A Review of Plasma Synthesis Methods for Polymer Films and Nanoparticles under Atmospheric Pressure Conditions

Abstract

In this paper, we present an overview of recent approaches in the gas/aerosol-through-plasma (GATP) and liquid plasma methods for synthesizing polymer films and nanoparticles (NPs) using an atmospheric-pressure plasma (APP) technique. We hope to aid students and researchers starting out in the polymerization field by compiling the most commonly utilized simple plasma synthesis methods, so that they can readily select a method that best suits their needs. Although APP methods are widely employed for polymer synthesis, and there are many related papers for specific applications, reviews that provide comprehensive coverage of the variations of APP methods for polymer synthesis are rarely reported. We introduce and compile over 50 recent papers on various APP polymerization methods that allow us to discuss the existing challenges and future direction of GATP and solution plasma methods under ambient air conditions for large-area and mass nanoparticle production.

Keywords: atmospheric-pressure plasma; nanoparticles; plasma polymerization; polymer films; room temperature growth; solution plasma.

Figure 1

Representative configuration of (a) gas/aerosol-through-plasma (GATP) methods (left: jet type, right: dielectric-barrier discharge (DBD) type) and (b) solution plasma methods (left: in-solution plasma, right: on-solution plasma).

Figure 2

Structures of pin–ring-electrode-type APPJs from (a) Zhang et al. [51], (b) Ricci Castro et al. [52], (c) Van Vrekhem et al. [53], and (d) Pandiyaraj et al. [54], and (e) schematic of experiment using a y-shaped APPJ with a ring powered electrode, by Doherty et al. [55].

Figure 3

Structures of pin electrode type in the APPJs of (a) Kodaira et al. [56], (b) Hossain et al. [57], and (c) Malinowski et al. [58].

Figure 4

(a) Setup [59] and (b) photo image [62] of the APPJ with three array jets and a GB system. (c) Configuration [63] and (d) photo image [64] of the pin-type APPJ with a GB system.

Figure 5

(a) The plasma jet instrument schematic (Plasmatreat AS400 with the single-nozzle-type PFW10) [65], and setup of (b) polymerization of HMDSO [67] and (c) in-line processing of carbon fiber [68].

Figure 6

The polymerization systems using planar DBD of (a) Pandivaraj et al. [69], (b) Mertens et al. [71], (c) Getnet et al. [72], and (d) Dvorˇáková et al. [73].

Figure 7

The polymerization systems using planar DBD with a movable top electrode (powered electrode) of (a) Bardon et al. [74,89], (b) Manakhov et al. [75], and (c) Obrusník et al. [76], and the image of the DBD system of (d) St’ahel et al. [77].

Figure 8

The polymerization systems using planar DBD with a movable substrate stage (bottom electrode) of (a) Demaude et al. [78], (b) Jalaber et al. [80], (c) Ma et al. [81], and (d) Loyer et al. [83].

Figure 9

Schematics of generation of the on-solution plasma systems of (a,b) Tan et al. [93,94], (c,d) Schäfer [95] et al., (e) Zhang et al. [96], and (f) Gamaleev et al. [97].

Figure 10

Representative figures on the generation of the in-solution plasma systems of (a) Hyun et al. [104], (b) Panomsuwan et al. [105], and (c) Morishita et al. [106].

Figure 11

Schematics of generation of the in-solution plasma systems of (a) Lee et al. [107], (b) Li et al. [108], and (c) Tipplook et al. [109].

Figure 12

Schematic diagrams of the in-solution plasma systems proposed by (a) Lee et al. [91] and (b) Li et al. [110].

Figure 13

Schematic diagrams of the in-solution plasma system with a gas channel proposed by (a,b) Shin et al. [111,112].

Figure 14

(a) Mechanisms of plasma polymerization [113]. (b) A scheme of a general plasma polymerization system [114]. (c) Comparison of a conventional polymer (left) and plasma polymer (right), derived from equivalent monomers [116].

Figure 15

Chemical structures identified via characterization of benzaldehyde-based polymer films using APP techniques, where (a) depicts benzaldehyde radical generation by π bond breakage from aldehyde, (b) depicts aliphatic chain production by aromatic ring breakage, (c) depicts hydrogenation of the aliphatic chain, (d) depicts the recombination process between benzaldehyde radicals and aliphatic chains, and (e) depicts benzaldehyde radical oxidation under plasma conditions [118].

Figure 16

APP polymerization mechanisms, from a chemical point of view, related to the formation of benzaldehyde-based polymer films.

Figure 17

Transmission electron microscopy (TEM) images of polypyrrole NPs with (a) single-crystalline and (b) polycrystalline properties [62]. (c) Superhydrophobicity of the coated films on the cotton fabrics [67]. (d) Hydrophilization of the surface of polypropylene [73].

Figure 18

(a,b) Antibacterial properties created by APP polymerization [72,77]. (c) Scratch tracks for coatings of DOCA, HdiA and HdiMA films [74]. (d) Estimation of the dielectric constant of insulating layers made by cyclic organosilicons [82]. (e) NO₂-sensing properties of a polythiophene film prepared using the APPJ technique [119].