Method of forming a hybrid polymer film

• US 6,214,422 B1
• Filed: 10/08/1998
• Issued: 04/10/2001
• Est. Priority Date: 11/04/1994
• Status: Expired due to Term

• Current Assignee: Sigma Laboratories Of Arizona LLC
• Original Assignee: Sigma Laboratories Of Arizona LLC
• Inventors: Yializis, Angelo
• Primary Examiner(s): PIANALTO, BERNARD D
• Application Number:
  US09/169,175
• Time in Patent Office: 915 Days
• Field of Search: 427/496, 427/497, 427/498, 427/491, 427/536, 427/537, 427/551, 427/322, 427/385.5, 427/404, 427/407.1, 427/488, 427/255.6, 427/255.7, 427/492, 427/507, 427/558, 427/559, 427/569, 427/576
• US Class Current: 427/488
• CPC Class Codes: B05D 1/60 Deposition of organic layers from vapour phase vapour phase deposition in general C23C14/00, C23C16/00
• CPC Class Codes: B05D 3/144 of polymeric substrates
• CPC Class Codes: B05D 3/147 Curing
• CPC Class Codes: B32B 27/00 Layered products comprising a layer of synthetic resin fibrous or filamentary layer made of a synthetic resin B32B5/02; particulate layer made of a synthetic resin B32B5/16; foamed layer made of a synthetic resin B32B5/18
• CPC Class Codes: C23C 14/20 on organic substrates
• CPC Class Codes: H01G 4/20 using combinations of dielectrics from more than one of groups H01G4/02 - H01G4/06 H01G4/12 takes precedence
• CPC Class Codes: Y10T 428/12569 Synthetic resin
• CPC Class Codes: Y10T 428/12576 Boride, carbide or nitride component
• CPC Class Codes: Y10T 428/1462 Polymer derived from material having at least one acrylic or alkacrylic group or the nitrile or amide derivative thereof [e.g., acrylamide, acrylate ester, etc.]
• CPC Class Codes: Y10T 428/31515 As intermediate layer
• CPC Class Codes: Y10T 428/31533 Of polythioether
• CPC Class Codes: Y10T 428/3154 Of fluorinated addition polymer from unsaturated monomers
• CPC Class Codes: Y10T 428/31678 Of metal
• CPC Class Codes: Y10T 428/31681 Next to polyester, polyamide or polyimide [e.g., alkyd, glue, or nylon, etc.]
• CPC Class Codes: Y10T 428/31692 Next to addition polymer from unsaturated monomers
• CPC Class Codes: Y10T 428/31699 Ester, halide or nitrile of addition polymer
• CPC Class Codes: Y10T 428/31855 Of addition polymer from unsaturated monomers
• CPC Class Codes: Y10T 428/31935 Ester, halide or nitrile of addition polymer

Abstract

A hybrid film, comprising a first polymer film having a plasma-treated surface and a second polymer film having first and second surfaces, with the first surface of the second polymer film being disposed along the first plasma-treated surface of the first polymer film, has superior thermal and mechanical properties that improve performance in a number of applications, including food packaging, thin film metallized and foil capacitors, metal evaporated magnetic tapes, flexible electrical cables, and decorative and optically variable films. One or more metal layers may be deposited on either the plasma-treated surface of the substrate and/or the radiation-cured acrylate polymer A ceramic layer may be deposited on the radiation-cured acrylate polymer to provide an oxygen and moisture barrier film. The hybrid film is produced using a high speed, vacuum polymer deposition process that is capable of forming thin, uniform, high temperature, cross-liked acrylate polymers on specific thermoplastic or thermoset films. Radiation curing is employed to cross-link the acrylate monomer. The hybrid film can be produced in-line with the metallization or ceramic coating process, in the same vacuum chamber and with minimal additional cost.

Claims

1. A method of forming a hybrid polymer film, the method comprising the steps of:

(a) cleaning and preparing a first surface of a substrate comprising a first polymer film by in-line plasma treatment under vacuum to form a first plasma-treated surface of the first polymer film; and

(b) forming a second polymer film on the plasma-treated surface of the first polymer film by

(1) in-line flash evaporation of at least one monomer under said vacuum, and

(2) in-line radiation curing of said monomer under said vacuum to form said second polymer film.

2. The method of claim 1, further comprising the step of:

plasma-treating a surface of the second polymer film to form a plasma-treated surface of the second polymer film.

3. The method of claim 2, further comprising the step of:

depositing a metal film on the plasma-treated surface of the second polymer film.

4. The method of claim 3, further comprising the step of:

forming a third polymer film on a surface of the metal film.

5. The method of claim 4, wherein the step of forming the third polymer film includes the steps of:

depositing a monomer film on the surface of the metal film; and

radiation-curing the monomer film.

6. The method of claim 1, further comprising the step of:

plasma-treating a second surface of the first polymer film to form a second plasma-treated surface of the first polymer film.

7. The method of claim 6, further comprising the step of:

forming a third polymer film on the second plasma-treated surface of the first polymer film.

8. The method of claim 7, wherein the step of forming the third polymer film includes the steps of:

depositing a monomer film on the second plasma-treated surface of the first polymer film; and

radiation-curing the monomer film.

9. The method of claim 1, further comprising the step of depositing a ceramic layer on the surface of the second polymer film.

10. A method of forming a hybrid polymer film, the method comprising the steps of:

(a) cleaning and preparing a first surface of a substrate comprising a first polymer film by in-line plasma treatment under vacuum to form a plasma-treated surface of the first polymer film;

(b) forming a metal film on the plasma-treated surface of the first polymer film under said vacuum; and

(c) forming a second polymer film on a surface of the metal film by

(1) in-line flash evaporation of at least one monomer under said vacuum, and

(2) in-line radiation curing of said monomer under said vacuum to form said second polymer film.

11. The method of claim 10, further comprising the step of:

plasma-treating a surface of the second polymer film to form a plasma-treated surface of the second polymer film.

12. The method of claim 11, further comprising the step of:

depositing a second metal film on the plasma-treated surface of the second polymer film.

13. The method of claim 12, further comprising the step of:

forming a third polymer film on the surface of the second metal film.

14. The method of claim 13, wherein the step of forming the third polymer film includes the steps of:

depositing a monomer film on the surface of the second metal film; and

radiation-curing the monomer film.

15. The method of claim 14, further comprising the step of:

plasma-treating a surface of the second polymer film to form a plasma-treated surface of the second polymer film.