synthesis of polymer/inorganic nanocomposite films using highly porous inorganic scaffolds
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Synthesis of polymer/inorganic nanocomposite films using highly porousinorganic scaffolds†
Huanjun Zhang,a Matthias Popp,b Andreas Hartwigb and Lutz M€adler*a
Received 19th December 2011, Accepted 27th January 2012
DOI: 10.1039/c2nr12029a
Polymeric/inorganic nanocomposite films have been fabricated through a combination of flame-spray-
pyrolysis (FSP) made inorganic scaffold and surface initiated polymerization of cyanoacrylate. The
highly porous structure of pristine SnO2 films allows the uptake of cyanoacrylate and the
polymerization is surface initiated by the water adsorbed onto the SnO2 surface. Scanning electron
microscopy study reveals a nonlinear increase in the composite particle size and the film thickness with
polymerization time. The structural change is rather homogeneous throughout the whole layer. The
composite is formed mainly by an increase of the particle size and not by just filling the existing pores.
High-resolution transmission electron microscopy imaging shows SnO2 nanoparticles embedded in the
polymeric matrix, constituting the nanocomposite material. Thermogravimetric analysis indicates that
the porosity of the nanocomposite films decreases from 98% to 75%, resulting in a significant
enhancement of the hardness of the films. DC conductivity measurements conducted in situ on the
nanocomposite layer suggest a gradual increase in the layer resistance, pointing to a loss of connectivity
between the SnO2 primary particles as the polymerization proceeds.
Introduction
Synthesis of polymeric/inorganic hybrid nanocomposite mate-
rials with structural control of both atomic and macroscopic
dimensions represents a key requirement for obtaining the
increased functionality from their interface. Through proper
combination of the inorganic and polymeric constituents, supe-
rior mechanical strength, thermal stability and electrochemical
reactivity can be achieved over the individual component mate-
rials, thanks to their high degree of hybridization.1
Conventional synthesis of hybrid composite materials gener-
ally relies on physical blending or chemical surface modification
of the constituents.2–4 Very often a chemical surface modification
is carried out first in order to improve particle-matrix compati-
bility, followed by physical mixing. In this regard we have carried
out extensive work on silica/epoxy nanocomposites.5,6 For
nanocomposites with a high inorganic loading, the chemical
surface modification is particularly attractive because it enables
introduction of a second component directly into a pre-formed
hosting matrix, leading to a defined distribution of the
aFoundation Institute of Materials Science (IWT), Department ofProduction Engineering, University of Bremen, Badgasteiner Strasse 3,28359 Bremen, Germany. E-mail: [email protected]; Fax:+49 421 2185378; Tel: +49 421 21851200bFraunhofer–Institute for Manufacturing Technology and AdvancedMaterials (IFAM), Wiener Strasse 12, 28359 Bremen, Germany.E-mail: [email protected]; Fax: +49 421 2246430;Tel: +49 421 2246470
† Electronic supplementary information (ESI) available: SEM imagesand powder XRD patterns. See DOI: 10.1039/c2nr12029a
2326 | Nanoscale, 2012, 4, 2326–2332
constituent species. This method has been successfully applied in
the fabrication of nanocomposites based on cyanoacrylate and
silica aerogels that act as the skeleton matrix.7 However, its
extension is rather difficult because of the very limited choice of
the inorganic components in an aerogel form, besides the strin-
gent (therefore costly) conditions required for making the aerogel
itself.8
Here, we present a low-cost and highly efficient method for the
fabrication of hybrid nanocomposite films based on surface-
initiated polymerization (SIP),9,10 which has proven to be
a powerful tool for chemical functionalization of the surface of
a wide range of materials including carbon nanotubes,11 silica,12
metals13 and polymers.14 The motivation of adopting the SIP
method here is to harness the surface polymerization process for
making film-structured nanocomposite materials. A highly
porous inorganic layer was first fabricated using flame spray
pyrolysis15 through thermophoretic deposition of metal oxide
nanoparticles onto a glass substrate. Subsequently, this porous
layer serves as a scaffold, around which polymer components
have been loaded through the polymerization of monomers
introduced via the vapor phase to generate the polymer/inorganic
nanocomposite films. Semiconducting SnO2 is chosen as the
inorganic material to examine the structure evolution by
measuring in situ the electrical conductivity of the composite
films. The vapor-phase introduction of a monomer is necessary
for achieving homogeneous dispersion of the SnO2 nanoparticles
in the polymer matrix, because, if liquid-phase polymerization is
employed, the inorganic scaffold is not mechanically strong
enough to withstand the forces (e.g. the capillary force), which
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can lead to the collapse of the scaffold and a composite product
with poor particle dispersion similar to composites obtained by
simple blending. A comparison between conventional ‘‘blending’’
and our ‘‘reverse’’ filling method is illustrated in Scheme 1.
Considering the wide spectrum of inorganic materials including
metal oxide semiconductors that can be generated by FSP, the
reverse filling method here should be generalizable to the fabri-
cation of various nanocomposites based on porous, inorganic
scaffolds.
Experimental
Fabrication of porous SnO2 films through FSP
SnO2 films composed of crystalline nanoparticle agglomerates
were deposited onto glass substrates in a flame spray reactor.
Detailed description of the setup can be found elsewhere.15 The
liquid precursor solution containing 0.5 mol L�1 Sn(II) ethyl-
hexanoate (90 wt% in 2-ethylhexanoic acid, STREM Chemicals)
in xylene (98.5%, BDH) was fed by a syringe pump (KD Scien-
tific) at a fixed flow rate of 5.0 mL min�1. The liquid was
dispersed into fine droplets by oxygen gas (5.0 L min�1, 1.5 bar;
99.95 vol%) at the spray nozzle exit. The spray was ignited by
a CH4/O2 (1.5 and 3.2 L min�1, respectively; CH4–99.5 vol%,
Westfalen) flame to form a self-sustained flame. The generated
SnO2 particles deposit thermophoretically onto a water-cooled
glass substrate (20 mm � 20 mm, 1.0 mm thick; Menzel-Gl€aser)
placed 20.0 cm above the nozzle. Before FSP deposition, the glass
substrates were cleaned by acetone (99.5%, Sigma-Aldrich) in an
ultrasonic bath. The flow rates of all gases were controlled by
calibrated mass flow controllers (Bronkhorst High-Tech).
Polymerization of cyanoacrylate in the SnO2 layer
Polymerization of ethyl cyanoacrylate (90 wt%, Henkel Loctite)
was carried out in an oven at 70 �C. The glass supported SnO2
layer was placed closely on top of a vial containing ethyl
cyanoacrylate, allowing for the penetration of the evaporated
cyanoacrylate molecules into the porous space in the SnO2 layer.
Water is present on the surface of SnO2 particles due to handling
under ambient conditions and the adsorbed water should initiate
the polymerization of cyanoacrylate. The duration of polymeri-
zation was controlled in order to study the kinetics of the growth
of the nanocomposite films.
Scheme 1 Strategies for fabricating nanocomposite films containing inorga
composites with usually low particle content, where surface treatment on the n
matrix and (b) ‘‘reverse’’ filling method presented here which uses surface-initia
leading to composites largely maintaining the particle connectivity.
This journal is ª The Royal Society of Chemistry 2012
Characterization
Powder XRD analysis. Both the as-deposited SnO2 films and the
filter-collected SnO2 powders were subjected to XRD analysis in
order to study the crystallinity of SnO2. Powder XRD patterns
were measured by a PANalytical X’pert diffractometer with a Cu
Ka radiation source. Rietveld refinement was performed on the
XRD patterns to estimate the average crystallite size of SnO2.
N2 physisorption analysis. The Brunauer–Emmett–Teller
(BET) specific surface area of the filter-collected SnO2 particles
was measured by N2 physisorption at liquid nitrogen tempera-
ture. High-resolution transmission electron microscopy (TEM)
of the SnO2 nanoparticles was conducted on an FEI Titan
microscope under a 300 kV acceleration voltage. Scanning elec-
tron microscopy (SEM, Leo 1530 Gemini, Zeiss) was employed
to investigate the morphology of the SnO2 films and to estimate
the thickness of both the SnO2 films and the polycyanoacrylate/
SnO2 composite films. The morphology of the polymer/SnO2
hybrid particles was investigated using transmission electron
microscopy (Philips CM20).
Thermogravimetric analysis (TGA). The nanocomposite films
were analyzed using a TGA Q5000 analyzer (TA Instruments)
between room temperature and 900 �C at the heating rate of 5 �Cmin�1 with air purging. The measured weight loss due to polymer
degradation was used to calculate the volumetric percentage of
the polymer phase. Combined with the film thickness data, the
porosity of the nanocomposite films was derived. The Martens
micro-hardness tests were performed on a Fischerscope HM2000
micro-indenter (Helmut Fischer).
DC electrical conductivity measurements. The electrical
conductivity of the polymer/SnO2 films was measured to provide
in-depth insights into the growth of the composite films during
polymerization. In particular, DC conductivity measurements
reveal the connectivity between SnO2 nanoparticles and predict
the overall percolating structure in the whole nanocomposite
films. To obtain reliable conductivity data, planar alumina
substrates carrying interdigitated Pt electrodes16 were used for
the deposition of SnO2 nanoparticles and subsequent polymeri-
zation of cyanoacrylate. The DC conductivity of the nano-
composite films was measured in situ with a FLUKE112 digital
multimeter during the polymerization process, where the SnO2-
coated electrode was placed above the monomer reservoir. At
nic nanoparticles and polymers: (a) conventional blending method for
anoparticles is often necessary to achieve good dispersion in the polymer
ted polymerization into porous, FSP-deposited nanoparticulate scaffolds,
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room temperature the resistance of the deposited pure SnO2 layer
is higher than 200MU, which is beyond the detection range of the
applied ohmmeter. To reduce its resistance, the SnO2 layer was
doped with Sb during the FSP process, which can render a drop
in resistance by several orders of magnitude, depending on the Sb
concentration.17 In the present work, the Sb concentration is 1%
in the weight ratio between Sb and SnO2.
Fig. 2 Cross-sectional SEM images of the polycyanoacrylate/SnO2
nanocomposite film showing a homogeneous thickness (a) and a porous
structure (b) after 30 minutes of polymerization.
Results and discussion
Pristine SnO2 scaffolds
Themorphology of the pristine SnO2 scaffolds deposited viaflame
spraypyrolysis on a glass substrate is shown inFig. 1.Thefilms are
highly porous with an even distribution of the pores over milli-
metre dimension (Fig. 1a). The film porosity was estimated to be
ca. 98% both experimentally and theoretically.15,18 A closer
inspection (Fig. 1b) of the SnO2 film reveals that it consists of
aggregates of SnO2 nanoparticles, forming a three-dimensional,
highly porous network. The SEM images here show that both
meso- andmacropores are present in the SnO2 film. PowderX-ray
diffraction combined with Rietveld refinement (Fig. 1c) was
conducted on the filter-collected particles, showing that the crys-
tallites have an average size of 8.7 nm.This value is consistentwith
the results from BET specific surface area analysis, which give
a specific surface area of 97.8 m2 g�1 and indicate an average grain
size of 8.8 nm as derived from the equation dBET ¼ 6/(r � SSA)
(where r is the density of bulk SnO2, 6.95 g cm�3; SSA stands for
the specific surface area of the powder, m2 g�1). The dBET error is
within�2% based on multiple measurements. These particles are
therefore individually single-crystalline, which is further sup-
ported by TEM characterization (Fig. 1, inset).
Polymer/SnO2 nanocomposite films
The morphology and structure of the SnO2 film after being
subjected to polymerization of cyanoacrylate are shown in Fig. 2.
Fig. 1 Characterization of SnO2 layers and powders obtained from FSP: (a)
layer showing inter-connected strands of nanoparticles; and (c) Rietveld refi
8.7 nm—in black is the raw data, in red is the calculated pattern and in blue is t
the diffraction peaks of SnO2). The inset shows a high-resolution TEM of th
between 5 and 10 nm, in consistence with the XRD results.
2328 | Nanoscale, 2012, 4, 2326–2332
The cross-sectional image (Fig. 2a) indicates a highly even
thickness of the composite film, i.e. 54.2 mm, which is 35% thicker
than the starting pristine SnO2 films (40 mm) after 30 min of
vapor phase polymerization. Higher-resolution imaging of the
particles at the cross-section region (Fig. 2b) reveals an average
particle size of 23.0 nm, based on the measurement of at least 200
particles. Considering the initial average particle size of SnO2, i.e.
8.8 nm, nearly a three-fold increase in particle size resulted from
polymerization for 30 minutes. The composite film remains
porous and contains both meso- and macropores as shown in
the SEM image (Fig. 2b). The morphological resemblance of the
composite film to the pristine SnO2 film suggests that the
SEM top-view of the SnO2 layer; (b) higher-resolution SEM of the SnO2
nement of the powder XRD profile giving an average crystallite size of
he difference between them (the vertical bars below denote the positions of
e SnO2 nanoparticles with high crystallinity and an average particle size
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polymerization of cyanoacrylate within the porous film should be
initiated on the surface of SnO2, i.e. by the surface adsorbed
water on SnO2 nanoparticles, similar to the room-temperature
chemical vapor deposition of cyanoacrylate in silica aerogels.7
The water content in the collected SnO2 powders was estimated
as 3.7% (weight percentage) from thermogravimetric analysis.
This value corresponds to a 1.4 monolayer of water molecules on
the surface of SnO2 particles, which give rise to –OH groups or
OH� ions as the initiator.
Growth of the nanocomposite films
In order to reveal how the nanocomposite film grows during the
polymerization process, we investigated the morphology and
structure evolution of the composite films that have been sub-
jected to polymerization for various durations. The cross-
sectional SEM images were recorded for polymerization times of
10, 30, 60, 120 and 180 minutes corresponding to Fig. 3a–e,
respectively. At the same polymerization temperature (70 �C),apparently the average size of the polymer/SnO2 composite
particles is increasing as the reaction time increases. The porous
structures within the films seem also preserved within 180
minutes. Fig. 3f shows the structure of a pure polycyanoacrylate
layer grown in 120 minutes on glass at the same temperature. The
layer possesses a distinctly different morphology and much lower
porosity as compared with the nanocomposite counterparts
(Fig. 3a–e). The scale bar of 500 nm applies to Fig. 3a–f.
Although the images in Fig. 3a–e were recorded for the top-layer
Fig. 3 Cross-sectional SEM images of the polycyanoacrylate/SnO2
nanocomposite films generated after different polymerization times: (a)
10 min, (b) 30 min, (c) 60 min, (d) 120 min and (e) 180 min. A pure
polycyanoacrylate layer grown on the glass substrate is shown in (f). The
scale bar representing 500 nm applies to all images.
This journal is ª The Royal Society of Chemistry 2012
region of the films, it is important to note that the morphological
feature for each sample is homogeneous throughout its cross-
sectional region (ESI, Fig. S1†).
The evolution of the average composite particle size is shown
in Fig. 4a. After 10 minutes of polymerization the composite
particles (see Fig. 3a) were found to be slightly larger than the
starting SnO2 particles (Fig. 1b), indicative of the formation of
a thin polymer layer coating individual SnO2 particles. As the
polymerization time increases, the particle size grows further.
After 120 minutes the measured average particle size reached
�150 nm, nearly 18 times that of the pristine SnO2 particles.
However, it seems rather unlikely that each SnO2 particle has
been coated by a thick layer (�70 nm) of polycyanoacrylate.
Such a huge increase in the particle size indicates that several
SnO2 particles are now engulfed in a single ‘‘composite’’ particle,
accounting for the steep increase of the particle size after 30
minutes of polymerization (Fig. 4a), which suggests a coating
mechanism different from that occurred during the initial poly-
merization stage (i.e., within 10 minutes).
Fig. 3d and e show that the composite particle size ceases to
grow after 120 minutes of polymerization, suggesting a termina-
tion of the polymeric chain growth. A similar trend was also
observed in the thickness change of the composite films. As
shown in Fig. 4b, the film thickness increases in a nonlinear
fashion, and it almost doubles the original SnO2 layer thickness
after polymerization for 180 minutes (�75 mm). Actually after
120 minutes, the thickness of the composite film appears to reach
a plateau. A control experiment was conducted by refreshing the
monomer reservoir during the polymerization process, which
Fig. 4 Variation of the average size of the nanocomposite particles (a)
and the film thickness (b) during polymerization. A sudden rise in the
slope of the particle size curve suggests a change in the mode of the
composite particle growth.
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resulted in a thicker composite film than that obtained without
refreshing the monomer reservoir (Fig. S2†). This indicates that
the slowing down of the nanocomposite film growth should be
caused by the decrease in the monomer supply from the reservoir,
because the moisture inside the reaction chamber could also
initiate polymerization within the reservoir body, thus reducing
the evaporation rate of the monomer into the vapor phase.
While SEM provides valuable information on the thickness
and composite particle size of the nanocomposite films, it is also
important to closely study the interface between the polymer and
the semiconductor particles. Considering Fig. 2b, apparently the
SnO2 nanoparticles are embedded in the polymer surroundings.
A critical question is, how are the semiconductor particles
spatially arranged inside individual nanocomposite particles? We
address this question by examining the samples using high-
resolution transmission electron microscopy (HRTEM). As
shown in Fig. 5, the nanocomposite particle consists of an
ellipsoidal-shaped polymer matrix which embeds several SnO2
nanocrystals (Fig. 5a, the low contrast in the amorphous region
is expected between the polycyanoacrylate and the amorphous
carbon from the TEM grid). The crystal lattice fringes of SnO2
can be clearly identified in Fig. 5b. These observations suggest
that the polymerization propagates by filling the small pores by
capillary condensation with a concomitant polymerization of the
cyanoacrylate. As a result, several neighboring particles are
‘‘bound’’ to form virtually one bigger particle, which accounts for
the sudden increase in the average particle size as shown in
Fig. 4a.
Fig. 5 HRTEM images of polycyanoacrylate/SnO2 nanocomposite
particles: (a) one composite particle composed of several SnO2 nano-
crystals (darker particles) embedded in polycyanoacrylate and (b) the
lattice fringes of the SnO2 crystals are observable with higher magnifi-
cation at the framed region in (a).
2330 | Nanoscale, 2012, 4, 2326–2332
Thermogravimetric analysis, porosity and Martens hardness
The weight percentage of PCA in the nanocomposite films was
measured by TGA, in order to estimate the porosity of the
products. Since the density of PCA in this study is not exactly
known, we assume a density of 1 g cm�3 in order to calculate the
volume ratio between PCA and SnO2. The time-dependent
variations of both the PCA weight percentage and the film
porosity are shown in Fig. 6. The PCA weight% increases with
the polymerization time and it reaches 73% after 180 min, which
is nearly three times that of the inorganic phase. Considering the
larger density difference between PCA (assuming 1 g cm�3) and
SnO2 (6.95 g cm�3), the volume ratio between the two phases is
significant.
The porosity is calculated from the solid volume percentage
(i.e., summation of both the polymer and inorganic phases),
which is estimated by combining TGA and thickness data. The
porosity drops from 98% for the pure SnO2 layer (data not
shown here) to 75% after 180 minutes of polymerization.
Therefore, the nanocomposite films remain rather porous after
polymerization. As the porosity decreases, an increase in the
Martens hardness is observed: the hardness after 180 min is 22
times that after 10 minutes of polymerization, suggesting that the
mechanical strength of the scaffold has been significantly
improved after incorporating the polymer phase. However, the
hardness of the nanocomposite films is still much lower than that
of pure PCA, 141.4 N mm�2. This can also be explained by the
porosity difference, because the pure PCA layer is quite compact
and shows very low porosity (Fig. 3f). The results shown here are
consistent with the reported dependence of the mechanical
properties on porosity for a wide range of materials, being
micro-, meso- or macro-porous.19–21
DC conductivity and particle connectivity
Another important issue concerns the connectivity between the
SnO2 nanoparticles after being immersed in or surrounded by the
polymer matrix. TEM encounters great difficulties in resolving
this question because: (1) TEM images are 2D projections of 3D
structures and (2) TEM provides only local information. To
study on a macroscopic level the connectivity between the SnO2
Fig. 6 Variation of the polymer weight percentage, film porosity and
micro-hardness of the layers as the polymerization time increases.
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particles, we measured in situ the conductivity of the nano-
composite films. Because polycyanoacrylate is non-conductive,
the conductivity of the nanocomposite film solely depends on the
conductivity of the SnO2 particles that form the percolating
conductive pathways.22,23
We have used such an interdigital electrode-carrying substrate
as shown in Fig. 7a to measure the in situ variation of the film
conductivity. Taking the advantage of FSP that can easily dope
a semiconductor material, we doped SnO2 with antimony to
obtain a higher electrical conductivity of the deposited films.24
One percent (wt%) of Sb renders an SnO2 layer resistance low
enough for us to precisely measure the resistance of the films
during polymerization using an ohmmeter. The pure and 1 wt%
Sb-doped SnO2 samples give almost identical powder XRD
patterns (Fig. S3†). Their BET surface areas are 97.8 and 96.7 m2
g�1 for the pure and doped SnO2, respectively. These data suggest
that Sb doping should bring negligible change to the SnO2
nanoparticles and the structure of the SnO2 layers during the
FSP process. Hence, the polymerization results obtained using
the Sb-doped SnO2 scaffolds should reflect insights that are
transferrable to the pure SnO2 system.
Fig. 7b schematically illustrates the experimental setup, where
the semiconductor layer should cover only the region of the elec-
trode arrays and leave the contact pads exposed. As the polymer-
ization proceeds, an increase in the resistance is observed (Fig. 7c,
which plots the reciprocal of resistance vs. polymerization time),
largely because of the rupture of the percolating pathways.
In a very simplified model, which assumes that each perco-
lating pathway is a single strand of particles in connection, the
reciprocal of resistance values are proportional to the specific
Fig. 7 Electrical conductivity measurement on polycyanoacrylate/SnO2
nanocomposite films: (a) a substrate carrying electrode arrays for Sb-
doped SnO2 scaffold deposition, (b) schematic illustration of the
conductivity measurement setup and (c) the reciprocal resistance varia-
tion with the polymerization time.
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conductivity and hence the number of the undisturbed perco-
lating pathways: after 30 minutes, more than 50% of the perco-
lating pathways remains; even after 2 hours, there is still about
20% of the pathways undisturbed by the polymerization. From
a more realistic point of view, neighboring particles coated with
a very thin layer of PCA (hence separated by a rather short
distance) might still constitute a conductive pathway because of
the tunneling effect. Considering that it takes only disconnecting
two neighboring SnO2 particles within a percolating strand
(typically consisting of tens of particles) to shut down its
conductivity, we expect that the average connectivity of SnO2
particles should be still higher than estimated by the conductivity
measurement. This conclusion is highly encouraging for the
design and fabrication of inorganic/polymer nanocomposite
materials. But on a level more sophisticated than this simplified
model here, further work needs to be done to reveal the details of
the nanocomposite growth.
Conclusions
We demonstrate a facile and a highly efficient method of fabri-
cating polymeric/inorganic nanocomposite films by making use
of the highly porous nature of the inorganic films generated from
flame spray pyrolysis. Polycyanoacrylate was successfully loaded
into the inorganic SnO2 layer through surface-initiated anionic
polymerization. The dispersion of SnO2 nanoparticles was
largely maintained during the polymerization process, leading to
a nanocomposite material with an inorganic constituent
throughout the polymeric matrix forming a percolation struc-
ture. Such a structure cannot be obtained by incorporation of
comparably low amounts of particles into the polymer. Because
flame spray pyrolysis is capable of generating a wide range of
metal-oxide materials,25 the method presented here can have
widespread applicability in the fabrication of nanocomposites
covering a large variety of polymer/metal-oxide constituents.
From our measurement results, we propose the following
model for the formation of the composite with low inorganic-
particle loading but proper inter-particle contact. The cyanoac-
rylate vapor is adsorbed on the surface of the SnO2 particles
which bear the adsorbed water to initiate the polymerization of
the cyanoacrylate and lead to an increase of the composite
particle diameter. Consumption of the cyanoacrylate by poly-
merization maintains the monomer concentration gradient. This
is supported by capillary condensation, leading to quick filling of
the small pores and the formation of composite particles con-
taining SnO2 particles separated by a polymer layer. In general,
the anionic polymerization of the cyanoacrylate is a living kind
of polymerization, but contamination on the particle surfaces
can lead to termination. And if all water on the surface is
consumed, no further polymerization is initiated. Reduced
supply of the monomer from its reservoir can also lead to the
saturation in the composite particle size and the film thickness
while the film is still porous.
Acknowledgements
The authors would like to thank Deutsche For-
schungsgemeinschaft (DFG) for funding this project within the
Research Training Group 1375 ‘‘Nonmetallic Porous Structures
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for Physical–Chemical Functions.’’ The support from the Univer-
sity of Bremen under the Initiative ‘‘Func-Band’’ is also gratefully
acknowledged.
Notes and references
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