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Polymer nanocomposite (PNC) films are of interest for many applications including electronics, energy storage, and advanced coatings. In phase-separating PNCs, the interplay between thermodynamic and kinetic factors governs the assembly of polymer-grafted nanoparticles (NPs), which directly influences material properties. Understanding how processing parameters affect the structure-property relationship of PNCs is important for designing advanced materials. This thesis provides insight by investigating a model PNC system of poly(methyl methacrylate)-grafted nanoparticles (PMMA-NPs) embedded in a poly(styrene-ran-acrylonitrile) (SAN) matrix. Time-of-flight secondary ion mass spectrometry (ToF-SIMS) was developed to quantify the distribution of NPs within PMMA-NP/SAN films, enabling precise 3D reconstruction of PNC structures. Experimental parameters such as primary ion beam angle and charge compensation were optimized to enhance secondary ion signals and depth resolution. Upon annealing in the twophase region, PMMA-NP/SAN films exhibited phase separation and surface segregation, leading to morphological evolutions characterized by atomic force microscopy (AFM), ToF-SIMS, water contact angle measurements, and transmission electron microscopy. By systematically exploring the effects of film thickness on PNC structures, we found that film thickness-induced confinement reduces lateral phase separation and enhances NP dispersion at the surface. A dimensional crossover from three to two dimensions was observed around 240 nm, below which surface-directed spinodal decomposition is suppressed. As a result of phase separation and surface segregation, six distinct bulk morphologies were identified, allowing for the construction of a morphology map correlating film thickness and annealing time. Among these morphologies, percolated structures were found to improve mechanical properties such as hardness and reduced modulus, as measured using AFM nanoindentation. Notably, interconnected networks show the highest hardness and modulus at both low and high force loadings. Additionally, Marangoni-induced hexagonal honeycomb patterns were observed in spin-coated as-cast PMMA-NP/SAN films. By changing to a less volatile solvent, these defects were eliminated, demonstrating the importance of solvent selection in achieving uniform and high-quality thin films. These findings demonstrate the potential for precise control of surface-enriched and phase-separated microstructures in PNC films through tailoring processing conditions. This thesis advances the understanding of processing-structure-property relationships in PNCs, providing a foundation for designing highly functional materials with broad industrial applications. 

This study investigates Marangoni effect-induced structural changes in spin-coated polymer nanocomposite (PNC) films composed of poly(methyl methacrylate)-grafted silica nanoparticles (NPs) and poly(styrene-ran-acrylonitrile). Films cast from methyl isobutyl ketone (MIBK) solvent exhibit distinct hexagonal honeycomb cells with thickness gradients driven by surface tension variations. Atomic force microscopy reveals protruded ridges and junctions at cell intersections, where NP concentration is the highest. Upon annealing at 155 degrees C, NPs segregate to the surface due to their lower surface energy, and the initially protruding features flatten and eventually form depressed channels while maintaining higher NP density than surrounding areas. Time-of-flight secondary ion mass spectrometry corroborated these findings, highlighting enhanced surface segregation of NPs in MIBK films. These defects can be eliminated using methyl isoamyl ketone (MIAK) as a solvent that produces homogeneous films of uniform thickness. This study highlights the impact of the Marangoni effect on the microstructure and surface properties of PNC films, providing insights for enhancing film quality and performance. 

This study investigates the interplay between film thickness and the surface and internal morphologies in polymer nanocomposite (PNC) films. The PNC is 25 wt.% poly(methyl methacrylate)-grafted silica nanoparticles (NPs) in poly(styrene-ran-acrylonitrile) annealed in the two-phase region. At greatest confinement (120 nm), NP surface density remains constant and lateral phase separation is inhibited upon annealing. For thicker films (240 nm to 1400 nm), surface density increases with time before approaching ca. 740 NP/μm2, consistent with 2D random close packing. Moreover, lateral domain growth exhibits a dimensional crossover as thickness increases from 𝑡 to , consistent with domain coalescence. Water contact angles 1/2 𝑡1/3 decrease upon annealing in agreement with the lateral domain composition. For thickest films (1400 nm to 4000 nm), a morphology map summarizes the distinct internal arrangements of NPs: disordered aggregates, continuous vertical pillars, discrete vertical pillars, isolated domains, and random networks. This study of PNC films provides guidance for controlling surface and bulk structure which can lead to improved barrier, mechanical and transport properties. 

Polymer infiltrated nanoporous gold is prepared by infiltrating polymer melts into a bicontinuous, nanoporous gold (NPG) scaffold. Polystyrene (PS) films with molecular weights (Mw) from 424 to 1133 kDa are infiltrated into a NPG scaffold (∼120 nm), with a pore radius (Rp) and pore volume fraction of 37.5 nm and 50%, respectively. The confinement ratios (Γ=RgRp) range from 0.47 to 0.77, suggesting that the polymers inside the pores are moderately confined. The time for PS to achieve 80% infiltration (τ80%) is determined using in situ spectroscopic ellipsometry at 150 °C. The kinetics of infiltration scales weaker with Mw, τ80%∝Mw1.30±0.20, than expected from bulk viscosity Mw3.4. Furthermore, the effective viscosity of the PS melt inside NPG, inferred from the Lucas–Washburn model, is reduced by more than one order of magnitude compared to the bulk. Molecular dynamics simulation results are in good agreement with experiments predicting scaling as Mw1.4. The reduced dependence of Mw and the enhanced kinetics of infiltration are attributed to a reduction in chain entanglement density during infiltration and a reduction in polymer–wall friction with increasing polymer molecular weight. Compared to the traditional approach involving adding discrete particles into the polymer matrix, these studies show that nanocomposites with higher loading can be readily prepared, and that kinetics of infiltration are faster due to polymer confinement inside pores. These films have potential as actuators when filled with stimuli-responsive polymers as well as polymer electrolyte and fuel cell membranes.