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A new concept for molecular interface design in metal-polymer systems is presented. The main features of this concept are the replacement of weak physical interactions by strong covalent bonds, the flexibilization of the interface for compensating different thermal expansions of materials by using long-chain flexible and covalently bonded spacers between the metal and the polymer as well as its design as a moisture-repellent structure for hindering diffusion of water molecules into the interface and hydrolysis of chemical bonds.
For this purpose, the main task was to develop plasmachemical and chemical techniques for equipping polymer surfaces with monotype functional groups of adjustable concentration. The establishing of monotype functional groups allows grafting the functional groups by spacer molecules by applying usual wet-chemical reactions. Four processes were favoured for production of monotype functional groups by highly selective reactions: the plasma bromination, the plasma deposition of plasma polymers, the post-plasma chemical reduction of O-functionalities to OH-groups, and the chemical replacement of bromine groups by NH2-groups. The grafting of flexible organic molecules as spacers between the metal layer and polymer improved the peel strength of the metal. To obtain maximal peel strength of aluminium coatings to polypropylene films and occurrence of cohesive failure in the polypropylene substrate, about 27 OH groups per 100 C-atoms or 6 COOH groups per 100 C-atoms were needed. Introducing C6-11-aliphatic spacers 1 OH or COOH group per 100 C-atoms contributed about 60% of the maximal peel strength of the Al-PP system, i.e. 2 or 3 spacer molecules per 100 C-atoms were sufficient for maximal peel strength.
ToF-SIMS has been used to study the surface functionalization of polypropylene and polyethylene samples by exposure to low-pressure ammonia plasma. Static secondary ion mass spectrometry is an appropriate tool to determine hydrogen isotopes as elements and in fragment ions with high sensitivity and selectivity. Specifically the exchange of hydrogen isotopes and the incorporation of N-containing moieties in the near-surface layer of the polyolefins have been studied in ND3 plasma experiments with conventional polypropylene (h-PP) and polyethylene (h-PE) and NH3 plasma experiments with deuterated polyethylene (d-PE). Considering the exchange of hydrogen between the plasma and the polymer surface studied by using deuterated ammonia and polyolefin samples the conclusion has been derived that polypropylene with its side chain methyl groups is more susceptible to hydrogen exchange reactions. For ND3 plasma treatment of polyethylene and polypropylene similar N-containing fragments were obtained and the measured semi-quantitative ToF-SIMS N-uptake data are rather similar. The observation of a wide range of characteristic mixed CkNlHmDn+ secondary fragment ions suggests complex and manifold reaction pathways at the polymer–plasma interface besides simple grafting of –ND2 or –NH2 moieties formed by ammonia fragmentation in the plasma. Finally, indications of an isotopic effect for hydrogen isotopes in the plasma process have been observed by comparison of ND3/h-PE results with those of NH3/d-PE.
Thin coatings of poly(acrylic acid) (PAA) and poly(hydroxyethylmethacrylate) (PHEMA) were deposited onto carbon fibers by means of the electrospray ionization (ESI) technique in ambient air. These high-molecular weight polymer layers were used as adhesion promoters in carbon fiberepoxy resin composites. Within the ESI process, the carbon fibers were completely enwrapped with polymer in the upper 10 plies of a carbon fiber roving. As identified with scanning electron microscopy also shadowed fibers in a bundle as well as backsides of fiber rovings were pinhole-free coated with polymers (electrophoretic effect'). Under the conditions used, the layers have a granular structure. Residual solvent was absent in the deposit. PAA and PHEMA films did not show any changes in composition and structure in comparison with the original polymers as analyzed by X-ray photo-electron spectroscopy and matrix-assisted laser desorption/ionization time-of-flight mass spectrometry. Single-fiber pullout tests of coated fibers embedded in epoxy resin showed significantly increased interfacial shear strength. It is assumed that chemical bonds between carbon fiber poly(acrylic acid) and epoxy resin contribute significantly to the improved interactions.
Plasma polymers and electrospray-ionization (ESI) polymer layers are compared for most efficient adhesion promotion in carbon fiber-epoxy resin composites. The ultra-thin ESI layers (2–30 nm) of commercial poly(acrylic acid) and poly-(hydroxyethylmethacrylate) produce an significant increase of adhesion measured by single-fiber pull out tests.
However, plasma Treatment has also advantages, such as simultaneous activation of the fiber substrate. Chemical structure and composition are rather far from the regular structure of commercial polymers as deposited by ESI processing.
Polyolefin surfaces (polyethylene and polypropylene) were exposed to haloform (CHX3) plasmas for introduction of monosort halogen groups. Bromoform and chloroform plasmas produced selectively C-Br (100 Br/100 C) and C-Cl (200 Cl/100 C) groups in high yields. The bromoform plasma showed 1-3 and the chloroform plasma 2-7 post-plasma introduced O-functionalities per 100 C. The polyolefin C-Br groups were grafted wet-chemically or by exposure to the vapour of amines, diols and glycols. Thus, spacer molecules could be covalently bonded to maximal 15 spacer molecules per 100 C for the smallest grafted molecules and 1.2 molecules/100 C for larger molecules as octaaminophenylene-POSS. After metal evaporation the end groups of these polymer-bonded spacer molecules formed also covalent bonds to the metal. Thus, flexible, hydrophobic and barrier elements were introduced into the polymer-metal interfaces for high-impact, high-durable and water-resistant metal-polymer composites as measured by means of peel strengths.
Selektiv funktionalisierte Oberflächen von Polyolefinen sind für verschiedenste Einsatzgebiete wie Adhäsions-, Chemie-, Medizin- und Biotechnik von großem Interesse. Eine Möglichkeit Polymeroberflächen effizient zu funktionalisieren ist, diese durch eine plasmaphysikalisch angeregte Gasphase unter Einsatz geeigneter Präkursoren chemisch zu modifizieren. Im Rahmen der vorliegenden Arbeit wurde die Wirkung bromhaltiger Gasphasenplasmen, die Bromoform, Allybromid oder tert-Butylbromid enthielten, auf Polyethylen (PE) und Polypropylen (PP) untersucht. Überraschenderweise wurde hierbei eine hochselektive und hochdichte monosortige Br-Funktionalisierung beobachtet. Um die für diese hohe Selektivität verantwortlichen Prozesse zu untersuchen, wurden analoge halogenhaltige Plasmen, die Tetrafluormethan, Fluoroform, Chloroform, Bromoform und Diiodmethan enthielten, auf ihre chemische Selektivität, ihre Funktionalisierungseffizienz und ihr Ionisationspotential und Elektronentemperatur charakterisiert. Es wurde untersucht, ob die Halogenidfunktionalität als CX oder als C-CXn-Gruppe an der Oberfläche gebildet wird. Für die Bewertung der Langzeitstabilität der Funktionalisierung wurde die Nachoxidation der plasmamodifizierten Polymeroberflächen kontrolliert. Im Anschluss wurde die Umsetzbarkeit mit systematisch variierten organischen Verbindungen bestimmt. Ziel hierbei war zu untersuchen, wie gut sich die Bromidfunktionalität als universelle Abgangsgruppe zur Kopplung flexibilisierender Spacer- Moleküle in der Metall-Polymer-Grenzfläche eignet. Es wurden dazu Kopplungsreaktionen mit unterschiedlich langen und steifen endständigen Alkohol-, Amin- und Glykol- Verbindungen durchgeführt. Darüber hinaus wurden Umfunktionalisierungsreaktionen an bromierten Oberflachen durchgeführt. Auf diese Weise konnte gezeigt werden, dass es möglich ist, die C-Br- Funktionalität gegen eine andere auszutauschen. Spezielles Augenmerk wurde auf die Umfunktionalisierung zu primären Aminogruppen gelegt. Diese wurden über einfache Substitutionsreaktionen mit konzentriertem oder verflüssigtem Ammoniak erzeugt. Auch oberflachengebundene Hydroxylgruppen konnten erzeugt werden. Dazu wurden Bromidfunktionen durch Substitution mit Kalium- und Natriumhydroxid in geeigneten Lösungsmitteln umgesetzt. Polypropylenoberflächen, die mit verschiedenen Spacern ausgerüstet worden waren, wurden im Vakuum mit dünnen Filmen aus Aluminium und Kupfer bedampft. Die Haftfestigkeit dieser Beschichtung wurde anschließend durch Schalfestigkeitsmessungen untersucht.