Conformational Change in the Bulk State during Mechanical Deformation

Although polymers are most often used within bulk materials, investigating their conformations and dynamics has long been a challenging endeavor in this configuration, particularly under external forces. Addressing this, we utilize single-molecule localization microscopy as a powerful imaging tool to visualize bottlebrush poly(n-butyl acrylate) chains in the bulk state under spherical indentation, quantitatively describing changes in behavior of single polymer chains. We compare these experiments to displacement fields determined analytically and confirmed through finite element analysis. This study pioneers visualizing polymer conformational changes in their native environment in situ, offering transformative insights into polymer behavior and dynamics.

Superwetting Gels: Wetting Principles, Applications, and Challenges

Along with the in-depth understanding of wetting behaviors in nature, superwetting gels have received a lot of attention in the past decade. The viscoelasticity of gel materials makes wetting characteristics different from those of rigid materials and brings diverse functionality. In this Review, we summarize the current progress in principles of gel wettability from two aspects: wetting on gels and wetting of gels. Distinct from rigid substrates, the viscoelasticity and solid-liquid coexistence of gel materials introduce additional factors, including surface tension and deformation, resulting in various wetting phenomena. Besides, the similarity between gels and tissues broadens its applications in biomedical devices and smart interfacial regulation. We further conclude the current application that utilizes superwetting gels. Finally, we provide our perspective for future research directions.

Strain on the upper surface of a perpendicularly peeled soft film

Soft films serve as the primary support materials for flexible devices. These films are frequently peeled perpendicularly during device preparation and application, resulting in large compression on the upper surface of the bending region and significant damage to the device's performance. Accurately assessing this damage is challenging because of the difficulties in calculating the compression in perpendicularly peeled large-deformation films. In this study, we propose a method to calculate the compressive strain on the upper surface of a bending soft film using only its thickness as the key parameter. Furthermore, we demonstrate that the length of the compressive region is directly proportional to the soft film thickness, whereas the maximum strain is inversely proportional to the thickness. These results provide theoretical guidance for applying soft films in flexible devices.

Rayleigh-Taylor Instability in Soft Viscoelastic Solids

We present an experimental characterization of the gravity-driven Rayleigh-Taylor instability in viscoelastic solids. The instability creates periodic patterns on the free surface of the soft solids that are distinct from the previously studied elastic Rayleigh-Taylor instability. The experimental results are supported by the linear stability analysis reported here. We identify the dependence of the steady-state pattern of deformations on the gel's geometry, complex shear modulus, and surface tension. This study provides quantitative measures applicable to the design of tunable surface textures, soft machines, and 3D structures.

Interface Stabilization in Adhesion Caused by Elastohydrodynamic Deformation

Interfacial instabilities are common phenomena observed during adhesion measurements involving viscoelastic polymers or fluids. Typical probe-tack adhesion measurements with soft adhesives are conducted with rigid probes. However, in many settings, such as for medical applications, adhesives make and break contact from soft surfaces such as skin. Here we study how detachment from soft probes alters the debonding mechanism of a model viscoelastic polymer film. We demonstrate that detachment from a soft probe suppresses Saffman-Taylor instabilities commonly encountered in adhesion. We suggest the mechanism for interface stabilization is elastohydrodynamic deformation of the probe and propose a scaling for the onset of stabilization.

Swelling induced debonding of thin hydrogel films grafted on silicon substrates

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

Rate-Dependent Pattern Evolution in Peeling Adhesive Tape Driven by Cohesive Failure

In the case of low-rate peeling, an adhesive can undergo a large tensile deformation through the viscous flow and form the fingering pattern at the peeling interface, resulting in homogeneous stripes on the peeled surface. In the case of high-rate peeling, no larger viscous deformation occurs, and no surface patterns will be generated. However, it is still unclear how the surface pattern evolves when an adhesive is peeled from a relatively low rate to a high rate. Here, by peeling an adhesive tape at 180° over a wide range of rates, we find that the adhesive tape can undergo a steady peeling. As the peeling rate increases, it is observed that the surface pattern in the peeled adhesive tape tends to evolve from the initial striped pattern to a crescent pattern, then to a spotted pattern. Even in the case of the stick-slip peeling at a small angle, the patterned region also presents the same evolutionary trend. By exploiting a high-speed camera to track the deformation process of the adhesive, it is found that this evolution is actually driven by the cohesive failure of the peeling adhesive. We describe the failure process, revealing the formation mechanism of the crescent pattern. We also discuss the effect of the peeling rate on the interface instability morphology by combining the finite element simulations, elucidating how the surface pattern evolves with the peeling rate.

Debonding of a soft adhesive fibril in contact with an elastomeric pillar

The debonding criterion of fibrils of soft adhesive materials is a key element regarding the quantitative modelisation of pressure sensitive adhesive tapes' peeling energy. We present in this article an experimental study of the detachment of a commercial acrylic adhesive tape from the top surface of a single micrometric pillar of PDMS elastomer. During an experiment, the pillar and the adhesive, after being put in contact, are separated at a constant displacement rate, resulting in the formation, the elongation and the final detachment of a fibril of adhesive material. A systematic study allows us to uncover power laws for the maximum force and the critical elongation of the fibril at debonding as a function of the diameter of the cylindrical pillar which controls the diameter of the fibril. The scaling law evidenced for the critical elongation appears as a first step toward the understanding of the debonding criterion of fibrils of soft adhesive materials. In addition, viscoelastic digitation at the triple debonding line is observed during detachment for large pillar diameters. The wavelength and penetration length of the fingers that we report appear to be consistent with existing models based on pure elastic mechanical response.

Hydrodynamic Fingering Induced by Gel Film Formation in Miscible Fluid Systems: An Experimental and Mathematical Study

Hydrodynamic fingering induced by gel formation shares common features with growing biofilms, bacterial colonies, and the instability of a confined chemical garden. Fluid displacement with gel formation is also essential in various engineering applications, including CO2 leakage remediation from storage reservoirs and enhanced oil recovery. We conducted Hele-Shaw cell displacement experiments for a miscible fluid system using skim milk and aqueous citric acid solution. This study aimed to investigate the effects of gel film formation on the fingering instability of a miscible fluid system and develop a mathematical model of the sequential growth of gel film formation at the fingertip. We found that the gel film formation thickens with time, resulting in instability at the interface. A distinctive fingering pattern, resembling tentacles, appears where miscibility is suppressed, and the growth of the finger is localized at the fingertip. The finger width remains constant with increasing flow rate, whereas the number of fingers increases linearly before the fingers merge. The gap width significantly limits the finger width. Finally, a mathematical model of sequential film thickness growth for a bubble-like fingertip structure was developed. This model is based upon the interplay between the diffusion of citric acid through the existing gel film formation and elongation of the fingertip. The model provides an understanding of the fundamental mechanism of the growth of the bubble-like fingertip.

Adhesion-Induced Instability Regulates Contact Mechanics of Soft Thin Elastic Films

Adhesive contact of soft materials plays an essential role in flexible electronics, soft robots, and biological systems. Classical contact mechanics theories assume that the contact region between a spherical indenter and a flat surface is circular. In this paper, however, we show that fingering instability and inner cavitation may appear and disappear during the loading-unloading process when a soft thin elastic film is indented with a spherical indenter. We further demonstrate that this adhesion-induced instability can enhance the resistance to deformation and thus significantly increase contact force. Finally, we find an important dimensionless number, defined as the ratio of adhesion energy to elastic energy, and thus reveal that the competition between adhesion energy and elastic energy yields the critical condition for adhesion-induced instability. Thus, our findings bridge the gap between contact mechanics and interfacial instabilities of soft materials and may have many important implications for the applications of soft materials.

Fingering instability during fracture of a gel block subjected to shear loading

We report here an alternative kind of fingering instability observed during fracture of an unconfined gel consisting of two cuboids joined by a thin gel disk, and all prepared monolithically. When the blocks are sheared across the joint, fracture ensues with the appearance of fingers at the fracture front. The spacing between the fingers remains independent of the shearing speed, planar shape of the joint, and the shear modulus of gel. Importantly this instability appears without any effect of confinement of the gel block, and its wavelength remains dependent on the lateral size of the disk, in contrast to all known instances of fingering phenomena in confined viscous, elastic, and viscoelastic systems.

Chemically Coupled Interfacial Adhesion in Multimaterial Printing of Hydrogels and Elastomers

Functional devices that use hydrogels as ionic conductors and elastomers as dielectrics have the advantage of being soft, stretchable, transparent, and biocompatible, making them ideal for biomedical applications. These devices are typically fabricated by manual assembly. Techniques for the manufacturing of soft materials have generally not looked at integrating multiple dissimilar materials. Silane coupling agents have recently shown promise for creating strong bonds between hydrogels and elastomers but have yet to be used in the extrusion printing of complex devices that integrate both hydrogels and elastomers. Here, we demonstrate the viability of silane coupling agents in a system with the rheology and functional composition necessary for three-dimensional (3D) extrusion printing of hydrogel-elastomer materials, specifically polyacrylamide (PAAm) hydrogel and poly(dimethylsiloxane) (PDMS) hydrophobic elastomer. By introducing a charge-neutral surfactant in the PDMS and adjusting silane concentrations in the PAAm, cast material samples demonstrate strong adhesion. We were also able to achieve an interfacial toughness of up to Γ = 193 ± 6.3 J/m² for a fully extrusion printed PAAm hydrogel-on-PDMS bilayer. This result demonstrates that an integration strategy based on silane coupling agents makes it possible for extrusion printing of a wide variety of hydrogel and silicone elastomers.

The shape of hanging elastic cylinders

Deformations of heavy elastic cylinders with their axis in the direction of earth's gravity field are investigated. The specimens, made of polyacrylamide hydrogels, are attached from their top circular cross section to a rigid plate. An equilibrium configuration results from the interplay between gravity that tends to deform the cylinders downwards under their own weight, and elasticity that resists these distortions. The corresponding steady state exhibits fascinating shapes which are measured with lab-based micro-tomography. For any given initial radius to height ratio, the deformed cylinders are no longer axially symmetric beyond a critical value of a control parameter that depends on the volume force, the height and the elastic modulus: self-similar wrinkling hierarchies develop, and dimples appear at the bottom surface of the shallowest samples. We show that these patterns are the consequences of elastic instabilities.

Bending to Kinetic Energy Transfer in Adhesive Peel Front Microinstability

We report an extensive experimental study of a detachment front dynamics instability, appearing at microscopic scales during the peeling of adhesive tapes. The amplitude of this instability scales with its period as A_{mss}∝T_{mss}^{1/3}, with a prefactor evolving slightly with the peel angle θ, and increasing systematically with the bending modulus B of the tape backing. Establishing a local energy budget of the detachment process during one period of this microinstability, our theoretical model shows that the elastic bending energy stored in the portion of tape to be peeled is converted into kinetic energy, providing a quantitative description of the experimental scaling law.

Peeling an elastic film from a soft viscoelastic adhesive: experiments and scaling laws

The functionality of adhesives relies on their response under the application of a load. Yet, it has remained a challenge to quantitatively relate the macroscopic dynamics of peeling to the dissipative processes inside the adhesive layer. Here we investigate the peeling of a reversible adhesive made of a polymer gel, measuring the relationship between the peeling force, the peeling velocity, and the geometry of the interface at small-scale. Experiments are compared to a theory based on the linear viscoelastic response of the adhesive, augmented with an elastocapillary regularization approach. This theory, fully quantitative in the limit of small surface deformations, demonstrates the emergence of a "wetting" angle at the contact line and exhibits scaling laws for peeling which are in good agreement with the experimental results. Our findings provide a new strategy for design of reversible adhesives, by quantitatively combining wetting, geometry and dissipation.

Adhesion between Hydrophobic Elastomer and Hydrogel through Hydrophilic Modification and Interfacial Segregation

Recent progress in the printing of soft materials has made it possible to fabricate soft stretchable devices for a range of engineering applications. These devices tend to be heterogeneous systems, and their reliability depends to a large extent on the integrity of the interfaces between the various materials in the system. Previous studies on the printing of hydrogels have highlighted the need to investigate the adhesion between extrusion printable dielectric elastomers and hydrogels. Here we consider polydimethylsiloxane (PDMS) and a polyacrylamide hydrogel that contains lithium chloride and a nonionic rheological modifier. We show that the adhesion between oxygen plasma-treated PDMS and the hydrogel increases with time to reach a stable value of 15 J m^-2 after ∼6 days. During that time, the contact angle of water on the PDMS interface remains constant at ∼30°, suggesting that hydrophobic recovery of plasma-treated PDMS is suppressed by the presence of the hydrogel. It is further observed that a thin viscous layer develops at the interface between PDMS and hydrogel, which results in energy dissipation upon debonding and which allows full recovery of the adhesion after debonding and rejoining. This viscous layer develops only in the presence of the rheological modifier in the hydrogel and the hydrophilic surface treatment of the PDMS.

A review of Winkler's foundation and its profound influence on adhesion and soft matter applications

Few advanced mechanics of materials solutions have found broader and more enduring applications than Emil Winkler's beam on elastic foundation analysis, first published in 1867. Now, 150 years after its introduction, this concept continues to enjoy widespread use in its original application field of civil engineering, and has also had a profound effect on the field of adhesion mechanics, including for soft matter adhesion phenomena. A review of the model is presented with a focus on applications to adhesion science, highlighting classical works that utilize the model as well as recent usages that extend its scope. The special case of the behavior of plates on incompressible (e.g., elastomeric and viscous liquid) foundations is reviewed because of the significant relevance to the behavior of soft matter interlayers between one or more flexible adherends.

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.

The effect of shape on the fracture of a soft elastic gel subjected to shear load

For brittle solids, the fracture energy is the energy required to create a unit area of new surface through the process of division. For crosslinked materials, it is a function of the intrinsic properties like crosslinking density and bond strength of the crosslinks. Here we show that the energy released due to fracture can depend also on the shape of a joint made of this material. Our experiment involves two gel blocks connected via a thin gel disk. The disk is formed into different regular and exotic shapes, but with identical areas of cross-section. When one of the blocks is sheared with respect to the other, the shear load increases with vertical displacement, eventually causing a fracture at a threshold load. The maximum fracture load is different for different disks and among different regularly shaped disks, it is at a maximum for pentagon and hexagon shapes. The fracture energy release rate of the joint depends also on the aspect ratio (height/width) of the shapes. Our experiments also throw light on possible reasons for such a dependence on the shape of the joints.

Programmable Nanopatterns by Controlled Debonding of Soft Elastic Films

We report a facile patterning technique capable of creating nanostructures with different feature heights (h_S), periodicities (λ_S), aspect ratios (A_R), and duty ratios (D_R), using a single grating stamp with fixed feature height h_P and periodicity λ_P. The proposed method relies on controlling the extent of debonding and morphology of the contact instability features, when a rigid patterned stamp is gradually debonded from a soft elastic film to which it was in initial conformal contact. Depending on whether the instability wavelength (λ_F scales with the film thickness h_F as λ_F ≈ 3h_F) and the periodicity of the stamp feature (λ_P) are commensurate or not, it is possible to obtain features along each stamp protrusion when λ_F ≈ λ_P or patterns that span several stripes of the stamp when λ_F > λ_P. In both cases, the patterns fabricated during debonding are taller than the original stamp features (h_S > h_P). We show that h_S can be modulated by controlling the extent of debonding as well as the shear modulus of the film (μ). Additionally, when λ_F > λ_P, progressive debonding leads to the gradual peeling of replicated features, which, in turn, allows possible tuning of the duty ratio (D_R) of the patterns. Finally we show that by the simultaneous modulation of A_R, D_R, and h_S, it becomes possible to create surfaces with controlled wettability.

Rayleigh-Taylor instability in soft elastic layers

This work investigates the morphological stability of a soft body composed of two heavy elastic layers attached to a rigid surface and subjected only to the bulk gravity force. Using theoretical and computational tools, we characterize the selection of different patterns as well as their nonlinear evolution, unveiling the interplay between elastic and geometric effects for their formation. Unlike similar gravity-induced shape transitions in fluids, such as the Rayleigh-Taylor instability, we prove that the nonlinear elastic effects saturate the dynamic instability of the bifurcated solutions, displaying a rich morphological diagram where both digitations and stable wrinkling can emerge. The results of this work provide important guidelines for the design of novel soft systems with tunable shapes, with several applications in engineering sciences.This article is part of the themed issue 'Patterning through instabilities in complex media: theory and applications.'

Composite Pillars with a Tunable Interface for Adhesion to Rough Substrates

The benefits of synthetic fibrillar dry adhesives for temporary and reversible attachment to hard objects with smooth surfaces have been successfully demonstrated in previous studies. However, surface roughness induces a dramatic reduction in pull-off stresses and necessarily requires revised design concepts. Toward this aim, we introduce cylindrical two-phase single pillars, which are composed of a mechanically stiff stalk and a soft tip layer. Adhesion to smooth and rough substrates is shown to exceed that of conventional pillar structures. The adhesion characteristics can be tuned by varying the thickness of the soft tip layer, the ratio of the Young's moduli and the curvature of the interface between the two phases. For rough substrates, adhesion values similar to those obtained on smooth substrates were achieved. Our concept of composite pillars overcomes current practical limitations caused by surface roughness and opens up fields of application where roughness is omnipresent.

An anti-ultrasonic-stripping effect in confined micro/nanoscale cavities and its applications for efficient multiscale metallic patterning

We report a method to reliably and efficiently fabricate high-fidelity metallic structures from a ten-nanometer to a millimeter scale based on an anti-ultrasonic-stripping (AUS) effect in confined micro/nanoscale cavities. With this AUS effect, metallic structures, which are surrounded by the pre-patterned closed templates, could be defined through selectively removing the evaporated metallic layer at the top and outside of the templates by ultrasonic-cavitation-induced stripping. Because only pre-patterned templates are required for exposure in this multiscale patterning process, this AUS-based process enables much smaller and more reliable plasmonic nanogaps due to the mitigated proximity effect and allows rapid fabrication of multiscale metallic structures which require both tiny and large structures. With unprecedented efficiency and resolution down to a ten-nanometer scale, various metallic structures were fabricated using this AUS-effect-based multiscale patterning process. This AUS effect paves the way for direct writing of metallic structures with a high resolution over a large area for practical applications in plasmonics and nanogap-based electronics.

"Sketch and Peel" Lithography for High-Resolution Multiscale Patterning

We report a unique lithographic process, termed "Sketch and Peel" lithography (SPL), for fast, clean, and reliable patterning of metallic structures from tens of nanometers to submillimeter scale using direct writing technology. The key idea of SPL process is to define structures using their presketched outlines as the templates for subsequent selective peeling of evaporated metallic layer. With reduced exposure area, SPL process enables significantly improved patterning efficiency up to hundreds of times higher and greatly mitigated proximity effect compared to current direct writing strategy. We demonstrate that multiscale hierarchical metallic structures with arbitrary shapes and minimal feature size of ∼15 nm could be defined with high fidelity using SPL process for potential nanoelectronic and nano-optical applications.

A geometric model for the periodic undulation of a confined adhesive crack

Inspired by experiments on the instability of confined interfacial cracks, we construct a minimal mathematical model based on symmetry arguments that can reproduce the form of the crack front in a confined domain. We show that the model can be interpreted in terms of the buckling and post-buckling response of a compressed elastica with a nonuniform bending stiffness that is adhered to a linearly elastic substrate. The model has three parameters that allow us to capture the primary wavelength associated with the onset of an undulatory instability of a straight crack front, as well as the finger amplitudes and finger widths in the nonlinear development of the instability. We determine these parameters using an optimization procedure that minimizes the square error between the computed profile and experimental observations. The results of this procedure yield numerical solutions that agree well with the finger profiles experimentally observed in films of different thicknesses. Our approach shows the efficacy of simple models based on symmetry in explaining interfacial instabilities governed by different physical mechanisms.

Tough bonding of hydrogels to diverse non-porous surfaces

In many animals, the bonding of tendon and cartilage to bone is extremely tough (for example, interfacial toughness ∼800 J m(-2); refs ,), yet such tough interfaces have not been achieved between synthetic hydrogels and non-porous surfaces of engineered solids. Here, we report a strategy to design tough transparent and conductive bonding of synthetic hydrogels containing 90% water to non-porous surfaces of diverse solids, including glass, silicon, ceramics, titanium and aluminium. The design strategy is to anchor the long-chain polymer networks of tough hydrogels covalently to non-porous solid surfaces, which can be achieved by the silanation of such surfaces. Compared with physical interactions, the chemical anchorage results in a higher intrinsic work of adhesion and in significant energy dissipation of bulk hydrogel during detachment, which lead to interfacial toughness values over 1,000 J m(-2). We also demonstrate applications of robust hydrogel-solid hybrids, including hydrogel superglues, mechanically protective hydrogel coatings, hydrogel joints for robotic structures and robust hydrogel-metal conductors.

Splitting-induced surface patterns on the surface of polystyrene thin films

An AFM image of the surface gratings formed on the surface of the irradiated PS films with the irradiation dose of 1.548 J cm⁻², and variation of the apparent surface stress with the thickness of the irradiated PS films.

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.

Adhesion-induced instabilities and pattern formation in thin films of elastomers and gels

A hydrostatically stressed soft elastic film circumvents the imposed constraint by undergoing a morphological instability, the wavelength of which is dictated by the minimization of the surface and the elastic strain energies of the film. While for a single film, the wavelength is entirely dependent on its thickness, a co-operative energy minimization dictates that the wavelength depends on both the elastic moduli and thicknesses of two contacting films. The wavelength can also depend on the material properties of a film if its surface tension has a pronounced effect in comparison to its elasticity. When such a confined film is subjected to a continually increasing normal displacement, the morphological patterns evolve into cracks, which, in turn, govern the adhesive fracture behavior of the interface. While, in general, the thickness provides the relevant length scale underlying the well-known Griffith-Kendall criterion of debonding of a rigid disc from a confined film, it is modified non-trivially by the elasto-capillary number for an ultra-soft film. Depending upon the degree of confinement and the spatial distribution of external stress, various analogs of the canonical instability patterns in liquid systems can also be reproduced with thin confined elastic films.

Elastocapillarity can control the formation and the morphology of beads-on-string structures in solid fibers

Beads-on-string patterns have been experimentally observed in solid cylinders for a wide range of material properties and structural lengths, from millimetric soft gels to nanometric hard fibers. In this work, we combine theoretical analysis and numerical tools to investigate the formation and nonlinear dynamics of such beaded structures. We show that this morphological transition is driven by elastocapillarity, i.e., a complex interplay between the effects of surface tension and bulk elasticity. Unlike buckling or wrinkling, the presence of an axial elongation is found here to favor the onset of fiber beading, in agreement with existing experimental results on electrospun fibers, hydrogels, and nerves. Our results also prove that the applied stretch can be used in fabrication techniques to control the morphology of the emerging beads-on-string patterns. Such quantitative predictions open the way for several applications, from tissue engineering to the design of stretchable electronics and the microfabrication of functionalized surfaces.

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.

Debonding mechanisms of soft materials at short contact times

A carefully controlled, custom-built adhesion testing device was developed which allows a precise, short dwell time on the order of milliseconds to be applied during a contact adhesion experiment. The dwell time dependence of the adhesive strength of crosslinked poly(dimethylsiloxane) (PDMS) in contact with glass and uncrosslinked styrene butadiene rubber (SBR) in contact with glass and with itself was tested with a spherical probe in a confined Johnson-Kendall-Roberts (JKR) geometry. Analysis of the contact images revealed several unique separation mechanisms which are dependent on dwell time and interfacial properties. PDMS-glass interfaces show essentially no dependence of adhesion on the dwell time while the adhesive strength and separation mechanisms of SBR interfaces are shown to vary drastically for dwell times ranging from 40 to 10,000 ms. This influence of dwell time is particularly pronounced for polymer-polymer (SBR-SBR) interfaces. Observations of cavitation due to trapped air pockets in the center of the contact at very short contact times illustrate a transition between a defect-controlled debonding and an interface-controlled debonding which has not been previously reported.

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.

Electro-hydrodynamic instability of stressed viscoelastic polymer films

We study the stability of a viscoelastic thin polymer film under two destabilization factors: the application of an electric field normal to the surface--as in typical electro-hydrodynamic destabilization experiments--and the presence of a frozen-in internal residual stress, stemming from the preparation process of the film, typically spin-coating. At the film-substrate interface we consider a general boundary condition, containing perfect gliding on slippery substrates, as well as perfect sticking of the film to the substrate as limiting cases. We show that the interplay of the two sources of stress, the viscoelasticity and the boundary condition, leads to a rich behavior, especially as far as the fastest growing wave number (or wavelength) is concerned. The latter determines the initial growth of the instability, and often also the final pattern obtained in small capacitor gaps, and is the main experimental observable.

Scaling normal adhesion force capacity with a generalized parameter

The adhesive response of a rigid flat cylindrical indenter in contact with a compliant elastic layer of varying confinement is investigated experimentally and described analytically. Using a soft elastic gel with substrate thickness, t, and indenter radius, a, 28 unique combinations of the confinement parameter, a/t, are examined over a range of 0.016 < a/t < 7.2. Continuous force capacity predictions as a function of a/t and material properties are provided through a scaling theory and are found to agree well with the experimental data. We further collapse all of the data over orders of magnitude in adhesive force capacity onto a single line described by a generalized reversible adhesion scaling parameter, A/C, where A is the contact area and C is the compliance. As the scaling analysis does not assume a specific separation mechanism the adhesive force capacity is well described during both axisymmetric edge separation and during interfacial fingering and cavitation instabilities. We discuss how the geometry of the contact, specifically increasing the degree of confinement, allows reversible adhesive materials to be designed that are not "sticky" or "tacky", yet can be very strong and provide high performance.

Bulk elastic fingering instability in Hele-Shaw cells

We demonstrate experimentally the existence of a purely elastic, nonviscous fingering instability which arises when air penetrates into an elastomer confined in a Hele-Shaw cell. Fingers appear sequentially and propagate within the bulk of the material as soon as a critical strain, independent of the elastic modulus, is exceeded. Key elements in the driving force of the instability are the confinement of the gel and its adhesion to the plates of the cell, which result in a considerable expense of elastic energy during the growth of the air bubble.

Digital instability of a confined elastic meniscus

Thin soft elastic layers serving as joints between relatively rigid bodies may function as sealants, thermal, electrical, or mechanical insulators, bearings, or adhesives. When such a joint is stressed, even though perfect adhesion is maintained, the exposed free meniscus in the thin elastic layer becomes unstable, leading to the formation of spatially periodic digits of air that invade the elastic layer, reminiscent of viscous fingering in a thin fluid layer. However, the elastic instability is reversible and rate-independent, disappearing when the joint is unstressed. We use theory, experiments, and numerical simulations to show that the transition to the digital state is sudden (first-order), the wavelength and amplitude of the fingers are proportional to the thickness of the elastic layer, and the required separation to trigger the instability is inversely proportional to the in-plane dimension of the layer. Our study reveals the energetic origin of this instability and has implications for the strength of polymeric adhesives; it also suggests a method for patterning thin films reversibly with any arrangement of localized fingers in a digital elastic memory, which we confirm experimentally.

Voltage-controlled surface wrinkling of elastomeric coatings

Wrinkling of elastomeric coatings by an electric field is reported. The associated changes in the coating's optical properties yield switchable mirrors and windows. The field Ec needed to induce wrinkling is a factor of 4.4 lower than the theoretically predicted value, which is attributed to space-charge injection.

Direct measurement of the surface tension of a soft elastic hydrogel: exploration of elastocapillary instability in adhesion

An adhesively stressed thin film of a soft hydrogel confined between two rigid flat substrates autoroughens with its dominant wavelength (λ) exhibiting pronounced dependence on the film thickness (H). A linear stability analysis confirmed that this long wavelength instability (λ ~ 7H) is due to an elastocapillary effect, the implementation of which required direct measurements of the surface tension and the elasticity of the gel. The surface tension of the gel was estimated from the fundamental spherical harmonic of a hemispherical cap of the gel that was excited by an external noise. The shear modulus (μ) of the gel was determined from its resonant shear mode in a confined geometry. During the course of this study, it was found that a high density steel ball submerges itself inside the gel by balancing its excess weight with the accumulated strain induced elastic force that allows another estimation of its elastic modulus. The large ratio (1.8 mm) of the surface tension to its elasticity ascertains the role of elastocapillarity in the adhesion-induced pattern formation with such gels. Experimental results are in accord with a linear stability analysis that predicts that the rescaled wavelength λ(μH/γ)(0.27) is linear with H, which also modifies the conventional stress to pull a flat rigid object out of a very soft film by a multiplicative factor: (γ/μH)(1/4). The analysis also suggests some new results related to the role of the finite dilation of a material in interfacial pattern formation that may have nontrivial consequences in the adhesive delamination of very thin and/or soft elastic films via self-generated cracks.

Kinetically driven self-assembly of a binary solute mixture with controlled phase separation via electro-hydrodynamic flow of corona discharge

This feature article describes a new and facile process to fabricate a variety of thin films of non-volatile binary solute mixtures suitable for high performance organic electronic devices via electro-hydrodynamic flow of conventional corona discharge. Both Corona Discharge Coating (CDC) and a modified version of CDC, Scanning Corona Discharge Coating (SCDC), are based on utilizing directional electric flow, known as corona wind, of the charged uni-polar particles generated by corona discharge between a metallic needle and a bottom plate under a high electric field (5-10 kV cm(-1)). The electric flow rapidly spreads out the binary mixture solution on the bottom plate and subsequently forms a smooth and flat thin film in a large area within a few seconds. In the case of SCDC, the static movement of the bottom electrode on which a binary mixture solution is placed provides further control of thin film formation, giving rise to a film highly uniform over a large area. Interesting phase separation behaviors were observed including nanometer scale phase separation of a polymer-polymer binary mixture and vertical phase separation of a polymer-organic semiconductor mixture. Core-shell type phase separation of either polymer-polymer or polymer-colloidal nanoparticle binary mixtures was also developed with a periodically patterned microstructure when the relative location of the corona wind was controlled to a binary solution droplet on a substrate. We also demonstrate potential applications of thin functional films with controlled microstructures by corona coating to various organic electronic devices such as electroluminescent diodes, field effect transistors and non-volatile polymer memories.

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.

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.

Reusable antifouling viscoelastic adhesive with an elastic skin

Although the viscoelasticity or tackiness of a pressure-sensitive adhesive gives it strength owing to energy dissipation during peeling, it also renders it nonreusable because of structural changes such as the formation of fibrils, cohesive failure, and fouling. However, an elastic layer has good structural integrity and cohesive strength but low adhesive energy. We demonstrate an effective composite adhesive in which a soft viscoelastic bulk layer is imbedded in a largely elastic thin skin layer. The composite layer is able to meet the conflicting demands of the high peel strength comparable to the viscoelastic core and the structural integrity, reusability, and antifouling properties of the elastic skin. Our model adhesive is made of poly(dimethylsiloxane), where its core and skin are created by varying the cross-linking percentage from 2 to 10%.