Solvent-free modification of surfaces with polymers: The case for initiated and oxidative chemical vapor deposition (CVD)

Accessing Thin Film Wetting Regimes during Polymer Growth by Initiated Chemical Vapor Deposition

We investigate the growth of a fluorinated polymer via initiated chemical vapor deposition onto a suite of isotropic and mesogenic liquids with a range of refractive indices. The polymer morphology at fluid interfaces was found to deviate from conformal films predicted by the positive spreading coefficient, and the resulting morphology is attributed to long-range van der Waals interactions during the deposition process. Experiments systematically vary the deposition conditions and compare the liquid phase (isotropic or nematic) to evaluate the effect of kinetic factors and the liquid substrate phase on the interfacial polymer morphology and spatial organization.

Vapor Deposition of Silicon-Containing Microstructured Polymer Films onto Silicone Oil Substrates

In this study, a silicon-containing cross-linked polymer, poly(1,3,5,7-tetravinyl-1,3,5,7-tetramethylcyclotetrasiloxane-co-ethylene glycol diacrylate) (p(V4D4-co-EGDA)), was deposited onto high-viscosity silicone oil using initiated chemical vapor deposition (iCVD). The ratio of the feed flow rate of V4D4 to EGDA was systematically studied, and the chemical composition and morphology of the top and bottom surfaces of the films were analyzed. The films were microstructured, and the porosity and thickness of the films increased with increasing V4D4 content. The top of the film was composed of densely packed and loosely packed microstructured regions. X-ray photoelectron spectroscopy on the top and bottom surfaces of the films showed a heterogeneous chemical composition along the thickness of the film, with higher silicon content on the top surface compared to that on the bottom surface. To the best of our knowledge, this is the first study of iCVD deposition of a silicon-containing polymer film onto silicone oil. The results of this study can be used for the synthesis of polymer precursor films for the fabrication, via pyrolysis, of silicon-based inorganic membranes for use in hydrogen production using silicone oil to prevent infiltration of monomer into the underneath membrane support structure during vapor deposition.

Robust Thin Film Surface with a Selective Antibacterial Property Enabled via a Cross-Linked Ionic Polymer Coating for Infection-Resistant Medical Applications

Fabrication of new antibacterial surfaces has become a primary strategy for preventing device-associated infections (DAIs). Although considerable progress has recently been made in reducing DAIs, current antibacterial coating methods are technically complex and do not allow selective bacterial killing. Here, we propose novel anti-infective surfaces made of a cross-linked ionic polymer film that achieve selective bacteria killing while simultaneously favoring the survival of mammalian cells. A one-step polymerization process known as initiated chemical vapor deposition was used to generate a cross-linked ionic polymer film from 4-vinylbenzyl chloride and 2-(dimethylamino) ethyl methacrylate monomers in the vapor phase. In particular, the deposition process produced a polymer network with quaternary ammonium cross-linking sites, which provided the surface with an ionic moiety with an excellent antibacterial contact-killing property. This method confers substrate compatibility, which enables various materials to be coated with ionic polymer films for use in medical implants. Moreover, the ionic polymer-deposited surfaces supported the healthy growth of mammalian cells while selectively inhibiting bacterial growth in coculture models without any detectable cytotoxicity. Thus, the cross-linked ionic polymer-based antibacterial surface developed in this study can serve as an ideal platform for biomedical applications that require a highly sterile environment.

Foldable and Disposable Memory on Paper

Foldable organic memory on cellulose nanofibril paper with bendable and rollable characteristics is demonstrated by employing initiated chemical vapor deposition (iCVD) for polymerization of the resistive switching layer and inkjet printing of the electrode, where iCVD based on all-dry and room temperature process is very suitable for paper electronics. This memory exhibits a low operation voltage of 1.5 V enabling battery operation compared to previous reports and wide memory window. The memory performance is maintained after folding tests, showing high endurance. Furthermore, the quick and complete disposable nature demonstrated here is attractive for security applications. This work provides an effective platform for green, foldable and disposable electronics based on low cost and versatile materials.

A Simple, Cost-Efficient Method to Separate Microalgal Lipids from Wet Biomass Using Surface Energy-Modified Membranes

For the efficient separation of lipid extracted from microalgae cells, a novel membrane was devised by introducing a functional polymer coating onto a membrane surface by means of an initiated chemical vapor deposition (iCVD) process. To this end, a steel-use-stainless (SUS) membrane was modified in a way that its surface energy was systemically modified. The surface modification by conformal coating of functional polymer film allowed for selective separation of oil-water mixture, by harnessing the tuned interfacial energy between each liquid phase and the membrane surface. The surface-modified membrane, when used with chloroform-based solvent, exhibited superb permeate flux, breakthrough pressure, and also separation yield: it allowed separation of 95.5 ± 1.2% of converted lipid (FAME) in the chloroform phase from the water/MeOH phase with microalgal debris. This result clearly supported that the membrane-based lipid separation is indeed facilitated by way of membrane being functionalized, enabling us to simplify the whole downstream process of microalgae-derived biodiesel production.

Nanothin Coculture Membranes with Tunable Pore Architecture and Thermoresponsive Functionality for Transfer-Printable Stem Cell-Derived Cardiac Sheets

Coculturing stem cells with the desired cell type is an effective method to promote the differentiation of stem cells. The features of the membrane used for coculturing are crucial to achieving the best outcome. Not only should the membrane act as a physical barrier that prevents the mixing of the cocultured cell populations, but it should also allow effective interactions between the cells. Unfortunately, conventional membranes used for coculture do not sufficiently meet these requirements. In addition, cell harvesting using proteolytic enzymes following coculture impairs cell viability and the extracellular matrix (ECM) produced by the cultured cells. To overcome these limitations, we developed nanothin and highly porous (NTHP) membranes, which are ∼20-fold thinner and ∼25-fold more porous than the conventional coculture membranes. The tunable pore size of NTHP membranes at the nanoscale level was found crucial for the formation of direct gap junctions-mediated contacts between the cocultured cells. Differentiation of the cocultured stem cells was dramatically enhanced with the pore size-customized NTHP membrane system compared to conventional coculture methods. This was likely due to effective physical contacts between the cocultured cells and the fast diffusion of bioactive molecules across the membrane. Also, the thermoresponsive functionality of the NTHP membranes enabled the efficient generation of homogeneous, ECM-preserved, highly viable, and transfer-printable sheets of cardiomyogenically differentiated cells. The coculture platform developed in this study would be effective for producing various types of therapeutic multilayered cell sheets that can be differentiated from stem cells.

Initiated Chemical Vapor Deposition (iCVD) of Highly Cross-Linked Polymer Films for Advanced Lithium-Ion Battery Separators

We report an initiated chemical vapor deposition (iCVD) process to coat polyethylene (PE) separators in Li-ion batteries with a highly cross-linked, mechanically strong polymer, namely, polyhexavinyldisiloxane (pHVDS). The highly cross-linked but ultrathin pHVDS films can only be obtained by a vapor-phase process, because the pHVDS is insoluble in most solvents and thus infeasible with conventional solution-based methods. Moreover, even after the pHVDS coating, the initial porous structure of the separator is well preserved owing to the conformal vapor-phase deposition. The coating thickness is delicately controlled by deposition time to the level that the pore size decreases to below 7% compared to the original dimension. The pHVDS-coated PE shows substantially improved thermal stability and electrolyte wettability. After incubation at 140 °C for 30 min, the pHVDS-coated PE causes only a 12% areal shrinkage (versus 90% of the pristine separator). The superior wettability results in increased electrolyte uptake and ionic conductivity, leading to significantly improved rate performance. The current approach is applicable to a wide range of porous polymeric separators that suffer from thermal shrinkage and poor electrolyte wetting.

Direct Observation of a Carbon Filament in Water-Resistant Organic Memory

The memory for the Internet of Things (IoT) requires versatile characteristics such as flexibility, wearability, and stability in outdoor environments. Resistive random access memory (RRAM) to harness a simple structure and organic material with good flexibility can be an attractive candidate for IoT memory. However, its solution-oriented process and unclear switching mechanism are critical problems. Here we demonstrate iCVD polymer-intercalated RRAM (i-RRAM). i-RRAM exhibits robust flexibility and versatile wearability on any substrate. Stable operation of i-RRAM, even in water, is demonstrated, which is the first experimental presentation of water-resistant organic memory without any waterproof protection package. Moreover, the direct observation of a carbon filament is also reported for the first time using transmission electron microscopy, which puts an end to the controversy surrounding the switching mechanism. Therefore, reproducibility is feasible through comprehensive modeling. Furthermore, a carbon filament is superior to a metal filament in terms of the design window and selection of the electrode material. These results suggest an alternative to solve the critical issues of organic RRAM and an optimized memory type suitable for the IoT era.

PDMS-based turbulent microfluidic mixer

Over the past decade, homogeneous mixing in microfluidic devices has been a critical challenge, because of the inherently low flow rates in microfluidic channels. Although several mixer designs have been suggested to achieve efficient mixing, most of them involve intricate structures requiring a series of laborious fabrication processes. Operation at high flow rates can greatly enhance mixing by induction of turbulence, but devices that can resist such a high pressure drop to induce turbulence in microfluidic channels are difficult to fabricate, especially for commonly used poly(dimethylsiloxane) (PDMS)-based microfluidic devices. We have developed a Y-shaped, turbulent microfluidic mixer made of PDMS and a glass substrate by strong bonding of the substrates to a nanoadhesive layer deposited via initiated chemical vapor deposition. The high bonding strength of the nanoadhesive layer enables safe operation of the PDMS/glass turbulent microfluidic mixer at a total water flow rate of 40 mL min(-1), corresponding to a Reynolds number, Re, of ~4423, one of the highest values achieved in a microfluidic channel. The turbulence generated as a result of the high Re allows rapid mixing of the input fluids on contact. Image analysis showed that mixing started as soon as the fluids were introduced into the mixer. The experimental results matched the numerical predictions well, demonstrating that convective mixing was dominant as a result of turbulence induced in the microfluidic channel. Using the turbulent microfluidic mixer, we have demonstrated high throughput formation of emulsions with narrower size distribution. It was shown that as the flow rate increases inside the microfluidic channel, the size distribution of resulting emulsions decreases owing to the increase in the turbulent energy dissipation. The turbulent microfluidic mixer developed in this work not only enables rapid mixing of streams, but also increases throughputs of microfluidic reactors.

Drop impact and rebound dynamics on an inclined superhydrophobic surface

Due to its potential in water-repelling applications, the impact and rebound dynamics of a water drop impinging perpendicular to a horizontal superhydrophobic surface have undergone extensive study. However, drops tend to strike a surface at an angle in applications. In such cases, the physics governing the effects of oblique impact are not well studied or understood. Therefore, the objective of this study was to conduct an experiment to investigate the impact and rebound dynamics of a drop at various liquid viscosities, in an isothermal environment, and on a nanocomposite superhydrophobic surface at normal and oblique impact conditions (tilted at 15°, 30°, 45°, and 60°). This study considered drops falling from various heights to create normal impact Weber numbers ranging from 6 to 110. In addition, drop viscosity was varied by decreasing the temperature for water drops and by utilizing water-glycerol mixtures, which have similar surface tension to water but higher viscosities. Results revealed that oblique and normal drop impact behaved similarly (in terms of maximum drop spread as well as rebound dynamics) at low normal Weber numbers. However, at higher Weber numbers, normal and oblique impact results diverged in terms of maximum spread, which could be related to asymmetry and more complex outcomes. These asymmetry effects became more pronounced as the inclination angle increased, to the point where they dominated the drop impact and rebound characteristics when the surface was inclined at 60°. The drop rebound characteristics on inclined surfaces could be classified into eight different outcomes driven primarily by normal Weber number and drop Ohnesorge numbers. However, it was found that these outcomes were also a function of the receding contact angle, whereby reduced receding angles yielded tail-like structures. Nevertheless, the contact times of the drops with the coating were found to be generally independent of surface inclination.

Simple and reliable method to incorporate the Janus property onto arbitrary porous substrates

Economical fabrication of waterproof/breathable substrates has many potential applications such as clothing or improved medical dressing. In this work, a facile and reproducible fabrication method was developed to render the Janus property to arbitrary porous substrates. First, a hydrophobic surface was obtained by depositing a fluoropolymer, poly(3,3,4,4,5,5,6,6,7,7,8,8,9,9,10,10,10-heptadecafluorodecyl methacrylate) (PHFDMA), on various porous substrates such as polyester fabric, nylon mesh, and filter paper. With a one-step vapor-phase deposition process, termed as initiated chemical vapor deposition (iCVD), a conformal coating of hydrophobic PHFDMA polymer film was achieved on both faces of the porous substrate. Since the hydrophobic perfluoroalkyl functionality is tethered on PHFDMA via hydrolyzable ester functionality, the hydrophobic functionality on PHFDMA was readily released by hydrolysis reaction. Here, by simply floating the PHFDMA-coated substrates on KOH(aq) solution, only the face of the PHFDMA-coated substrate in contact with the KOH(aq) solution became hydrophilic by the conversion of the fluoroalkyl ester group in the PHFDMA to hydrophilic carboxylic acid functionality. The hydrophilized face was able to easily absorb water, showing a contact angle of less than 37°. However, the top side of the PHFDMA-coated substrate was unaffected by the exposure to KOH(aq) solution and remained hydrophobic. Moreover, the carboxylated surface was further functionalized with aminated polystyrene beads. The porous Janus substrates fabricated using this method can be applied to various kinds of clothing such as pants and shirts, something that the lamination process for Gore-tex has not allowed.

A vapor-phase deposited polymer film to improve the adhesion of electroless-deposited copper layer onto various kinds of substrates

The adhesion of electrodeposited metal film to polymeric circuit board substrate is one of the key elements to successful miniaturization of electronic devices. However, as the size of the circuit pattern continuously decreases, a novel method is urgently required to increase the adhesion of the metal film on the substrate, especially on the smooth surface, which is critical to decrease the minimum feature size of the metal pattern. In this research, we developed an adhesion promoter layer by depositing metal chelating poly(4-vinylpyridine) (P4VP) film onto various organic and inorganic substrates via initiated chemical vapor deposition process (iCVD) to enhance the adhesion between the electroless deposited copper (Cu) layer and the substrate. The highest peel strength obtained between the electroless deposited Cu layer and P4VP coated substrate was 1.22 kgf/cm. Many advantageous characteristics of the adhesion promoter layer, including extreme thinness, the improved adhesion strength, conformal coverage, scalability of the deposition process, and short process time, will prompt the applicability of this adhesion promoter layer to industrial scale production.

25th anniversary article: CVD polymers: a new paradigm for surface modification and device fabrication

Well-adhered, conformal, thin (<100 nm) coatings can easily be obtained by chemical vapor deposition (CVD) for a variety of technological applications. Room temperature modification with functional polymers can be achieved on virtually any substrate: organic, inorganic, rigid, flexible, planar, three-dimensional, dense, or porous. In CVD polymerization, the monomer(s) are delivered to the surface through the vapor phase and then undergo simultaneous polymerization and thin film formation. By eliminating the need to dissolve macromolecules, CVD enables insoluble polymers to be coated and prevents solvent damage to the substrate. CVD film growth proceeds from the substrate up, allowing for interfacial engineering, real-time monitoring, and thickness control. Initiated-CVD shows successful results in terms of rationally designed micro- and nanoengineered materials to control molecular interactions at material surfaces. The success of oxidative-CVD is mainly demonstrated for the deposition of organic conducting and semiconducting polymers.

A doubly cross-linked nano-adhesive for the reliable sealing of flexible microfluidic devices

Along with the expansion of microfluidics into many areas of applications such as sensors, microreactors and analytical tools, many other materials besides poly(dimethylsiloxane) (PDMS) have been suggested such as poly(imide) (PI) or poly(ethylene terephthalate) (PET). However, the sealing methods for these materials are not reliable in that many of the methods are specific to the substrate materials. Here, we report a novel robust doubly cross-linked nano-adhesive (DCNA) for bonding of various heterogeneous substrates. By depositing 200 nm of epoxy-containing polymer, poly(glycidyl methacrylate), via initiated chemical vapour deposition (iCVD) onto various substrates and cross-linking them with ethylenediamine, a strong adhesion was obtained between the substrates. This adhesive system was not only able to bond various difficult-to-bond substrates, such as PET or PI, but it could also preserve the complicated morphology of the surfaces owing to the thin nature of the DCNA system. The DCNA allowed fabrication of microfluidic devices using both rigid substrates, such as silicon wafer and glass, and flexible substrates, such as PDMS, PET and PI. The burst pressure of the devices sealed with DCNA exceeded 2.5 MPa, with a maximum burst pressure of 11.7 MPa. Furthermore, the adhesive system demonstrated an exceptional chemical and thermal resistance. The adhesion strength of the adhesive sandwiched between glass substrates remained the same even after a 10 day exposure to strong organic solvents such as toluene, acetone, and tetrahydrofuran (THF). Also, exposure to 200 °C for 15 h was not able to damage the adhesion strength. Using the high adhesive strength and flexibility of DCNA, flexible microfluidic devices that can be completely folded or rolled without any delamination during the operation were fabricated. The DCNA bonding is highly versatile in the sealing of microfluidic systems, and is compatible with a wide selection of materials, including flexible and foldable substrates, even upon sealing few-μm-sized channels.

Plasma-enhanced copolymerization of amino acid and synthetic monomers

In this paper we report the use of plasma-enhanced chemical vapor deposition (PECVD) for the simultaneous deposition and copolymerization of an amino acid with other organic and inorganic monomers. We investigate the fundamental effects of plasma-enhanced copolymerization on different material chemistries in stable ultrathin coatings of mixed composition with an amino acid component. This study serves to determine the feasibility of a direct, facile method for integrating biocompatible/active materials into robust polymerized coatings with the ability to plasma copolymerize a biological molecule (L-tyrosine) with different synthetic materials in a dry, one-step process to form ultrathin coatings of mixed composition. This process may lead to a method of interfacing biologic systems with synthetic materials as a way to enhance the biomaterial-tissue interface and preserve biological activity within composite films.

CVD of polymeric thin films: applications in sensors, biotechnology, microelectronics/organic electronics, microfluidics, MEMS, composites and membranes

Polymers with their tunable functionalities offer the ability to rationally design micro- and nano-engineered materials. Their synthesis as thin films have significant advantages due to the reduced amounts of materials used, faster processing times and the ability to modify the surface while preserving the structural properties of the bulk. Furthermore, their low cost, ease of fabrication and the ability to be easily integrated into processing lines, make them attractive alternatives to their inorganic thin film counterparts. Chemical vapor deposition (CVD) as a polymer thin-film deposition technique offers a versatile platform for fabrication of a wide range of polymer thin films preserving all the functionalities. Solventless, vapor-phase deposition enable the integration of polymer thin films or nanostructures into micro- and nanodevices for improved performance. In this review, CVD of functional polymer thin films and the polymerization mechanisms are introduced. The properties of the polymer thin films that determine their behavior are discussed and their technological advances and applications are reviewed.