Combinatorial investigation of dewetting: polystyrene thin films on gradient hydrophilic surfaces

Film stability and dewetting is important to control for applications in coatings such as photoresists, paints, adhesives, lubricants, and biomaterials. We demonstrate the use of 2D combinatorial libraries to investigate thin film dewetting. Substrate libraries with gradients in contact angle (θ) were prepared by immersing Si–H passivated Si in a Piranha solution (H2SO4/H2O2/H2O) at a controlled rate. Libraries of thin films of polystyrene on gradient etched silicon substrates containing orthogonal continuous variation of thickness were screened for dewetting behavior using automated optical microscopy. After comparing the high-throughput screening method to conventional studies of thickness effect on dewetting, a detailed morphological phase-map of the effects of contact angle on dewetting of polystyrene film was generated. Dewetting trends were visibly apparent. The number of polygons of dewetted polymer is sensitive to surface hydrophilicity as characterized by contact angle studies.