Inorganic surface nanostructuring by atmospheric pressure plasma-induced graft polymerization.

Surface graft polymerization of 1-vinyl-2-pyrrolidone onto a silicon surface was accomplished by atmospheric pressure (AP) hydrogen plasma surface activation followed by graft polymerization in both N-methyl-2-pyrrolidone (NMP) and in an NMP/water solvent mixture. The formation of initiation sites was controlled by the plasma exposure period, radio frequency (rf) power, and adsorbed surface water. The surface number density of active sites was critically dependent on the presence of adsorbed surface water with a maximum observed at approximately a monolayer surface water coverage. The surface topology and morphology of the grafted polymer layer depended on the solvent mixture composition, initial monomer concentration, reaction temperature, and reaction time. Grafted polymer surfaces prepared in pure NMP resulted in a polymer feature spacing of as low as 5-10 nm (average feature diameter of about 17 nm), an rms surface roughness range of 0.18-0.72 nm, and a maximum grafted polymer layer thickness of 5.5 nm. Graft polymerization in an NMP/water solvent mixture, however, resulted in polymer feature sizes that increased up to a maximum average feature diameter of about 90 nm at [NMP] = 60% (v/v) with polymer feature spacing in the range of 10-50 nm. The surface topology of the polymer-modified silicon surfaces grafted in an NMP/water solvent mixture exhibited a bimodal feature height distribution. In constrast, graft polymerization in pure NMP resulted in a narrow feature height distribution of smaller-diameter surface features with smaller surface spacing. The results demonstrated that, with the present approach, the topology of the grafted polymer surface was tunable by adjusting the NMP/water ratio. The present surface graft polymerization method, which is carried out under AP conditions, is particularly advantageous for polymer surface structuring via radical polymerization and can, in principle, be scaled to large surfaces.