Moisture resistant coating for barrier films

• US 9,254,506 B2
• Filed: 07/02/2010
• Issued: 02/09/2016
• Est. Priority Date: 07/02/2010
• Status: Active Grant

• Current Assignee: 3M Innovative Properties Company (3M Company)
• Original Assignee: 3M Innovative Properties Company (3M Company)
• Inventors: Roehrig, Mark A., Nachtigal, Alan K., Weigel, Mark D.
• Primary Examiner(s): STACHEL, KENNETH J
• Application Number:
  US12/829,535
• Publication Number:
  US 20120003484A1
• Time in Patent Office: 2,048 Days
• Field of Search: None
• US Class Current: 1/1
• 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 2252/02 of indefinite length
• CPC Class Codes: B05D 3/068 using ionising radiations (gamma, X, electrons)
• CPC Class Codes: B05D 7/04 to surfaces of films or sheets producing layered products by applying coatings of pasty or pulverulent plastics B29C41/00
• CPC Class Codes: B05D 7/586 each layer being cured, at least partially, separately
• CPC Class Codes: C08J 7/0423 with at least one layer of inorganic material and at least one layer of a composition containing a polymer binder
• CPC Class Codes: C08J 7/043 Improving the adhesiveness of the coatings per se, e.g. forming primers adhesives in the form of films or foils characterised by the primer layers between the polymer carriers and the adhesives C09J7/50
• CPC Class Codes: C08J 7/046 Forming abrasion-resistant coatings; Forming surface-hardening coatings
• CPC Class Codes: C23C 14/08 Oxides C23C14/10 takes precedence
• CPC Class Codes: C23C 14/081 of aluminium, magnesium or beryllium
• CPC Class Codes: C23C 14/10 Glass or silica
• CPC Class Codes: C23C 14/12 Organic material
• CPC Class Codes: C23C 14/24 Vacuum evaporation
• CPC Class Codes: C23C 14/34 Sputtering
• CPC Class Codes: C23C 14/54 Controlling or regulating the coating process
• CPC Class Codes: H10K 50/8445 multilayered coatings having a repetitive structure, e.g. having multiple organic-inorganic bilayers
• CPC Class Codes: Y10T 428/31663 As siloxane, silicone or silane

Abstract

A barrier film having a substrate, a base polymer layer applied to the substrate, an oxide layer applied to the base polymer layer, and a top coat polymer layer applied to the oxide layer. An optional inorganic layer can be applied over the top coat polymer layer. The top coat polymer includes a silane and an acrylate co-deposited to form the top coat layer. The use of a silane co-deposited with an acrylate to form the top coat layer of the barrier films provide for enhanced resistance to moisture and improved peel strength adhesion of the top coat layer to the underlying barrier stack layers.

Claims

1. A process for making a barrier film, comprising:

providing a substrate;

vapor depositing and curing a base polymer layer to the substrate;

applying an oxide layer to the base polymer layer;

forming a mixture comprising a cyclic azasilane and an acrylate; and

vapor depositing and curing the mixture to form a top coat polymer layer on the oxide layer, wherein the cyclic azasilane is N-n-butyl-aza-2,2-dimethoxysilacyclopentane, the acrylate is tricyclodecane dimethanol diacrylate and the mixture comprises the cyclic azasilane at about 3 weight percent of the acrylate.

2. A barrier film formed by the process of claim 1.

3. The barrier film of claim 2, further comprising a plurality of alternating layers of the base polymer layer and the oxide layer between the substrate and the top coat polymer.

4. The barrier film of claim 2, wherein the substrate comprises a flexible transparent film.

5. The barrier film of claim 2, wherein the base polymer layer comprises an acrylate smoothing layer.

6. The barrier film of claim 2, wherein the oxide layer comprises a layer of an inorganic silicon aluminum oxide.

7. The barrier film of claim 2, further comprising an inorganic layer applied to the top coat polymer layer.

8. The barrier film of claim 7, wherein the inorganic layer comprises a layer of an inorganic silicon aluminum oxide.

9. The process of claim 1, wherein the applying the oxide layer step comprises sputter depositing an oxide onto the base polymer layer to form the oxide layer.

10. The process of claim 1, further comprising repeating the vapor depositing step and the applying step to apply a plurality of alternating layers of the base polymer layer and the oxide layer between the substrate and the top coat polymer layer.

11. The process of claim 1, wherein the applying the oxide layer step comprises applying a layer of an inorganic silicon aluminum oxide to the base polymer layer.

12. The process of claim 1, further comprising applying an inorganic layer to the top coat polymer layer.

13. The process of claim 12 wherein the applying the inorganic layer step comprises applying a layer of an inorganic silicon aluminum oxide.