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Self-limiting thermal embedding creates surface-accessible nanoparticle monolayers on polymers
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DOI：10.1038/s43246-026-01320-9.png)
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Abstract
En 中文
Nanoparticle-functionalized polymer surfaces must reconcile particle retention with interfacial accessibility, a balance central to catalytic and multifunctional surfaces. Existing architectures use binders, primers or grafting layers that bury active area or add chemical complexity. Here we show that mild annealing below the main bulk-softening regime partially embeds nanoparticles into cured polymer surfaces, forming a close-packed, one-particle-thick monolayer through two coupled self-limiting processes: particles above the polymer-contacting layer remain removable, while the retained layer approaches a finite embedding depth. On a commercial epoxy, CeO2 nanoparticles embed to approximately their radius, providing anchoring while remaining partially exposed. The monolayer withstands vortexing, ultrasonication and repeated tape peeling, retains reversible Ce3+/Ce4+ cycling, and suppresses degradation during peroxide cycling, short-term outdoor exposure and artificial-seawater immersion. Density-functional theory supports a vacancy-mediated peroxide-decomposition pathway consistent with redox regeneration. Spray deposition and Ag embedding on low-density and high-density polyethylene support transferability across deposition routes, nanoparticle chemistries and polymer substrates. Contact-layer-selective, depth-limited thermal embedding thus establishes a geometry-based, grafting-free design principle that provides mechanical retention while preserving interfacial accessibility, with broader relevance to catalytic and other functional polymer interfaces. Nanoparticle-functionalized polymer surfaces must balance particle retention with surface accessibility, but current methods often reduce active area or add complexity. Here, the authors show that mild thermal annealing creates a durable nanoparticle monolayer that preserves surface accessibility, catalytic activity, and stability without complex grafting methods.
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