Molding, production method therefor, part for electronic devices and electronic device

• US 9,556,513 B2
• Filed: 07/27/2011
• Issued: 01/31/2017
• Est. Priority Date: 08/20/2010
• Status: Active Grant

• Current Assignee: Lintec Corporation
• Original Assignee: Lintec Corporation
• Inventors: Iwaya, Wataru, Kondo, Takeshi
• Primary Examiner(s): Nelson, Michael B
• Application Number:
  US13/818,050
• Publication Number:
  US 20130202899A1
• Time in Patent Office: 2,015 Days
• US Class Current: 1/1
• CPC Class Codes: B05D 1/62 Plasma-deposition of organic layers plasma deposition in general C23C14/00, C23C16/00
• CPC Class Codes: B05D 2252/02 of indefinite length
• 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: B29C 2059/147 Low pressure plasma; Glow discharge plasma
• CPC Class Codes: B29C 59/14 by plasma treatment plasma tubes per se H01J
• CPC Class Codes: C08J 2367/02 Polyesters derived from dicarboxylic acids and dihydroxy compounds; C08J2367/06 takes precedence
• CPC Class Codes: C08J 2433/12 Homopolymers or copolymers of methyl methacrylate
• CPC Class Codes: C08J 2483/16 in which all the silicon atoms are connected by linkages other than oxygen atoms
• CPC Class Codes: C08J 7/0423 with at least one layer of inorganic material and at least one layer of a composition containing a polymer binder
• CPC Class Codes: C08J 7/0427 with only one layer of a composition containing a polymer binder with more layers C08J7/042
• 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 7/044 Forming conductive coatings; Forming coatings having anti-static properties
• CPC Class Codes: C08J 7/048 Forming gas barrier coatings
• CPC Class Codes: C08J 7/123 Treatment by wave energy or particle radiation C08J7/18 takes precedence
• CPC Class Codes: C23C 14/48 Ion implantation
• CPC Class Codes: Y10T 428/31667 Next to addition polymer from unsaturated monomers, or aldehyde or ketone condensation product

Abstract

The invention is a formed article including a gas barrier layer, the gas barrier layer including a surface layer part that is formed of a material that includes at least a carbon atom, an oxygen atom, and a silicon atom, the surface layer part having a carbon atom content rate of more than 0 and not more than 70%, an oxygen atom content rate of 10 to 70%, a nitrogen atom content rate of 0 to 35%, and a silicon atom content rate of 20 to 55%, based on a total content rate of carbon atoms, oxygen atoms, nitrogen atoms, and silicon atoms; a method for producing the formed article; an electronic device member including the formed article; and an electronic device comprising the electronic device member. The formed article of the invention exhibits an excellent gas barrier capability, excellent transparency, and excellent bending resistance. The method for producing a formed article of the invention can efficiently, safely, and conveniently produce the formed article of the invention. The electronic device member of the invention may suitably be used for electronic devices such as displays and solar cells.

Claims

1. A formed article comprising a base layer and a gas barrier layer,

wherein the formed article has a thickness of 5 to 300 μ

m, and has a water vapor transmission rate at a temperature of 40°

C. and a relative humidity of 90% of 0.1 g/m²/day or less;

wherein the gas barrier layer;

includes a surface layer part in the area of 0-10 nm in depth from the surface that is formed of a material that includes at least a carbon atom, an oxygen atom, and a silicon atom, the surface layer part having a carbon atom content rate of more than 0 and not more than to 70%, an oxygen atom content rate of 10 to 70%, a nitrogen atom content rate of 1.16 to 35%, and a silicon atom content rate of 20 to 55%, based on a total content rate of carbon atoms, oxygen atoms, nitrogen atoms, and silicon atoms,

includes a polysilazane compound and an acrylic resin, wherein the weight average molecular weight of the acrylic resin is 100,000-1,000,000;

wherein the acrylic resin is selected from the group consisting of (i) a homopolymer of a (meth)acrylic acid-based compound, (ii) a copolymer of two or more (meth)acrylic acid-based compounds, and (iii) a copolymer of a (meth)acrylic acid-based compound and an additional functional monomer;

wherein when the acrylic resin is the copolymer (iii) the content of a repeating unit derived from a (meth)acrylic acid-based compound in the acrylic resin is 50 mol % or more based on the total repeating units in the acrylic resin;

wherein a total content of the polysilazane compound and the acrylic resin in the gas barrier layer is 70 mass % or more;

has an acrylic resin content of 50 to 60 mass % based on a total content of the polysilazane compound and the acrylic resin, and

includes a layer that is obtained by implanting ions into a layer that includes the polysilazane compound and the acrylic resin, the ions being obtained by ionizing at least one gas selected from the group consisting of argon, helium, neon, xenon, krypton in the absence of oxygen ion or nitrogen ion, and implanted into the layer that includes the polysilazane compound and the acrylic resin having a thickness of 30-500 nm by a plasma ion implantation method,

the material for forming the base layer being at least one polymer 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, acrylic resins, cycloolefin polymers, and aromatic resin polymers.

2. The formed article according to claim 1, wherein the surface layer part has the carbon atom content rate of 9.45 to 10.56%, oxygen atom content rate of 61.23 to 63.42%, nitrogen atom content rate of 1.16 to 2.97%, and silicon atom content rate of 24.29 to 25.97%, based on a total content rate of carbon atoms, oxygen atoms, nitrogen atoms, and silicon atoms.

3. An electronic device member comprising the formed article according to claim 1.

4. An electronic device comprising the electronic device member according to claim 3.

5. A method for producing the formed article according to claim 1, the method comprising a step of implanting ions into a surface area of a layer that is included in a formed body and includes a polysilazane compound and an acrylic resin, the formed body including the layer that includes the polysilazane compound and the acrylic resin in its surface area, the ions being at least one gas selected from the group consisting of argon, helium, xenon, neon, and krypton in the absence of oxygen ion or nitrogen ion.

6. A method for producing the formed article according to claim 5, the method comprising implanting ions into a layer that is included in a long formed body and includes a polysilazane compound and an acrylic resin while feeding the formed body in a given direction, the formed body including the layer that includes the polysilazane compound and the acrylic resin in its surface area.