Barrier coatings and methods of making same
First Claim
1. A multi-layer environmental barrier coating, comprising:
- a flexible substrate;
a foundation stack, comprising;
a foundation barrier layer comprising at least one ply of a first inorganic material deposited over the flexible substrate, and an organic layer comprising at least one ply of an organic material deposited over the foundation barrier layer, at least one barrier stack deposited over the foundation stack, the barrier stack comprising;
a barrier-stack barrier layer comprising at least one ply of a second inorganic material, and an organic layer comprising at least one ply of an organic material deposited over the barrier-stack barrier layer; and
a topmost isolation layer comprising a third inorganic material deposited over the barrier stack, wherein at least one of the inorganic plies is plasma-treated.
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Accused Products
Abstract
A multi-layer barrier coating on a flexible substrate exhibits improved resistance to gas and liquid permeation. The multi-layer barrier coating generally comprises alternating polymer and inorganic layers, and the layer immediately adjacent to the flexible substrate and the topmost isolation layer may both be inorganic layers. The surface of each deposited inorganic layers may be plasma-treated prior to the deposition of the polymer layer thereon, while the surfaces of the polymer layers are generally not plasma-treated. The multi-layer barrier coating is lightweight, preferably transparent, and has improved flexibility and resiliency, as well as resistance to cracking and delaminating
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Citations
54 Claims
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1. A multi-layer environmental barrier coating, comprising:
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a flexible substrate;
a foundation stack, comprising;
a foundation barrier layer comprising at least one ply of a first inorganic material deposited over the flexible substrate, and an organic layer comprising at least one ply of an organic material deposited over the foundation barrier layer, at least one barrier stack deposited over the foundation stack, the barrier stack comprising;
a barrier-stack barrier layer comprising at least one ply of a second inorganic material, and an organic layer comprising at least one ply of an organic material deposited over the barrier-stack barrier layer; and
a topmost isolation layer comprising a third inorganic material deposited over the barrier stack, wherein at least one of the inorganic plies is plasma-treated. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, 20, 21, 22, 23, 24, 25, 26, 27, 28, 29, 30)
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31. A multi-layer environmental barrier coating, comprising:
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a flexible substrate;
a foundation barrier layer comprising at least one ply of a first inorganic material deposited over the flexible substrate; and
at least two barrier stacks deposited over the foundation barrier layer, each barrier stack comprising, in sequence;
an organic layer comprising at least one ply of an organic material; and
thereover, a barrier-stack barrier layer comprising at least one ply of a second inorganic material. - View Dependent Claims (32, 33)
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34. A method of manufacturing a multi-layer environmental barrier coating, the method comprising the steps of:
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(a) providing a flexible substrate;
(b) depositing a foundation stack over the flexible substrate, comprising the steps of;
(i) depositing a foundation barrier layer comprising at least one ply of a first inorganic material over the flexible substrate, (ii) depositing over the foundation barrier layer a foundation organic layer comprising at least one ply of an organic material, and (iii) polymerizing the foundation organic layer;
(c) depositing at least one barrier stack over the foundation stack, comprising the steps of;
(i) depositing a barrier-stack barrier layer, (ii) depositing a barrier-stack organic layer over the barrier-stack barrier layer, and (iii) polymerizing the barrier-stack organic layer; and
(d) depositing over the at least one barrier stack a topmost isolation layer, the topmost isolation layer comprising at least one ply of a third inorganic material. - View Dependent Claims (35, 36, 37, 38, 39, 40, 41, 42)
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43. A method of fabricating a multi-layer environmental barrier coating on a flexible web substrate, the method comprising the steps of:
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(a) providing first and second bi-directional rollers for handling the flexible web substrate, a travel path extending between the rollers;
(b) providing, in series along the travel path, a sequence of process stations comprising (i) a first surface treater, (ii) at least one first inorganic deposition system, (iii) a second surface treater, (iv) a first curing system, (v) a monomer deposition system, (vi) a second curing system, (vii) a third surface treater, (viii) at least one second inorganic deposition system, and (ix) a fourth surface treater;
(c) operating the rollers to alternately draw the flexible web substrate across the travel path in opposite directions; and
(d) operating the process stations to apply a series of organic and inorganic plies on the flexible web substrate, the applied plies being arranged as a series of adjacent organic and inorganic layers each comprising at least one ply. - View Dependent Claims (44, 45, 46, 47, 48, 49, 50, 51, 52, 53, 54)
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Specification