Vertical Composition Profile During Hydrodynamic-Evaporative Film Thinning: The Physics of Spin Casting Dilute Solutions Stefan Karpitschka,∗ Constans M. Weber, and Hans Riegler We analyze the evolution of the vertical composition profile during hydrodynamic-evaporative film thinning as it typically occurs during spin casting mixtures of non-volatile solutes and volatile solvents. We assume that the solvent dominates the hydrodynamic-evaporative film thinning. The internal spatio-temporal evolution of the composition is analyzed with a diffusive-advective approach. The analysis provides transparent physical insights into the influence of the experimental conditions on the evolution of the internal composition. We present power laws that link the process control parameters to the composition evolution, process duration, and final solute coverage. The analysis reveals a characteristic Sherwood Number as fundamental process parameter. It identifies for which stages of the process our analysis is quantitatively relevant and discloses the dominance of either diffusion or evaporation. The analysis is valid for dilute solutions e.g., for the deposition of solute (sub)monolayers. But it is also relevant for the deposition of thicker (polymer) films. PACS numbers: 68.03.Fg, 47.57.eb, 47.85mb, 82.70.-y Many studies have analyzed this process experimentally [2–45] and theoretically [1, 46–161]. Most of them focus on the radial (in)stability of the film [2– 5, 7, 10, 12, 13, 16, 18, 20, 26, 29, 30, 32, 40–44, 46, 51, 52, 54, 55, 60, 61, 70, 71, 73–75, 78–80, 83–85, 91– 94, 97, 99, 100, 103, 106, 109–117, 119–121, 124, 126– 136, 139–145, 147–151, 153, 154, 157, 158, 161], or systems with complicated rheologies such as polymer solutions [2–4, 6, 7, 9–11, 13, 17, 21, 26–28, 30, 31, 33–35, 37– 39, 43, 45, 50–52, 58, 65, 76, 81, 89, 98, 105, 122, 125, 155, 156] (the main application of spin casting is depositing polymer films) or other non-newtonian liquids [40, 44, 46, 49, 51, 54, 78, 94, 95, 102, 103, 142, 143, 161]. Rather few studies [48, 57, 65–68, 76, 78–80, 86, 146, 155, 156] aim at elucidating the general, fundamental physics of this process. Due to different approximations/approaches there is no agreement on the final amount of solute deposition [65, 86, 156, 162]. Very few studies explicitly investigate the evolution of the internal film composition. Often they assume specific cases and/or approximations such as solute ”boundary layers” [65, 76, 78], or ”split mechanism models” [86]. Some analysis is solely based on numerics [66–68] or combining numerics with analytical considerations assuming complicated nonlinear viscosity and diffusivity behavior [156]. In any case, all those studies early phase (spin-off dominated) film Introduction.—Excess amounts of liquid deposited on a spinning, planar, wettable substrate form a thinning film of uniform thickness h as the liquid flows outward [1]. Evaporation of volatile film components adds to the film thinning (Fig. 1). Nonvolatile components continuously enrich, eventually exceed saturation, and precipitate. The general, fundamental physics questions in this hydraulic-evaporative (spin cast) process are: How thins the film with time? How evolves the film composition during thinning? How much nonvolatile solute is finally deposited? height h arXiv:1205.3295v3 [physics.flu-dyn] 10 Jan 2014 Max-Planck-Institut für Kolloid- und Grenzflächenforschung, Potsdam-Golm, Germany (Dated: January 13, 2014) z late phase (evaporation dominated) solvent evaporation (rate E) flow field spinning support solute enrichment r angular frequency w 2 spin-off coefficient K µ w FIG. 1: Schematics of spin-casting with processes dominating early and late stages. use vertical ”initial” Peclet numbers based on inappropriate (see [86]) ”initial” film heights [174]. Thus their validity ranges are ill-defined and the insight into the general physics of this interesting hydraulic-evaporative process is limited. Increasingly spin casting is used for fundamental nucleation and growth studies [163, 164] and for the deposition of structured (sub)monolayers (particle arrays, “evaporation-induced self-assembly” [164–172]). This means dilute solutions, which behave rather ideally during most of the spin cast process. This is the motivation and basis of our analysis. In this report we focus on the evolution of the vertical composition profile during the hydrodynamicevaporative film thinning. To reveal its general aspects we neglect any complicated, non-linear solution behavior. Thus, for the first time palpable, universal relations between the process parameters and the compositional evolution are presented. The key process parameter, its characteristic Sherwood number Shtr is introduced. It is demonstrated that the analysis is indeed quantitatively valid for low solute concentrations but also yields valuable insights into the behavior of higher concentrated so- 2 10 Hydrodynamic film thinning (E = 0, dashed) dominates ≈30% of the spin cast time; ≈70% is evaporationdominated (K = 0, dashed). All this agrees well with experimental results (see inset in Fig. 2 and supplement [176]). II. Solute concentration evolution — During spin casting, non-volatile solute enriches at the free surface (where the solvent evaporates) and migrates into the film via diffusion. The spatio-temporal evolution of the solute concentration c is described by ttr ÷tsc 1 only evaporatio 0.01 Reflectometry Fit of Eq. (5) 4 htr = 3.08 ± 0.01 µm tsc = 1.20 ± 0.01 s 2 0 0.0 0.001 0.0 Toluene, 3000 rpm, 20°C 6 h [µm] h÷htr 8 0.1 only spinning n 0.2 0.4 0.2 0.6 0.8 1.0 1.2 t [s] 0.4 0.6 0.8 1.0 ∂t c = D ∂z2 c + K z 2 (3h − z) ∂z c, t/ t sc FIG. 2: Universal thinning curve h/htr = f (t/tsc ) (dashed lines: thinning due to spinning/evaporation only). Inset: Measured thinning curve in physical units for toluene and its fit according to the theory (Eq. 5). lutions including polymeric solutes. I. Hydrodynamic-evaporative film thinning — The thinning of a Newtonian, volatile liquid film of thickness h on a rotating support is described by [48]: dh/dt = −2K h3 − E , (1) with spin-off coefficient K = ω 2 /(3ν), ω = rotational speed, ν = kinematic viscosity and E = evaporation rate. The fundamental form of Eq. 1, dξ/dτ = −ξ 3 − 1 , (2) is obtained by rescaling ξ = h/htr and τ = t/t∗sc i.e., by the system inherent “natural” scales (see [146]): htr = (E/2K) /3 , (3) t∗sc = (2E 2 K)− /3 . (4) 1 1 htr is the “transition height” where evaporative and hydrodynamic thinning are equal. t∗sc is the ”reduced process duration” (Eq. 6). The inverse of Eq. 2 can be integrated [146] [175]: ) √ ( 1 − 2ξ 3 1 1 − ξ + ξ2 τ (ξ) = π + 2 arctan √ , (5) + √ log 6 (1 + ξ)2 3 3 with integration constants so that τ = 0 for ξ → ∞. The total spin cast time (from h → ∞ to h = 0) is tsc = (2π/33/2 )(2E 2 K)− /3 = (2π/33/2 ) · t∗sc . 1 (6) Fig. 2 shows the universal thinning curve (the inverse of Eq. 5) on scaled axes. The transition time, ttr , at which htr is reached, is universal for all spin cast processes described by Eq. 1: √ ttr = 2π − 3 log 4 /(4π) · tsc ≈ 0.309 · tsc . (7) with boundary conditions D ∂z cz=h = E cz=h , ∂z cz=0 = 0. (8) (9) The advective term in Eq. 8 is derived from the radial velocity field u(r, z) of a Newtonian fluid rotating with its solid support (no slip), with a free surface at the top (no stress) [1]: u(r, z) = 3K r z (h − z/2) . (10) r and z are the radial respectively vertical coordinates. The radial volumetric flux φ dz is φ dz = 2π r u(r, z) dz = 6π K r2 z (h − z/2) dz. (11) With the continuity equation this yields the thinninginduced vertical motion of the horizontal stream lines: Z z ∂r φ dz ′ = −K z 2 (3h − z) . (12) dZ/dt = −1/(2π r) 0 In order to solve Eq. 8, h(t) is required but not known explicitly, only its inverse, t(h) (Eq. 5). Since h(t) respectively τ (ξ) are bijective, the time variable can be changed 1 to ξ: ∂t c = dτ /dt · dξ/dτ · ∂ξ c = −(2E 2 K) /3 (ξ 3 + 1) ∂ξ c. Rescaling y = z/h (y ∈ [0, 1], from substrate to surface) avoids the moving boundary. This leads to: ∂y2 c (ξ y)2 (3 − y) y ∂ξ c = − ∂y c, − − Shtr ξ 2 (ξ 3 + 1) 2(ξ 3 + 1) ξ (13) ∂y cy=1 = Shtr ξ cy=1 , ∂y cy=0 = 0, (14) where the Sherwood number, Shtr , parameterizes the ratio of evaporative to diffusive mass transport on the characteristic length scale of the system, htr : Shtr = E htr /D = E 4/3 (2K)− /3 /D. 1 (15) By scaling c with the initial solute concentration c0 the initial condition is cξ→∞ = 1. Thus the system is parametrized completely by Shtr . Eq. 13 can be solved numerically with ξ as independent variable. Eq. 5 then provides τ as function of ξ i.e., finally, c(t, z). 3 1.2 20 2.0 Sh = 4.00 Sh = 1.00 Sh = 0.25 Time / c c0 3.0 0.4 0.6 0.8 100 1.0 z/h FIG. 3: Solute concentration profiles (resulting from Eq. 13) for three different Sherwood numbers Shtr at three different moments respectively heights h/htr . c c0 N A c0 htr III. General aspects of the concentration evolution — Based on the solution of Eq. 13 the impact of Shtr (i.e., of the individual system parameters K, E, and D) is now analyzed. Fig. 3 shows profiles of c during film thinning for Shtr larger and smaller than 1 (i.e., convection dominating over diffusion and vice versa) and for film heights larger and smaller than htr , respectively. It reveals the competition between evaporative enrichment, spin-off, and diffusive dilution. In general, larger Shtr means more pronounced gradients in c. If h ≫ htr , solute enrichment occurs only locally near the free surface and c ≈ c0 near the substrate. If h ≪ htr , c also increases near the substrate. Shtr = 1 and h = htr mark the transition: The solute gradient just reaches the film/substrate interface and c just begins to increase globally. Fig. 4 shows as function of h/htr : A) The total solute A 20 10 5 2 1 20.0 10.0 5.0 2.0 1.0 Time Total Solute Amount Surface c c0 Sh 10- 3 Sh 2 102 B Sh Sh Sh 0.25 1.00 4.00 C Sh Sh Sh 1.00 0.25 1.00 4.00 cmax hmax 0.5 1.0 5.0 10.0 0.1 1 10 100 Sh FIG. 5: Normalized final solute coverage, N (h → 0)/(Ac0 htr ) and c/c0 at the film surface for h = htr as function Shtr . Rh amount N per unit area A (N/A = 0 c dz); B) c/c0 at the surface respectively substrate/film interface; C) The difference between the surface and the substrate/film interface concentrations, ∆c/c0 i.e., the relative enrichment. Both, h = htr and Shtr = 1 mark transitions between distinctly different behaviors. I) For h ≫ htr spin-off dominates film thinning. Therefore, globally c/c0 remains approximately constant and N/A decreases. Nevertheless, there is a surficial solute enrichment due to evaporation. But this ∆c/c0 only becomes substantial for Shtr > 1. It has a maximum at h = hpeak (hpeak ≈ htr for Shtr ≈ 1). II) For h ≪ htr , evaporation dominates. Solvent loss leads to increasing c/c0 while N/A and ∆c/c0 remain constant (because spin-off becomes negligible). Remarkably, for h < htr , N/(Ac0 htr ) remains approximately constant and independent from Shtr whereas ∆c/c0 increases with increasing Shtr . Fig. 5 shows c(z = h = htr )/c0 , the concentration at the free surface for h = htr , and N (h → 0)/(Ac0 htr ), the rescaled final coverage. Both are plotted as function of Shtr . For Shtr ≪ 1 diffusion dominates and c is mostly homogeneous (Fig. 3). In this case c0 Etsc is the total amount of solute that is not spun off with the solvent. Distributing this into a film with htr yields c/c0 = Etsc /htr = 2π/33/2 ≈ 1.2 (Fig. 5). The final solute coverage for Shtr < 1 is (in agreement with [88]) 1 0.10 0.1 0.01 Γ = N (h → 0)/A ≈ c0 htr ≈ 0.8 c0 (K/E)− /3 . Substrate 5.00 0.9 0.8 1.0 0.2 1.0 5 1 0.001 4. 0.0 10 2 1 1.5 1.1 c0 htr c z h htr c0 h/htr = 0.25 NAh 0 5.0 h htr FIG. 4: For various Sherwood numbers Shtr are shown as function of the reduced film thickness h/htr : A) Total solute amount N per per unit area A (scaled by c0 htr ); B) Concentrations c at the surface respectively film/substrate interface (scaled by c0 ); C) ∆c, the difference between the surface and the substrate/film interface concentrations, respectively (scaled by c0 ). (16) For Shtr ≫ 1 it is only ≈ 6% lower. IV. Relative surficial enrichment maximum — Fig. 6 shows ∆cpeak /c0 and its spatio-temporal properties as function of Shtr . Symbols denote the results from the numerical analysis. The solid lines show power laws for Shtr < 1 which are rationalized by analyzing the underlying processes. Panel A) shows hpeak rescaled by htr i.e., the film thickness at which ∆c = ∆cpeak as function of Shtr . ∆cpeak emerges from the competition between evaporative enrichment, spin-off, and diffusional equilibration. Evaporation and spin-off dominate at opposite ranges of h. For large h, surficial spin-off efficiently suppresses enrichment: ∆cpeak requires 2Kh3peak < E (from Eq. 1). However, for small h, diffusional equilibration is fast, so 4 10.00 hmax htr A 1.00 0.10 tmax tsc B 1.00 0.10 0.01 cmax C0 100 C 1 0.01 10 4 0.001 0.01 0.1 1 10 Sh 100 FIG. 6: ∆cpeak /c0 as a function of Shtr and related spatio temporal properties (hpeak =h∆c and tpeak =t∆c ). The peak peak symbols indicate numerical results, the lines the underlying power laws for Shtr < 1. ∆cpeak requires D/hpeak < E. Optimizing both conditions simultaneously (E is linear and protagonistic in both cases, and therefore cancels out) reveals the same power law as numerics (which supplies the prefactor): hpeak ≈ (D/K) /4 ≈ 1.2 htr Shtr − /4 . 1 1 (17) Panel B) shows the time tpeak rescaled by tsc i.e., the time at which ∆c = ∆cpeak . Before reaching hpeak , thinning is dominated by spin-off. Hence tpeak can be estimated by inserting hpeak into h = (2K t)−1/2 (the solution to Eq. 1 with E = 0): tpeak /tsc ≈ 0.31 E /3 K − /6 D− /2 ≈ 0.35 2 1 1 p Shtr . (18) Panel C presents ∆cpeak /c0 , reflecting the balance between evaporative enrichment and diffusive equilibration 3 i.e., Shtr h = E hpeak /D = Shtr /4 . With Eq. 17 this peak means: ∆cpeak /c0 ≈ 0.46 E K − /4 D− /4 ≈ 0.55 Shtr 1 3 3/4 . (19) Discussion and Conclusions — Section I introduces the system-specific fundamental length and time scales (htr , t∗sc ) for the spin casting process of an ideal Newtonian volatile liquid. These reduce the general spin cast equation (Eq. 1) to its fundamental form [146] and lead to a universal film thinning behavior (Eq. 5). The total spin coating time, tsc is calculated (Eq. 6) as function of the process parameters (E, K, D). For any combination of these parameters, in the first 30% of the process time, thinning is governed by hydrodynamics. During 70% of the time evaporative thinning dominates until complete drying. Sections II through IV analyze the spin cast process of a mixture of a volatile solvent and a non-volatile solute assuming constant process parameters E, K, and D. It is found that the spatio-temporal evolution of the solute concentration within the thinning film is universally characterized by a Sherwood number, Shtr , scaled to the system-inherent fundamental length, htr (it reflects the competition between evaporative solute enrichment and diffusional dilution at htr ). For Shtr < 1 (diffusion dominates) the spatio-temporal occurrence of the relative surficial enrichment maximum is related to the process parameters via universal power laws (Eqs. 17, 18, and 19, see Fig. 6). These findings are rationalized semiquantitatively with the underlying physics. At last, the final solute coverage Γ is calculated from the process parameters (Eq. 16). To examine the relevance of our analysis for real cases, where E, K, and D are not necessarily always constant (e.g. depending on the solute concentration), we assume a typical solvent (e.g. toluene) with molar mass MS ≈ 0.1 kg/mol, density ρS ≈ 103 kg/m3 , ν = 6 · 10−7 m−2 s−1 , and E = 10−6 m/s [18]. We consider two examples: A) A typical polymer solution [162]; B) A nanoparticle solution for submonolayer deposition. Case A): Polymer with MP = 100 kg/mol, ρP = 103 kgm−3 , and c0,P = 10 kgm−3 (i.e., mole fractions x0,P = 10−6 and x0,S ≈ 1), DP = 10−11 m2 s−1 [173] and K = 1011 m−2 s−1 (≈ 4000 rpm). This yields: htr ≈ 1.7 · 10−6 m (Eq. 3), Shtr ≈ 0.17 (Eq. 15), cP (htr )/c0,P ≈ 1.2 (Figs. 3 and 5) and Γp ≈ 17 ∗ 10−6 kgm−2 (Eq. 16) i.e., a final film thickness of ≈ 17 nm. This is in reasonable agreement with experimental results [162]. Case B): Spheres with radius rNP = 36 nm. DNP = 10−11 m2 s−1 (estimation: Stokes-Einstein) as in case A) and thus htr and Shtr are identical to case A). A 50% monolayer coverage means ΓNP ≈ 1014 m−2 i.e., c0,NP ≈ 5 · 10−5 mol/m3 (x0,NP ≈ 5 · 10−9 , x0,S ≈ 1) with Eq. 16. In both cases the initial solute mole fraction is small. Therefore film thinning to htr will follow Eq. 1 with K and E remaining approximately constant because thinning is hydrodynamically dominated and the solute concentration barely changes. Hence Γ can be calculated with Eq. 16, which is not affected by changes in K and E occurring after reaching htr . For both examples Shtr < 1. Therefore our analysis regarding hpeak , tpeak , and ∆cpeak is relevant even quantitatively because all three maxima occur at h > hpeak i.e., the (surficial) solute concentration has not yet increased substantially above c0 (Figs. 5 and 6). Accordingly, also Eqs. 17, 18 and 19 are applicable. Of course, evaporative film thinning at h < hpeak will eventually increase the solute concentration and thus change E and K. However, in particular for ”evaporation-structured” submonolayer particle array deposition, non-ideality will only become relevant for h ≪ htr , when h is already in the range of rNP , because 5 typically x0,NP ≪ 1. For low solubilities our analysis reveals quantitatively whether solute aggregation occurs first at the top surface (if evaporative solute enrichment dominates) or globally homogeneous (or heterogeneously at the substrate) if diffusive equilibration is more efficient at the corresponding film thickness. Last not least, our analysis predicts a quantifiable behavior based on measurable parameters of the initial solution. In particular the predicted Γ and h(t) [18] are easily measurable. Thus not only the validity of the approach can be evaluated. It is possible to specifically address the influence of individual parameters of the multi-parameter spin casting process. For instance, parameters not related to mixing properties (e.g., temperature changes induced by evaporation) can be probed, because a sufficient reduction of c0 will per definition render the solution behaving approximately “ideally”. All this proposes our approach as a future basis for incorporating specific (non)-linear properties of specific systems. Due to the predominantly analytic approach such a refined approach still will reveal general physical insights. We thank Andreas Vetter and John Berg for scientific discussions, Helmuth Möhwald for scientific advice and general support. 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