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What are the three main processes of polymer film formation?
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In the chemistry of surface coatings, polymer film formation occurs through three primary processes, which may also be used in combination for specific applications:1
- Evaporation of solvent or carrier liquid: In this method, a fully developed polymer is dissolved in a solvent. Once applied to a substrate, the film forms solely as the solvent evaporates, leaving behind a solid coating.12
- Cross-linking of polymer precursors: This process involves the reaction of low-molecular-weight, low-viscosity polymer precursors to build a three-dimensional, cross-linked network. This can occur through oxidative reactions with atmospheric oxygen (as seen in traditional drying oils) or through modern reactive systems, such as the formation of polyurethane.13
- Coalescence of small particles: This process involves the flow and fusion of small polymer particles (typically 0.05 to 1.0 micrometres) into a continuous film. It is common in latex systems and powder coating, where particles are fused by surface-mediated forces or heat.41