In attempting to reduce the size of functional devices, the thickness of polymer films has reached values even smaller than the diameter of the unperturbed molecule. However, despite enormous efforts for more than a decade, our understanding of the origin of some puzzling properties of such thin films is still not satisfactory and several peculiar observations remain mysterious. For example, under certain conditions, such films show negative expansion coefficients or show undesirable rupture although energetically they are expected to be stable. Here, we demonstrate that many of these extraordinary effects can be related to residual stresses within the film, resulting from the preparation of these films from solution by fast evaporation of the solvent. Consequently, depending on thermal history and ageing time, such films show significant changes even in the glassy state, which we quantify by dewetting experiments and corresponding theoretical studies. Identifying the relevance of frozen-in polymer conformations gives us a handle for manipulating and controlling properties of nanometric thin polymer films.

Performing detailed studies of viscoelastic dewetting of thin polystyrene films on solid substrates, we demonstrate the existence of residual stress due to strongly out of equilibrium chain conformations and a reduced entanglement density resulting from film preparation by spin coating. The ratio of stress over elastic modulus was found to increase strongly with decreasing film thickness and increasing chain length. Full equilibration of chain conformations required long times comparable to bulk reptation times. However, for chains longer than about 3000 monomers, the residual stress relaxed faster, at a rate independent of chain length.

Thin films of fluids are playing a leading role in countless natural and industrial processes. Here we study the stability and dewetting dynamics of viscoelastic polymer thin films. The dewetting of polystyrene close to the glass transition reveals unexpected features: asymmetric rims collecting the dewetted liquid and logarithmic growth laws that we explain by considering the nonlinear velocity dependence of friction at the fluid/solid interface and by evoking residual stresses within the film. Systematically varying the time so that films were stored below the glass-transition temperature, we studied simultaneously the probability for film rupture and the dewetting dynamics at early stages. Both approaches proved independently the significance of residual stresses arising from the fast solvent evaporation associated with the spin-coating process.