Microstructured Films Formed on Liquid Substrates via Initiated Chemical Vapor Deposition of Cross-Linked Polymers

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.

Vapor-deposited functional polymer thin films in biological applications

Functional polymer coatings have become ubiquitous in biological applications, ranging from biomaterials and drug delivery to manufacturing-scale separation of biomolecules using functional membranes. Recent advances in the technology of chemical vapor deposition (CVD) have enabled precise control of the polymer chemistry, coating thickness, and conformality. That comprehensive control of surface properties has been used to elicit desirable interactions at the interface between synthetic materials and living organisms, making vapor-deposited functional polymers uniquely suitable for biological applications. This review captures the recent technological development in vapor-deposited functional polymer coatings, highlighting their biological applications, including membrane-based bio-separations, biosensing and bio-MEMS, drug delivery, and tissue engineering. The conformal nature of vapor-deposited coatings ensures uniform coverage over micro- and nano-structured surfaces, allowing the independent optimization of surface and bulk properties. The substrate-independence of CVD techniques enables facile transfer of surface characteristics among different applications. The vapor-deposited functional polymer thin films tend to be biocompatible because they are free of remnant toxic solvents and precursor molecules, potentially lowering the barrier to clinical success.

Copolymer Solid-State Electrolytes for 3D Microbatteries via Initiated Chemical Vapor Deposition

Reliable integration of thin film solid-state polymer electrolytes (SPEs) with 3D electrodes is one major challenge in microbattery fabrication. We used initiated chemical vapor deposition (iCVD) to produce a series of nanoscale copolymer films comprising hydroxyethyl methacrylate and ethylene glycol diacrylate. Conformal copolymer coatings were applied to a variety of patterned 3D electrodes and subsequently converted into ionic conductors by lithium salt doping. Broad tunability in ionic conductivity was achieved by optimizing the copolymer cross-linking density and matrix polarity, resulting in a room-temperature conductivity of (6.1 ± 2.7) × 10^-6 S cm^-1, the highest value reported for conformal, nanoscale SPEs.

Liquid Marbles: From Industrial to Medical Applications

Liquid marbles are versatile structures demonstrating a pseudo-Leidenfrost wetting regime formed by encapsulating microscale volumes of liquid in a particle shell. The liquid core is completely separated from the exterior through air pockets. The external phase consists of hydrophobic particles, in most cases, or hydrophilic ones distributed as aggregates. Their interesting features arise from the double solid-fluid character. Thus, these interesting formations, also known as “dry waters”, have gained attention in surface science. This review paper summarizes a series of proposed formulations, fabrication techniques and properties, in correlation with already discovered and emerging applications. A short general review of the surface properties of powders (contact angle, superficial tension) is proposed, followed by a presentation of liquid marbles’ properties (superficial characteristics, elasticity, self-propulsion etc.). Finally, applications of liquid marbles are discussed, mainly as helpful and yet to be exploited structures in the pharmaceutical and medical field. Innovative pharmaceutical forms (Pickering emulsions) are also means of use taken into account as applications which need further investigation.

Two-Stage Growth of Polymer Nanoparticles at the Liquid-Vapor Interface by Vapor-Phase Polymerization

In this article, we study the growth of polymer nanoparticles that are formed on the surface of silicone oils via initiated chemical vapor deposition. The average radius of the particles can be increased by decreasing the silicone oil viscosity, increasing the deposition time, or increasing the deposition rate. The time series data indicates that there are two stages for particle growth. Particle nucleation occurs in the first stage and the particle size is dependent on the liquid viscosity and deposition rate. Particle growth occurs in the second stage, during which the particle size is dependent only on the amount of deposited polymer. This two-step process allows us to make core-shell particles by sequentially depositing different polymers. The benefits of our nanoparticle synthesis process are that solvents and surfactants are not required and the size of the nanoparticles can be controlled over a wide range of radii with a relatively narrow distribution.

Direct Synthesis of Porous Polyurea Films by Vapor Deposition Polymerization in Ionic Liquid

Most network-structured, porous polymer materials have so far been synthesized in bulk solution processes, which can sometimes be a drawback in their thin-film applications. In this communication, we propose a new route to the direct synthesis of porous polyurea (PU) films by vapor deposition polymerization in ionic liquid (IL), which is based on our original process "IL-assisted vacuum deposition". When 4,4'-methylenebis (2-chlorophenyl isocyanate) (MBCI) and 2,7-diaminofluorene (DAF) monomer molecules were codeposited onto an IL-coated substrate in vacuum, the PU films were found to have a percolated pore and network structure with a high degree of polymerization even without the postannealing treatment, which is required to proceed with the polymerization of PU films in the conventional vapor deposition polymerization. The porous PU film after annealing was still as rigid as the plain PU films and possessed a stronger water repellency, with contact angles exceeding 100°, than the plain PU films.

Vapor-based grafting of crosslinked poly(N-vinyl pyrrolidone) coatings with tuned hydrophilicity and anti-biofouling properties

Vapor-based one-step synthesis and grafting of poly(N-vinyl pyrrolidone) enable potent and durable anti-biofouling coatings with tailored structures.

Fabricating Polymer Canopies onto Structured Surfaces Using Liquid Scaffolds

In this work, we study the use of initiated chemical vapor deposition in conjunction with liquid scaffolds to deposit polymer canopies onto structured surfaces. Liquid is applied to micropillar and microstructure surfaces to act as a scaffolding template such that the deposited polymer films take the shape of the liquid surface. Two methods for directing the location of the scaffolding liquid were examined. In the first method, high surface tension liquids rest in a Cassie-Baxter state over the structured surfaces, allowing for control over the canopy location and size by varying the position and volume of the liquid. In the second method, the structured surfaces are inverted onto a thin layer of low surface tension liquid, allowing the coverage and height of the canopy to be controlled by varying the area and thickness of the liquid layer. Although the canopies demonstrated in this study were fabricated using initiated chemical vapor deposition, the generality of our scaffolding method can easily be translated to other vapor deposition processes.