Barrier film for limiting transmission of oxygen and moisture therethrough

• US 20030068459A1
• Filed: 02/21/2001
• Published: 04/10/2003
• Est. Priority Date: 11/04/1994
• Status: Active Grant

• Current Assignee: Sigma Laboratories Of Arizona LLC
• Original Assignee: Sigma Laboratories Of Arizona LLC
• Inventors: Yializis, Angelo
• Granted Patent: US 6,706,412 B2
• Time in Patent Office: Days
• US Class Current: 428/41.5
• 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-linked 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 hybrid polymer film, comprising:

a first polymer film having a plasma-treated surface; and

a second polymer film having first and second surfaces, the first surface of the second polymer film being disposed along the first plasma-treated surface of the first polymer film.

2. The hybrid polymer film of claim 1, wherein the second polymer film is formed from a radiation-cured monomer film.

3. The hybrid polymer film of claim 2, wherein the second polymer film is an acrylate polymer film.

4. The hybrid polymer film of claim 3, wherein the second polymer film is a fluorinated acrylate polymer film.

5. The hybrid polymer film of claim 2, wherein the second surface of the second polymer film is a plasma-treated surface.

6. The hybrid polymer film of claim 1, wherein the second surface of the second polymer film is a plasma-treated surface.

7. The hybrid polymer film of claim 1, wherein the first polymer film is formed from a thermoplastic polymer.

8. The hybrid polymer film of claim 1, wherein the first polymer film is formed from a thermoset polymer.

9. The hybrid polymer film of claim 1, wherein the first plasma-treated surface of the first polymer film has a microroughness greater than about 1 nanometer.

10. The hybrid polymer film of claim 1, further comprising a metal film having first and second surfaces, the first surface of the metal film disposed along the second surface of the second polymer film.

11. The hybrid polymer film of claim 5, further comprising a metal film having first and second surfaces, the first surface of the metal film disposed along the plasma-treated surface of the second polymer film.

12. The hybrid polymer film of claim 10, further comprising a third polymer film having first and second surfaces, the first surface of the third polymer film being disposed along the second surface of the metal film.

13. The hybrid polymer film of claim 11, further comprising a third polymer film having first and second surfaces, the first surface of the third polymer film being disposed along the second surface of the metal film.

14. The hybrid polymer film of claim 12, wherein the third polymer film is formed from a radiation-cured monomer film.

15. The hybrid polymer film of claim 1, wherein the first polymer film has a second plasma-treated surface.

16. The hybrid polymer film of claim 15, further comprising a third polymer film disposed along the second plasma-treated surface of the first polymer film.

17. The hybrid polymer film of claim 16, wherein the third polymer film is an acrylate polymer film.

18. The hybrid polymer film of claim 17, wherein the third polymer film is a fluorinated acrylate polymer film.

19. The hybrid polymer film of claim 1, further comprising a ceramic layer disposed along the second surface of the second polymer film.

20. The hybrid polymer film of claim 19, wherein the ceramic layer comprises a material selected from the group consisting of aluminum oxide, a silicon oxide, tantalum oxide, aluminum nitride, silicon nitride, silicon oxy-nitride, zinc oxide, indium oxide, and indium tin oxide.

21. The hybrid polymer film of claim 20, wherein the ceramic layer comprises a material selected from the group consisting of aluminum oxide and a silicon oxide.

22. A hybrid polymer film, comprising:

a first polymer film having a plasma-treated surface; and

a first metal film having first and second surfaces, the first surface of the first metal film being disposed along the first plasma-treated surface of the first polymer film.

23. The hybrid polymer film of claim 22, wherein the first metal film is formed from a material selected from the group consisting of aluminum, zinc, nickel, cobalt, iron, iron on aluminum, zinc on silver, zinc on copper, zinc on aluminum, nickel-cobalt alloy, and nickel-cobalt-iron alloy.

24. The hybrid polymer film of claim 22, wherein the first polymer film is formed from a thermoplastic polymer.

25. The hybrid polymer film of claim 22, wherein the first polymer film is formed from a thermoset polymer.

26. The hybrid polymer film or claim 22, wherein the first plasma-treated surface of the first polymer film has a microroughness greater than about 1 nanometer.

27. The hybrid polymer film of claim 22, further comprising a second polymer having first and second surfaces, the first surface of the second polymer film disposed along the second surface of the first metal film.

28. The hybrid polymer film of claim 27, wherein the second polymer film is formed from a radiation-cured monomer film.

29. The hybrid polymer film of claim 28, wherein the second polymer film has a plasma-treated surface.

30. The hybrid polymer film of claim 28, wherein the second polymer film is an acrylate polymer film.

31. The hybrid polymer film of claim 27, further comprising a second metal film having first and second surfaces, the first surface of the second metal film disposed along the second surface of the polymer film.

32. The hybrid polymer film of claim 29, further comprising a second metal film having first and second surfaces, the first surface of the second metal film disposed along the plasma-treated surface of the second polymer film.

33. The hybrid polymer film of claim 31, further comprising a third polymer film disposed along the second surface of the second metal film.

34. The hybrid polymer film of claim 33, wherein the third polymer film is formed from a radiation-cured monomer film.

35. The hybrid polymer film of claim 32, further comprising a third polymer film disposed along the second surface of the second metal film.

36. The hybrid polymer film of claim 35, wherein the third polymer film is formed from a radiation-cured monomer film.

37. The hybrid polymer film of claim 36, wherein the third polymer film has a plasma-treated surface.

38. The hybrid polymer film of claim 33, wherein the first metal film comprises a reflective film of aluminum, the second polymer film comprises an acrylate polymer having a thickness that is ¼

wavelength of visible light, the second metal film comprises a semi-transparent film of aluminum, and the third polymer film comprises an acrylate polymer.

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

plasma-treating a first surface of a first polymer film to form a first plasma-treated surface of the first polymer film; and

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

40. The method of claim 39, wherein the step of forming a second polymer film includes the steps of:

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

radiation-curing the monomer film.

41. The method of claim 40, 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.

42. The method of claim 41, further comprising the step of:

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

43. The method of claim 42, further comprising the step of:

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

44. The method of claim 43, 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.

45. The method of claim 39, 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.

46. The method of claim 45, further comprising the step of:

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

47. The method of claim 46, 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.

48. The method of claim 39, further comprising the step of depositing a ceramic layer on the surface of the second polymer film.

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

plasma-treating a first surface of a first polymer film to form a plasma-treated surface of the first polymer film; and

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

50. The method of claim 49, further comprising a step of:

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

51. The method of claim 50, wherein the step of forming the second polymer film includes the steps of:

depositing a monomer film on the metal film; and

radiation-curing the monomer film.

52. The method of claim 51, 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.

53. The method of claim 52, further comprising the step of:

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

54. The method of claim 53, further comprising the step of:

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

55. The method of claim 54, 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.

56. The method of claim 55, 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.