We investigated the effects of molecular weight and film thickness on the crystallization and microphase separation in semicrystalline block copolymer polystyrene-block-poly(L-lactic acid) (PS-b-PLLA) thin films, at the early stage of film evolution (when Tg < T < TODT) by in situ hot stage atomic force microscopy. For PS-b-PLLA 1 copolymer which had lower molecular weight and higher PLLA fraction, diffusion-controlled break-out crystallization started easily. For PS-b-PLLA 2 with higher molecular weight, crystallization in nanometer scales occurs in local area. After melting of the two copolymer films, islands were observed at the film surface: PS-b-PLLA 1 film was in a disordered phase mixed state while PS-b-PLLA 2 film formed phase-separated lamellar structure paralleling to the substrate. Crystallization-melting and van der Waals forces drove the island formation in PS-b-PLLA 1 film. Film thickness affected the crystallization rate. Crystals grew very slowly in much thinner film of PS-b-PLLA 1 and remained almost unchanged at long time annealing. The incompatibility between PS and PLLA blocks drove the film fluctuation which subsequently evolved into spinodal-like morphology.

In this paper, the effect of solvent selectivity on the transition between crystallization and microphase separation of the semicrystalline diblock copolymer polystyrene-b-poly(ethylene oxide) (PS-b-PEO) thin films was investigated. Square-shaped crystals formed due to lower barrier of crystalline nucleation in both poor and good solvent vapor for PEO. However, in poor solvent (cyclohexane) vapor for PEO, crystalline structure changed to microphase separated structure in the square platelets due to the high mobility of PS blocks. Then breakout crystals dominated the morphology of the film. While, in good solvent (water) vapor for PEO, competition between nucleation and dissolution of crystallization caused the formation of imperfect crystals. Then imperfect crystals dissolved due to the high mobility of PEO blocks, and microphase separation dominated the morphology of the film. The gain of free volume of soluble block and the low swelling of crystalline block are keys for microphase separation and crystallization, respectively.