Polymeric materials have widespread application due to their versatile characteristics, cost-effectiveness, and highly tailored production. The science of polymer synthesis allows for excellent control over the properties of a bulk polymer sample. However, surface interactions of polymer substrates are an essential area of study in biotechnology, nanotechnology, and in all forms of coating applications. In these cases, the surface characteristics of the polymer and material, and the resulting forces between them largely determine its utility and reliability. In biomedical applications for example, the bodily response to foreign material, and thus biocompatibility, is governed by surface interactions. In addition, surface science is integral part of the formulation, manufacturing, and application of coatings.
Chemical methods A polymeric material can be functionalized by the addition of small moieties, oligomers, and even other polymers (grafting copolymers) onto the surface or interface.
Grafting copolymers
Grafting, in the context of polymer chemistry, refers to the addition of polymer chains onto a surface. In the so-called 'grafting onto' mechanism, a polymer chain adsorbs onto a surface out of solution. In the more extensive 'grafting from' mechanism, a polymer chain is initiated and propagated at the surface. Because pre-polymerized chains used in the 'grafting onto' method have a thermodynamically favored conformation in solution (an equilibrium hydrodynamic volume), their adsorption density is self-limiting. The radius of gyration of the polymer therefore is the limiting factor in the number of polymer chains that can reach the surface and adhere. The 'grafting from' technique circumvents this phenomenon and allows for greater grafting densities. The processes of grafting "onto", "from", and "through" are all different ways to alter the chemical reactivity of the surface they attach with. Grafting onto allows a preformed polymer, generally in a "mushroom regime", to adhere to the surface of either a droplet or bead in solution. Due to the larger volume of the coiled polymer and the steric hindrance this causes, the grafting density is lower for 'onto' in comparison to 'grafting from'. The surface of the bead is wetted by the polymer and the interaction in the solution caused the polymer to become more flexible. The 'extended conformation' of the polymer grafted, or polymerized, from the surface of the bead means that the monomer must be in the solution and there for lyophilic. This results with a polymer that has favorable interactions with the solution, allowing the polymer to form more linearly. Grafting from therefore has a higher grafting density since there are more access to chain ends. Peptide synthesis can provide one example of a 'grafting from' synthetic process. In this process, an amino acid chain is grown by a series of condensation reaction from a polymer bead surface. This grafting technique allows for excellent control over the peptide composition as the bonded chain can be washed without desorption from the polymer. Polymeric coatings are another area of applied grafting techniques. In the formulation of water-borne paint, latex particles are often surface modified to control particle dispersion and thus coating characteristics such as viscosity, film formation, and environmental stability (UV exposure and temperature variations).
Oxidation Plasma processing, corona treatment, and flame treatment can all be classified as surface oxidation mechanisms. These methods all involve cleavage of polymer chains in the material and the incorporation of carbonyl, and hydroxyl functional groups. The incorporation of oxygen into the surface creates a higher surface energy allowing the substrate to be coated.
Methodology
Oxidizing polymeric surfaces
Corona treatment Corona treatment is a surface modification method using a low temperature corona discharge to increase the surface energy of a material, often polymers and natural fibers. Most commonly, a thin polymer sheet is rolled through an array of high-voltage electrodes, using the plasma created to functionalize the surface. The limited penetration depth of such treatment provides vastly improved adhesion while preserving bulk mechanical properties. Commercially, corona treatment has been used widely for improved dye adhesion before printing text and images on plastic packaging materials. The hazardous nature of remnant ozone after corona treatment stipulates careful filtration and ventilation during processing, restricting its implementation to applications with strict catalytic filtered systems. This limitation prevents widespread use within open-line manufacturing processes Several factors influence the efficiency of the flame treatment such as air-to-gas ratio, thermal output, surface distance, and oxidation zone dwell time. Upon conception of the process, a corona treatment immediately followed film extrusions, but the development of careful transportation techniques allows treatment at an optimized location. Conversely, in-line corona treatments have been implemented into full-scale production lines such as those in the newspaper industry. These in-line solutions are developed to counteract the decrease in wetting characteristics caused by excessive solvent use.
Atmosphere- and pressure-dependent plasma processing Plasma processing provides interfacial energies and injected monomer fragments larger than comparable processes. However, limited fluxes prevent high process rates. In addition, plasmas are thermodynamically unfavorable and therefore plasma-processed surfaces lack uniformity, consistency, and permanence. These obstacles with plasma processing preclude it from being a competitive surface modification method within industry. The process begins with production of plasma via ionization either by deposition on monomer mixtures or gaseous carrier ions. The power required to produce the necessary plasma flux can be derived from the active volume mass/energy balance:
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