Structural relaxation of spin-cast glassy polymer thin films as a possible factor in dewetting

Evolution of Surface Morphology of Spin-Coated Poly(methyl methacrylate) Thin Films

The morphology of sub-micron poly(methyl methacrylate) films coated to glass supports by spin coating from toluene is examined using surface profilometry. Wrinkled surfaces with local quasi-sinusoidal periodicity were seen on the surfaces of films with thicknesses of larger than 75 nm. The surface wrinkles had large aspect ratios with wavelengths in the tens of microns and amplitudes in the tens of nanometers. Wrinkles that formed during spin-coating are attributed to surface perturbations caused by Rayleigh-Bénard-Marangoni convective instabilities. The effects of film thickness, coating solution concentration, and drying rate on the thin film surface morphology are investigated. The results can be used to prepare surfaces with controlled morphology, either smooth or with periodic wrinkles.

Combined specular and off-specular reflectometry: elucidating the complex structure of soft buried interfaces

Neutron specular reflectometry (SR) and off-specular scattering (OSS) are nondestructive techniques which, through deuteration, give a high contrast even among chemically identical species and are therefore highly suitable for investigations of soft-matter thin films. Through a combination of these two techniques, the former yielding a density profile in the direction normal to the sample surface and the latter yielding a depth-resolved in-plane lateral structure, one can obtain quite detailed information on buried morphology on length scales ranging from the order of ångströms to ∼10 µm. This is illustrated via quantitative evaluation of data on SR and OSS collected in time-of-flight (ToF) measurements of a set of films composed of immiscible polymer layers, protonated poly(methyl methacrylate) and deuterated polystyrene, undergoing a decomposition process upon annealing. Joint SR and OSS data analysis was performed by the use of a quick and robust originally developed algorithm including a common absolute-scale normalization of both types of scattering, which are intricately linked, constraining the model to a high degree. This, particularly, makes it possible to distinguish readily between different dewetting scenarios driven either by the nucleation and growth of defects (holes, protrusions etc.) or by thermal fluctuations in the buried interface between layers. Finally, the 2D OSS maps of particular cases are presented in different spaces and qualitative differences are explained, allowing also the qualitative differentiation of the in-plane structure of long-range order, the correlated roughness and bulk defects by a simple inspection of the scattering maps prior to quantitative fits.

Boron-Loaded Polymeric Sensor for the Direct Detection of Thermal Neutrons

We report the first demonstration of a solid-state, direct-conversion sensor for thermal neutrons based on a polymer/inorganic nanocomposite. Sensors were fabricated from ultrathick films of poly(triarylamine) (PTAA) semiconducting polymer, with thicknesses up to 100 μm. Boron nanoparticles (NPs) were dispersed throughout the PTAA film to provide the neutron stopping power arising from the high thermal neutron cross section of the isotope ¹⁰B. To maximize the quantum efficiency (QE) of the sensor to thermal neutrons, a high volume fraction of homogeneously dispersed boron nanoparticles was achieved in the thick PTAA film using an optimized processing method. Thick active layers were realized using a high molecular weight of the PTAA so that molecular entanglements provide a high cohesive strength. A nonionic surfactant was used to stabilize the boron dispersion in solvent and hence suppress the formation of agglomerates and associated electrical pathways. Boron nanoparticle loadings of up to ten volume percent were achieved, with thermal neutron quantum efficiency estimates up to 6% resulting. The sensors' neutron responses were characterized under a high flux thermal neutron exposure, showing a linear correlation between the response current and the thermal neutron flux up to ∼10⁷ cm^-2 s^-1. Polymer-based boron nanocomposite sensors offer a new neutron detection technology that uses low-cost, scalable solution processing and provides an alternative to traditional neutron sensors that use rare isotopes, such as ³He.

Glass transition of polymers in bulk, confined geometries, and near interfaces

When cooled or pressurized, polymer melts exhibit a tremendous reduction in molecular mobility. If the process is performed at a constant rate, the structural relaxation time of the liquid eventually exceeds the time allowed for equilibration. This brings the system out of equilibrium, and the liquid is operationally defined as a glass-a solid lacking long-range order. Despite almost 100 years of research on the (liquid/)glass transition, it is not yet clear which molecular mechanisms are responsible for the unique slow-down in molecular dynamics. In this review, we first introduce the reader to experimental methodologies, theories, and simulations of glassy polymer dynamics and vitrification. We then analyse the impact of connectivity, structure, and chain environment on molecular motion at the length scale of a few monomers, as well as how macromolecular architecture affects the glass transition of non-linear polymers. We then discuss a revised picture of nanoconfinement, going beyond a simple picture based on interfacial interactions and surface/volume ratio. Analysis of a large body of experimental evidence, results from molecular simulations, and predictions from theory supports, instead, a more complex framework where other parameters are relevant. We focus discussion specifically on local order, free volume, irreversible chain adsorption, the Debye-Waller factor of confined and confining media, chain rigidity, and the absolute value of the vitrification temperature. We end by highlighting the molecular origin of distributions in relaxation times and glass transition temperatures which exceed, by far, the size of a chain. Fast relaxation modes, almost universally present at the free surface between polymer and air, are also remarked upon. These modes relax at rates far larger than those characteristic of glassy dynamics in bulk. We speculate on how these may be a signature of unique relaxation processes occurring in confined or heterogeneous polymeric systems.

Influence of physical ageing on rim instability during solvent-induced dewetting of a thin polymer film

Combining experiments with molecular dynamic simulation to examine the influence of physical ageing on rim instability during solvent-induced dewetting.

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.

Hierarchical Micro/Nano Structures by Combined Self-Organized Dewetting and Photopatterning of Photoresist Thin Films

Photoresists are the materials of choice for micro/nanopatterning and device fabrication but are rarely used as a self-assembly material. We report for the first time a novel interplay of self-assembly and photolithography for fabrication of hierarchical and ordered micro/nano structures. We create self-organized structures by the intensified dewetting of unstable thin (∼10 nm to 1 μm) photoresist films by annealing them in an optimal solvent and nonsolvent liquid mixture that allows spontaneous dewetting to form micro/nano smooth dome-like structures. The density, size (∼100 nm to millimeters), and curvature/contact angle of the dome/droplet structures are controlled by the film thickness, composition of the dewetting liquid, and time of annealing. Ordered dewetted structures are obtained simply by creating spatial variation of viscosity by ultraviolet exposure or by photopatterning before dewetting. Further, the structures thus fabricated are readily photopatterned again on the finer length scales after dewetting. We illustrate the approach by fabricating several three-dimensional structures of varying complexity with secondary and tertiary features.

Instability of hydrophobic and viscoelastic polymer thin films in water at room temperature

The instability of a polyisoprene (PI) thin film on a silicon substrate at room temperature in an aqueous environment was investigated by atomic force microscopy and optical microscopy. The instability mechanism changes from spinodal dewetting to hole nucleation with increasing film thickness, with the transitional thickness found to be around 46-50 nm. For PI films ≥50 nm, the dewetting was observed to proceed via successive stages of hole nucleation and growth, hole coalescence, cellular pattern formation and droplet formation. There is also a slowing down in the rate of the PI dewetting process and an increase in the pattern size as the film thickness is increased. In those films with observable holes, we also observed the coexistence of fine cellular cracking that is on a much smaller scale of hundreds of nanometres and extends only a few nanometres in depth from the film surface.

Can Thickness and Interfacial Interactions Univocally Determine the Behavior of Polymers Confined at the Nanoscale?

The behavior of polymers confined in ultrathin films (thickness < 200 nm) can sensitively differ from that observed in macroscopic samples. Based on the simple arguments of finite size and interfacial effects, film thickness, and surface interactions should be sufficient to univocally determine the deviation from bulk behavior. However, recent models suggest that a third key parameter, namely, the interfacial free volume, should also be considered. We describe a novel methodology that quantifies the volume available for structural relaxation at the interface between a thin polymer layer and its supporting substrate. Experiments performed at different annealing conditions verified that the shift in glass transition temperature, measured in thin films upon confinement, is proportional to the degree of adsorption and, thus, to the interfacial free volume.

Stimuli responsive poly(1-[11-acryloylundecyl]-3-methyl-imidazolium bromide): dewetting and nanoparticle condensation phenomena

A stimuli-responsive homopolymer poly(ILBr) is fabricated via a "two-phase" atom transfer radical polymerization (ATRP) process, where ILBr stands for the reactive ionic liquid surfactant, 1-[11-acryloylundecyl]-3-methyl-imidazolium bromide. An extraordinarily wide molecular weight distribution (PDI = 6.0) was obtained by introducing the initiator (4-bromomethyl methyl benzoate) in a heterogeneous two-phase process. The molecular weight distribution of poly(ILBr) was characterized by size-exclusion chromatography (SEC). The resulting homopolymer was found to be surface active and stimuli responsive. Poly(ILBr) films coated on quartz exhibit stimuli-responsive dewetting after ion exchange of Br(-) by PF(6)(-). This dewetting phenomenon can be understood in chain segmental terms as a stimuli-induced structural relaxation and appears to be the first such reported stimuli-responsive polymeric dewetting. Titrating aqueous poly(ILBr) with aqueous bis(2-ethylhexyl)sulfosuccinate induces nanophase separation and results in the condensation of nanoparticles 30-60 nm in diameter.

Study on the combined effects of solvent evaporation and polymer flow upon block copolymer self-assembly and alignment on topographic patterns

Microphase separation of a polystyrene-block-polyisoprene-block-polystyrene triblock copolymer thin film under confined conditions (i.e., graphoepitaxy) results in ordered periodic arrays of polystyrene cylinders aligned parallel to the channel side-wall and base in a polyisoprene matrix. Polymer orientation and translational ordering with respect to the topographic substrate were elucidated by atomic force microscopy (AFM) while film thickness and polymer profile within the channel were monitored by cross-sectional transmission electron microscopy (TEM) as a function of time over a 6 h annealing period at 120 degrees C. Upon thermal annealing, the polymer film simultaneously undergoes three processes: microphase separation, evaporation of trapped solvent, and mass transport of polymer from the mesas into the channels. A significant volume of solvent is trapped within the polymer film upon spin coating arising from the increased polymer/substrate interfacial area due to the topographic pattern. Mass transport of polymer during this process results in nonuniform films, where subtle changes in the film thickness within the channel have profound effects on the microphase separation process. The initially disordered structure within the film underwent an orientation transition via an intermediate formation of perpendicular cylinders (nonequilibrium) to a parallel (equilibrium) orientation with respect to the channel base. Herein, we present a time-resolved study of the cylinder reorientation process detailing how changing film thickness during the annealing process dramatically affects both the local and lateral orientation of the observed structure. Finally, a brief mathematical model is provided to evaluate spin coating over a complex topography following a classical asymptotic approximation of the Navier-Stokes equations for the as-deposited films.

Friction at the liquid/liquid interface of two immiscible polymer films

We studied the friction between two immiscible polymer melts of polybutadiene (PBD) and polydimethylsiloxane (PDMS). Polymer films (100-300 nm thick) were coated onto smooth mica substrates, and then were brought into contact and sheared (slid) to and fro in a surface forces apparatus (SFA). Stop-wait-start experiments were also carried out at different sliding velocities to investigate the characteristic relaxation times of the interdigitation and disinterdigitation processes at both the static and shearing interfaces. By virtue of their limited interdigitation/interpenetration across the contact interface, immiscible polymers never fully coalesce into a continuous homogeneous material. This affects both their dynamic adhesion and friction forces. The immiscible interface exhibits various "characteristic" parameters such as its static and dynamic widths and at least two relaxation times: the static interpenetration time and the velocity adaptation time. The interfacial width saturates at some small but finite value, resulting in Stribeck-like behavior for the friction force as a function of the sliding velocity, characterized by F having a minimum value at some characteristic sliding velocity V. The presence of solvents at the immiscible interface can have a dramatic effect on the friction or lubrication forces. The implications of the results regarding the depth and dynamics of interdigitation and interpenetration of immiscible chains across an interface are discussed in relation to the adhesion, friction, and strength of polymer composites and the coalescence of immiscible droplets.

Quantifying residual stress in nanoscale thin polymer films via surface wrinkling

Residual stress, a pervasive consequence of solid materials processing, is stress that remains in a material after external forces have been removed. In polymeric materials, residual stress results from processes, such as film formation, that force and then trap polymer chains into nonequilibrium stressed conformations. In solvent-cast films, which are central to a wide range of technologies, residual stress can cause detrimental effects, including microscopic defect formation and macroscopic dimensional changes. Since residual stress is difficult to measure accurately, particularly in nanoscale thin polymer films, it remains a challenge to understand and control. We present here a quantitative method of assessing residual stress in polymer thin films by monitoring the onset of strain-induced wrinkling instabilities. Using this approach, we show that thin (>100 nm) polystyrene films prepared via spin-coating possess residual stresses of approximately 30 MPa, close to the crazing and yield stress. In contrast to conventional stress measurement techniques such as wafer curvature, our technique has the resolution to measure residual stress in films as thin as 25 nm. Furthermore, we measure the dissipation of residual stress through two relaxation mechanisms: thermal annealing and plasticizer addition. In quantifying the amount of residual stress in these films, we find that the residual stress gradually decreases with increasing annealing time and plasticizer amounts. Our robust and simple route to measure residual stress adds a key component to the understanding of polymer thin film behavior and will enable identification of more effective processing routes that mitigate the detrimental effects of residual stress.

Physical aging of glassy PMMA/toluene films: influence of drying/swelling history

Gravimetry experiments in a well-controlled environment have been performed to investigate aging for a glassy PMMA/toluene film. The temperature is constant and the control parameter is the solvent vapor pressure above the film (i.e. the activity). Several experimental protocols have been used, starting from a high activity where the film is swollen and rubbery and then aging the film at different activities below the glass transition. Desorption and resorption curves have been compared for the different protocols, in particular in terms of the softening time, i.e. the time needed by the sample to recover an equilibrium state at high activity. Non-trivial behaviors have been observed, especially at small activities (deep quench). A model is proposed, extending the Leibler-Sekimoto approach to take into account the structural relaxation in the glassy state, using the Tool formalism. This model well captures some of the observed phenomena, but fails in describing the specific kinetics observed when aging is followed by a short but deep quench.

Residual stresses in thin polymer films cause rupture and dominate early stages of dewetting

In attempting to reduce the size of functional devices, the thickness of polymer films has reached values even smaller than the diameter of the unperturbed molecule. However, despite enormous efforts for more than a decade, our understanding of the origin of some puzzling properties of such thin films is still not satisfactory and several peculiar observations remain mysterious. For example, under certain conditions, such films show negative expansion coefficients or show undesirable rupture although energetically they are expected to be stable. Here, we demonstrate that many of these extraordinary effects can be related to residual stresses within the film, resulting from the preparation of these films from solution by fast evaporation of the solvent. Consequently, depending on thermal history and ageing time, such films show significant changes even in the glassy state, which we quantify by dewetting experiments and corresponding theoretical studies. Identifying the relevance of frozen-in polymer conformations gives us a handle for manipulating and controlling properties of nanometric thin polymer films.

Dynamics of ultrathin films in the glassy state

We report hole growth experiments in free-standing polystyrene (PS) films at temperatures up to 10 degrees C below the bulk glass transition. The data show an unexpected result: the growth rate of nucleated holes increases with increasing molecular weight, up to a limiting value beyond which the rate is approximately constant. Film thicknesses of 45, 80, and 100 nm were studied, using PS molecular weights ranging from 65K to 11.4 Mg/mol. Hole diameters grew linearly with time, and no growing rims were observed to form around the developing holes. Possible explanations in terms of elasticity, yield, and influence of sample preparation and confinement effects are discussed.

Thickness dependence of structural relaxation in spin-cast, glassy polymer thin films

The isothermal structural relaxation of glassy, spin-cast polymer thin films has been investigated. Specifically, the thickness h of freshly cast poly(methyl methacrylate) thin films was measured over time using spectroscopic ellipsometry. The spin-cast films exhibit a gradual decrease in thickness, which is attributed to structural relaxation of the glass combined with simultaneous solvent loss. In all cases, h was found to be greater than the equilibrium thickness h(infinity) , which is obtained by cooling slowly from the melt. It is observed that both the rate of the volume relaxation and the fractional departure from h(infinity) (referred to as delta(0) ) increase with increasing film thickness. In the limit of very thin films, the initial h is close to h(infinity) , and delta(0) is small, whereas in thick films (>500 nm) , a plateau value of delta(0) of 0.16 is observed, which is close to the volume fraction of the solvent at the vitrification point. This dependence of delta(0) on thickness is observed regardless of the substrate, polymer molecular weight, or angular velocity during spin casting. Enhanced mobility near film surfaces could be leading to greater relaxation in thinner films prior to, and immediately after, the vitrification of the polymer during the deposition process.

Capillary instabilities by fluctuation induced forces

The spontaneous break-up of thin films is commonly attributed to the destabilizing effect of van der Waals forces. Dispersion forces can be considered in terms of the confinement of the electromagnetic fluctuation spectrum. The principle of confinement is more general than the usual argument of interacting dipole fluctuations. It includes also disjoining pressures that are caused by thermal fluctuations. In this context, we review recent publications on the dewetting of thin polymer films, and argue that the presence of an acoustic disjoining pressure is necessary to adequately describe some of these experimental results.