Electropolymerization of pyrrole on oxidizable metal under high frequency ultrasound irradiation. Application of focused beam to a selective masking technique

A novel masking technique against polymer deposition based on High Intensity Focused Ultrasound (HIFU) irradiation was developed for the first time. With this in mind, a variety of background salts were tested. Sodium salicylate was found to be the most effective electrolytic medium for pyrrole sonoelectropolymerization on copper as it leads to a very efficient passivating oxide layer preventing copper dissolution while enabling polymer formation independently from sonication. In such a medium, high frequency ultrasound greatly refines surface structure, and a slight increase in doping level is observed. Finally, it was proved that focused ultrasound increases copper dissolution in sodium oxalate electrolyte while preventing polypyrrole deposition. A selected zone on the copper substrate was thus irradiated by the focused ultrasound beam to protect it from polymerization. In a second stage, a self-assembled monolayer was deposited on this polymer-free area to create a surface biphased substrate. This type of masking technique can be proposed as an interesting alternative to lithography as it is easier to carry out and allows chemical waste reduction.