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This paper introduces an instantaneous and robust strategy for bonding a variety of non-silicon substrates such as thermoplastics, metals, an alloy, and ceramics to poly(dimethylsiloxane) (PDMS) irreversibly, mediated by one-step chemical modification using a mercaptosilane at room temperature followed by corona treatment to realize heterogeneous assembly also at room temperature. The mercapto functional group is one of the strongest nucleophiles, and it can instantaneously react with electrophiles of substrates, resulting in an alkoxysilane-terminated substrate at room temperature. In this way, prior oxidation of the substrate is dispensed with, and the alkoxysilane-terminated substrate can be readily oxidized and irreversibly bonded with oxidized PDMS at room temperature. A commercially available Tesla coil was used for surface oxidation, replacing a bulky and expensive plasma generator. Surface characterization was conducted by water contact angle measurement and X-ray photoelectron spectroscopy (XPS) analysis. A total of fifteen non-silicon substrates including polycarbonate (PC), two types of poly(vinylchloride) (PVC), poly(methylmethacrylate) (PMMA), polystyrene (PS), polyimide (PI), two types of poly(ethylene terephthalate) (PET), polypropylene (PP), iron (Fe), aluminum (Al), copper (Cu), brass, alumina (Al2O3), and zirconia (ZrO2) were bonded successfully with PDMS using this method, and the bond strengths of PDMS-PMMA, PDMS-PC, PDMS-PVC, PDMS-PET, PDMS-Al, and PDMS-Cu assemblies were measured to be approximately 335.9, 511.4, 467.3, 476.4, 282.2, and 236.7 kPa, respectively. The overall processes including surface modification followed by surface oxidation using corona treatment for bonding were realized within 12 to 17 min for most of the substrates tested except for ceramics which required 1 h for the bonding. In addition, large area (10 × 10 cm(2)) bonding was also successfully realized, ensuring the high reliability and stability of the introduced method.

Here, we introduce a simple and facile method for bonding poly(dimethylsiloxane) (PDMS) to various plastics irreversibly via a one-step chemical treatment at room temperature. This was mediated by poly[dimethylsiloxane-co-(3-aminopropyl)methylsiloxane] (amine-PDMS linker), a chemical composed of a PDMS backbone incorporating an amine side group. Room temperature anchoring of the linker was achieved via a reaction between the amine functionality of the linker and the carbon backbone of the plastics, thereby producing urethane bonds. This resulted in the PDMS functionality being exposed on the plastic surface, mimicking the surface properties of bulk PDMS. Following corona treatment of the PDMS-modified plastic and a sheet of PDMS, the two surfaces were placed in contact with each other and heated at 80 °C for 1 h. This resulted in permanent bonding between PDMS and the plastic. To examine the effectiveness of the amine-PDMS linker coating procedure, the surfaces were characterized by measuring water contact angles and by employing X-ray photoelectron spectroscopy (XPS). Polycarbonate (PC), poly(ethylene terephthalate) (PET), poly(vinylchloride) (PVC), and polyimide (PI) were bonded successfully to PDMS using this method, with bond strengths of PC, PET, and PVC with PDMS measured to be approximately 428.5 ± 17.9, 361.7 ± 31.2, and 430.0 ± 14.9 kPa, respectively. The bond strength of a PC-PC homogeneous assembly, also realized using the proposed method, was measured to be approximately 343.9 ± 7.4 kPa. Delamination tests revealed that the PC-PC assembly was able to withstand intense introduction of a liquid whose per-minute injection volume was approximately 278 times greater than the total internal volume of the microchannel fabricated in PC. This demonstrated the robustness of the seal formed using the proposed technique.