A Review of Plasma Synthesis Methods for Polymer Films and Nanoparticles under Atmospheric Pressure Conditions

Comparison of Plasma-Polymerized Thin Films Deposited from 2-Methyl-2-oxazoline and 2-Ethyl-2-oxazoline: I Film Properties

Poly(2-oxazoline) is a promising new class of polymeric materials due to their antibiofouling properties and good biocompatibility. Poly(2-oxazoline) coatings can be deposited on different substrates via plasma polymerization, which can be more advantageous than other coating methods. The aim of this study is to deposit poly(2-oxazoline) coatings using a surface dielectric barrier discharge burning in nitrogen at atmospheric pressure using 2-methyl-2-oxazoline and 2-ethyl-2-oxazoline vapours as monomers and compare the film properties. For the comparison, the antibacterial and cytocompatibility tests were peformed according to ISO norms. The antibacterial tests showed that all the deposited films were highly active against Staphylococcus aureus and Escherichia coli bacteria. The chemical composition of the films was studied using FTIR and XPS, and the film surface's properties were studied using AFM and surface energy measurement. The cytocompatibility tests showed good cytocompatibility of all the deposited films. However, the films deposited from 2-methyl-2-oxazoline exhibit better cytocompatibility. This difference can be explained by the different chemical compositions and surface morphologies of the films deposited from different monomers.

Structural and optical behaviours of methyl acrylate-vinyl acetate composite thin films synthesized under dynamic low-pressure plasma

Low-pressure (33.33 Pa) plasma polymerized methyl acrylate and vinyl acetate composite thin films with various monomer compositions were deposited onto glass substrates. Under the same plasma conditions, the homopolymer thin films were also prepared. The thickness of the composite films was observed to vary between 117 and 213 nm depending on the monomer ratio. The composite films exhibit a smooth, pinhole-free, and immaculate surface morphology, surpassing that of the homopolymers. The energy dispersive x-ray study shows that the films contain mainly carbon and oxygen with 26.09-37.20 at% and 35.03 - 40.10 at%, respectively. The composite films contain more carbon contents which enhance the film stability. The appearance of some broad absorption bands in the Fourier transform infrared spectroscopy indicates structural changes in the PP films caused by the restructuring or dilapidation of monomer molecules while forming the polymer. The UV-visible spectra analysis reveal that the composite films exhibited a tunable optical band gap by adjusting the monomer ratio. The decrease of methyl acrylate monomer reduces the direct and indirect optical band-gap values of composite films from 3.15 to 3.00 eV and 2.35 to 1.74 eV, respectively. While Urbach energy values increases from 0.33 eV to 0.90 eV. All the films showed good transmittance properties (86 - 96%) in the visible range wavelength (550 - 800 nm). Other optical parameters are also found better in composite films which indicates the aptness of the composite films in various optoelectronic or electronic applications.

Review of Plasma Processing for Polymers and Bio-Materials Using a Commercial Frequency (50/60 Hz)-Generated Discharge

This manuscript introduces the properties and diverse applications of plasma generated using commercial frequencies of 50/60 Hz. Commercial frequency (CF) derived plasma exhibits characteristics similar to DC discharge but with an electrical polarity and a non-continuous discharge. Due to the low-frequency nature, the reactor configurations usually are capacitively coupled plasma type. The advantages of this method include its simple power structure, low-reaction temperature, and low substrate damage. The electrical polarity can prevent charge buildup on the substrates and deposited films, thereby reducing substrate damage. The simple, low-cost, and easy-to-operate power structure makes it suitable for laboratory-scale usage. Additionally, the various applications, including plasma-enhanced vapor deposition, sputtering, dielectric barrier discharge, and surface modification, and their outcomes in the CF-derived plasma processes are summarized. The conclusion drawn is that the CF-derived plasma process is useful for laboratory-scale utilization due to its simplicity, and the results of the plasma process are also outstanding.

Substrate-independent and widely applicable deposition of antibacterial coatings

Antibacterial coatings are regarded as a necessary tool to prevent implant-related infections. Substrate-independent and widely applicable coating techniques are gaining significant interest to synthesize different types of antibacterial films, which can be relevant from a fundamental and application-oriented perspective. Plasma polymer- and polydopamine-based antibacterial coatings represent the most widely studied and versatile approaches among these coating techniques. Both single- and dual-functional antibacterial coatings can be fabricated with these approaches and a variety of dual-functional antibacterial coating strategies can still be explored in future work. These coatings can potentially be used for a wide range of different implants (material, shape, and size). However, for most implants, significantly more fundamental knowledge needs to be gained before these coatings can find real-life use.

Critical review of polymer and hydrogel deposition methods for optical and electrochemical bioanalytical sensors correlated to the sensor's applicability in real samples

Sensors, ranging from in vivo through to single-use systems, employ protective membranes or hydrogels to enhance sample collection or serve as filters, to immobilize or entrap probes or receptors, or to stabilize and enhance a sensor's lifetime. Furthermore, many applications demand specific requirements such as biocompatibility and non-fouling properties for in vivo applications, or fast and inexpensive mass production capabilities for single-use sensors. We critically evaluated how membrane materials and their deposition methods impact optical and electrochemical systems with special focus on analytical figures of merit and potential toward large-scale production. With some chosen examples, we highlight the fact that often a sensor's performance relies heavily on the deposition method, even though other methods or materials could in fact improve the sensor. Over the course of the last 5 years, most sensing applications within healthcare diagnostics included glucose, lactate, uric acid, O₂, H⁺ ions, and many specific metabolites and markers. In the case of food safety and environmental monitoring, the choice of analytes was much more comprehensive regarding a variety of natural and synthetic toxicants like bacteria, pesticides, or pollutants and other relevant substances. We conclude that more attention must be paid toward deposition techniques as these may in the end become a major hurdle in a sensor's likelihood of moving from an academic lab into a real-world product.

Strategies for Improved Wettability of Polyetheretherketone (PEEK) Polymers by Non-Equilibrium Plasma Treatment

Polyetheretherketone (PEEK) is the material of choice in several applications ranging from the automotive industry to medicine, but the surface properties are usually not adequate. A standard method for tailoring surface properties is the application of gaseous plasma. The surface finish depends enormously on the processing parameters. This article presents a review of strategies adapted for improved wettability and adhesion of PEEK. The kinetics of positively charged ions, neutral reactive plasma species, and vacuum ultraviolet radiation on the surface finish are analyzed, and synergies are stressed where appropriate. The reviewed articles are critically assessed regarding the plasma and surface kinetics, and the surface mechanisms are illustrated. The directions for obtaining optimal surface finish are provided together with the scientific explanation of the limitations of various approaches. Super-hydrophilic surface finish is achievable by treatment with a large dose of vacuum ultraviolet radiation in the presence of oxidizing gas. Bombardment with positively charged ions of kinetic energy between about 100 and 1000 eV also enable high wettability, but one should be aware of excessive heating when using the ions.

Development of an Atmospheric Pressure Plasma Jet Device Using Four-Bore Tubing and Its Applications of In-Liquid Material Decomposition and Solution Plasma Polymerization

In this study, we describe an atmospheric pressure plasma jet (APPJ) device made of four-bore tubing operable in inhospitable humid environments and introduce two potential applications of liquid material processing: decomposition of aqueous phosphorus compounds and solution-plasma polymerization. A four-bore tube was used as the plasma transfer conduit and two diagonal bores contained metal wires. In the proposed APPJ device, the metal wires serving as electrodes are completely enclosed inside the holes of the multi-bore glass tube. This feature allows the APPJ device to operate both safely and reliably in humid environments or even underwater. Thus, we demonstrate that the proposed electrode-embedded APPJ device can effectively decompose aqueous phosphorus compounds into their phosphate form by directly processing the solution sample. As another application of the proposed APPJ device, we also present the successful synthesis of polypyrrole nanoparticles by solution plasma polymerization in liquid pyrrole.

Classification, Synthetic, and Characterization Approaches to Nanoparticles, and Their Applications in Various Fields of Nanotechnology: A Review

Nanoparticles typically have dimensions of less than 100 nm. Scientists around the world have recently become interested in nanotechnology because of its potential applications in a wide range of fields, including catalysis, gas sensing, renewable energy, electronics, medicine, diagnostics, medication delivery, cosmetics, the construction industry, and the food industry. The sizes and forms of nanoparticles (NPs) are the primary determinants of their properties. Nanoparticles’ unique characteristics may be explored for use in electronics (transistors, LEDs, reusable catalysts), energy (oil recovery), medicine (imaging, tumor detection, drug administration), and more. For the aforementioned applications, the synthesis of nanoparticles with an appropriate size, structure, monodispersity, and morphology is essential. New procedures have been developed in nanotechnology that are safe for the environment and can be used to reliably create nanoparticles and nanomaterials. This research aims to illustrate top-down and bottom-up strategies for nanomaterial production, and numerous characterization methodologies, nanoparticle features, and sector-specific applications of nanotechnology.

Estimation of in vivo toxicity of MgO/ZnO core/shell nanoparticles synthesized by eco-friendly non-thermal plasma technology

MgO/ZnO core/shell nanoparticles were synthesized using the atmosphere plasma jets technique. The physical properties of the synthesized nanoparticles were investigated by a series of techniques, including X-ray diffraction (XRD), X-ray dispersive spectroscopy (EDS), and transmission electron microscopy (TEM). XRD and EDS analyses confirmed the purity of the nanoparticles synthesized with an average nanoparticle crystallite size of 36 nm. TEM confirmed the successful synthesis of spindle-shaped MgO/ZnO core/shell nanoparticles with an average size of 70 nm. To evaluate their toxicity, the MgO/ZnO core/shell nanoparticles were tested in vivo. Twenty-five albino female rats were randomly divided into five groups (five rats in each group); one was used as the control group and the other four as the experimental groups. Doses of the MgO/ZnO core/shell nanoparticles solution were orally administered to the test groups to examine the toxicity. For 30 consecutive days, each rat in test groups 2–5 received 1 mL of the MgO/ZnO core/shell nanoparticles solution at the respective doses of 1.25, 2.5, 5, and 10 mg L⁻¹. The rats’ growth, hematology, thyroid gland function, and histopathology were examined after 30 days. Findings indicate that the growth retardation in the rats treated with MgO/ZnO core/shell nanoparticles may be due to their infection by Hyperthyroidism. The hematology results show the nonsignificant effect of MgO/ZnO core/shell nanoparticles on white blood cells, implying that these nanoparticles have no harmful impact on the immune system. Moreover, the levels of the thyroxine and thyroid‐stimulating hormones increased, and that of the triiodothyronine hormone decreased. The histological analysis results show that low concentrations of MgO/ZnO core/shell nanoparticles are safe for desired biomedical applications.

Long-term adherence of human brain cells in vitro is enhanced by charged amine-based plasma polymer coatings

Advances in cellular reprogramming have radically increased the use of patient-derived cells for neurological research in vitro. However, adherence of human neurons on tissue cultureware is unreliable over the extended periods required for electrophysiological maturation. Adherence issues are particularly prominent for transferable glass coverslips, hindering imaging and electrophysiological assays. Here, we assessed thin-film plasma polymer treatments, polymeric factors, and extracellular matrix coatings for extending the adherence of human neuronal cultures on glass. We find that positive-charged, amine-based plasma polymers improve the adherence of a range of human brain cells. Diaminopropane (DAP) treatment with laminin-based coating optimally supports long-term maturation of fundamental ion channel properties and synaptic activity of human neurons. As proof of concept, we demonstrated that DAP-treated glass is ideal for live imaging, patch-clamping, and optogenetics. A DAP-treated glass surface reduces the technical variability of human neuronal models and enhances electrophysiological maturation, allowing more reliable discoveries of treatments for neurological and psychiatric disorders.

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DAP-coated glass optimally supports long-term adhesion of human brain cells in vitro

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DAP-coated glass coverslips or plates are optimal for patch-clamping, live imaging, and optogenetic applications in vitro

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DAP coating combined with laminin reduces experimental loss due to cell detachment in long-term in vitro studies

Improvement of Nanostructured Polythiophene Film Uniformity Using a Cruciform Electrode and Substrate Rotation in Atmospheric Pressure Plasma Polymerization

In atmospheric pressure (AP) plasma polymerization, increasing the effective volume of the plasma medium by expanding the plasma-generating region within the plasma reactor is considered a simple method to create regular and uniform polymer films. Here, we propose a newly designed AP plasma reactor with a cruciform wire electrode that can expand the discharge volume. Based on the plasma vessel configuration, which consists of a wide tube and a substrate stand, two tungsten wires crossed at 90 degrees are used as a common powered electrode in consideration of two-dimensional spatial expansion. In the wire electrode, which is partially covered by a glass capillary, discharge occurs at the boundary where the capillary terminates, so that the discharge region is divided into fourths along the cruciform electrode and the discharge volume can successfully expand. It is confirmed that although a discharge imbalance in the four regions of the AP plasma reactor can adversely affect the uniformity of the polymerized, nanostructured polymer film, rotating the substrate using a turntable can significantly improve the film uniformity. With this AP plasma reactor, nanostructured polythiophene (PTh) films are synthesized and the morphology and chemical properties of the PTh nanostructure, as well as the PTh-film uniformity and electrical properties, are investigated in detail.

Potential Application of Pin-to-Liquid Dielectric Barrier Discharge Structure in Decomposing Aqueous Phosphorus Compounds for Monitoring Water Quality

Here, we proposed a pin-to-liquid dielectric barrier discharge (DBD) structure that used a water-containing vessel body as a dielectric barrier for the stable and effective treatment of aqueous solutions in an open atmosphere. To obtain an intense pin-to-liquid alternating current discharge using a dielectric barrier, discharge characteristics, including the area and shape of a ground-plate-type electrode, were investigated after filling the vessel with equivalent amounts of water. Consequently, as the area of the ground electrode increased, the discharge current became stronger, and its timing became faster. Moreover, we proposed that the pin-to-liquid DBD reactor could be used to decompose phosphorus compounds in water in the form of phosphate as a promising pretreatment method for monitoring total phosphorus in water. The decomposition of phosphorus compounds using the pin-to-liquid DBD reactor demonstrated excellent performance—comparable to the thermochemical pretreatment method—which could be a standard pretreatment method for decomposing phosphorus compounds in water.

Low-Temperature Atmospheric Pressure Plasma Processes for the Deposition of Nanocomposite Coatings

Low-temperature atmospheric pressure (AP) plasma technologies have recently proven to offer a range of interesting opportunities for the preparation of a variety of nanocomposite (NC) coatings with different chemical compositions, structures, and morphologies. Since the late 2000s, numerous strategies have been implemented for the deposition of this intriguing class of coatings by using both direct and remote AP plasma sources. Interestingly, considerable progress has been made in the development of aerosol-assisted deposition processes in which the use of either precursor solutions or nanoparticle dispersions in aerosol form allows greatly widening the range of constituents that can be combined in the plasma-deposited NC films. This review summarizes the research published on this topic so far and, specifically, aims to present a concise survey of the developed plasma processes, with particular focus on their optimization as well as on the structural and functional properties of the NC coatings to which they provide access. Current challenges and opportunities are also briefly discussed to give an outlook on possible future research directions.

Sensitivity Enhancement in Plasma Polymer Films for Surface Acoustic Wave Based Sensor Applications

Plasma polymer films (PPF), widely used as sensing layers in surface acoustic wave (SAW) based gas and liquid phase sensors, have a major drawback: high concentrations of the sensed analytes easily drive these films into saturation, where accurate measurements are no longer possible. This work suggests a solution to this problem by modifying the PPF with the sensed chemical compound to improve the overall sorption properties and sensor dynamic range. Thin polymer films were synthesized from hexamethyldisiloxane (HMDSO) and triethylsilane (TES) monomers in a plasma-enhanced chemical vapor deposition (PECVD) process using a RF plasma reactor. We used these Si-containing compounds because they are known for their excellent sensing properties. In this work, the layers were deposited onto the active surface of high-Q 438 MHz Rayleigh SAW two-port resonators, used as mass sensitive sensor elements. We call these devices quartz surface microbalances (QSM). In a second step, ammonia plasma modification was applied to the HMDSO and TES films, in order to achieve a higher sensitivity to NH3. The sensors were probed at different NH3 gas concentrations in a computer controlled gas probing setup. A comparison with unmodified films revealed a 74% to 85% improvement in both the sensitivity and sorption ability of the HMDSO sensing layers, and of about 8% for the TES films.

Improvement of the Uniformity and Electrical Properties of Polyaniline Nanocomposite Film by Addition of Auxiliary Gases during Atmospheric Pressure Plasma Polymerization

The morphological and chemical properties of polyaniline (PANI) nanocomposite films after adding small amounts of auxiliary gases such as argon, nitrogen, and oxygen during atmospheric pressure (AP) plasma polymerization are investigated in detail. A separate gas-supply line for applying an auxiliary gas is added to the AP plasma polymerization system to avoid plasma instability due to the addition of auxiliary gas during polymerization. A small amount of neutral gas species in the plasma medium can reduce the reactivity of monomers hyperactivated by high plasma energy and prevent excessive crosslinking, thereby obtaining a uniform and regular PANI nanocomposite film. The addition of small amounts of argon or nitrogen during polymerization significantly improves the uniformity and regularity of PANI nanocomposite films, whereas the addition of oxygen weakens them. In particular, the PANI film synthesized by adding a small amount of nitrogen has the best initial electrical resistance and resistance changing behavior with time after the ex situ iodine (I₂)-doping process compared with other auxiliary gases. In addition, it is experimentally demonstrated that the electrical conductivity of the ex situ I₂-doped PANI film can be preserved for a long time by isolating it from the atmosphere.

Comparative Study of Natural Terpenoid Precursors in Reactive Plasmas for Thin Film Deposition

If plasma polymer thin films are to be synthesised from sustainable and natural precursors of chemically heterogeneous composition, it is important to understand the extent to which this composition influences the mechanism of polymerisation. To this end, a well-studied monoterpene alcohol, terpinen-4-ol, has been targeted for a comparative study with the naturally occurring mix of terpenes (viz. Melaleuca alternifolia oil) from which it is commonly distilled. Positive ion mode mass spectra of both terpinen-4-ol and M. alternifolia oil showed a decrease in disparities between the type and abundance of cationic species formed in their respective plasma environments as applied plasma power was increased. Supplementary biological assay revealed the antibacterial action of both terpinen-4-ol and M. alternifolia derived coatings with respect to S. aureus bacteria, whilst cytocompatibility was demonstrated by comparable eukaryotic cell adhesion to both coatings. Elucidating the processes occurring within the reactive plasmas can enhance the economics of plasma polymer deposition by permitting use of the minimum power, time and precursor pre-processing required to control the extent of monomer fragmentation and fabricate a film of the desired thickness and functionality.