Method of processing coated flexible substrates for encapsulation applications

Abstract

A method of processing a coated flexible substrate is described. The method of processing a coated flexible substrate includes: providing the coated flexible substrate, the coated flexible substrate including: a flexible substrate including a first surface and a second surface opposite the first surface, and at least one barrier layer on the first surface of the flexible substrate; and simultaneously providing a beam of charged particles to the at least one barrier layer and the flexible substrate of the coated flexible substrate in a substantially oxygen-free atmosphere.

Description

TECHNICAL FIELD

[0001] Embodiments of the present disclosure relate to a method of treating a coated flexible substrate for packaging applications.

[0002] BACKGROUND

[0003] Coated flexible substrates made of a polymer flexible substrate and a barrier layer deposited on the polymer flexible substrate are known in the packaging industry for packaging food, chemicals, pharmaceuticals or agricultural products and for protecting these packaged goods from harmful moisture and / or oxygen.

[0004] The most commonly used coated flexible substrates comprise a polymer flexible substrate with at least one barrier layer deposited on the polymer flexible substrate. Currently, in most cases, metals (e.g. aluminum and tinplate), polymers (e.g. EVOH or PVDC), polymers coated with a thin metal or oxide layer are used as barrier layer material. In order to produce such coated flexible substrates, one or more barrier layers can be deposited at the surface of the polymer flexible substrate by an evaporation process. In some cases, an uppermost layer made of a polymer is additionally provided on the barrier layer.

[0005] While such commonly used barrier layers provide a good protection against moisture and / or oxygen, it is observed that their barrier properties degrade over time. Furthermore, in case of damage of the barrier layer, for example during transportation of the goods protected by the coated flexible substrate, the barrier properties of the coated flexible substrate are also reduced. Furthermore, the protection of very sensitive goods, such as electronic devices, from moisture and / or oxygen requires a coated flexible substrate with an extremely low oxygen transmission rate.

[0006] Therefore, there is an ongoing need for a method for generally improving the barrier properties of coated flexible substrates for packaging applications. SUMMARY

[0007] In view of the foregoing, a method of treating a coated flexible substrate for packaging applications is provided. It is an object of the present disclosure to provide a method of improving the oxygen barrier properties of a coated flexible substrate for packaging applications. Further, it is an object of the present disclosure to improve the oxygen barrier properties of a coated flexible substrate without the need for additional barrier layer materials or complex production systems. Thus, the method is low in manufacturing cost and high in production efficiency. Further, it is an object of the present disclosure to provide a coated flexible substrate with additional protection that can act in the event of damage to the barrier layer disposed on the flexible substrate or when oxygen reaches the flexible substrate after diffusing through the barrier layer disposed on the flexible substrate. Further, it is an object of the present disclosure to create a new function acting as an oxygen scavenger in the already existing flexible substrate of a coated flexible substrate, thereby providing additional oxygen barrier properties.

[0008] Further aspects, benefits, and features of the present disclosure are apparent from the claims, the specification, and the accompanying drawings.

[0009] According to an aspect of the present disclosure, a method of treating a coated flexible substrate for packaging applications is provided. The method of treating a coated flexible substrate includes providing a coated flexible substrate comprising: a flexible substrate including a first surface and a second surface opposite the first surface, and at least one barrier layer on the first surface of the flexible substrate. The method further includes simultaneously providing a beam of charged particles to the at least one barrier layer and the flexible substrate of the coated flexible substrate in an atmosphere substantially free of oxygen.

[0010] BRIEF DESCRIPTION OF THE DRAWINGS

[0011] For a more detailed understanding of the above-mentioned features of the present disclosure, reference can be made to the more particular description of the disclosure that is briefly described below. The accompanying drawings relate to embodiments and are described as follows:

[0012] Figure 1 A flow chart showing a method of treating a coated flexible substrate for packaging applications according to embodiments described herein is shown;

[0013] Figure 2 A schematic diagram showing a method of treating a coated flexible substrate for packaging applications according to embodiments described herein is shown, including a microscopic view of the coated flexible substrate;

[0014] Figures 3A to 3C A schematic cross-sectional side view of a coated flexible substrate for packaging applications according to embodiments described herein is shown;

[0015] Figure 4 A schematic of an apparatus for processing a coated flexible substrate for packaging applications according to embodiments described herein is shown. DETAILED DESCRIPTION

[0016] Reference will now be made in detail to various embodiments, one or more examples of which are illustrated in the drawings. Within the following description of each drawing, same reference numbers refer to same components. Generally, only the differences between respective embodiments are described. Each example is provided by way of explanation of the disclosure and is not meant as a limitation thereof. Further, features illustrated or described as part of one embodiment can be used with other embodiments, or vice versa, to produce yet a further embodiment. It is intended that the description included herein be considered as exemplary only and that the scope of the disclosure be determined by the claims.

[0017] Coated flexible substrates (e.g., made of a polymer flexible substrate and a barrier layer deposited on the polymer flexible substrate to prevent moisture and / or oxygen diffusion or passage through the coated flexible substrate) are known in the packaging industry for packaging food, chemicals and pharmaceuticals, and technical products or other agricultural products. However, it has been observed that the barrier properties of the coated flexible substrates degrade over time. For example, in the event that the barrier layer deposited on the flexible substrate is damaged during transportation of the items protected by the coated flexible substrate, the barrier properties of the coated flexible substrate are reduced. Further, over time, oxygen diffuses through the barrier layer provided on the flexible substrate, which also reduces the protection of the items from oxygen. Further, the protection of certain items (e.g., electronic devices) from oxygen requires a coated flexible substrate having an extremely low oxygen transmission rate.

[0018] However, it is an object of the present disclosure to provide a method of improving the oxygen barrier properties of a coated flexible substrate for packaging applications. Examples of packaging applications can include modified atmosphere packaging. In particular, the provision of a beam of charged particles into a coated flexible substrate comprising at least one barrier layer and a flexible substrate in an atmosphere substantially free of oxygen helps to create a new function acting as an oxygen scavenger in the already existing flexible substrate of the coated flexible substrate. The newly created function provides the coated flexible substrate with additional oxygen barrier properties.

[0019] Furthermore, providing the charged particle beam into the coated flexible substrate comprising the at least one barrier layer and the flexible substrate in an atmosphere substantially free of oxygen leads to a breaking of polymer chains of a portion of the flexible substrate, which imparts additional oxygen barrier properties to the flexible substrate. In other words, due to the provision of the charged particle beam into the coated flexible substrate and the corresponding breaking of polymer chains of a portion of the flexible substrate, free radicals are generated in the flexible substrate of the coated flexible substrate. The free radicals act as oxygen scavengers once oxygen reaches the flexible substrate after diffusion through the at least one barrier layer, e.g. once the at least one barrier layer is damaged during transportation of the article to be protected.

[0020] It is an object of the present disclosure to improve the oxygen barrier properties of a coated flexible substrate without the need for additional barrier layer materials or complex production systems. Thus, the method of the present disclosure is performed at low manufacturing costs and high production efficiency.

[0021] With exemplary reference to Figure 1 A method 100 of treating a coated flexible substrate for packaging applications according to the present disclosure is described. Starting with a start 110, the method 100 can comprise providing a coated flexible substrate comprising a flexible substrate comprising a first surface and a second surface opposite to the first surface, and at least one barrier layer on the first surface of the flexible substrate (stage 120). Furthermore, the method 100 of treating a coated flexible substrate for packaging applications can comprise simultaneously providing a charged particle beam into the at least one barrier layer and the flexible substrate of the coated flexible substrate in an atmosphere substantially free of oxygen (stage 130). The method 100 can end with an end 140.

[0022] Before various further embodiments of the present disclosure are described in more detail, some aspects regarding some terms used herein are explained.

[0023] In the present disclosure, the “flexible substrate” can be characterized in that the substrate is bendable. For example, the flexible substrate can be a foil or a web. In particular, it is to be understood that embodiments as described herein can be used to treat any kind of coated flexible substrate for packaging applications. The flexible substrate as described herein can comprise a substrate material selected from the group consisting of polyethylene, polypropylene, polyisobutylene, polyvinylidene chloride, polytetrafluoroethylene, polyamide, polyethylene terephthalate, polystyrene, polyethylene vinyl alcohol, polyethylene vinyl acetate, polyethyl methacrylate, and combinations thereof. In particular, the flexible substrate is a polymeric flexible substrate. The substrate thickness T S may be T S ≤ 250 pm, in particular 5 pm ≤ T S ≤ 150 pm, more particularly 5 pm ≤ T S≤ 100 pm, for example T S = 50 pm ± 1 nm. It will be appreciated that selecting a flexible substrate having a thickness T S of as specified herein can be beneficial to provide for a breaking of polymer chains of portions of the flexible substrate and, thus, to provide free radicals to act as oxygen scavengers without degrading the mechanical properties of the flexible substrate.

[0024] In the present disclosure, the term "charged particle" can be understood as a particle carrying an electric charge. For example, the charged particle can be an ion or an electron. According to one embodiment, the charged particle is an electron.

[0025] In the present disclosure, the term "barrier layer" can be understood as a coating, layer or film providing the coated flexible substrate with oxygen barrier properties, in particular oxygen and moisture barrier properties. The barrier layer and / or the at least one barrier layer can have oxygen barrier properties, in particular oxygen and moisture barrier properties.

[0026] For example, when referring to the term "on", for example on the at least one barrier layer on the first surface of the flexible substrate, it is to be understood that starting from the flexible substrate, the at least one barrier layer is positioned on the flexible layer. In other words, the term "on" is used to define the order of the at least one barrier layer of the flexible substrate, the plurality of barrier layers of the flexible substrate and / or the flexible substrate, wherein the starting point is the flexible substrate. This is independent of whether the coated flexible substrate is depicted upside down or not.

[0027] Figure 2 A schematic diagram showing a method 100 of processing a coated flexible substrate for encapsulation applications is shown, according to embodiments described herein, including a microscopic view of the coated flexible substrate. In particular, the coated flexible substrate can comprise a flexible substrate 210 comprising a first surface and a second surface opposite to the first surface, and at least one barrier layer 220 on the first surface of the flexible substrate 210. In some embodiments, the at least one barrier layer 220 can be directly on the first surface of the flexible substrate 210.

[0028] According to some embodiments, which can be combined with other embodiments, providing the coated flexible substrate can further comprise providing the at least one barrier layer 220 on the first surface of the flexible substrate 210, in particular directly on the first surface of the flexible substrate 210.

[0029] In some embodiments, providing the coated flexible substrate can further include providing the coating composition on the at least one barrier layer 220, in particular directly on the at least one barrier layer 220, for example in an atmosphere substantially free of oxygen. In this case, the coated flexible substrate can further include the coating composition. Moreover, simultaneously providing the charged particle beam 240 to the at least one barrier layer 220 and the flexible substrate 210 of the coated flexible substrate in an atmosphere substantially free of oxygen can further include simultaneously providing the charged particle beam 240 to the coating composition in an atmosphere substantially free of oxygen. In some embodiments, the coating composition can include acrylate monomers, methacrylate monomers, acrylate oligomers, methacrylate oligomers, and combinations thereof.

[0030] The coating composition can form an uppermost layer on the at least one barrier layer 220, for example after being cured or polymerized by providing the charged particle beam. The uppermost layer can provide mechanical protection to the at least one barrier layer, for example against mechanical damage. The uppermost layer can also have oxygen barrier properties, in particular moisture and oxygen barrier properties. The coating composition can be provided on the at least one barrier layer 220 by using a coating method, in particular by a solution coating method, in particular selected from the group consisting of gravure coating, flow coating, curtain coating, dip coating, spray coating, print coating, and combinations thereof. In some embodiments, the thickness T c of the uppermost layer can be 0.1 pm ≤ T c ≤ 1.5 pm, in particular 0.1 pm ≤ T c ≤ 0.7 pm, more particularly 0.1 pm ≤ T c ≤ 0.5 pm.

[0031] As Figure 2Exemplarily shown, according to embodiments combinable with other embodiments described herein, the beam of charged particles 240 can be provided by a source of charged particles 230 positioned on the at least one barrier layer 220 or on the coating composition. Such a position of the source of charged particles 230 can be beneficial, as the curing or polymerization of the coating composition on the at least one barrier layer 220 can additionally be performed during the processing of the coated flexible substrate for packaging applications according to the present disclosure. Thus, in embodiments with a coating composition on the at least one barrier layer 220, the simultaneous provision of the beam of charged particles 240 to the coating composition of the coated flexible substrate, the at least one barrier layer 220 and the flexible substrate 210 in an atmosphere substantially free of oxygen can further comprise curing or polymerizing the coating composition on the at least one barrier layer 220, e.g. by employing the beam of charged particles 240. According to the present disclosure, curing or polymerizing the coating composition on the at least one barrier layer 220 and processing the coated flexible substrate for packaging applications can be performed simultaneously.

[0032] Further, the position of the source of charged particles 230 allows for curing or polymerizing the coating composition on the at least one barrier layer 220 without the need to cross the beam of charged particles 240 across the substrate thickness T of the flexible substrate 210 S and thus, the curing or polymerizing of the barrier layer of the at least one barrier layer 220 is achieved at a reduced energy E of the charged particles. Further, such a position of the source of charged particles 230 can be beneficial, as only once oxygen diffuses through the at least one barrier layer to the flexible substrate, or once the at least one barrier layer is damaged, e.g. during transportation of an article protected by the coated flexible substrate, the free radicals generated in the flexible substrate act as oxygen scavengers. However, it should be understood that the position of the source of charged particles 230 is not limited to a position on the at least one barrier layer 220 or on the coating composition, and any suitable position allowing for curing or polymerizing the coating composition on the at least one barrier layer 220 can be used.

[0033] It should be understood that embodiments of the present disclosure are not limited to the source of charged particles 230 for providing the beam of charged particles 240. The embodiments described herein serve to explain the concept of the method of processing the coated flexible substrate for packaging applications. Thus, it should be understood that more than one source of charged particles for providing the beam of charged particles 240 can be implemented.

[0034] In some embodiments, the beam of charged particles 240 can have a conical shape. For example, the conical shape can be substantially symmetrical with respect to the main direction of the respective beam. In Figure 2 In the figure, the main direction 240M is indicated.

[0035] According to some embodiments that can be combined with other embodiments, the charged particle energy E of the charged particles in the charged particle beam 240 can be 5keV ≤ E ≤ 250keV, particularly 30keV ≤ E ≤ 220keV, and more particularly 50keV ≤ E ≤ 220keV. In some embodiments, the charged particle dose of the charged particle beam 240 can be from 1000 to 1×10⁻⁶. 5 Gray, especially 3000 to 1×10 4 Gray, more specifically 3000 to 8000 Gray. It should be understood that the values ​​of the charged particle energy E and the charged particle dose of the charged particle beam 240 can be adjusted according to the material and / or the thickness of at least one barrier layer and / or flexible substrate.

[0036] like Figure 2 As exemplarily indicated by the double-headed arrows, for example, when processing a coated flexible substrate for an encapsulation application according to the method of this disclosure, the flexible substrate may be moved in the transport direction T. Therefore, the method of processing a coated flexible substrate for an encapsulation application may further include moving the coated flexible substrate in the transport direction T. For example, moving the coated flexible substrate may include moving it at a speed of 1 m / s ≤ V s ≤15m / s, especially 2m / s≤V s ≤10m / s, and more particularly 3m / s≤V s ≤7m / s, for example, V s =4.5m / s ± 0.5m / s or V s The velocity V = 6.0 m / s ± 0.5 m / s s The coated flexible substrate is moved. According to another example, the coated flexible substrate moves at a speed V. s It can be 12m / s≤V s ≤15m / s.

[0037] like Figure 2 As exemplarily shown, a beam of charged particles 240 simultaneously provided to at least one barrier layer 220 and a flexible substrate 210 of a coated flexible substrate in a substantially oxygen-free atmosphere can simultaneously penetrate the at least one barrier layer 220 and the flexible substrate 210 of the coated flexible substrate. In embodiments where a coating composition is present on at least one barrier layer 220, the beam of charged particles 240 simultaneously provided to the coating composition, at least one barrier layer 220 and the flexible substrate 210 of the coated flexible substrate in a substantially oxygen-free atmosphere can simultaneously penetrate the coating composition, at least one barrier layer 220 and the flexible substrate 210 of the coated flexible substrate.

[0038] In some embodiments, simultaneously providing the beam of charged particles 240 to the at least one barrier layer 220 and the flexible substrate 210 of the coated flexible substrate in an atmosphere substantially free of oxygen can further comprise adjusting at least one of the charged particle energy E of the charged particles of the beam of charged particles 240 and the charged particle dose of the beam of charged particles 240. In embodiments in which the at least one barrier layer 220 has a coating composition on it, simultaneously providing the beam of charged particles 240 to the coating composition, the at least one barrier layer 220 and the flexible substrate 210 of the coated flexible substrate in an atmosphere substantially free of oxygen can further comprise adjusting at least one of the charged particle energy E of the charged particles of the beam of charged particles 240 and the charged particle dose of the beam of charged particles 240.

[0039] Thus, varying the charged particle energy E of the charged particles of the beam of charged particles 240 adjusts the average penetration depth 210p of the beam of charged particles 240 in the flexible substrate 210. Thus, the breaking of polymer chains and corresponding free radicals of the flexible substrate 210 can be created at different penetration depths in the flexible substrate 210. Furthermore, varying the charged particle dose of the beam of charged particles 240 adjusts the number of broken polymer chains and corresponding free radicals of the flexible substrate 210 at the average penetration depth 210p in the flexible substrate 210.

[0040] The term “penetration depth” in the present disclosure refers to the distance of the beam of charged particles 240 penetrating the flexible substrate 210, e.g. along a thickness direction, from a first surface of the flexible substrate 210, e.g. on which the at least one barrier layer is positioned or deposited. In some embodiments, the average penetration depth 210p of the charged particles of the beam of charged particles 240 in the flexible substrate 210 from the first surface is equal to at least 10% of the substrate thickness T S of the flexible substrate, in particular at least 40% of the substrate thickness T S of the flexible substrate, more particularly at least 70% of the substrate thickness T S of the flexible substrate.

[0041] Figure 2 A schematic cross-sectional side view of a coated flexible substrate for encapsulation applications according to embodiments described herein is shown. In Figures 3A to 3C , the coated flexible substrate according to the present application comprises a flexible substrate 310 comprising a first surface and a second surface opposite to the first surface, and at least one barrier layer 320 on the first surface of the flexible substrate 310, in particular directly on the first surface of the flexible substrate 310.

[0042] In some embodiments, as Figures 3A to 3CExemplarily shown, the coated flexible substrate according to the present disclosure can include a flexible substrate 310 including a first surface and a second surface opposite to the first surface, and a barrier layer 320 on the first surface of the flexible substrate 310, in particular directly on the first surface of the flexible substrate 310.

[0043] In some embodiments, as Figure 3A Exemplarily shown, the coated flexible substrate according to the present disclosure can include a flexible substrate 310 including a first surface and a second surface opposite to the first surface, a first barrier layer 320a on the first surface of the flexible substrate 310, in particular directly on the first surface of the flexible substrate 310, and a second barrier layer 320b on the first barrier layer 320a, in particular directly on the first barrier layer 320a. Thus, the at least one barrier layer 320 can include the first barrier layer 320a and the second barrier layer 320b. As an example, the first barrier layer 320a can include aluminum or aluminum oxide. Further, the second barrier layer 320b can include an organic material such as acrylate monomer, methacrylate monomer, acrylate oligomer, methacrylate oligomer, polyacrylate, polymethacrylate, melamine resin, and combinations thereof.

[0044] In some embodiments, as Figure 3BIllustratively shown, the coated flexible substrate according to the present disclosure can include: a flexible substrate 310 including a first surface and a second surface opposite the first surface; a first barrier layer 320a on the first surface of the flexible substrate 310, particularly directly on the first surface of the flexible substrate 310; a second barrier layer 320b on the first barrier layer 320a, particularly directly on the first barrier layer 320a; and a third barrier layer 320c on the second barrier layer 320b, particularly directly on the second barrier layer 320b. Thus, the at least one barrier layer 320 can include the first barrier layer 320a, the second barrier layer 320b, and the third barrier layer 320c. As an example, the first barrier layer 320a can include aluminum or aluminum oxide. Further, the second barrier layer 320b can include silicon dioxide. Further, the third barrier layer 320c can include an organic material, such as an acrylate monomer, a methacrylate monomer, an acrylate oligomer, a methacrylate oligomer, a polyacrylate, a polymethacrylate, a melamine resin, and combinations thereof. As another example, the first barrier layer 320a can include polyvinyl alcohol and / or polyethylene vinyl alcohol. Further, the second barrier layer 320b can include aluminum, aluminum oxide, and / or silicon dioxide. Further, the third barrier layer 320c can include an organic material, such as an acrylate monomer, a methacrylate monomer, an acrylate oligomer, a methacrylate oligomer, a polyacrylate, a polymethacrylate, a melamine resin, and combinations thereof.

[0045] The at least one barrier layer 320 or at least one of the barrier layers of the at least one barrier layer 320, such as the first barrier layer 320a, the second barrier layer 320b, or the third barrier layer 320c, can include a material selected from the group consisting of aluminum, aluminum oxide, aluminum nitride, silicon, silicon dioxide, an organic material, and combinations thereof. Examples of the organic material are polyvinyl alcohol, polyethylene vinyl alcohol, polyvinylidene chloride, an acrylate monomer, a methacrylate monomer, an acrylate oligomer, a methacrylate oligomer, a polyacrylate, a polymethacrylate, a melamine resin, and combinations thereof. However, it should be appreciated that the material of the at least one barrier layer 320 or at least one of the barrier layers of the at least one barrier layer 320 is not limited to aluminum, aluminum oxide, aluminum nitride, silicon, silicon dioxide, an organic material, and combinations thereof, and any suitable material having oxygen barrier properties, particularly moisture and oxygen barrier properties, can be used as the material of the at least one barrier layer 320 or at least one of the barrier layers of the at least one barrier layer 320.

[0046] In some embodiments, at least one of the at least one barrier layer 320 or at least one of the barrier layers of the at least one barrier layer 320, e.g., the first barrier layer 320a, the second barrier layer 320b, or the third barrier layer 320c, can be an oxygen barrier. In some embodiments, at least one of the at least one barrier layer 320 or at least one of the barrier layers of the at least one barrier layer 320, e.g., the first barrier layer 320a, the second barrier layer 320b, or the third barrier layer 320c, can be a moisture and oxygen barrier.

[0047] In some embodiments, the coated flexible substrate treated according to the methods of the present disclosure can have a water vapor transmission rate (WVTR; in grams per cm2per day) and / or an oxygen transmission rate (OTR) of less than 10, in particular less than 1, more in particular about 0.5. The oxygen transmission rate and the water vapor transmission rate can be determined using Mocon Oxtran 2 / 22 and Systech Illinois 8001 for oxygen permeation and Mocon Permatran-W 3 / 33 and Systech Ilinois 7001 for water vapor permeation according to ASTM D3985-17 and ASTM F1249-20. 2

[0048] According to some embodiments, at least one of the at least one barrier layer 320 or at least one of the barrier layers of the at least one barrier layer 320, e.g., the first barrier layer 320a, the second barrier layer 320b, or the third barrier layer 320c, can be manufactured by chemical vapor deposition or physical vapor deposition, e.g., sputtering or evaporation. Examples of physical vapor deposition can be electron beam physical vapor deposition and sputter deposition. In some embodiments, providing the coated flexible substrate can comprise depositing the at least one barrier layer on the flexible substrate, in particular directly on the flexible substrate.

[0049] Alternatively, e.g., when at least one of the barrier layers of the at least one barrier layer 320, e.g., the first barrier layer 320a, the second barrier layer 320b, or the third barrier layer 320c, is liquid and comprises an organic material, e.g., polyvinyl alcohol, polyethylene vinyl alcohol, acrylate monomers, methacrylate monomers, acrylate oligomers, methacrylate oligomers, polyacrylate, polymethacrylate, melamine resin, and combinations thereof, at least one of the at least one barrier layer 320 or at least one of the barrier layers of the at least one barrier layer 320, e.g., the first barrier layer 320a, the second barrier layer 320b, or the third barrier layer 320c, can be provided on the flexible substrate 310 by using a coating method and in particular by a solution coating method, in particular selected from the group consisting of gravure coating, flow coating, curtain coating, dip coating, spray coating, and combinations thereof. In some embodiments, the thickness T b ​may be 0.05 pm < T < 5 pm, in particular 0.1 pm < T < 5 pm b may be 0.05 pm < T < 5 pm, in particular 0.1 pm < T < 5 pm b may be 0.05 pm < T < 5 pm, in particular 0.1 pm < T < 5 pm b may be 0.05 pm < T < 5 pm, in particular 0.1 pm < T < 5 pm

[0050] According to an aspect of the present disclosure, a coated flexible substrate for encapsulation applications is provided. In some embodiments, the coated flexible substrate can be a substrate that has been treated by the methods of the present disclosure. The coated flexible substrate can comprise: a flexible substrate comprising a first surface and a second surface opposite the first surface; and at least one barrier layer on the first surface of the flexible substrate. In some embodiments, the at least one barrier layer can be directly on the first surface of the flexible substrate. The properties of the flexible substrate for encapsulation applications and the at least one barrier layer of the treated coated flexible substrate, such as the substrate thickness T s , the substrate material, the thickness Tb, and the material of the at least one barrier layer are as described in the present disclosure. In some embodiments, the coated flexible substrate, e.g., after having been treated according to the methods of the present disclosure, can have a water vapor transmission rate (WVTR; in g / cm 2 / day) and / or an oxygen transmission rate (OTR) of less than 10, in particular less than 1, more particularly about 0.5. The oxygen and water vapor transmission rates can be determined as described in the present disclosure.

[0051] With exemplary reference to Figure 3C , an apparatus 400 for treating a coated flexible substrate 440 for encapsulation applications according to the present disclosure is described. According to embodiments, which can be combined with other embodiments described herein, the apparatus 400 comprises a treatment drum 410 for guiding the coated flexible substrate 440. In addition, the apparatus 400 comprises a printing arrangement 420 for printing, e.g., a coating composition, on the at least one barrier layer of the coated flexible substrate 440. For example, the at least one barrier layer can comprise aluminum or aluminum oxide. Further, the apparatus 400 comprises a charged particle source 430 for treating the coated flexible substrate 440.

[0052] With exemplary reference to Figure 4The printing arrangement 420 may include a supply device 421 for supplying the coating composition. For example, the supply device 421 may be a monomer reservoir. Furthermore, the printing arrangement 420 may include a first roller 422 (e.g., an anilox roller) and a second roller 424 (e.g., a transfer roller). Specifically, the first roller 422 may be arranged parallel to the processing drum 410 and the second roller 424. Between the transfer roller and the processing drum 410, a coated flexible substrate 440 may be transported during processing, for example, by coating or printing the coating composition onto at least one barrier layer of the coated flexible substrate 440. Therefore, it should be understood that the coating composition may be applied from the reservoir to the surface of the first roller 422 (e.g., the surface of the anilox roller) as the surface of the first roller 422 passes through the reservoir. Furthermore, as... Figure 4 Figure 4 As exemplarily shown, a typical printing arrangement 420 includes a doctor blade assembly 423 having at least one elongated doctor blade extending in a direction parallel to the axis of rotation of the first roller 422.

[0053] This written description uses examples to disclose the contents of this disclosure, including best practices, and also enables any person skilled in the art to practice the described subject matter, including making and using any device and performing any combined methods. Although various specific embodiments have been disclosed in the foregoing, the non-exclusive features of the embodiments described above can be combined with each other. The scope of patent protection is defined by the claims, and other examples are contemplated within the scope of the claims, provided that such other examples have structural elements that are not different from the literal language of the claims, or provided that the claims include equivalent structural elements that are not substantially different from the literal language of the claims.

[0054] While the foregoing describes some implementations, other and further implementations are conceivable without departing from the basic scope, and the scope is defined by the appended claims.

Claims

1. A method of treating a flexible substrate for encapsulation applications, comprising: providing a flexible substrate, the flexible substrate comprising a first surface and a second surface opposite the first surface; depositing a plurality of barrier layers on the first surface of the flexible substrate; and simultaneously providing a beam of charged particles to the plurality of barrier layers and the flexible substrate in an atmosphere substantially free of oxygen; and and determining that the water vapor transmission rate and / or oxygen transmission rate of the flexible substrate having the plurality of barrier layers deposited thereon is less than 10; wherein simultaneously providing a beam of charged particles to the plurality of barrier layers and the flexible substrate in an atmosphere substantially free of oxygen comprises adjusting a charged particle energy E of the charged particles of the beam of charged particles; wherein the charged particle beam penetrates from the first surface of the flexible substrate to an average penetration depth, the average penetration depth being equal to at least 10% of a substrate thickness T of the flexible substrate S .

2. The method of claim 1, wherein the beam of charged particles is provided from a source of charged particles positioned above the plurality of barrier layers.

3. The method of claim 1, wherein simultaneously providing a beam of charged particles to the plurality of barrier layers and the flexible substrate in an atmosphere substantially free of oxygen further comprises adjusting a charged particle dose of the beam of charged particles.

4. The method of claim 1, wherein a charged particle energy E of the charged particles of the beam of charged particles is 5 keV < E < 250 keV.

5. The method of claim 1, wherein a charged particle energy E of the charged particles of the beam of charged particles is 30 keV < E < 220 keV.

6. The method of claim 1, wherein the charged particle dose of the charged particle beam is 1000 to 1 x 10 5 Gy.

7. The method of claim 1, wherein the charged particle dose of the charged particle beam is 3000 to 1 x 10 4 Gy.

8. The method according to any of claims 1 to 5, wherein the average penetration depth of the charged particles of the charged particle beam in the flexible substrate from the first surface is equal to at least 40% of a substrate thickness T of the flexible substrate. S 8. The method according to any of claims 1 to 5, wherein the average penetration depth of the charged particles of the charged particle beam in the flexible substrate from the first surface is equal to at least 40% of a substrate thickness T of the flexible substrate. S 8. The method according to any of claims 1 to 5, wherein the average penetration depth of the charged particles of the charged particle beam in the flexible substrate from 9. The method according to any of claims 1 to 5, wherein the flexible substrate has a substrate thickness T < 250 pm S .

10. The method according to any one of claims 1 to 5, wherein the flexible substrate has a substrate thickness T S ≤ 150 pm. S .

11. The method of any one of claims 1 to 5, wherein the flexible substrate comprises a substrate material selected from the group consisting of polyethylene, polypropylene, polyisobutylene, polyvinylidene chloride, polytetrafluoroethylene, polyamide, polyethylene terephthalate, polystyrene, polyvinyl alcohol, polyethylene vinyl acetate, polymethyl acrylate, and combinations thereof.

12. The method of any one of claims 1 to 5, wherein the charged particles are electrons.

13. The method of any one of claims 1 to 5, wherein the total thickness T of the plurality of barrier layers is 0.05 pm < T < 5 pm. b b 5 pm.​ 14. The method of any one of claims 1 to 5, wherein the plurality of barrier layers have a thickness T b 0.1 pm < T b ≤ 2 pm.

15. The method of any one of claims 1 to 5, wherein the plurality of barrier layers comprises a first barrier layer selected from the group consisting of aluminum, aluminum oxide, aluminum nitride, silicon, and silicon dioxide, and a second barrier layer consisting of an organic material selected from the group consisting of acrylate monomers, methacrylate monomers, acrylate oligomers, methacrylate oligomers, polyacrylates, polymethacrylates, melamine resins, and combinations thereof.

16. The method of claim 1, wherein a charged particle energy E of the charged particles of the beam of charged particles is 50 keV < E < 220 keV.

17. The method of any one of claims 1 to 5, wherein the charged particles are ions.

18. The method of any one of claims 1 to 5, wherein the plurality of barrier layers are oxygen and moisture barriers.

19. The method of any one of claims 1 to 5, further comprising providing a coating composition on the plurality of barrier layers, and wherein providing a beam of charged particles further comprises simultaneously providing a beam of charged particles to the coating composition in a substantially oxygen-free atmosphere.

20. The method of claim 19, wherein the coating composition comprises acrylate monomers, methacrylate monomers, acrylate oligomers, methacrylate oligomers, and combinations thereof.

21. The method of claim 19, wherein the coating composition is polymerized to form an uppermost layer on the plurality of barrier layers by providing the beam of charged particles.

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