Chemical vapor deposition (CVD) polymerization utilizes the delivery of vapor-phase monomers to form chemically well-defined polymeric films directly on the surface of a substrate. CVD polymers are desirable as conformal surface modification layers exhibiting strong retention of organic functional groups, and, in some cases, are responsive to external stimuli. Traditional wet-chemical chain- and step-growth mechanisms guide the development of new heterogeneous CVD polymerization techniques. Commonality with inorganic CVD methods facilitates the fabrication of hybrid devices. CVD polymers bridge microfabrication technology with chemical, biological, and nanoparticle systems and assembly. Robust interfaces can be achieved through covalent grafting enabling high-resolution (60 nm) patterning, even on flexible substrates. Utilizing only low-energy input to drive selective chemistry, modest vacuum, and room-temperature substrates, CVD polymerization is compatible with thermally sensitive substrates, such as paper, textiles, and plastics. CVD methods are particularly valuable for insoluble and infusible films, including fluoropolymers, electrically conductive polymers, and controllably crosslinked networks and for the potential to reduce environmental, health, and safety impacts associated with solvents. Quantitative models aid the development of large-area and roll-to-roll CVD polymer reactors. Relevant background, fundamental principles, and selected applications are reviewed.

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Membranes with high flux, ∼1 nm pore size, and unprecedented protein fouling resistance were prepared by forming selective layers of self-assembling zwitterionic amphiphilic random copolymers on porous supports by a simple coating method. Random copolymers were prepared from the hydrophobic monomer 2,2,2-trifluoroethyl methacrylate (TFEMA) and four zwitterionic monomers (sulfobetaine methacrylate, sulfobetaine 2-vinylpyridine, sulfobutylbetaine 2-vinylpyridine, and 2-methacryloyloxyethyl phosphorylcholine) by free radical polymerization. All copolymers microphase separated to form bicontinuous ∼1.2 nm nanodomains with the zwitterionic domains acting as nanochannels for the permeation of water and solutes. The resultant membranes all had a ∼1 nm size cutoff independent of zwitterion chemistry. There were, however, significant differences in the hydrophilicity, water uptake, water flux, and fouling resistance among membranes prepared with different zwitterionic monomers. Membranes prepared from the copolymer with 2-methacryloyloxyethyl phosphorylcholine were the most hydrophilic and had the highest water permeance, higher than that of commercial membranes of similar pore size. Furthermore, these membranes showed unprecedented fouling resistance, exhibiting no measurable flux decline throughout a 24 h protein fouling experiment. The structure-property relationships gleaned from this survey of different zwitterion structures serves as a guideline to develop new zwitterionic materials for various applications such as membranes, drug delivery, and sensors.

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High-aspect ratio hydrophobic, cylindrical nanopores having diameters as low as 5 nm are rapidly fabricated using conformal vapor deposition of fluorinated polymeric layers into porous track-etched polycarbonate membranes. The resultant selectivity of these membranes for pairs of small molecules of similar size, but of different hydrophobicity, arises from solute-pore wall interactions emphasized by confinement. Increasing selectivity was observed as pore diameter decreased and as the surface of the pore became more hydrophobic. Cylindrical pores provided higher selectivity than bottleneck-shaped pores having the same minimum diameter. A maximum selectivity of 234 was achieved between mesitylene and phloroglucinol by the best performing membrane. Membranes with small fluorinated pores exhibited an effective cutoff based on the polar surface area of the molecules, with limited correlation with solute size. This technology could lead to a new generation of membrane separations based on specific interactions.