Moisture barrier coatings

• US 20070020451A1
• Filed: 07/20/2005
• Published: 01/25/2007
• Est. Priority Date: 07/20/2005
• Status: Abandoned Application

• Current Assignee: 3M Innovative Properties Company (3M Company)
• Original Assignee: 3M Innovative Properties Company (3M Company)
• Inventors: Padiyath, Raghunath, David, Moses
• Application Number:
  US11/185,078
• Publication Number:
  US 20070020451A1
• Time in Patent Office: Days
• US Class Current: 428/336
• CPC Class Codes: B05D 1/62 Plasma-deposition of organic layers plasma deposition in general C23C14/00, C23C16/00
• CPC Class Codes: B05D 7/546 each layer being cured, at least partially, separately
• CPC Class Codes: B05D 7/58 No clear coat specified
• 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: 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 16/26 Deposition of carbon only
• CPC Class Codes: C23C 16/545 for coating elongated substrates
• CPC Class Codes: H10K 30/88 Passivation; Containers; Encapsulations
• CPC Class Codes: H10K 50/8423 Metallic sealing arrangements
• CPC Class Codes: H10K 50/8445 multilayered coatings having a repetitive structure, e.g. having multiple organic-inorganic bilayers
• CPC Class Codes: H10K 59/8721 Metallic sealing arrangements
• CPC Class Codes: H10K 59/8731 multilayered coatings having a repetitive structure, e.g. having multiple organic-inorganic bilayers
• CPC Class Codes: Y10T 428/26 Web or sheet containing structurally defined element or component, the element or component having a specified physical dimension
• CPC Class Codes: Y10T 428/265 1 mil or less
• CPC Class Codes: Y10T 428/30 Self-sustaining carbon mass or layer with impregnant or other layer
• CPC Class Codes: Y10T 428/31504 Composite [nonstructural laminate]
• CPC Class Codes: Y10T 428/31935 Ester, halide or nitrile of addition polymer

Abstract

A barrier assembly having a flexible or rigid substrate overcoated with an all polymer multilayer stack. A multilayer on the substrate includes alternating diamond-like glass or carbon layers with polymer layers. Another multilayer includes alternating polymer layers using different types of polymers. The barrier layers can be used to mount, cover, encapsulate or form composite assemblies for protection of moisture or oxygen sensitive articles

Claims

1. A composite assembly for protection of a moisture or oxygen sensitive article, comprising:

a substrate;

a first polymer layer overcoated on the substrate; and

a second polymer layer overcoated on the first polymer layer,

wherein the first polymer layer is composed of a first polymer and the second polymer layer is composed of a second polymer different from the first polymer, and wherein the second polymer comprises a plasma polymer.

2. The assembly of claim 1, wherein the substrate comprises a rigid material or a flexible material.

3. The assembly of claim 1, wherein the first polymer layer comprises a plasma polymer.

4. The assembly of claim 1, wherein the first polymer layer comprises a UV cured acrylate.

5. The assembly of claim 1, wherein the second polymer layer overcoated on the first polymer layer comprises a dyad and wherein the assembly has a plurality of the dyads overcoated on the substrate.

6. The assembly of claim 5, further comprising an additional layer between at least two of the dyads.

7. A composite assembly for protection of a moisture or oxygen sensitive article, comprising:

a substrate;

a polymer layer overcoated on the substrate; and

a diamond-like carbon layer overcoated on the polymer layer.

8. The assembly of claim 7, wherein the substrate comprises a rigid material or a flexible material.

9. The assembly of claim 7, wherein the diamond-like carbon layer comprises a coating comprising approximately 50 to 90 atomic percent carbon and approximately 10 to 50 atomic percent hydrogen, with a gram atom density of between approximately 0.20 and approximately 0.28 gram atoms per cubic centimeter, and composed of approximately 50 to approximately 90% tetrahedral bonds.

10. The assembly of claim 7, wherein the polymer layer overcoated on the diamond-like carbon layer comprises a dyad and wherein the assembly has a plurality of the dyads overcoated on the substrate.

11. The assembly of claim 10, further comprising an additional layer between at least two of the dyads.

12. A composite assembly for protection of a moisture or oxygen sensitive article, comprising:

a substrate;

a polymer layer overcoated on the substrate; and

a diamond-like glass layer overcoated on the polymer layer.

13. The assembly of claim 12, wherein the substrate comprises a rigid material or a flexible material.

14. The assembly of claim 12, wherein the diamond-like glass layer comprises an at least substantially amorphous glass including carbon and silicon.

15. The assembly of claim 14, wherein the diamond-like glass layer further comprises one or more components selected from the group including hydrogen, nitrogen, oxygen, fluorine, sulfur, titanium, and copper.

16. The assembly of claim 12 wherein the diamond-like glass layer comprises an oxygen depleted layer having an oxygen to silicon ratio of less than approximately 1.5.

17. The assembly of claim 12, wherein the polymer layer overcoated on the diamond-like glass layer comprises a dyad and wherein the assembly has a plurality of the dyads overcoated on the substrate.

18. The assembly of claim 17, further comprising an additional layer between at least two of the dyads.

19. The assembly of claim 12, wherein the diamond-like glass layer, when approximately one micron thick, is at least 70% transmissive to radiation at substantially all wavelengths from about 400 nm to about 800 nm.

20. A process for fabricating a composite assembly for protection of a moisture or oxygen sensitive article, comprising:

providing a substrate;

overcoating a first polymer layer on the substrate; and

overcoating a second polymer layer on the first polymer layer,

wherein the first polymer layer is composed of a first polymer and the second polymer layer is composed of a second polymer different from the first polymer.

21. The process of claim 20, further comprising performing the step of overcoating the second polymer layer in an environment having a pressure of less than 10 mTorr and a substrate bias of greater than 500 V.

22. The process of claim 20, wherein the overcoating the second polymer step includes overcoating a plasma polymer.

23. A process for fabricating a composite assembly for protection of a moisture or oxygen sensitive article, comprising:

providing a substrate;

overcoating a polymer layer on the substrate; and

overcoating a diamond-like carbon layer on the polymer layer.

24. The process of claim 23, further comprising performing the step of overcoating the polymer layer in an environment having a pressure of less than 10 mTorr and a substrate bias of greater than 500 V.

25. A process for fabricating a composite assembly for protection of a moisture or oxygen sensitive article, comprising:

providing a substrate;

overcoating a polymer layer on the substrate; and

overcoating a diamond-like glass layer on the polymer layer.

26. The process of claim 25, further comprising performing the step of overcoating the polymer layer in an environment having a pressure of less than 10 mTorr and a substrate bias of greater than 500 V.

27. The process of claim 25, wherein the step of overcoating the diamond-like glass layer comprises overcoating an oxygen depleted layer having an oxygen to silicon ratio of less than approximately 1.5.