Controlled Radical Assisted Polymerization

Abstract

The present invention is directed to a method of forming a polymer coating on a substrate. The method comprising the steps of providing in an evacuated reaction chamber a substrate having a surface to be coated; and providing a first source of polymer forming material and a second source of radicals. According to the invention the first source and the second source are separated from each other and from the reaction chamber, and the polymer forming material as well as the radicals are, at least temporarily, conducted contemporaneously but spatially separated to the substrate's surface, so that a reaction of the polymer forming material with the radicals is avoided before they reach the substrate's surface. Further, the present invention is directed to a device for carrying out the method according to the invention.

What is claimed is: 
     
         1 . A method of forming a polymer coating on a substrate, said method comprising the steps of:
 providing in an evacuated reaction chamber a substrate having a surface to be coated;   providing a first source of polymer forming material and a second source of radicals, wherein the first source and the second source are separated from each other and from the reaction chamber, and   spatially separated, and at least temporarily contemporaneously conducting the polymer forming material and the radicals to a surface of the substrate, such that a reaction of the polymer forming material with the radicals is avoided before the polymer forming material and the radicals reach the surface of the substrate.   
     
     
         2 . The method according to  claim 1 , wherein the polymer forming material is conducted via a first conduit means to the surface of the substrate to be coated and the radicals are conducted via a second conduit means to the surface of the substrate to be coated. 
     
     
         3 . The method according to  claim 2 , wherein the polymer forming material and the radicals are each sprayed essentially perpendicularly onto the surface of the substrate. 
     
     
         4 . The method according  claim 3 , wherein the polymer forming material and the radicals are at least partially sprayed onto the surface of the substrate in the form of essentially parallel streams, and wherein the streams of polymer forming material and the streams of radicals are sprayed onto the surface of the substrate in a spatially alternating manner. 
     
     
         5 . The method according to  claim 4 , wherein the polymer forming material and the radicals are separately guided by the first and second conduit means and sprayed onto the surface of the substrate at a distance of less than 2 cm from the surface of the substrate. 
     
     
         6 . The method according to  claim 5 , wherein the polymer forming material and the radicals are separately guided by the first and second conduit means and sprayed onto the surface of the substrate at a distance of less than 1 cm from the surface of the substrate. 
     
     
         7 . The method according to  claim 5 , wherein the polymer forming material and the radicals are separately guided by the first and second conduit means and sprayed onto the surface of the substrate at a distance of less than 0.5 cm from the surface of the substrate.