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Surface graft polymerization of 1-vinyl-2-pyrrolidone onto a silicon surface was accomplished by atmospheric pressure (AP) hydrogen plasma surface activation followed by graft polymerization in both N-methyl-2-pyrrolidone (NMP) and in an NMP/water solvent mixture. The formation of initiation sites was controlled by the plasma exposure period, radio frequency (rf) power, and adsorbed surface water. The surface number density of active sites was critically dependent on the presence of adsorbed surface water with a maximum observed at approximately a monolayer surface water coverage. The surface topology and morphology of the grafted polymer layer depended on the solvent mixture composition, initial monomer concentration, reaction temperature, and reaction time. Grafted polymer surfaces prepared in pure NMP resulted in a polymer feature spacing of as low as 5-10 nm (average feature diameter of about 17 nm), an rms surface roughness range of 0.18-0.72 nm, and a maximum grafted polymer layer thickness of 5.5 nm. Graft polymerization in an NMP/water solvent mixture, however, resulted in polymer feature sizes that increased up to a maximum average feature diameter of about 90 nm at [NMP] = 60% (v/v) with polymer feature spacing in the range of 10-50 nm. The surface topology of the polymer-modified silicon surfaces grafted in an NMP/water solvent mixture exhibited a bimodal feature height distribution. In constrast, graft polymerization in pure NMP resulted in a narrow feature height distribution of smaller-diameter surface features with smaller surface spacing. The results demonstrated that, with the present approach, the topology of the grafted polymer surface was tunable by adjusting the NMP/water ratio. The present surface graft polymerization method, which is carried out under AP conditions, is particularly advantageous for polymer surface structuring via radical polymerization and can, in principle, be scaled to large surfaces.

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Controlled radical polymerization of 4‐vinylpyridine (4VP) was achieved in a 50 vol % 1‐methyl‐2‐pyrrolidone/water solvent mixture using a 2,2′‐azobis(2,4‐dimethylpentanitrile) initiator and a CuCl2/2,2′‐bipyridine catalyst–ligand complex, for an initial monomer concentration of [M]0 = 2.32–3.24 M and a temperature range of 70–80 °C. Radical polymerization control was achieved at catalyst to initiator molar ratios in the range of 1.3:1 to 1.6:1. First‐order kinetics of the rate of polymerization (with respect to the monomer), linear increase of the number–average degree of polymerization with monomer conversion, and a polydispersity index in the range of 1.29–1.35 were indicative of controlled radical polymerization. The highest number–average degree of polymerization of 247 (number–average molecular weight = 26,000 g/mol) was achieved at a temperature of 70 °C, [M]0 = 3.24 M and a catalyst to initiator molar ratio of 1.6:1. Over the temperature range studied (70–80 °C), the initiator efficiency increased from 50 to 64% whereas the apparent polymerization rate constant increased by about 60%. © 2007 Wiley Periodicals, Inc. J Polym Sci Part A: Polym Chem 45: 5748–5758, 2007