Barrier layer for an article and method of making said barrier layer by expanding thermal plasma
First Claim
1. An article, said article comprising:
- a)a substrate; and
b)at least one barrier layer disposed on at least one surface of said substrate, wherein said barrier layer comprises an inorganic material, and wherein said barrier layer is resistant to transmission of moisture and oxygen therethrough and has a water vapor transmission rate (WVTR) at 25°
C. and 100% relative humidity of less than about 2 g/m2-day and an oxygen transmission rate (OTR) at 25°
C. and 100% oxygen concentration of less than about 2 cc/m2-day.
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Accused Products
Abstract
An article comprising a substrate having a barrier layer. The barrier layer is disposed on the surface of the substrate and resistant to transmission of moisture and oxygen. Methods of depositing such a barrier layer on the substrate are also disclosed. The article may include additional layers, such as, but not limited to, an adhesion layer, abrasion resistant layers, radiation-absorbing layers, radiation-reflective layers, and conductive layers. Such articles include, but are not limited to, light emitting diodes (LEDs), liquid crystal displays (LCDs), photovoltaic articles, electrochromic articles, and organic electroluminescent devices (OELDs).
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Citations
103 Claims
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1. An article, said article comprising:
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a)a substrate; and
b)at least one barrier layer disposed on at least one surface of said substrate, wherein said barrier layer comprises an inorganic material, and wherein said barrier layer is resistant to transmission of moisture and oxygen therethrough and has a water vapor transmission rate (WVTR) at 25°
C. and 100% relative humidity of less than about 2 g/m2-day and an oxygen transmission rate (OTR) at 25°
C. and 100% oxygen concentration of less than about 2 cc/m2-day. - 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)
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26. A barrier layer deposited on a substrate, said barrier layer comprising at least one of a metal oxide, a metal nitride, a metal carbide, and combinations thereof, and wherein each of said metal nitride, said metal carbide, and said metal oxide contains at least one of silicon, aluminum, zinc, indium, tin, a transition metal, and combinations thereof, and wherein said barrier layer is resistant to transmission of moisture and oxygen therethrough and has a water vapor transmission rate (WVTR) at 25°
- C. and 100% relative humidity of less than about 2 g/m2-day and an oxygen transmission rate (OTR) at 25°
C. and 100% oxygen concentration of less than about 2 cc/m2-day. - View Dependent Claims (27, 28, 29, 30, 31, 32, 33, 34, 35, 36)
- C. and 100% relative humidity of less than about 2 g/m2-day and an oxygen transmission rate (OTR) at 25°
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37. An article, said article comprising:
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a)a substrate; and
b)at least one barrier layer, said at least one barrier layer comprising at least one of a metal oxide, a metal nitride, a metal carbide, and combinations thereof, wherein each of said metal nitride, said metal carbide, and said metal oxide contains at least one of silicon, aluminum, zinc, indium, tin, a transition metal, and combinations thereof, and wherein said barrier layer is resistant to transmission of moisture and oxygen therethrough and has a water vapor transmission rate (WVTR) at 25°
C. and 100% relative humidity of less than about 2 g/m2-day and an oxygen transmission rate (OTR) at 25°
C. and 100% oxygen concentration of less than about 2 cc/m2-day. - View Dependent Claims (38, 39, 40, 41, 42, 43, 44, 45, 46, 47, 48, 49, 50, 51, 52, 53, 54, 55, 56, 57, 58, 59)
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60. A method of forming a coated article, the coated article comprising a substrate and a barrier layer disposed thereon, wherein the barrier layer is resistant to transmission of moisture and oxygen therethrough and has a water vapor transmission rate (WVTR) at 25°
- C. and 100% relative humidity of less than about 2 g/m2-day and an oxygen transmission rate (OTR) at 25°
C. and 100% oxygen concentration of less than about 2 cc/m2-day, the method comprising the steps of;
a)providing a substrate;
b)generating an thermal plasma, the thermal plasma having an electron temperature of less than about 1 eV;
c)injecting at least one reagent into the thermal plasma;
d)reacting the at least one reagent in the thermal plasma to form at least one deposition precursor;
e)depositing the at least one deposition precursor on the substrate at a rate of at least about 200 nm/min to form the barrier layer on the substrate. - View Dependent Claims (61, 62, 63, 64, 65, 66, 67, 68, 69, 70, 71, 72, 73, 74, 75, 76, 77, 78, 79, 80)
- C. and 100% relative humidity of less than about 2 g/m2-day and an oxygen transmission rate (OTR) at 25°
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81. A method of forming a barrier layer on a substrate, wherein the barrier layer is resistant to transmission of moisture and oxygen therethrough and has a water vapor transmission rate (WVTR) at 25°
- C. and 100% relative humidity of less than about 2 g/m2-day and an oxygen transmission rate (OTR) at 25°
C. and 100% oxygen concentration of less than about 2 cc/m2-day, and wherein the barrier layer comprises at least one of a metal oxide, a metal nitride, a metal carbide, and combinations thereof, wherein each of the metal nitride, the metal carbide, and the metal oxide contains at least one of silicon, aluminum, zinc, indium, tin, a transition metal, and combinations thereof, the method comprising the steps of;
a)generating a thermal plasma, the thermal plasma having an electron temperature of less than about 1 eV;
b)injecting a first reagent into the thermal plasma, the first reagent comprising at least one of silicon, aluminum, zinc, indium, tin, a transition metal, and combinations thereof;
c)injecting a second reagent into the thermal plasma, the second reagent comprising at least one of oxygen, nitrogen, and ammonia;
d)reacting the first reagent and the second reagent in the thermal plasma to form at least one deposition precursor; and
e)depositing the at least one deposition precursor on the substrate at a rate of at least about 200 nm/min, thereby forming the barrier layer comprising at least one of a metal oxide, a metal nitride, a metal carbide, and combinations thereof on the substrate. - View Dependent Claims (82, 83, 84, 85)
- C. and 100% relative humidity of less than about 2 g/m2-day and an oxygen transmission rate (OTR) at 25°
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86. A method of forming a coated article, the coated article comprising a substrate and a barrier layer disposed thereon, wherein the barrier layer has a water vapor transmission rate (WVTR) at 25°
- C. and 100% relative humidity of less than about 2 g/m2-day and an oxygen transmission rate (OTR) at 25°
C. and 100% oxygen concentration of less than about 2 cc/m2-day, and wherein the barrier layer comprises at least one of at least one of a metal oxide, a metal nitride, a metal carbide, and combinations thereof, wherein each of the metal nitride, the metal carbide, and the metal oxide contains at least one of silicon, aluminum, zinc, indium, tin, a transition metal, and combinations thereof, the method comprising the steps of;
a)providing a substrate;
b)generating a thermal plasma, the thermal plasma having an electron temperature of less than about 1 eV;
c)injecting a first reagent into the thermal plasma, the first reagent comprising at least one of silicon, aluminum, zinc, indium, tin, a transition metal, and combinations thereof;
d)injecting a second reagent into the thermal plasma, the second reagent comprising at least one of oxygen, nitrogen, water, and ammonia;
e)reacting the first reagent and the second reagent in the thermal plasma to form at least one deposition precursor; and
f)depositing the at least one deposition precursor on the substrate at a rate of at least about 200 nm/min, thereby forming the barrier layer comprising at least one of a metal oxide, a metal nitride, a metal carbide, and combinations thereof on the substrate. - View Dependent Claims (87, 88, 89, 90, 91, 92, 93, 94, 95, 96, 97, 98, 99, 100, 101, 102, 103)
- C. and 100% relative humidity of less than about 2 g/m2-day and an oxygen transmission rate (OTR) at 25°
Specification