Lecture 8 Flashcards
How do we synthesise linear Polydimethylsiloxane (PDMS)? How can we branch the polymer or terminate it?
One way to make PDMS is by the hydrolysis of its monomer dimethylsiloxane, as shown in digital notes. This reaction would lead to linear PDMS since each molecule can only react twice. By adding monomers like [Si(CH3)Cl3] or [SiCl4] one can promote branching as the additional chlorines can lead to points where more than two monomers can attach.
By contrast, adding [Si(CH3)3Cl] would serve to limit the growth of the polymer chains since this additional monomer can only react with one monomer thus functioning as a chain termination agent
What are PDMS useful properties?
PDMS has several useful properties: It is transparent, it is chemically inert, it can be transformed into silica by calcination, it is heat resistant, and it has widely tunable mechanical properties.
In short, we could say that PDMS displays some of the great properties of silica, with the added advantage of widely controllable mechanical characteristics
How are the mechanical properties of PDMS controlled?
The mechanical properties can be controlled by the length of the polymer chains (their molecular weight, MW), their branching, their crosslinking density, and the use of fillers.
What is the main difference between the surface of PDMS and the surface of silica?
The main difference between the surface of PDMS and the surface of Silica is the extremely low silanol density on the PDMS surface and the presence of organic methyl (-CH3) groups. Both factors imply a larger hydrophobicity, a lower surface charge, and a lower surface energy.
Given its low surface energy. PDMS generally has a low adhesion to most surfaces; this adhesion can be easily modified by exposure to plasma treatment which, just as for silica, temporarily increases the number of silanols on the surface.
What is soft lithography and why how does PDMS relate to it?
Soft lithography is a way of creating a surface pattern on a micro- or nanoscale which relies on self-assembly and template replication.
The tunable and adhesive properties of PDMS have been used to develop this method! The objective was to create a platform for surface patterning through chemistry, which could be cheap and reusable!
How do we prepare a PDMS stamp? IMP!
NOTE: the first step to creating the surface patterning is to prepare a PDMS stamp
Procedure:
The pattern is first designed into a master, which is usually made in silicon by the conventional lithography methods; this master will function as a template for the formation of our stamp. The silicon is first exposed to oxygen plasma and then made hydrophobic with molecules like trimethylsilyl chloride (CH3)3SiCl or perfluorooctyltrichlorosilane CF3(CF2)7SiCl3; A PROCESS CALLED SILANIZATION. the plasma will introduce silanol on the passivating silica layer on the surface of silicon. The silanization reacts most of the surface silanols, thereby reducing the surface reactivity and adhesion with PDMS, and increasing the accuracy of the template replication.
The PDMS pre-polymer is then poured over the master. This step is fairly delicate as you have to make sure not to form bubbles which might remain trapped in the viscous pre-polymer.
The PDMS then undergoes curing during which the pre-polymer molecules crosslink with each other forming the extended moleculear network which will imbue the final stamp with rubber-like properties.
The stamp can be successfully peeled off the master, providing a very accurate free-standing replica of the master and can be used in a multitude of ways to generate surface patterns.
What is the formal definition of silanization?
Silanization is the process of reacting surface silanols
What are the different procedures that use the PDMS stamp to generate surface patterns?
- Microcontact printing
- Micromolding
- Microebossing
- Microlithography
(All of the above are examples of soft lithography
What is microcontact printing and its procedure?
Microcontact printing is where a stamp transfers a specific ‘ink’ from one substrate to another employing the different adhesion characteristics of the substrates involved (see figure 4.1 in digital notes); the inks can be molecules, polymers, nanocrystals, nanowires, colloids, and whole thin films.
Procedure:
You initially deposit the ink on a substrate for which it has very low adhesion, for example, a silanized piece of silica, silicon or even PDMS itself. The stamp is then put in conformal contact with the ink, and if the adhesion of the ink towards the stamp is larger, the ink will transfer to the stamp in those protruding regions of the stamp designed in the master.
The next step is the printing step; the stamp, wet with ink, is put in contact with the desired substrate which, different from the first substrate, must have a strong adhesion for the ink. In this way, when the stamp is peeled off the desired substrate, the ink will remain on the substrate and not on the stamp.
(EXAMPLE) Sometimes it is necessary to use a trick to facilitate ink transfer, such as using a functional group that can react with the final substrate but not with the initial one; for example is the final substrate is gold you can choose to ‘dress’ your ink with a thiol group and to use as a first substrate a silica substrate: the thiol will not react with the silica or the PDMS stamp but will react promptly with the gold surface. In this way it is very easy to produce pattered self-assembled monolayers (SAMs) on metallic surfaces.
What is micromolding and its procedure?
It is a technique that uses a PDMS stamp as a template to create a negative replica of a chosen material.
Procedure:
The stamp is pressed against the desired substrate and the ink flows into channels, drawn by capillary forces; if the ink has a reasonable affinity for the substrate, placing a drop of the ink on one end of the channels will cause the ink to diffuse into the channels. Another requirement is of course that the ink must be fluid enough for it to diffuse into the channels of the stamp.
The ink is then consolidated, which can mean different things for different inks: Monomers can be polymerized, nanocrystals can be dried, and molecules, used to make a SAM on the substrate, can just flow through reacting as they pass.
The stamp is then peeled off leaving a patterned material behind.
What is microembossing?
A similar approach to micromolding (see Figure 4.1) in which the ink is first deposited on the desired substrate and then the stamp is strongly pressed against the substrate leading to an embossed pattern of ink on the substrate.
What is microlithography and its procedure?
Microlithography is one of the most sophisticated forms of patterning that can be performed with soft lithography. This technique is a combination of bottom-up and top-down techniques. This method is able to fashion material below 10 microns!!
Procedure:
The first step is to contact print an ink on a sacrificial layer which has been deposited onto the desired substrate. The stamp is peeled off leaving behind a sacrificial layer coated with a pattern of ink; the ink has here the tole of protecting the underlying sacrificial layer from etaching.
The whole structure is dipped into a wet etchant that will selectively etch the sacrificial layer only in the exposed regions in the case the sacrificial layer is SiO2 and the substrate is silicon you can use HF solution. This process leaves behind a pattern of posts from the sacrificial layer that will work as a template for the subsequent deposition of the desired material on the chosen substrate. Such depositions can be made via the Vapour phase (Like chemical vapour deposition, CVD) or liquid phase, depending on which is the most convenient and compatible with the survival of the template.
After the desired material is deposited the template is removed by first removing the ink with an appropriate solvent, and then removing the sacrificial layer with the appropriate etchant.
This process mimics standard photolithography in which the sacrificial layer is a photoresist, a material which can permanently change properties, like solubility, upon irradaition with light.
A final note about Soft lithography.
With soft lithography, you can pattern any substrate, even a curved one, since PDMS is a rubber and it can be made conformal with surfaces other than planar ones.
An important point before talking about Size
All the techniques that will be mentioned in this subchapter are ones that exploit the polymeric nature of PDMS (with it being fairly compressible and their porosity being small); meaning that they could not be applied on rigid stamps!
What are the soft reduction techniques in soft lithography?
- Reduction by compression
- Reduction by swelling
- Reducion by filler extraction
- Double printing
- Reactive spreading
- Overpressure contact printing
- V-shaped features
- Nanoskiving
What is the procedure for reduction by compression?
In the first step you wet your PDMS stamp with your chosen ink; you then apply the stamp to the surface and, in doing so, you strongly compress the stamp, leading to a lateral expansion of the protruding features and, as a consequence, of the printed pattern. After peeling off the stamp you can see that the distance between the printed regions is smaller than the distance between the protruding regions in the uncompressed stamp. The reduction in feature size is tracked in Figure 4.2 with the thin black lines
What is solvent-induced swelling? (procedure in the next flash card)
Solvent-induced swelling is a more elegant and controllable technique that is used to decrease the separation between the protruding features.
This is based on the phenomenon between the PDMS and certain solvents. Where PDMS is principally a single molecule: no part of it is chemically disconnected to any other. The main consequence of this is that polymer networks are not soluble in any solvent because the constituent atoms cannot disassociate from one another because every atom is covalently bound to the network. What the solvent can instead do is to penetrate and swell the polymer network! For the same reason you can compress a PDMS stamp - the vast amount of free volume in the network and the elasticity of the PDMS individual changes - the opposite can happen: The PDMS stamp can well in certain solvents. This happens for energetic reasons.
What is the procedure for solvent-induced swelling?
The technique is based on the following steps (Figure 4.2). The stamp is swollen in toluene (or any other good solvent for PDMS); the swollen sample is put in contact with the ink, which is transferred into the stamp; the stamp is then used to print the pattern on the desired substrate. Also, in this case, the lateral swelling of the protruding features leads to a reduction of the feature sizes in the printed pattern.
What is the reduction by filler extraction and its procedure?
A polymer network can be crosslinked in the presence of fillers (or additives), which are often used to fine-tune the properties of the final network; such fillers are 3D defects in the network as they are not covalently bound to the network.
Now that you have prepared a stamp filled with filler, you can always remove it by using a proper solvent like toluene, for example. Toluene will sell the PDMS stamp, as we just saw, and will remove the soluble components from it, including the filler. After having removed the toluene from the stamp, the resulting stamp will be smaller in size by a volume equal to the volume of filler you included. As shown in the scanning electron microscopy (SEM) micrographs in Figure 4.2, this allows one to strongly reduce the feature size of the printed pattern.
Note: In the example we show in Figure 4.2 the filler was PDMS oligomers. The reason why they used PDMS oligomers and not oligomers of another polymer is that they wanted to ensure thorough mixing of the filler into the network without PHASE SEPARATION. always consider that when solving problems!
What is double printing and its procedure?
Double printing is another way to get size reduction, even though in a hardly controllable way, is to print the ink twice. As shown in Figure 4.2, you can print twice, reducing the feature size. In the SEM micrograph is shown an example of the kind of pattern, called Moire patterns, you can make by printing twice a set of stripes at slightly different angles!
What is reactive spreading and its procedure?
It is a method based on ink diffusion. In the case in which your ink has low viscosity, you can let the stamp sit on the substrate long enough for the ink to diffuse laterally, thus reducing the feature size, as shown in Figure 4.2. The higher the ink viscosity the more slowly the ink diffuses and spreads on the surface. As you can see in the SEM micrographs below, by tracking the time of diffusion you can reliably control the feature size.
What is overpressure contact printing and its procedure?
It is an adaptation of the “Reduction of compression” printing. In this case, you completely wet the PDMS stamp with ink so that also the recessed regions are coated with ink. When the stamp is then used for printing, you can apply enough pressure to bring the recessed regions of the stamp in contact with the substrate (Figure 4.2). By this method, you can halve the feature size of your original stamp
What is ‘V-shaped features’ and its procedure?
This technique relies on the different ways to prepare the master. Instead of using flat-bottomed features, you can etch the silicon anisotropically to yield V-groovers.
Note that the anisotropic etching of silicon is founded upon the distinct etch rates of different crystallographic planes of single-crystal silicon.
If you use such a V-grover master to prepare a PDMS stamp, the protruding region of PDMS corresponding to the sharp apices of the V-grooves can be made as small as a few nanometers.
A shortcoming of this method is in the design of the master, as the specific etching method to produce grooves relies on the crystallographic orientation of silicon and thus you are limited in the angle you can have between features. The achievable resolution of the method also depends on the extent of crosslinking of the PDMS because the deformability of the tips will control the fidelity of the replication process.
What is nanoskiving and its procedure?
It is a method where the scientist transfers the fine control currently available for producing thin films to the production of 2D features.
Procedure:
The stamp is silanized and epoxy pre-polymer is poured on it. The epoxy is then cured and the PDMS stamp is peeled off. After this, you can deposit the material of interest on the epoxy mold in any way you like. In this case, we show gold as it can be easily sputtered or thermally evaporated on surfaces with nanometer control of the thickness.
After this step is completed epoxy pre-polymer is again poured and cured on the gold-coated epoxy mold. At the end of this step, you have a solid piece of epoxy with a film of gold having controlled thickness on a nanometer scale and morphology that is defined by the first PDMS stamp. What you can do now is slice this epoxy block with a microtome.
The slices are transfered to the desired substrate and the epoxy is selectively removed from each slice by plasma etching. What is left behind is a 2D pattern in the material of choice with nanometer thickness and lateral size.