Nanoparticles for dewetting suppression of thin polymer films used in chemical sensors

Addition of fullerenes (C-60 or buckyballs) to a linear polymer has been found to eliminate dewetting when a thin (similar to 50 nm) film is exposed to solvent vapor. Based on neutron reflectivity measurements, it is found that the fullerenes form a coherent layer approximately 2 nm thick at the substrate - polymer film interface during the spin-coating process. The thickness and relative fullerene concentration (similar to 29 vol%) is not altered during solvent vapor annealing and it is thought this layer forms a solid-like buffer shielding the adverse van der Waals forces promoted by the underlying substrate. Several polymer films produced by spin- or spray-coating were tested on both silicon wafers and live surface acoustic wave sensors demonstrating fullerenes stabilize many different polymer types, prepared by different procedures and on various surfaces. Further, the fullerenes drastically improve sensor performance since dewetted films produce a sensor that is effectively inoperable.