Highly Efficient Rubber-to-Stainless Steel Bonding by Nanometer-Thin Cross-linked Polymer Brushes

Polymer Brush Coating and Adhesion Technology at Scale

Creating strong joints between dissimilar materials for high-performance hybrid products places high demands on modern adhesives. Traditionally, adhesion relies on the compatibility between surfaces, often requiring the use of primers and thick bonding layers to achieve stable joints. The coatings of polymer brushes enable the compatibilization of material surfaces through precise control over surface chemistry, facilitating strong adhesion through a nanometer-thin layer. Here, we give a detailed account of our research on adhesion promoted by polymer brushes along with examples from industrial applications. We discuss two fundamentally different adhesive mechanisms of polymer brushes, namely (1) physical bonding via entanglement and (2) chemical bonding. The former mechanism is demonstrated by e.g., the strong bonding between poly(methyl methacrylate) (PMMA) brush coated stainless steel and bulk PMMA, while the latter is shown by e.g., the improved adhesion between silicone and titanium substrates, functionalized by a hydrosilane-modified poly(hydroxyethyl methacrylate) (PHEMA) brush. This review establishes that the clever design of polymer brushes can facilitate strong bonding between metals and various polymer materials or compatibilize fillers or nanoparticles with otherwise incompatible polymeric matrices. To realize the full potential of polymer brush functionalized materials, we discuss the progress in the synthesis of polymer brushes under ambient and scalable industrial conditions, and present recent developments in atom transfer radical polymerization for the large-scale production of brush-modified materials.

Stimuli-responsive degrafting of polymer brushes via addressable catecholato-metal attachments

Surface attached catecholato-metal complexes serve as polymer brush initiators with well-defined densities and enable stimuli-responsive degrafting of polymer brushes.

Hydrosilane-Modified Poly(2-Hydroxyethyl Methacrylate) Brush as a Nanoadhesive for Efficient Silicone Bonding

Leaching of chemicals from adhesion promoters is, in particular, problematic for the food, water, pharmaceutical, and MedTech industries where any chemical contamination is unacceptable. A solution to this issue is to employ covalently attached nanoscale polymer brushes as adhesive layers for plastics. One of the industrially most relevant adhesion targets in that respect is poly(dimethylsiloxane) (PDMS), being used for many high-end applications such as catheters and breast implants. In this work, we have synthesized a novel surface-immobilized poly(2-hydroxyethyl methacrylate)-based brush adhesive containing reactive hydrosilane groups that can bond directly to PDMS. Two different medical grades of addition-cured PDMS were molded on top of titanium substrates already coated with the polymer brush. Titanium plates were used for the chemical analysis, and titanium rods were used for adhesion testing. Adhesion testing revealed a high adhesive force, in which cohesive failure was observed in the bulk PDMS. The necessity of the hydrosilane group in the polymer brush adhesive layer was demonstrated in comparative studies using similar brushes lacking this functionality.