Open Access Article
Hamed Sharifi
Dehsari
,
Jasper J.
Michels
* and
Kamal
Asadi
*
Max Planck Institute for Polymer Research, Ackermannweg 10, 55128, Mainz, Germany. E-mail: michels@mpip-mainz.mpg.de; asadi@mpip-mainz.mpg.de
First published on 14th August 2017
Solution casting under ambient conditions of thin films of the ferroelectric copolymer poly(vinylidene fluoride-co-trifluoroethylene) (P(VDF-TrFE)) is highly attractive for cost-effective production of flexible memory devices. However, rough and porous films obtained under ambient conditions typically give a low yield of working devices. A major challenge is ambient water vapor condensing into the drying solution, causing non-solvent vapor-induced phase separation (VIPS). By integrating solution-stage modeling, microscopic analysis and thin-film device characterization, we show that the hydrophilicity of solvent is a deciding factor in obtaining properly functioning capacitive memory elements based on P(VDF-TrFE) under ambient conditions. Our numerical study, involving the ternary phase diagram of the polymer/water/solvent blend as well multicomponent dynamic phase field modeling, predicts the occurrence of VIPS for a given solvent hygroscopicity and demonstrates an increase in early stage domain size with decreasing relative humidity, whereas the opposite trend is predicted for the rate of demixing. Experimentally observed morphologies are consistent with the numerical simulations. For a sufficiently low solvent hygroscopicity, >90% production yield of devices operating at voltages on par with upscaled thin-film flexible electronics is achieved.
Limited device yield and concomitant large scatter in coercive voltage hinder upscaling of integrated arrays of P(VDF-TrFE) memory elements, especially under ambient conditions (20 °C, 50% relative humidity (RH)). Generally, P(VDF-TrFE) is cast from dimethylformamide (DMF) or ketones, which are often hygroscopic. For the homopolymer poly(vinylidene fluoride) (PVDF), it has been shown that condensation of ambient water into the DMF solution causes vapor-induced phase separation (VIPS), as water is a non-solvent for PVDF.14,15 The resulting domain structure prohibitively compromises the integrity and smoothness of PVDF films. Smooth PVDF films have so far only been obtained under an inert atmosphere,15–18 or at an elevated substrate temperature,15,19 conditions that are not beneficial for cost-effective production. VIPS is also expected to occur for P(VDF-TrFE) since its properties are similar to PVDF. Although avoiding processing-related film defects is still a major challenge for sub-200 nm thin-films, consistent studies considering the full spectrum of material properties, processing conditions, microstructure formation and thin film device performance are unfortunately still lacking.
The present work aims to lift this hiatus and provides novel insight into the dynamics of the early stages of VIPS, and how these relate to dry film integrity and device performance. This work covers all aspects of device preparation, starting with modeling and simulation of VIPS to pre-estimate solution behavior, proceeds with detailed microstructural analysis of cast P(VDF-TrFE) films and finally discusses device fabrication and electrical characterization. As such, a direct link is established between material properties, processing conditions and device performance. The generality of our approach makes the work not only relevant to the field of thin-film electronics, but hopefully to any technology relying on polymer/solvent/non-solvent processing, perhaps most prominently the manufacture of microporous membranes.
We consider P(VDF-TrFE) thin film processing from three different solvents with different hygroscopicities: DMF, cyclohexanone and cyclopentanone. Calculation of the ternary phase diagrams, combined with numerical simulation of structure formation under simultaneous solvent evaporation and water vapor dissolution, not only predicts the occurrence of VIPS as a function of solvent polarity, but also shows how initial domain size and demixing dynamics depend on ambient humidity. The calculations are validated by subjecting wire-bar coated P(VDF-TrFE) films under conditions of controlled temperature and relative humidity to extensive atomic force microscopy (AFM) analysis. Using the insight gained, we fabricate ferroelectric capacitors under ambient conditions, i.e. 20 °C, 50% RH, to establish how device yield and the scattering in coercive voltage are influenced by solvent polarity and ambient humidity.
000 (PDI = 2.5) was purchased from Solvay. Poly(3,4-ethylenedioxythiophene)-poly(styrenesulfonate) (PEDOT:PSS) was purchased from Clevios. N,N-Dimethylformamide (DMF), anhydrous DMF (a-DMF) (≥99.9%), cyclohexanone and cyclopentanone were purchased from Sigma Aldrich. All the chemicals were used as-received without further purification.
The phase diagram of DMF (Fig. 1a) is shown completely, whereas in the case of the phase diagrams of cyclohexanone and cyclopentanone (Fig. 1b and c), which are of comparable nature to that of DMF, only the top part is shown for the sake of clarity. The phase diagrams are characteristic of a polymer/non-solvent/solvent ternary, evidenced by (i) a large miscibility gap, (ii) a pronounced asymmetry, and (iii) steeply tilted tie-lines. The first feature is mainly due to the high value of the polymer–nonsolvent interaction parameter (χPW = 2.8, see ESI†). The asymmetry is a result of the difference in molecular size between a polymer and a water molecule and the tilt in the tie lines shows that if VIPS occurs, the solvent strongly prefers the polymer-poor phase. Fig. 1c shows that a lower solvent polarity somewhat reduces the miscibility gap.
The colored curves in Fig. 1b and c represent calculated (mean) composition trajectories resulting from simultaneous solvent evaporation and water ingress from/into the drying polymer solution, at various RH levels (see the legend). These curves were calculated assuming the volume flux σi of a blend component i across the liquid–vapor interface to be governed by the difference between its partial pressure just above the film and the applied partial pressure p∞i away from the vapor–liquid interface. Just above the drying film, a liquid–vapor equilibrium is assumed, so that the fluxes of water and solvent are given by:
![]() | (1) |
the vapor pressure of the pure substance (tabulated for all solvents and water, see the ESI†), and k the mass transfer coefficient expressed in units of Pa−1 s−1 and for simplicity taken equal for water and solvent. The coefficient matrix on the RHS of eqn (1) enforces incompressibility. By defining
and
and by combining eqn (1) with the generalized 2D-diffusion model we published earlier,25,28,29 we not only track composition as a function of time, but also model the actual dynamics of structure formation due to VIPS.
The calculations (Fig. 1b and c) assume an initially dry solution with a polymer concentration of 3 vol%. In the case of cyclohexanone the mean composition (dashed lines) readily enters the spinodal region, whereas for the more hydrophobic cyclopentanone, the trajectories remain within the single phase region. The calculations hence predict that for cyclohexanone spinodal VIPS occurs, but probably not for cyclohexanone. For DMF the results were similar to cyclohexanone and are hence not explicitly shown. We further note that although the model's simplifications (i.e. reduction by one space dimension and assuming a fixed mass transfer coefficient) together with the, at best, semi-quantitative nature of Flory–Huggins theory,30 does not allow for a fully quantitative description. However, trends regarding the dependence of demixing dynamics and initial domain size on relative humidity can certainly be identified and will be discussed below.
Fig. 1b (solid lines) shows that VIPS results in two coexisting liquid phases, one poor/rich and one rich/poor in polymer/solvent.31 Interestingly, the water fraction is similar in both phases due to the fact that the tie-lines run almost parallel to the solvent axis of the phase diagram. The shift in the bifurcation point (open symbols) with relative humidity suggests that the dynamics of VIPS, as well as the initial liquid-stage domain size, depends on the ambient conditions. This is shown in Fig. 2, which plots (Fig. 2a) composition ν as a function of dimensionless time
(see the caption for definition), as well as the initial liquid-stage morphology for various relative humidities (Fig. 2b–e). While the demixing time scale increases with decreasing relative humidity, the opposite trend is observed for the initial domain size. This is explained by the fact that with decreasing humidity the bifurcation point approaches the spinodal and at the same time moves towards criticality (dash-dotted black line in Fig. 1b).
![]() | ||
Fig. 2 Numerical simulation of water vapor-induced spinodal decomposition of P(VDF-TrFE) in cyclohexanone for RH = 99–54%. (a) Composition ν = ϕP/(ϕP + ϕW) plotted as a function of dimensionless time = tD0S/κ, with D0S the self-diffusivity of the solvent (in m2 s−1) and κ (in m2) a thermal energy-normalized stiffness coefficient determining the liquid–liquid interface width30 (see the ESI†). (b–e) Initial liquid-stage demixed morphology (yellow = polymer rich, black = polymer devoid) corresponding to 99%, 72%, 63%, and 54% RH. | ||
In summary, going from high to low humidity a transition takes place from a structure wherein the polymer rich domains are dispersed in a solvent-rich matrix towards a more bicontinuous morphology of the polymer- and solvent-rich phases. At high relative humidity droplets are small and concentrated in the polymer, whereas at low humidity the polymer-rich phase consists of relatively large droplets in which the solid concentration is low. We emphasize that although models for nonsolvent-VIPS have been proposed,14,32 the level of detail provided by combining the calculated ternary phase diagram with numerical simulations of the demixing dynamics and associated structural evolution has so far not been given.
Just as observed previously for PVDF in DMF,15 and in line with the modeling results, the morphologies in Fig. 3a, c and d form due to water-vapor induced phase separation, initially giving polymer-rich droplets suspended in a DMF-swollen medium (e.g. depicted in Fig. 2b–e). During evaporation ripening and coalescence of the P(VDF-TrFE)-rich droplets take place until solvent is depleted and the film solidifies. The grain structure in the dry film suggests that at some point coarsening halts and the droplets impinge onto each other. The fact that DMF and anhydrous DMF give similar structure sizes indicates that water ingress is fast compared to solvent evaporation. VIPS seems to be virtually absent at 65 °C, even at 50% RH, which suggests (i) a decreased water miscibility at elevated temperature and/or (ii) suppression of VIPS domain growth due to fast solidification upon enhanced solvent evaporation. We note that a similar decrease in roughness with substrate temperature has also been observed for DMF-cast films of PVDF.15
Fig. 4 shows AFM topology images of P(VDF-TrFE) films cast from cyclohexanone (Fig. 4a and b) and cyclopentanone (Fig. 4c and d) at 20 °C, with the RH values varying between 10%, 50% and 80%. In excellent agreement with the model, microstructure formation due to VIPS is observed for cyclohexanone and not for cyclopentanone, even at 80% RH. It is however fair to note that the significantly lower vapor pressure of cyclohexanone (see the ESI†) further suppresses possible VIPS due to fast solidification of the film. The effect of solidification, which for P(VDF-TrFE) probably partly relies on crosslink formation via nano-crystallization, is not taken into account in our model.
We note that the cyclohexanone used was not anhydrous. Hence, demixing might have been induced by water already present in solution prior to casting. This may also be the reason for the fact that similar structure sizes were obtained for different RH values, which contradicts the model prediction (Fig. 2b). In contrast, the predicted trend of an increasing structure size with decreasing humidity is in fact nicely reproduced in the older study on PVDF (Fig. 3a in that work).15 Just as for DMF, the cyclohexanone solutions produce smooth and uniform films at elevated substrate temperature (Fig. S4 of the ESI†). In the case of cyclopentanone, the surface roughness and morphology does not change substantially upon increasing the substrate temperature (see the ESI,† Fig. S5). Evidently, for ambient processing of P(VDF-TrFE), VIPS can only be avoided if a hydrophobic solvent with a water-miscibility well below 10 wt% is used.
In order to discriminate the VIPS-related dry film features from possible spherulitic crystallization, we also scanned the topology at the polymer–substrate interface. To this end, dry films were floated on the substrate and placed upside down under the AFM tip (see the Experimental section for details). The recorded images are given in Fig. 5 for cyclohexanone (Fig. 5a) and cyclopentanone (Fig. 5b). Since in both cases the topological and microstructural features are the same as those at the polymer–vapor interface heterogeneously nucleated spherulitic crystal growth can be ruled out, as that would not lead to topological gradients at the polymer–substrate interface.
Film thickness and rms roughness acquired at 50% RH for all three solvents are plotted in Fig. 6 as a function of substrate temperature (also for 10% RH in Fig. S6, ESI†). Fig. 6a shows that for the films processed from DMF and cyclohexanone under ambient conditions the apparent mean thickness is strongly overestimated due to the large topological features resulting from VIPS (see also Fig. S7 in the ESI†). With increasing substrate temperature the structure densifies and the apparent mean thickness saturates at a value of 300 nm. Expectedly, the rms roughness follows the same trend (Fig. 6b). For cyclopentanone, however, due to the absence of VIPS, a dense smooth film of 300 nm with ∼10 nm rms roughness is already obtained at room temperature, irrespective of relative humidity.
![]() | ||
| Fig. 6 (a) Layer thickness and (b) rms roughness plotted as a function of substrate temperature measured for films prepared at a fixed relative humidity of 50%. | ||
In contrast, viscoeleastic structure development is driven by a dynamic asymmetry between the phases in a fluid mixture.36 In this case structure development is governed by the partitioning of the total stress between the phases, as governed by the force balance condition. In contrast to elastic demixing, morphologies develop in which the temporarily harder, i.e. more viscoelastic, phase forms the network surrounding domains of the “softer”/more fluid phase. We argue that the impinged dry film morphologies form under the influence of elastic rather than viscoelastic stress. We hypothesize that the elastic anisotropy, and the concomitant stagnation of coarsening, is introduced by late-stage development of P(VDF-TrFE) crystallites, giving rise to a gel-like state in polymer-rich regions.
A typical hysteresis loop of P(VDF-TrFE) is presented in the inset of Fig. 7a. The ferroelectric remanent polarization of all the capacitors was about the same and amounted to 6–7 μC cm−2, in agreement with literature data.3–5 The graph in Fig. 7a shows that the yield of functioning thin-film capacitors drops substantially with increasing water miscibility of the solvent: while no functional capacitor was obtained using DMF, cyclohexanone gave a yield of ∼50%. However, processing devices using cyclopentanone gave an impressive yield of >93%, the few non-working devices probably resulting from particle-induced short-circuits, rather than morphological flaws. Ferroelectric thin-film quality is also reflected by scatter in the coercive voltage, i.e. the voltage at which the polarization switches sign. Fig. 7b shows the histogram of the coercive voltages measured for capacitors fabricated from cyclohexanone and cyclopentanone. While the coercive voltage of cyclohexanone-processed devices shows significant scatter, a narrow distribution of 7.3 ± 0.5 V is obtained in the case of cyclopentanone, reflecting the low surface roughness and excellent film uniformity (ESI,† Fig. S9b).
Footnote |
| † Electronic supplementary information (ESI) available. See DOI: 10.1039/c7tc01495c |
| This journal is © The Royal Society of Chemistry 2017 |