Polymer Substrates Research Articles

Cellulose Nanostructures as Tunable Substrates for Nanocellulose-Metal Hybrid Flexible Composites.

Nanocomposite represents the backbone of many industrial fabrication applications and exerts a substantial social impact. Among these composites, metal nanostructures are often employed as the active constituents, thanks to their various chemical and physical properties, which offer the ability to tune the application scenarios in thermal management, energy storage, and biostable materials, respectively. Nanocellulose, as an emerging polymer substrate, possesses unique properties of abundance, mechanical flexibility, environmental friendliness, and biocompatibility. Based on the combination of flexible nanocellulose with specific metal fillers, the essential parameters involving mechanical strength, flexibility, anisotropic thermal resistance, and conductivity can be enhanced. Nowadays, the approach has found extensive applications in thermal management, energy storage, biostable electronic materials, and piezoelectric devices. Therefore, it is essential to thoroughly correlate cellulose nanocomposites' properties with different metallic fillers. This review summarizes the extraction of nanocellulose and preparation of metal modified cellulose nanocomposites, including their wide and particular applications in modern advanced devices. Moreover, we also discuss the challenges in the synthesis, the emerging designs, and unique structures, promising directions for future research. We wish this review can give a valuable overview of the unique combination and inspire the research directions of the multifunctional nanocomposites using proper cellulose and metallic fillers.

Highly permeable and shelf-stable aquaporin biomimetic membrane based on an anodic aluminum oxide substrate

Aquaporin (AQP) biomimetic membranes are a coming-of-age technology for water purification. Although several studies have reported aquaporin biomimetic membrane fabrication to date, these membranes show low water flux mainly due to the low porosity and inherently dense structure of the polymeric substrate materials. Herein, we report a ceramic-based aquaporin biomimetic membrane based on anodic aluminum oxide (AAO) as a substrate, which has a uniform porous structure with a high aspect ratio and pore density compared to conventional polymer substrates and exhibits a high water flux of 27.6 ± 3.6 LMH (L m−2 h−1) and superior membrane selectivity of 0.11 g L−1. Briefly, the AAO substrate was functionalized with amino-silane followed by polydopamine coating, then the AQP vesicles were immobilized on the functionalized AAO substrate surface using an electrokinetic method, and the water rejection performance of the membrane was analyzed in a forward osmosis system. Furthermore, a simple cryodesiccation method is introduced to improve the storage stability and easy transportation of aquaporin membranes, which does not require special environmental conditions to transport or store them.

Density-controlled electrochemical synthesis of ZnO nanowire arrays using nanotextured cathode

Zinc oxide (ZnO) nanowires fabricated via wet chemical synthesis on flexible polymer substrates are inherently unstable against mechanical bending stress because of their high density and weak adhesion to the substrate. We introduce a novel method for controlling the density of such ZnO nanowire arrays using a three-dimensional corrugated metal substrate. These metal substrates, featuring extruded and recessed patterns fabricated via nanoimprint lithography, were employed as cathodes during the electrochemical deposition of ZnO nanowire arrays. The ZnO nanowire arrays synthesized on the patterned metal thin film exhibited smaller diameters and lower densities compared to those on non-patterned metal films. This reduction in density can be attributed to aligned nucleation and limited growth on the patterned metal surface. Crucially, ZnO nanowires synthesized on patterned metal substrates displayed remarkable mechanical robustness against external forces, a direct consequence of their reduced density. In contrast, nanowires synthesized on non-patterned metal substrates were broken under mechanical bending. Detailed morphological analyses performed after mechanical bending tests confirm that ZnO nanowires synthesized on nanoimprinted metal electrodes exhibited enhanced mechanical characteristics compared to those on non-patterned metal electrodes. These findings clearly demonstrate the promise of utilizing density-controlled ZnO nanowires in piezoelectric devices.

On the role of defects in modelling approaches for thin film gas barrier coatings on polymer substrates: I. Model development

We present a method to model the gas permeation through silicon-oxide thin film coatings that are afflicted with nanoscale defects. With it, we are able to give an estimation of the diffusion coefficient in bulk by subtracting the influence of the defects. The model is based on data obtained from positron annihilation spectroscopy, which is processed to yield possible defect allocation patterns of the coatings. For a systematic evaluation of these patterns, a path through the coating is calculated and then subjected to in-depth analysis to evaluate the used approach as well as to interpret the results for insights on the permeation mechanisms. The model appears to function as intended and no unexpected behaviour is observed. The defect volume share is overestimated, which can be retraced to the underlying algorithm, and a correction method is applied to the resulting bulk diffusion coefficient. The model gives reasonable results both for oxygen and water vapor permeation. These results can be used in following works that build on the presented model.

Surface topology modification using 3D printing techniques to enhance the interfacial bonding strength between polymer substrates and prepreg carbon fibre-reinforced polymers

Carbon fibre-reinforced polymers (CFRPs) are increasingly utilised in combination with plastics and metals to manufacture hybrid components. Although hybrid components provide a combination of the advantages of the constituent materials, there are some challenges for the manufacture of high-quality hybrid components, including potentially weak interfacial bonding between the constituent materials. This paper presents a study focused on enhancing the interfacial strength of hybrid components by using additive manufacturing (AM) to manipulate the surface topology of a substrate component. Specifically, the study involved conducting experiments on a polyamide/CFRP hybrid component in which the PA12 substrates were manufactured with a controlled surface topology using polymer powder bed fusion. The mechanical testing study revealed several key findings, including an increase in bonding strength by modifying the substrate surface features, and significant improvements in out-of-plane interlaminar bonding strength by adding substrate surface features such as pins or fluorite lattices. It is shown that normal strength was enhanced by up to 53% between the substrate and pure epoxy, and by 126% between the substrate and a CFRP laminate. These results highlight the potential benefits of using AM technologies to enhance the interfacial strength of hybrid components and suggest directions for future research in this area.

Fabrication of hydrophobic optical diffuser film for LED lights through induction-aided hot embossing using micro-textured mold fabricated by μ-WEDM: parametric analysis, wettability study and optical characterization

This study used an in-house designed induction-aided hot embossing (IHE) setup to make polymer-based hydrophobic optical diffuser film for LED lights. Negative-featured micron sized V-shaped grooves (Width and depth −300 μm, angle −60°, adjacent distance-500 μm) were fabricated on the mold to develop the micro-textured mold required for the hot embossing via μ-WEDM. In this study, polyethylene terephthalate (PET), polymethyl methacrylate (PMMA), and polycarbonate (PC) were used as working substrates. Initially, the parametric investigation was carried out by considering the four main parameters of IHE, i.e., embossing temperature-(Te), pressure-(Pe), duration-(te), and deembossing temperature-(Tde). Parametric analysis shows that the height of the embossed micron-sized V-shaped-grooves on the polymer substrate significantly affects the embossed diffuser film’s wettability and lighting efficiency. Embossed PC diffuser film showed the highest height, WCA, and illumination in all parametric investigations. Finally, PC diffuser film was made with the optimal IHE parameters: Te−225 °C, Pe−40 Kg cm−2, te−600 s, Tde−30 °C. This set of settings resulted in a maximum V-groove height of 273.35 ± 4.71 μm and a 94.52% replication rate. Illumination analysis of embossed PC diffuser film (171×102 (lux)) compared to traditional/bare film (71×102 (lux)) revealed a 137.5% percentile gain in illumination. A laser-based optical system was employed for optical characterization, and the X-direction diffused light length on the white screen was measured. The best diffused light length was 109.35 mm for embossed PC diffuser film. To compare plain and embossed diffuser film lighting effectiveness, RGB photos captured by CCD-RGB camera were converted to HSI images to determine hue, saturation, and intensity. The intensity dropped most with embossed PC diffuser film. It shows that embossed PC diffuser sheet diffuses light better. Finally, wettability study showed that all embossed diffuser film surfaces are hydrophobic. Embossed PC diffuser film had the highest WCA (95.3°) and 27.71% higher wettability than bare film.

Fast insights into chitosan-cleaving enzymes by simultaneous analysis of polymers and oligomers through size exclusion chromatography

The thorough characterization of chitosan-cleaving enzymes is crucial to unveil structure–function relationships of this promising class of biomolecules for both, enzymatic fingerprinting analyses and to use the enzymes as biotechnological tools to produce tailor-made chitosans for diverse applications. Analyzing polymeric substrates as well as oligomeric products has been established as an effective way to understand the actions of enzymes, but it currently requires separate, rather laborious methods to obtain the full picture. Here, we present ultra high performance size exclusion chromatography coupled to refractive index and mass spectrometry detection (UHPSEC-RI-MS) as a straightforward method for the semi-quantitative analysis of chitosan oligomers of up to ten monomers in length. Additionally, the method allows to determine the average molecular weight of the remaining polymers and its distribution. By sampling live from an ongoing enzymatic reaction, UHPSEC-RI-MS offers the unique opportunity to analyze polymers and oligomers simultaneously—i.e., to monitor the molecular weight reduction of the polymeric substrate over the course of the digestion, while at the same time analyzing the emerging oligomeric products in a semi-quantitative manner. In this way, a single simple analysis yields detailed insights into an enzyme’s action on a given substrate.

Laser marking on polyoxymethylene (POM) polymer substrate for a lean manufacturing application

AbstractLaser marking is a critical production process step in most automated production systems. However, some materials such as polyoxymethylene (POM) can be quite challenging to laser to 80 kHz.mark, hence the need to develop new laser marking methods. By employing a wide range of marking parameters (marking speed 15–2000 mm/s, laser power from 10 to 100% of 30 W maximum, and frequencies mainly from 1 to 400 kHz) and characterization techniques, and with the use of marker inks as masking agents successful laser marking POM is demonstrated irrespective of its presentation (white or black coloured) using a new method akin to Laser Polymer Tattooing (LPT), and without prior modification of polymer composition (by addition of laser marking additives). Results indicate laser marking of acceptable quality can be obtained with black POM at marking speeds up to 2000 mm/s. For white POM, markings of acceptable quality were obtained at markings speeds up to 100 mm/s, with laser power ≥ 80% (of 30 W maximum), and with frequencies in the range of 20 kHz with the help of a masking agent. The effects of the laser marking parameters on marking quality and the changes induced in the material are presented and discussed. The wide range of marking parameters employed enabled the determination of feasible marking parameters for the development of a lean manufacturing-based automatic and self-evaluating and improving laser marking system with minimal human intervention.

Water Vapor Permeation in Alumina Films on Polymer Substrates

Herein, the water vapor transmission rate (WVTR) of aluminum oxide (Al2O3) films on polyethylene terephthalate (PET) substrates is investigated and is focused on the impact of the film defects on the transmission rate. The aluminum oxide films are prepared on PET substrates by magnetron sputtering, and the effects of the film thickness, sputtering power, temperature, and bias voltage on the WVTR are studied. The surface morphologies of the films are examined using atomic force microscopy (AFM), and a method for obtaining the defect ratio of the film from AFM images is proposed. Subsequently, the influences of the defect ratio on the WVTR are quantitatively evaluated based on a 3D diffusion model. The simulated WVTR values are well in agreement with the experimental ones.

Low-Temperature Atmospheric Pressure Plasma Jets and their Applications in the Surface Activation of some Polymeric Substrates for Advanced Electronic Packaging

The present study applied low-temperature atmospheric plasma (LTAPP) jets to modify polymer substrates used in chip packaging. These substrates include bismaleimide triazine (BT), polyimide (PI) and PTFE materials. All these materials play important roles in modern semiconductor packaging. During the study, focuses were aimed the effects of reactive species (mainly OH and atomic oxygen) generated by atmospheric plasma jets on surface energy, water contact angle (WCA) and surface composition of these three substrates. In order to better understand and apply LTAPP jets, another focus will be on the understanding of the relationship among (1) the generation and distribution of various reactive species, (2) parameters for generating LTAPP jet, and (3) plasma characteristics. The plasma activation mechanism of these substrates was also discussed. In addition to plasma generation using AC high-voltage supplies, plasma characterization using optical emission spectroscopy (i.e., analysis of electron density, electron temperature, plasma temperature, and reactive species), XPS and water WCA analysis were used to understand surface activation mechanisms. In sum, Ar and Ar-O2 plasma jets can be used to modify the surfaces of these three substrates, although the latter relies on the generation of O radicals, while the former relies on OH radicals more. According to the results obtained by XPS analysis, the formation of C-O and C=O bond after plasma treatment is the main reason for surface activation in this study.

The Influence of Titanium Dioxide (TiO2) Particle Size and Crystalline Form on the Microstructure and UV Protection Factor of Polyester Substrates.

The inclusion of particles in a polymeric substrate to achieve certain properties is a well-known practice. In the case of textile substrates, this practice may deeply affect the structure of the produced yarns, as even a filament with no textile applications can be obtained. In this manuscript, titanium dioxide (TiO2) particles were incorporated into polyester (PET) chips and the influence of these fillers on the properties of yarn and fabric, and the ultraviolet protection factor (UPF) was assessed. For this purpose, rutile and anatase crystalline forms of TiO2, as well as the size of the particles, were evaluated. Moreover, parameters such as mechanical properties, orientation of the macromolecules and thermal behavior were analyzed to ensure that the textile grade is maintained throughout the production process. The results showed that the inclusion of micro- and nanoparticles of TiO2 decreases the molecular weight and tenacity of PET. Also, although orientation and crystallinity varied during the textile process, the resulting heatset fabrics did not present important differences in those parameters. Finally, the attainment of textile-grade PET-TiO2 fabrics with UPF indexes of 50+ with both rutile and anatase and micro- and nano-sized TiO2 forms was demonstrated.

Polymer Metallization by Cold Spray Deposition of Polyamide-Copper Composite Coatings

Cold spray metallization of polymers is a promising surface engineering technique that enables the deposition of metal coatings onto polymer substrates at low process temperatures, resulting in improved surface properties, thus enhanced functionality of the polymeric material. However, deposition of well-adhering metallic coatings without causing surface damage to the polymer substrate is still a challenge. In this work, copper-polyamide composite coatings with different copper concentrations between 30 and 75 vol.% in the starting powders were deposited on polyamide substrates using a low-pressure cold spray system with two nozzle geometries of short and long diverging sections. The spray parameters were first developed for the deposition of polyamide powder (at gas temperature of 260 °C and gas pressures ranging from 0.41 to 1.37 MPa), and then used to spray the composite powder mixtures where the polyamide particles were acting as a binder for copper particles. Inflight and impact particle characteristics (velocity and temperature) of the polyamide powder were simulated to better understand the deposition properties. Considering that the selected conditions were suboptimal for the deposition of copper particles, no surface damage was caused as no penetration of the copper particles into the polymer substrate occurred. The results show that increasing the copper content in the powder mixtures significantly improved the resulting coating uniformity and the retained copper content. In addition, the coating deposited by spraying the powder mixture with a higher copper content of 75 vol.% and using the longer nozzle yielded the highest cohesion strength. To further improve coatings cohesion, two post-spray processing methods of furnace heating and hot pressing were used, and the effect of each process on coatings properties was investigated.Please confirm if the author names are presented accurately and in the correct sequence (given name, middle name/initial, family name). Given name: [Kintak Raymond] Last name [Yu]. Also, kindly confirm the details in the metadata are correct.The author names are now correct: Kintak Raymond given name and Yu last nameAll other details are corrects

Bipolar Current Collectors of Cu/polymer/Al Composite for Anode‐Free Batteries

AbstractThe all‐in‐one design of cathode and anode is a promising strategy to improve energy density and assembly efficiency for lithium batteries. However, it is an important prerequisite to combine negative and positive current collectors in a single sheet. Here, an asymmetric structure of bipolar composite current collector (BCCC), thin copper (Cu) and aluminum (Al) metal layers respectively deposited on each side of a thin polyethylene terephthalate (PET) polymer substrate is developed. Unlike conventional metal foils, the electronically insulative polymer blocks electron transfer between the cathode and anode coated on each side of BCCC. Buckling‐based mechanics measurement and molecular simulation are conducted to quantitatively evaluate the interfacial strength of metal/polymer, which is enhanced by introducing an intermediate chromium (Cr) layer. For applications in anode‐free wound batteries, the integrated sheet of separator/cathode/BCCC can simplify the alignment of the electrodes during the winding process. Without special surface and electrolyte optimizations, a higher Coulombic efficiency (99.1%) and larger capacity retention (50.0%) are achieved after 100 cycles in the LiNi0.8Co0.1Mn0.1O2 anode‐free battery than the battery using Cu foils.

Remote detection of the conductivity of current-carrying metallized traces

The weak magnetic fields generated by a current-carrying metallized traces are detected in view of their applications in bionic systems and neural-electrode interface technologies. The traces are formed by femtosecond laser processing of the surface of polydimethylsiloxane polymer substrate and further functionalization by electroless metallization. The measurements are performed by means of magneto-optical spectroscopy involving two optical beams, serving as pump and probe, where the magnetic field sensor is 87Rb atoms confined in a paraffin-coated optical cell. The experimental results show the feasibility of remote detection of the conductivity of metallized nickel traces.

Silver Nanoparticle-Assisted Electrochemically Exfoliated Graphene Inks Coated on PVA-Based Self-Healing Polymer Composites for Soft Electronics.

Smart sensors with self-healing capabilities have recently aroused increasing interest in applications in soft electronics. However, challenges remain in balancing the sensors' self-healing and compatibility between their sensing and substrate layers. This study evaluated several self-healing polymer substrates and graphene ink-based strain-sensing coatings. The optimum electrochemically exfoliated graphene (e-graphene)/silver nanoparticle-coated tannic acid (TA)/superabsorbent polymer/graphene oxide (GO) blended poly(vinyl alcohol) polymer composites exhibited improvements of 47.1 and 39.2%, respectively, for the healing efficiency in a substrate crack area and in the graphene-based sensing layer due to conductive layer adhesion. While TA was found to improve healing efficiency on the coating surface by forming hydrogen bonds between the sensing and polymer layers, GO healed the polymer surface due to its ability to form bonds in the polymer matrix. The superabsorbent polymer was found to absorb excess water in e-graphene dispersion due to its host-guest interaction, while also reducing the coating thickness.

Low-Temperature, Universal Synthetic Route for Mesoporous Metal Oxides by Exploiting Synergistic Effect of Thermal Activation and Plasma.

Mesoporous metal oxides exhibit excellent physicochemical properties and are widely used in various fields, including energy storage/conversion, catalysis, and sensors. Although several soft-template approaches are reported, high-temperature calcination for both metal oxide formation and template removal is necessary, which limits direct synthesis on a plastic substrate for flexible devices. Here, a universal synthetic approach that combines thermal activation and oxygen plasma to synthesize diverse mesoporous metal oxides (V2O5, V6O13, TiO2, Nb2O5, WO3, and MoO3) at low temperatures (150-200°C), which can be applicable to a flexible polymeric substrate is introduced. As a demonstration, a flexible micro-supercapacitor is fabricated by directly synthesizing mesoporous V2O5 on an indium-tin oxide-coated colorless polyimide film. The energy storage performance is well maintained under severe bending conditions.

Pulse irradiation synthesis of metal chalcogenides on flexible substrates for enhanced photothermoelectric performance

High synthesis temperatures and specific growth substrates are typically required to obtain crystalline or oriented inorganic functional thin films, posing a significant challenge for their utilization in large-scale, low-cost (opto-)electronic applications on conventional flexible substrates. Here, we explore a pulse irradiation synthesis (PIS) to prepare thermoelectric metal chalcogenide (e.g., Bi2Se3, SnSe2, and Bi2Te3) films on multiple polymeric substrates. The self-propagating combustion process enables PIS to achieve a synthesis temperature as low as 150 °C, with an ultrafast reaction completed within one second. Beyond the photothermoelectric (PTE) property, the thermal coupling between polymeric substrates and bismuth selenide films is also examined to enhance the PTE performance, resulting in a responsivity of 71.9 V/W and a response time of less than 50 ms at 1550 nm, surpassing most of its counterparts. This PIS platform offers a promising route for realizing flexible PTE or thermoelectric devices in an energy-, time-, and cost-efficient manner.

Adhesion of electron-beam evaporated SiO2/TiO2 anti-reflective coating on ion-treated polycarbonate substrate under xenon arc accelerated weathering test

Anti-reflective (AR) coatings on polymer substrates enhance light transmittance and minimize reflectance loss. However, durability of multi-layered AR coatings on polymer substrates under various weathering conditions (temperature, radiation, and humidity) can be challenging and affecting adhesion of the coating to the substrate. Therefore, in the present work, Xenon arc accelerated weathering test followed ISO 16474 guidelines was used to investigate durability of electron-beam evaporated SiO2/TiO2 stacking layer as the AR coating on an ion-treated polycarbonate (PC) substrate by varying anode voltage of the ion treatment, oxygen flow rate during the treatment, and thickness of a binding layer (Chromium-based alloy) sandwiched between AR coating and PC substrate. Crosshatch tape test based on ASTM D3359 was used to evaluate the adhesion performance. Physical changes of ion-treated PC surface were characterized by atomic force microscopy and scanning electron microscopy, whereas Fourier transform infrared spectroscopy was adopted to identify chemical functional groups on the treated PC surface. Residual stress and optical reflection of AR coating on the PC were measured by laser interferometry and UV–Vis spectrophotometry, respectively. As anode voltage increased with no oxygen flow, average surface roughness of PC increased but the roughness decreased as oxygen flow rate increased when the highest anode voltage (100 V) was applied. A reversed trend of the roughness achieved with the lowest anode voltage (80 V). Amount of C–O functional group on treated PC increased when the average surface roughness decreased. The adhesion improved by incorporating a binding layer, depending on anode voltage and oxygen flow rate, that can alter residual compressive stress of the material system, reduce moisture and UV attack without sacrificing optical performance of the AR coating. Generally, a better AR coating adhesion can be achieved with smoother PC surface having higher amount of C–O bonding, and higher overall residual compressive stress.

Lens epithelial cell response to polymer stiffness and polymer chemistry.

Posterior capsule opacification (PCO) is the most common complication of cataract surgery, and intraocular lens (IOL) implantation is the standard of care for cataract patients. Induction of post-operative epithelial-mesenchymal transition (EMT) in residual lens epithelial cells (LEC) is the main mechanism by which PCO forms. Previous studies have shown that IOLs made with different materials have varying incidence of PCO. The aim of this paper was to study the interactions between human (h)LEC and polymer substrates. Polymers and copolymers of 2-hydroxyethyl methacrylate (HEMA) and 3-methacryloxypropyl tris (trimethylsiloxy) silane (TRIS) were synthesized and evaluated due to the clinical use of these materials as ocular biomaterials and implants. The chemical properties of the polymer surfaces were evaluated by contact angle, and polymer stiffness and roughness were measured using atomic force microscopy. In vitro studies showed the effect of polymer mechanical properties on the behavior of hLECs. Stiffer polymers increased α-smooth muscle actin expression and induced cell elongation. Hydrophobic and rough polymer surfaces increased cell attachment. These results demonstrate that attachment of hLECs on different surfaces is affected by surface properties in vitro, and evaluating these properties may be useful for investigating prevention of PCO.

Fabrication of Self-Wrinkling Polymer Films with Tunable Patterns through an Interfacial-Fuming-Induced Surface Instability Process.

Inspired by the superglue fuming method for fingerprint collection, this study developed a novel interfacial-fuming-induced surface instability process to generate wrinkled patterns on polymeric substrates. High-electronegativity groups are introduced on the substrate surface to initiate the polymerization of monomer vapors, such as ethyl cyanoacrylate, which results in the formation of a stiff poly(ethyl cyanoacrylate) capping layer. Moreover, interfacial polymerization resulted in the covalent bonding of the substrate, which led to the volumetric shrinkage of the composite and the accumulation of compressive strain. This process ultimately resulted in the development and stabilization of wrinkled surface morphologies. The authors systematically examined parameters such as the modulus of the epoxy substrate, prestrain, the flow rate of fuming, and operating temperature. The aforementioned technique can be easily applied to architectures with complex outer morphologies and inner surfaces, thereby enabling the construction of surface patterns under ambient conditions without vacuum limitations or precise process control. This study is the first to combine fuming-induced interfacial polymerization with surface instability to create robust wrinkles. The proposed method enables the fabrication of intricate microwrinkled patterns and has considerable potential for use in various practical applications, including microfluidics, optical components, bioinspired adhesive devices, and interfacial engineering.