Wavefront kinetics of plasma oxidation of polydimethylsiloxane: limits for sub-μm wrinkling

Abstract

We investigate the surface plasma oxidation of polydimethylsiloxane (PDMS) elastomers and its implication for the morphologies attainable by wrinkling of glassy-elastomer ‘bilayers’. The kinetics of glassy skin formation is found to follow a logarithmic dependence with plasma exposure time t and, for various plasma intensities I, the relevant control variable is shown to be dose (≡I × t). We model the mechanism and kinetics of glassy film formation by plasma oxidation with a frontal propagation coarse-grained model, describing the spatio-temporal evolution of a conversion order parameter (ϕ) orthogonal to the film surface. The model is validated by X-ray reflectivity experiments, which confirm the logarithmic growth and quantify the initial growth of a transient, incomplete, skin layer during the early stage of plasma exposure. Three regimes are identified as (I) induction, (II) formation and (III) propagation with a combination of X-ray and wrinkling experiments. The simultaneous increase in thickness and skin mechanical modulus is found to be responsible for an unexpected minimum wavelength λ_min attainable, which depends on critical strain ε_c and is ultimately limited by mechanical failure of the elastomer (λ_min ≃ 140 nm is demonstrated at ε = 200%). We conclude by establishing a 1D surface morphology diagram, in terms of wavelength λ and amplitude A, limitations and capabilities for producing highly ordered (sub-)micropatterns over macroscopic areas using plasma oxidised PDMS under uniaxial strain.