Fundamentals of Plasma Polymerization

The plasma polymerization of ethylene is used as an example through which to discuss the elementary steps involved in forming a polymer in an electric discharge. The relationship of the experimentally controlled variables to the rate of formation of first generation active species is discussed. These species are related, in turn, to the overall rate of polymerization through a simple model. Two asymptotic conditions are discussed which correspond to minimal and total conversion of monomer to polymer. The dependence of polymer deposition rate on monomer flow rate predicted by the model is found to correspond very closely to that observed experimentally. The predicted effect of gas pressure on polymer deposition rate also agrees with that found experimentally.     

Distribution of polymer deposition in plasma polymerization. I. Acetylene,ethylene, and the effect of carrier gas

Factors which influence the distribution of polymer deposition in an electrodeless glow-discharge system were investigated for acetylene and ethylene. Under the conditions in which “full glow” is maintained, the distribution of polymer deposition from pure monomer flow systems is nearly independent of flow rate of monomer or of the system pressure in discharge, but is largely determined by the characteristic (absolute) polymerization rates (not deposition rate) of the monomers. Acetylene has a high tendency to deposit polymer near the monomer inlet, whereas ethylene deposits polymer more uniformly in wider areas in the reactor. The addition of carrier gas such as argon or partially copolymerizing gas such as N₂, H₂, and CCl₂F₂ was found to narrow the distribution of polymer deposition. The distribution of polymer deposition is also influenced by a glow characteristic which is dependent on flow rate and discharge power.     

Preparation of composite membranes by means of plasma polymerization of tiophene

The structure and the charge transport properties of poly(ethylene terephthalate) track membranes modified in a thiophene plasma were studied. It was found that polymer deposition on the surface of a track membrane via the plasma polymerization of thiophene results in composite membranes that, in the case of the formation of a semipermeable layer, exhibit conductivity asymmetry—rectifying effect—in electrolyte solutions. It was shown that chemical doping with iodine or photo-oxidation of the polymer layer produced in plasma leads to alteration in the electrochemical properties of plasma-modified membranes.     

A study of surface dynamics of polymers. III. Surface dynamic stabilization by plasma polymerization

As demonstrated in Part II of this series of studies, the hydrophobic character of CF₄ plasma-treated Nylon 6 and poly(ethylene terephthalate) (PET) decay with time of water immersion, and the rate of decay can be used as a measure for the surface mobility of (substrate) polymers. The same method of using fluorine-containing moieties introduced by CF₄ plasma treatment as surface labeling is applied to investigate the influence of a thin layer of plasma polymer of methane applied onto the surface of those polymers. An ultrathin layer of plasma polymer provides a barrier to the rotational and diffusional migration of the introduced chemical moieties from the surface into the bulk of the film. The influence of operational parameters of plasma polymerization on the surface dynamic stability are examined by measuring the decay rate constants for (subsequently) CF₄ plasma-treated samples. The rate constant was found to decrease sharply with increasing value of plasma energy input manifested by J/kg monomer, and no decay was observed as the energy input reached a threshold value (about 6.5 GJ/kg for PET, about 7.0 GJ/kg for Nylon 6), indicating that unperturbable surfaces can be created by means of plasma polymerization.     

Some aspects of plasma polymerization investigated by pulsed R.F. discharge

The polymerization of organic compounds in glow discharge (plasma polymerization) was investigated by using pulsed R.F. discharge (100 μsec on, 900 μsec off). The effects of pulsed discharge on polymer deposition rate, pressure change in plasma, ESR signals of free spins in both plasma polymer and substrate, and the contact angle of water on the plasma polymer surface were investigated for various organic compounds. The results are correlated to the mechanisms of polymer formation in plasma (plasma polymerization) which has been postulated as repeating processes of stepwise (propagation) reactions. The effect of the pulse is different from one group of organic compounds to another depending on whether or not they contain an olefinic double bond and/or a triple bond. The main difference seems to be the addition polymerization which can occur exclusively during the off-period of pulsed discharge. Ultraviolet emission from pulsed discharge is much less than from continuous discharge. Consequently, the fragmentation of the monomer and the free-radical formation in the substrate are less with the pulsed discharge. Properties of polymers from some organic compounds formed in continuous and in pulsed discharge were found to be significantly different, and the differences were postulated from the changes of polymerization mechanisms in the pulsed discharge.     

Effect of frequency on the deposition of microcrystalline silicon from tetrachlorosilane in low-pressure r.f. plasmas

The efficiency of reduction of silicon tetrachloride and the rate of deposition of Si in a low-pressure r.f. plasma was investigated at two frequencies (0.4 and 27 MHz) as a function of position with regard to the rf coil, pressure, and time of deposition. At 27 MHz the decomposition efficiency of silicon tetrachloride and the deposition rate of Si are about three times higher than at 0.4 MHz.     

The Role of Halogens in the Plasma Polymerization of Hydrocarbons

Vinyl chloride, vinyl fluoride, and tetrafluoroethylene were polymerized in a radio frequency electric glow discharge. It was found that when compared with the unhalogenated simple hydrocarbons, the rates of polymer deposition are in the order vinyl chloride, acetylene, tetrafluoroethylene, vinyl fluoride, ethylene. This observation can be rationalized by considering the ease with which free radical and unsaturated species can be formed in the plasma. IR spectra show that the structures of plasma-polymerized vinyl chloride and vinyl fluoride are in many respects similar to the plasma-polymerized hydrocarbon. The spectrum of plasma-polymerized tetrafluoroethylene, however, does not resemble that of conventional polytetrafluoroethylene. Addition of dichlorodifluoromethane to the monomer stream dramatically increased the polymer deposition rate; the effect is more subdued for chloromethane and is negligible for tetrafluoromethane. Elemental analysis indicates that little of the added halogens is present in the resultant polymers. Thus the halogenated compounds appear to act as a gas phase catalyst for the plasma polymerization of hydrocarbons.     

Some aspects of plasma polymerization of fluorine-containing organic compounds. II. Comparison of ethylene and tetrafluoroethylene

Plasma polymerizations of ethylene and tetrafluoroethylene are compared. In the plasma polymerization of ethylene and of tetrafluoroethylene, glow characteristics play an important role. Glow characteristic is dependent on a combined factor of W/F_m, where W is discharge power and F_m is monomer flow rate. At higher flow rates, higher wattages are required to maintain “full glow.” In the plasma polymerization of tetrafluoroethylene, simultaneous decomposition of the monomer competes with plasma polymerization. Above a certain value of W/F_m, decomposition becomes the predominant reaction, and the polymer deposition rate decreases with increasing discharge power. ESCA results indicate that the plasma polymer of tetrafluoroethylene that is formed in an incomplete glow region (low W/F_m) is a hybrid of polymers of plasma polymerization and of plasma-induced polymerization of the monomer. Polymers formed under conditions of high W/F_m to produce “full glow” are similar, regardless of the extent of decomposition of the monomer. They contain carbons with different numbers of F(CF₃, ? CF₂? , >CF? , >C<) and carbons bonded to other more electronegative substituents.     

Characterization of plasma polymerized C, H, and O containing compounds by MALDI mass spectrometry

Matrix-assisted laser desorption/ionization (MALDI) mass spectrometry is used for the first time to characterize radio frequency plasma-deposited polymers and for investigation of the plasma polymerization process. The MALDI mass spectra of the plasma polymers of allyl alcohol, di(ethylene glycol) vinyl ether and ethylene glycol butyl vinyl ether are all reported using solvent-based MALDI sample preparation approaches. The MALDI mass spectra of each of the three plasma polymers contain distinctive polymer series ion signals having molecular weight distributions below 2000 Da. Unexpectedly, however, the ion signals from each of the three plasma polymers show a common polymer repeat unit of 44 Da, for which the chemical formula is most likely -(C(2)H(4)O)-, and no evidence of the expected radical chain polymerization polymer is detected. These results are discussed in terms of the likely involvement of gas-phase radical species having different stabilities in the radio frequency plasma environment.     

In situ FTIR investigation of MMA plasmas,plasma-polymerized films,and reaction mechanisms

Methyl methacrylate (MMA) plasmas and plasma-polymerized methyl methacrylate (PPMMA) films were studied in situ with FTIR and FTIR/ATR (attenuated total reflection) in an r.f. capacitively coupled glow discharge. A statistically designed experiment was conducted by varying the r.f. power, process pressure, and MMA flow rate. MMA plasma fragments were identified from the gas-phase FTIR measurements. They include the intermediate species such as dimethylketene, formaldehyde, allene, and propene; small hydrocarbons such as acetylene, methane, and ethylene; and oxygenates such as carbon dioxide, carbon monoxide, and methanol. Statistical analysis techniques (correlation analysis, analysis of variance and regression analysis) were used on both gas and film data. Gas-phase reaction mechanisms are proposed, and the relationship between the gas and film data is investigated to understand the film deposition chemistry. The deposition rate is positively correlated to the relative concentrations of MMA fragments which are identified as the major film precursors in the deposition process. © 1998 John Wiley & Sons, Inc. J Polym Sci A: Polym Chem 36: 587–602, 1998     

Radiofrequency Plasma Polymers Containing Ionic Phosphonate Groups: Effect of Monomer Structure and Carrier Gas on Properties and Deposition Rate

Radiofrequency (RF) plasma polymers prepared from perfluoroallylphosphonic acid (PAPA) are hydrophilic and have ionic properties. Unfortunately, deposition rates are low. The current study focuses on RF plasma polymers prepared from PAPA and pentafluoroallyldiethylphosphonate (PADP) with and without argon carrier gas. Plasma polymerized PADP films were similar in composition, structure, and properties to plasma polymerized PAPA films, but were deposited at much higher rates. The addition of argon to the PAPA discharges resulted in a decrease in mean deposition rate from 41.7 Å/min to less than 20 Å/min, while the deposition rate of plasma polymerized PADP increased significantly with the addition of argon to the discharge. PADP derived plasma polymer deposition rates ranged from 136 Å/min to 390 Å/min, depending on position in the reactor and presence or absence of argon carrier gas. PAPA-derived plasma polymers exhibited deposition rates and properties that were uniform throughout the reactor, while PADP-derived plasma polymers had maximum deposition under the upstream induction coil and linearly decreasing deposition rate with downstream distance in the reactor. Additionally, the PADP-derived plasma polymers exhibited downstream changes in atomic composition, structure, and physical properties, such as wettability and hardness. These changes were attributed to a getter effect upstream in the reactor in which ablated hydrogen species scavenge etching fluorine species in the plasma phase.     

Characterization of low-fouling ethylene glycol containing plasma polymer films

Low-protein-fouling poly(ethylene glycol) (PEG-like) plasma polymer films were prepared using radio frequency glow discharge polymerization of diethylene glycol dimethyl ether (DGpp) on top of a heptylamine plasma polymer primer layer. By varying the plasma deposition conditions, the chemistry of the DGpp film was influenced, especially in regard to the level of ether content, which in turn influenced the relative levels of bovine serum albumin and lysozyme protein fouling. Surface potential measurements indicated that these surfaces carried a net negative charge. While protein fouling remained low ( approximately 10 ng/cm2), there was a slightly higher level of the positively charged protein adsorbed on these films than the negative protein. The interaction forces measured between a silica spherical surface on both "high"- and "low"-protein-fouling DGpp films were all repulsive and short ranged (2-3 nm). There was no correlation between the surface forces measured for high- and low-protein-fouling DGpp films. Thus, it appears that enthalpic effects are very important in reducing protein adsorption. We therefore conclude that it is the concentration of residual, ethylene glycol containing species that are the crucial parameter determining protein resistance due to a combination of both entropic and enthalpic effects.     

Plasma for Modification of Polymers

The effect of nonpolymer-forming plasma (e.g., plasma of hydrogen, helium, argon, nitrogen) can be viewed as the following two reactions: 1) reaction of active species with polymer, and 2) formation of free radicals in polymer which is mainly due to the UV emitted by the plasma. The incorporation of nitrogen into the polymer surface by N₂ plasma and the surface oxidation by O₂ plasma are typical examples of the first effect. The latter effect generally leads to incorporation of oxygen in the form of carbonyl and hydroxyl and to some degree of cross-linking depending on the type of substrate; however, the degradation of polymer at the surface manifested by weight loss occurs in nearly all cases when polymers are exposed to plasma for a prolonged period of time. The effects of polymer-forming plasma is predominated by the deposition of polymer (plasma polymer); however, with some plasma-susceptible polymer substrates the effect of UV emission from polymer-forming plasma cannot be neglected. The mechanism of polymer formation can be explained by the stepwise reaction of active species and/or of an active specie with a molecule, and the chain addition polymerization of some organic compounds (e.g., vinyl monomers) is not the main route of polymer formation.

Plasma polymers contain appreciable amount of trapped free radicals; however, the concentration is highly dependent on the chemical structure of the monomer. In plasma polymerization, 1) triple bond and/or aromatic structure, 2) double bond and/or cyclic structure, and 3) saturated structure are three major functions which determine the rate of polymer formation and the properties of plasma polymers. The changes of some properties of plasma polymers with time are directly related to the concentration of trapped free radicals in plasma polymers. The amount of trapped free radicals in a plasma polymer is also influenced by the conditions of discharge; however, the UV irradiation from the polymer-forming plasma is not the main cause of these free radicals. Excess amount of free radicals are trapped during the process of polymer formation (rather than forming free radicals in the deposited polymer by UV irradiation). The properties of a plasma polymer is generally different from what one might expect from the chemical structure of the monomer, due to the fragmentation of atoms and/or functions during the polymerization process. This is another important factor to be considered for the modification of polymer surfaces by plasma polymerization.     

Non-fouling surfaces produced by gas phase pulsed plasma polymerization of an ultra low molecular weight ethylene oxide containing monomer

The pulsed plasma polymerization of low molecular weight molecules containing only one (ethylene oxide vinyl ether) and two (diethylene oxide vinyl ether) ethylene oxide units were investigated. The surface density of EO units retained in the polymer films increases sharply with decreasing average power input during deposition, particularly at very low plasma duty cycles. The protein adsorption properties of these plasma synthesized polymer were investigated using ¹²⁵I-labeled albumin and fibrinogen. Surprisingly effective, non-fouling surfaces were observed with films synthesized from the monomer containing two ethylene oxide units; however, the monomer containing only one EO unit gave surfaces that were not particularly effective in preventing protein adsorptions. The results obtained show that ultra short chain length PEO modified surfaces can be biologically non-fouling. This, in turn, has interesting consequences in terms of trying to identify the basic reason for the effectiveness of EO units in preventing biomolecule adsorptions on surfaces.     

Plasma polymerization of tetrafluoroethylene. III. Reproducibility and effects of substrate and reactor materials

Plasma polylmerization occurs in plasmas surrounded by surfaces and polymer formation is one of the complicated interactions that take place between active species and molecules which constitute surfaces and gas phases. Effects of reactor wall, substrate materials, flow rate, and discharge power on polymer formation, and properties of polymer deposits were investigated by ESCA, IR (infrared) spectroscopy, and the measurement of system pressure. The effect of surface is important at the initial stage of plasma polymerization which can be easily detected by the system pressure change; however, integrated properties such as IR spectroscopy and the deposition rate show the effect in a less pronounced manner. ESCA, which reflects the properties of surface (approximately 20 A? in depth), showed the effect of surface in an even less sensitive manner. The amount and properties (including the effects of surfaces) are dependent on plasma polymerization parameter W/FM(W, wattage; F, volume flow rate; and M, molecualar weight of monomer) and the location of deposition within a reactor. IR and ESCA data clearly showed the dependence of polymer properties on W/FM; i.e., increase of W and decrease of M to be equivalent. When all these factors were kept under control, the reproducibility of plasma polymerization was found to be excellent.     

应用裂解色谱-质谱法研究乙烯等离子体聚合物结构

应用裂解色谱—质谱(PGC—MS)法研究化学法和等离子体法聚合得到的聚乙烯的裂解行为。比较了两种聚合物的结构差异。探讨了等离子体聚合条件对聚合物结构的影响及其聚合反应机理。     

Comparing Long‐Chain Branching Mechanisms for Ethylene Polymerization with Metallocenes and Other Single‐Site Catalysts: What Simulated Microstructures Can Teach Us

Three different long‐chain branch (LCB) formation mechanisms for ethylene polymerization with metallocenes in solution polymerization semi‐batch and continuous stirred‐tank reactors are modeled to predict the microstructure of the resulting polymer. The three mechanisms are terminal branching, C–H bond activation, and intramolecular random incorporation. Selected polymerization parameters are varied to observe how each mechanism affects polymer microstructure. Increasing the ethylene concentration during semi‐batch polymerization reduces the LCB frequency of polymers made with the terminal branching and intramolecular mechanisms, but has no effect on those made with the C–H bond activation mechanism, which disagrees with most previous data published in the literature. The intramolecular mechanism predicts that LCB frequencies hardly depend on polymerization time or ethylene conversion, which also disagrees with the published experimental data for these systems. For continuous polymerization reactors, experimental data relating polydispersity to LCB frequency can be well described with the terminal branching mechanism, but both C–H bond activation and intramolecular models fail to describe this experimental relationship. Therefore, detailed simulations confirm that the terminal branching mechanism is indeed the most likely mechanism for LCB formation when ethylene is polymerized with single‐site coordination catalysts such as metallocenes in solution polymerization reactors.     

Stereospecific polymerization of methacrylonitrile. II. Influence of polymerization conditions on polymerization and on properties of polymers

Stereospecific polymerization of methacrylonitrile with diethylmagnesium has been studied. Polymerization temperature has an important effect on polymerization. The conversion, stereoregularity, and intrinsic viscosity of the polymer increased significantly with increasing polymerization temperature. Stereoregularity of the polymer improved with increasing the polymerization time and the monomer concentration, but it is independent of the catalyst concentration. Intrinsic viscosity of the crystalline polymer increased with increasing monomer concentration but is independent of the polymerization time and the catalyst concentration. It is suggested that two mechanisms are involved in this polymerization: coordinated anionic polymerization to from the crystalline polymer, and probably conventional anionic polymerization to form the amorphous polymer. It is found that crystalline polymer can also be obtained in homogeneous phase such as in tetrahydrofuran solvent.     

The swelling interface number as a criterion for prediction of diffusional solute release mechanisms in swellable polymers

When a glassy polymer containing a uniformly dispersed solute is brought in contact with a penetrant, solute diffusion will be associated with the transport mechanism and penetration velocity of the penetrant in the polymer. Analysis and prediction of mechanisms of diffusional solute release may be obtained through a new dimensionless number, the swelling interface number, Sw, which compares the relative mobilities of the penetrant and the solute in the presence of macromolecular relaxations in the polymer. It is shown that a sufficient and necessary criterion for time-independent diffusional solute release rates from these swellable systems is that the Sw be smaller than 10^?2. The swelling interface number Sw may be related to easily determined structural and thermodynamic parameters of the solute/polymer/penetrant system. Preliminary experimental results of dynamic water swelling of poly(2-hydroxyethyl methacrylate-co-methyl methacrylate) and diffusional release of theophylline from initially glassy copolymers show that decreasing values of Sw are related to increased pseudo-case-II transport kinetics of the solute.     

Plasma polymerization. VI. An ESCA investigation of the RF plasma polymerization of perfluoro-2-butyl tetrahydrofuran

Perfluoro-2-butyl tetrahydrofuran was polymerized by an RF glow discharge technique and detailed ESCA studies were made of the resultant films. The rate of film deposition was sensitively dependent on the W/FM parameter and the site of deposition. The ESCA data show that the molecular rearrangement accompanying plasma polymerization and the oxygen functionality is at a significantly lower level than the starting material. Under appropriate conditions plasma polymerization produces material with a C:F stoichiometry of 1:2, although the ESCA data show that the polymer is drastically different from PTFE. ESCA studies are also reported on thin films of the monomer studied at low temperature.