Yusuf,

I would recommend getting a copy of "The Handbook of Adhesives", Third Edition, edited by Irving Skeist, Van Nostrand Reinhold, New York,1990 (ISBN 0-442-28013-0).  Polymer-metal bonding is discussed with respect to surface preparation and selection of adhesive.  If nothing else it will inform you as to the (or at least some of) options for the metal and polymer you want to bond.

The plasma processing can help you to improve the adhesion via etching or grafting of some functional groups. For this purpose you need to do plasma surface modification of metal and/or polymer.

Hi,

Good adhesion between metal particles and polymer could be achieved by cross linking between polymer chain and metal particles. You can cross link them by grafting some functional groups on metal/polymer or both.

Thanks for answers. I have a metal plate so I have no chance of grafting metal particles. So implementing some glue-like liquid on metal layer and sticking polymer and metal after plasma process seems possible. So I need to find proper test parameters and liquid for this. 

You can try to use some silane or other primer.

@ Yusuf ... grafting meant having some functional groups which have better affinity/adhesion with your adhesive( glue). Plasma cannot replace the role of adhesive. It can only assist in better adhesion by improving surface properties of metal/polymer.

@Nisha to put in simply I need to get an adhesive layer just like between glass and PDMS. Plasma worked for sticking these two parts strongly. 

It is possible. Generally speaking, you need strong polar groups in your polymeric surface able to interact with your metal. Literature describes hydroxyl and carbonyl groups as the ones that are more likely to adhere to metalic surfaces, so you can think about working with an additional layer of a latex, for instance, containing those functionalities. Some reactive surfactants containing oxygenated functions have also presented interesting results. Physical treatments as plasma, corona, etc, are an aternative way, but it is important to keep in mind, that their effect are expected to be easily reversed, so you may experience some delamination.

@ Yusuf ,  I agree , in case of glass & PDMS ,SiOH groups on polymer surface form Si-O-Si bond and  irreversible seal. However, this may not be possible in case of metal and polymer.

What metal are you working with and what sort of forces does the coating need to withstand?

@Andrew Metal is nickel. There is no specific force to withstand.

Yusuf,

I would recommend getting a copy of "The Handbook of Adhesives", Third Edition, edited by Irving Skeist, Van Nostrand Reinhold, New York,1990 (ISBN 0-442-28013-0).  Polymer-metal bonding is discussed with respect to surface preparation and selection of adhesive.  If nothing else it will inform you as to the (or at least some of) options for the metal and polymer you want to bond.

Yusuf,

I agree with John. For getting a appropriate adhesion you need a specific pre-treatment of the metal surface and  a primer or any other kind of binder that is compatible to your specific polymer system. 

This paper may be help you

Progress in Vacuum Deposited Lithium Metal Anode Structures

by

 R. Swisher, Sheldahl, Inc., Northfield, USA

E. Yadin, Sidrabe, Inc., Riga, Latvia

G. Pipkevich, Sidrabe, Inc., Riga, Latvia

18th International Seminar & Exhibit on Primary and Secondary Batteries, March 5, 2001, Ft. Landerdale, Florida, USA 1

For example, Sidrabe has extensive experience with depositing thick metal layers onto relatively thin polymeric films. Using a thermo-stabilization system with a proprietary, enhanced cooling system in the deposition zone, we have produced micron thick coatings of metals (Cu, Al, Ag, Ni) and of various alloys (stainless steel, Nichrome, Monel metal, etc.) on polymers. Coatings were produced at industrial speeds and coating thicknesses of up to 2 ... 5 micron

Dear Yusuf,

I would like to suggest you to take into account for some properties of polymer such as what kind of polymer, thickness of polymer layer, working temterature and environment to be  used. Stability and permeablity of polymers have to be considered. 

you have to select a suitable resin accordance to the functional groups of polymer and metal surface. silane coupling agent can improve the adhesion. 

There is one alternative way to enhance adhesion. Silane modification significantly improves interfacial strength. For more details go through below link.

http://www.sciencedirect.com/science/article/pii/S0032386116301227