Formed article, method for producing same, electronic device member, and electronic device

• US 9,540,519 B2
• Filed: 03/28/2011
• Issued: 01/10/2017
• Est. Priority Date: 03/31/2010
• Status: Active Grant

• Current Assignee: Lintec Corporation
• Original Assignee: Lintec Corporation
• Inventors: Iwaya, Wataru, Kondo, Takeshi
• Primary Examiner(s): STACHEL, KENNETH J
• Application Number:
  US13/634,713
• Publication Number:
  US 20130068136A1
• Time in Patent Office: 2,115 Days
• Field of Search: None
• US Class Current: 1/1
• CPC Class Codes: C08G 77/62 Nitrogen atoms
• CPC Class Codes: C08J 2367/02 Polyesters derived from dicarboxylic acids and dihydroxy compounds; C08J2367/06 takes precedence
• CPC Class Codes: C08J 2483/16 in which all the silicon atoms are connected by linkages other than oxygen atoms
• 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 7/048 Forming gas barrier coatings
• CPC Class Codes: C08K 2201/008 Additives improving gas barrier properties
• CPC Class Codes: C08K 3/346 Clay
• CPC Class Codes: C09D 1/00 Coating compositions, e.g. paints, varnishes or lacquers, based on inorganic substances
• CPC Class Codes: C09D 183/16 in which all the silicon atoms are connected by linkages other than oxygen atoms
• CPC Class Codes: C23C 14/48 Ion implantation
• CPC Class Codes: G02F 1/133305 Flexible substrates, e.g. plastics, organic film

Abstract

Provided a formed article comprising a layer that includes a polysilazane compound and a clay mineral, and having a water vapor transmission rate at a temperature of 40° C. and a relative humidity of 90% of 6.0 g/m²/day or less. Also provided are a method for producing the formed article, an electronic device member including the formed article, and an electronic device including the electronic device member. The formed article exhibiting an excellent gas barrier capability, excellent transparency, and excellent bending resistance, a method for producing the formed article, and an electronic device member, or the like, comprising the formed article are provided.

Claims

1. A method for producing a formed article comprising an ion-implanted layer, the method comprising:

implanting ions into a surface area of a layer comprising a polysilazane compound and a clay mineral to form said ion-implanted layer;

wherein a total content of the polysilazane compound and the clay mineral in the layer comprising the polysilazane compound and the clay mineral is 70 wt % or more.

2. The method according to claim 1, comprising implanting ions of at least one gas selected from the group consisting of hydrogen, nitrogen, oxygen, argon, helium, xenon, neon, krypton, a silicon compound, and a hydrocarbon into the surface area of the layer that includes the polysilazane compound and the clay mineral.

3. The method according to claim 1, wherein the formed article has a water vapor transmission rate at a temperature of 40°

C. and relative humidity of 90% of 6.0 g/m²/day or less.

4. The method according to claim 1, wherein the polysilazane compound is a compound that includes a repeating unit shown by a following formula (1):

5. The method according to claim 1, wherein a number average molecular weight of the polysilazane compound is 100 to 50,000.

6. The method according to claim 1, wherein a content of the clay mineral in the layer comprising the polysilazane compound and the clay mineral is 0.01 to 10 mass %, based on a total content (=100 mass %) of the polysilazane compound and the clay mineral.

7. The method according to claim 1, wherein a thickness of the layer comprising the polysilazane compound and the clay mineral is 30 nm to 500 nm.

8. The method for producing the formed article according to claim 1, the method comprising said implanting ions into the layer that includes the polysilazane compound and the clay mineral while feeding the layer including the polysilazane compound and the clay mineral in a given direction.

9. The method according to claim 8, wherein the ions are implanted by a plasma ion implantation method.

10. The method according to claim 1, wherein the ions are implanted by a plasma ion implantation method.

11. The method according to claim 10, wherein the plasma ion implantation method includes applying a negative high voltage pulse to a formed body that includes the layer comprising the polysilazane compound and the clay mineral, wherein the surface area of the layer comprising the polysilazane compound and the clay mineral is exposed to plasma containing ions.

12. The method according to claim 10, wherein the plasma ion implantation method includes implanting ions present in plasma generated by utilizing an external electric field into the surface area of the layer comprising the polysilazane compound and the clay mineral, the plasma ion implantation being performed under a plasma ion implantation pressure of 0.01 to 1 Pa.

13. The method according to claim 1, wherein the formed article further includes a base layer, and the layer comprising the polysilazane compound and the clay mineral is formed on one side or each side of the base layer.

14. The method according to claim 13, wherein a material for forming the base layer is a compound selected from the group consisting of polyimides, polyamides, polyamideimides, polyphenylene ethers, polyether ketones, polyether ether ketones, polyolefins, polyesters, polycarbonates, polysulfones, polyether sulfones, polyphenylene sulfides, polyallylates, clay minerals, cycloolefin polymers, and aromatic polymers.

15. A method for producing a formed article comprising an ion-implanted layer, the method comprising:

implanting ions into a surface area of a layer comprising a polysilazane compound and a clay mineral to form said ion-implanted layer;

wherein the ions are implanted by a plasma ion implantation method;

wherein the plasma ion implantation method includes applying a negative high voltage pulse to a formed body that includes the layer comprising the polysilazane compound and the clay mineral, wherein the surface area of the layer comprising the polysilazane compound and the clay mineral is exposed to plasma containing ions; and

wherein a pulse width when applying the negative high voltage pulse is 1 to 15 μ

s, and a voltage applied when generating plasma is −

1 to −

50 kV.