Processing of optical quality rigid-rod polymer thin films

Abstract

A novel process for the fabrication of optical quality thin films of rigid-rod polymers by coagulation from an isotropic solution is reported. This process consists of the following steps: (1) extrusion or doctor-blading of an isotropic rigid-rod polymer solution into a uniform thin solution layer; (2) relaxation of the solution in an atmosphere containing the vapour of a non-solvent for an appropriate length of time; and (3) coagulation of the solution in a non-solvent bath. Thin films of rigid-rod poly( p-phenylene benzobisthiazole) (PBZT) thus prepared do not show the large voids or line defects commonly observed in the extruded and subsequently coagulated PBZT thin films. A processing window based on the solution thickness and relaxation duration is outlined for a 1 wt% PBZT solution in methanesulfonic acid to fabricate void-free PBZT thin films up to 6 μm in thickness at room temperature. Optical spectra and micrographs show that the PBZT thin films prepared by the current process compare favourably with those extruded and then coagulated in terms of low optical loss and fewer defects.