Plasma Meets Chemistry: Combined Methods for Tailored Interface Design in Metal-Polymer Composites by Selective Chemical Reactions on Plasma Modified Surfaces

The applicability of polymer-metal composites is mainly determined by the durability of the adhesive strength between both components. Aluminium (Al) deposited on polypropylene (PP) exemplifies different options of interface design. By deposition of plasma polymers on PP the effect of the type of the functionality was investigated. Spacer insertion was accomplished to position the functional group away from the topmost surface. A further kind of interface design involved a partial condensation of functional groups. Hydroxyl and carboxyl groups were most effective to improve adhesion in Al-PP systems. Approximately 7–10 carboxyl or 25–27 hydroxyl groups per 100 C atoms were necessary to increase the peel strength up to ∼700 N/m. In this range, the failure of the composite propagated along the interface Al-tape (no peeling of the metal). Spacer molecules between surface and functional groups provoked the effect that the number of needed functional groups for maximum adhesion was strongly reduced. Linking of the functional groups resulted in non-peelable Al-PP laminates. Two adhesion tests were applied - the peel test and the centrifuge technology. For PP foils modified with chemically bonded and additionally linked silanol groups (no peeling) an adhesive strength of (2.5 ± 0.2) N/mm2 was determined by centrifuge technology. XPS inspection of both fracture surfaces indicated a sub-surface failure in the polymer.