Foundations of plasma surface functionalization of polymers for industrial and biological applications

Polymer materials are widely employed in many fields due to the ease with which they can be formed into complex shapes, their versatile mechanical properties, light weight, and low cost. However, many applications are hindered by the chemical compatibility of polymer surfaces, which are generally hydrophobic and bond poorly to other media such as paints, glues, metals and biological media. While polymer surfaces can be treated by wet chemical processes, the aggressive reagents employed are detrimental to the environment, limiting the range of modifications that can be achieved by this route. Plasma functionalization is an attractive alternative, offering great versatility in the processed surface characteristics, and generally using environmentally benign compounds such as rare gases, oxygen and nitrogen, as well as very small quantities of organic precursors. Since the modified surfaces are only a few monolayers thick, these processes are extremely rapid and low in cost. The first industrial process to be developed was plasma oxidation, which increases the surface energy of the polymer, improving the adhesion of paint, glue and metal to the component. Plasma oxidation can be achieved using both low-pressure and atmospheric pressure (APP) discharges. Subsequently, many other processes have emerged, allowing other functional groups to be grafted, including amines, hydroxyl and carboxylic acid groups. Plasma polymerization, starting from gaseous monomers, allows a whole new family of surface chemistries to be created. These processes have many exciting applications in the biomedical field due to the control they give on biocompatibility and selective interaction with living cells. This article will present the fundamentals of plasma interactions with polymers, the plasma devices employed (both at low-pressure and at APP) with their advantages and drawbacks, and a survey of current and future applications.