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.

Living anionic polymerization using a microfluidic reactor.

Living anionic polymerizations were conducted within aluminum-polyimide microfluidic devices. Polymerizations of styrene in cyclohexane were carried out at various conditions, including elevated temperature (60 degrees C) and high monomer concentration (42%, by volume). The reactions were safely maintained at a controlled temperature at all points in the reactor. Conducting these reactions in a batch reactor results in uncontrolled heat generation with potentially dangerous rises in pressure. Moreover, the microfluidic nature of these devices allows for flexible 2D designing of the flow channel. Four flow designs were examined (straight, periodically pinched, obtuse zigzag, and acute zigzag channels). The ability to use the channel pattern to increase the level of mixing throughout the reactor was evaluated. When moderately high molecular mass polymers with increased viscosity were made, the patterned channels produced polymers with narrower PDI, indicating that passive mixing arising from the channel design is improving the reaction conditions.

A microfluidic platform for integrated synthesis and dynamic light scattering measurement of block copolymer micelles.

Microfluidic devices were developed that integrate the synthesis of well defined block copolymers and dynamic light scattering (DLS) measurement of their micelle formation. These metal devices were designed to operate in contact with organic solvents and elevated temperatures for long periods, and thus were capable of continuous in-channel atom transfer radical polymerization (ATRP) of styrene and (meth)acrylate homopolymers and block copolymers. These devices were equipped with a miniaturized fiber optic DLS probe that included several technology improvements, including a measurement volume of only 4 microlitres, simple alignment, and reduced multiple scattering. To demonstrate the integrated measurement, poly(methyl methacrylate-b-lauryl methacrylate) and poly(methyl methacrylate-b-octadecyl methacrylate) block copolymers were processed on the device with a selective solvent, dodecane, to induce micelle formation. The in situ DLS measurements yielded the size and aggregation behavior of the micelles. For example, the block copolymer solutions formed discrete micelles (D(H) approximately = 25 nm) when the corona block was sufficiently long (f(MMA) < 0.51), but the micelles aggregated when this block was short. This study demonstrates the utility of these new devices for screening the solution behavior of custom synthesized polymeric surfactants and additives.

Miniaturized dynamic light scattering instrumentation for use in microfluidic applications.

Five designs for a miniaturized dynamic light scattering (DLS) instrument are described that incorporate microfluidic flow of the sample volume and fiber optic probes directly embedded into the sample. These instruments were demonstrated to accurately determine the size of 10-100 nm particles dispersed in organic and aqueous solvents with most sample sizes less than 150 microl. Small stir bars were incorporated directly into the instruments, and enabled blending of different solutions immediately prior to DLS measurements. Demonstration of the instruments' capabilities include high throughput measurements of the micelle to unimer transition for poly(styrene-b-isoprene) in mixed toluene/hexadecane solvent, obtained by systematically blending toluene-rich and hexadecane-rich polymer solutions. The critical solvent composition was quickly identified with less than 20 mg of polymer. Further capabilities include temperature control, demonstrated by identification of a critical micelle temperature of poly(ethylene oxide-b-propylene oxide-b-ethylene oxide), as well as multiangle DLS measurements.