Latex barrier thin film formation on porous substrates.

Here we present the formation of thin layers of barrier polymers onto mesoporous and macroporous substrates via dip coating of latex solutions. We investigated four commercially available latex solutions: polytetrafluoroethylene (PTFE), perfluoroalkoxy fluorothermoplastic (PFA), polyvinylidene chloride (PVDC), and polyolefin-based latex (Hypod). We examined the latex film formation on porous polymeric and ceramic substrates with a broad range of pore sizes from 10 to 200 nm. Our results show that both characteristics of the latex solution [glass transition temperature (Tg), particle size, and crystallinity] and the characteristics of the porous substrate (pore size and hydrophobicity) impact the film formation. We confirmed the defect-free, barrier nature of our latex thin films through scanning electron microscopy (SEM), atomic force microscopy (AFM), and hydraulically driven water permeation tests. Additionally, we found that latex concentration (not dipping time) is the most important parameter determining ultimate latex film thickness. We obtained defect-free films from PVDC and Hypod, which are "soft" polymers (Tg < room temperature), on mesoporous substrates under the conditions of slow evaporation rate of the solvent from these latex solutions. PTFE and PFA, which are "hard" polymers (Tg > room temperature), did not form continuous films on porous substrates.