Ma 1026324
Ma 1026324
pubs.acs.org/Macromolecules
r 2011 American Chemical Society 5436 dx.doi.org/10.1021/ma1026324 | Macromolecules 2011, 44, 5436–5442
Macromolecules ARTICLE
Figure 1. Process for fiber formation via flow coating and thin film melting and a representative image of fiber branching (h = 60 nm, 400 kDa PS). Some
fibers have thinned and necked beyond the point of being visible at 50 magnification, which appear as dangling ends. The red uniform circles in the
image are the supporting pillars, ∼15 μm in diameter with 75 μm spacing.
breakup of fibers in this network, a characteristic time scale can polystyrene standard samples were used (PS, Mn = 123, 400,
be derived. 2000, 6000 kDa, Mw/Mn = 1.08, 1.06, 1.20, 1.22, respectively,
In this study, fiber thinning as well as the branching lifetime Alfa Aesar). After flow coating, film thicknesses were measured
and breakup of suspended fibers is investigated via optical across the film’s gradient profile via a UVvis interferometer
microscopy. Ultrathin polystyrene films (h = 50100 nm), cast (Model F20, Filmetrics, Inc.). Films were then floated off the
via flow coating, are suspended atop lithographically patterned silicon substrate onto clean water (Milli-Q) and subsequently
arrays of pillars. The films are then annealed well above the bulk transferred atop a lithographically patterned array of pillars. The
glass transition temperature, Tg, of the polymer, randomly pillars have dimensions of 15 μm in diameter and 75 μm spacing.
forming holes which expand to form a branched network of Films were dried and annealed just below the Tg of the polymer
fibers. Details of hole expansion21,2330 of polymeric thin films film under vacuum for 24 h to remove water and residual
have been researched thoroughly in the literature. In this report, solvents.
the thinning of fiber radius is measured as a function of time and Fiber Thinning. Ultrathin film samples with varying thick-
compared for samples of varying molecular weights and thick- nesses were thermally annealed using an enclosed Linkham
nesses. The fiber radius evolution is used as a tool to explore LTS350 microscopy thermal stage and imaged via a Zeiss Axio
rheological properties of these samples. The characteristic time Imager M2m optical microscope at 50 magnification. Film
scale for the decay of the branched structures is calculated and samples were taken from room temperature and heated at 30 C/min
compared across the range of film thicknesses. This breakup time to the annealing temperature, 130 C for 400 kDa PS, and held
scale is dependent on entanglement molecular weight; thus, a while hole formation, subsequent expansion, fiber formation, and
transition into a confined regime where interchain entangle- branching/fiber breakup occurred. Samples of other molecular
ments are greatly reduced is shown, evidenced by a correspond-
weights were annealed at temperatures to match the zero shear
ing drastic increase in the breakup time scale.
rate viscosity, η0, of this experiment (1.73 109 Pa 3 s), calcu-
lated using the empirical WLF equation (116, 161, and 196 C
’ RESULTS AND DISCUSSION for 123, 2000, and 6000 kDa, respectively). Previous studies by
Thin Film Preparation. “Flow coating” is a technique, devel- Rathfon et al. have shown a new approach toward the fabrication
oped by Stafford et al., to fabricate ultrathin polymer films with a of suspended fibers from the melting and breakup of suspended
gradient thickness in the submicrometer to nanoscale regime, in ultrathin, polymer films.21,33 Upon heating above the Tg of
which a bead of polymer solution is sandwiched between a blade the polymer film, random hole nucleation occurs spontaneously
and is drawn across a substrate.31,32 A schematic of thin film in the suspended films either through a process analogous to
sample preparation for this branching study is given in Figure 1. spinodal decomposition or from defects such as dust or density
Gradient thickness polystyrene films, from approximately inhomogeneities (<0.2 μm).23,34 Holes observed in this report
50100 nm in thickness, were cast from 0.751.5 wt % solutions form spontaneously in the melt in random locations, consistent
in toluene using an acceleration of 6 mm/s2. Monodisperse with literature findings,23,26,30 and not at the pillar edges. These
5437 dx.doi.org/10.1021/ma1026324 |Macromolecules 2011, 44, 5436–5442
Macromolecules ARTICLE
Figure 2. Model for the evolution as a function of time for an elastic fluid filament stretched between two surfaces (a), adapted from McKinley.36 The
dashed line represents the linear response of a Newtonian fluid. A representative plot of the exponential thinning of capillary fibers (b), from a parent film
of 100 nm thickness, (400 kDa PS) with an inset of a thinning fiber. Equation 3 was fitted to the data using least-squares-regression.
Entov and Hinch show that radius evolution will approach a consistent with Anna and McKinley’s findings for thinning of
linear behavior at late times due to polymer chains becoming fully elastocapillary filaments.35 It is apparent that a steady-state
stretched, no longer being capable of resisting the increasing extensional viscosity plateau was not observed in these fiber
capillary pressure.37 At this time, the filament thins similarly to a thinning experiments. A higher Hencky strain regime could yield
very viscous Newtonian fluid and approaches a steady-state these values; however, in the current report, fiber networks
extensional viscosity, ηh¥. In order to model the two regimes of typically began to fail before the observation of a steady-state
fiber radius evolution, the following equation is used: plateau. A recent technique by Arratia et al. shows the acquisition
of transient extensional viscosity for polymeric filament thinning
Rmid ðtÞ
¼ Aet=B Ct þ D ð4Þ in a microfluidic channel, allowing for the attainment of the
R0 “elusive” steady-state extensional viscosity.39,40 The evolution in
where A, B, C, and D are fitting parameters. The value of B is ηhapp for samples of varying parent film thicknesses did not change
accordingly related to the longest relaxation time, λZ, and σ/C greatly, indicating fibers thinned similarly, for samples of the
determines the steady-state extensional viscosity, as will be seen same Mw, regardless of the differences in their initial strain
in eq 5. Equation 4 is fitted to each sample in order to better regimes. This observation is consistent with experimental ob-
model the radius behavior over the two thinning regimes. Figure 3 servation of capillary breakup of polymer solutions and melts and
shows a representative plot of fiber thinning behavior with the with the predictions of constitutive models like the Oldroyd-B
model eq 4 applied (see Supporting Information for all curves), and FENE dumbbell models discussed previously.
clearly showing both the initial exponential decay of fiber Branch Decay. To further probe the effects of confinement on
diameter then the linear response at long times. entanglements and the polymer dynamics in free-standing,
The transient extensional rheology of the PS samples is ultrathin PS films, the evolution of fibers with respect to
contained within the fiber radius evolution data and can be branching density was investigated. From the expression for
reexamined in the form of the transient extensional viscosity or the evolution of an elastic fluid capillary fiber (eq 3), the critical
apparent extensional viscosity, η time to breakup, tc, can be expressed as
happ. The forces on the filament
form a balance of viscous and viscoelastic stresses with the 4
capillary pressure; thus, by substituting eq 1, η
happ is determined tc ¼ 3λ ln L2 ðGR0 =σÞ4=3 ð6Þ
to be 3
Δτ σ=Rmid ðtÞ σ where λ is the longest relaxation time for the fluid fiber and L is
ηapp ¼ ¼ ¼ ð5Þ the finite extensibility parameter. Equation 6 is derived from eq 3
ε_ ε_ ðtÞ 2dRmid =dt
as the evolving fiber radius, Rmid, approaches zero; however, the
where Δτ is the tensile stress difference on the filament and ε· is finite extensibility of the polymer chain must be considered.35,36
the corresponding strain rate.35,36 Thus, η happ is inversely related Thus, tc gives a time based model for the breakup and decay of
to the first derivative of the fiber radius. Experimental data of fiber the fiber network. Equation 6 shows that the critical time to
radius over time were differentiated in order to determine the breakup is dependent upon the longest relaxation time, tc ∼ λ.
evolution of apparent extensional viscosity. In Figure 4, η happ is Because tc is proportional to λ, the breakup of fibers in the bulk is
plotted versus Hencky strain for samples with varying molecular dependent upon Mw, which relates directly to the previous
weights and parent film thicknesses, thus different initial strain statement of λ ∼ Mw3ν. Thus, there should be a strong correla-
regimes. These initial strain regimes were studied in a previous tion between the relaxation time and the effective molecular
report where shear viscosity values, for initial hole expansion weight of the chains, dictated by their interchain entanglements,
toward the formation of fibers, were on the order of 106 Pa 3 s with while in a regime with no confinement effects. With confinement,
shear strain rates of ∼0.5 s1.33 The resultant Trouton ratio interchain entanglements can be reduced having an influence on
values for the present study would range between 101 and 104, the effective molecular weight and thus the relaxation time of the
5439 dx.doi.org/10.1021/ma1026324 |Macromolecules 2011, 44, 5436–5442
Macromolecules ARTICLE
self-entanglements will dominate and few interchain entangle- confined regime, below a critical film thickness, breakup in
ments will exist, resulting in a drastically reduced network of response to an exponential strain with a characteristic time scale
chains, and thus a more fragile film. Figure 6 shows this reduction in a manner consistent with a drastic reduction in the interchain
in entanglements corresponding to a dimension approximately entanglement density. The entanglement density was found to
twice the calculated diameter of a chain in the bulk. Below this decrease in a regime below a corresponding critical parent film
dimension perturbation of the pervaded volume of bulk chains is thickness, comparable to the dimensions of bulk polymers,
expected to have a significant contribution, as chains would have h/2Ree < 2. This model agrees with previous explorations and
to begin to pack into a confined regime with the influence of the experiments with models for the perturbation of the pervaded
two air/polymer interfaces. Thus, the entanglement density of volume of polymer chains when in contact with interfaces.1,11 As
the parent film and therefore the time scale for the breakup of the a film becomes sufficiently thin, interfaces dominate and the
fiber network will be greatly reduced. proportion of self-entanglements increases and interchain en-
The reduced interchain entanglement density seen can be tanglements decrease, resulting in a much less stable network of
compared to other studies where confinement is shown to affect chains. The presented analysis of confinement effects on chain
the chain order, mobility, and dynamics at the surface boundary entanglement extends the understanding of ongoing studies into
layer. Baumchen et al. show how interfacial entanglement density suspended nanoscale fiber formation from the melting of free-
affects boundary conditions in polymer flow.12 Slippage is standing polymer thin films.
directly linked to chain entanglements and a reduced interchain
entanglement density at the solidliquid interface is found. The ’ ASSOCIATED CONTENT
onset of slippage correlates to the critical chain length for
entanglements where the slip length dependence on molecular bS Supporting Information. Fiber radii plots of exponential
weight corroborates the description by de Gennes for the sliding thinning for all samples; branch density versus time plot for all
chain end model.4 This reduced entanglement density at the samples; representative suspended fiber, branch decay movie.
boundary layer is similar to our study where a suspended film can This material is available free of charge via the Internet at http://
be thought of as having two boundaries and thus two surfaces pubs.acs.org.
with reduced entanglements. When a film becomes sufficiently
thin, these boundary layers can overlap, causing reduced en- ’ AUTHOR INFORMATION
tanglements throughout the film, leading to rapid breakup and a
reduced branching density time scale. Bodiguel et al. analyze the Corresponding Author
dewetting of thin polymer films on a liquid substrate and show a *E-mail: [email protected].
reduced viscosity in thin polymer films.41 Bodiguel et al. suggest
that reduced entanglements in the surface layer allow modes ’ ACKNOWLEDGMENT
other than reptation, and thus, the viscosity would be reduced in
a single surface layer on the order of the coil size. This viscosity The authors thank the National Science Foundation’s Nano-
reduction, attributed to a reduced interchain entanglement scale Interdisciplinary Research Team (ECCS 0506941) for their
density, is found to depend only on the ratio of film thickness generous support of this work. This work utilized facilities
to coil size of the polymer chain. Thus, we would expect a film supported in part by the National Science Foundation Materials
with two surface layers, such as the free-standing films in this Research Science and Engineering Center (DMR 0820506) and
study, to show entanglement reductions near or below a thick- Center for Hierarchical Manufacturing (CMMI 0531171).
ness corresponding to two polymer coils as there are two free
surfaces. In free-standing films, Dalnoki-Veress et al. showed ’ REFERENCES
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