Confocal scanning laser microscopy of polymer coatings

A new nondestructive technique, confocal scanning laser microscopy (CSLM), is described that is used to characterize the topography and morphology of polymer coatings. The topography of the coating can be determined even when the coating is completely opaque. When the coating is not completely opaque, CSLM has the distinct advantage of also being able to distinguish between the coating surface and the substrate, thus enabling coating thickness to be determined over a wide range of areas. In this study CSLM was successfully applied to poly(2-vinylpyridine) coatings formed on mild steel substrates by in situ electropolymerization. Satisfactory morphological details were obtained for areas ranging from 200 × 200 μm to 4 × 4 mm. Quantitative measurements of the coating thickness and the surface roughness distribution were also carried out. Although several other nondestructive techniques for coating morphological analyses are available, CSLM has unique advantages in being able to provide simultaneous qualitative and quantitative information on coating surfaces as well as measurements over a wide range of surface areas. A comparison of CSLM with other popularly used methods is provided and the characteristics and limitations of the various techniques are discussed. © 1998 John Wiley & Sons, Inc. J Appl Polym Sci 67: 149–158, 1998