Composite Layer via Vapour Deposition for Barrier Stability

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Solution Overview

Problem

Existing barrier films with metal or metal oxide layers face challenges such as sensitivity to solvents, brittleness, and degradation during processing and retort conditions, leading to issues with printing, extrusion lamination, and maintaining barrier properties over time.

Innovation Solution

A process involving the application of an oligomeric organic compound layer on a substrate with a metal or metal oxide layer via vapour deposition, performed in-line to enhance protection and processing properties, utilizing a roll-to-roll process at reduced pressure and temperature, with specific conditions to ensure adhesion and stability.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If a metal or metal oxide layer is applied to enhance barrier properties, then oxygen and water vapor transmission rates are reduced, but the surface tension drops and processing becomes difficult

Engineering Contradiction:

Improvebarrier propertiesVSAvoidprocessing

Core Design Contradiction:

ReliabilityVSEase of operation

Solution Approach 1:

An oligomeric organic compound layer is deposited on the metal or metal oxide layer during the same vacuum process, serving as a protective top coat that maintains surface tension and prevents deterioration during subsequent processing steps

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The invention creates a composite structure with three layers: substrate, metal/metal oxide barrier layer, and oligomeric organic compound top layer. This composite structure combines the barrier properties of metal layers with the processing-friendly surface properties of organic compounds

Inventive Principle:

Principle #40Composite materials

2Ease of operation

If alumina layer is corona treated to maintain surface tension, then processing is enabled, but time and cost increase

Engineering Contradiction:

ImproveprocessingVSAvoidprocessing delay

Core Design Contradiction:

Ease of operationVSLoss of time

Solution Approach 1:

The oligomeric organic compound layer is deposited in advance during the vacuum coating process, providing immediate surface protection and eliminating the need for subsequent corona treatment steps

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The invention combines the barrier layer deposition and protective top coat application into a single vacuum process step, eliminating separate processing steps and reducing overall processing time

Inventive Principle:

Principle #5Merging (Combining)

3Reliability

If a coating is applied off line to protect metal oxide layers, then the layers are protected, but the process becomes more complex and time-consuming

Engineering Contradiction:

Improveprotection of metal oxide layerVSAvoidprocess complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The protective coating application is merged with the vacuum coating process, allowing both the barrier layer and protective layer to be deposited in the same chamber during the same vacuum cycle, simplifying the overall process

Inventive Principle:

Principle #5Merging (Combining)

4Reliability

If crystalline organic compounds are used as barrier layers, then barrier properties are provided, but sensitivity to solvents and printing increases

Engineering Contradiction:

Improvebarrier propertiesVSAvoidsensitivity to solvents

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The invention changes the physical state of the organic compound from crystalline to amorphous, which alters the material's properties to reduce solvent sensitivity while maintaining barrier functionality

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The oligomeric organic compound provides localized protection at the surface level without requiring the entire structure to be crystalline, allowing the bulk metal oxide layer to maintain its barrier properties while the surface layer provides solvent resistance

Inventive Principle:

Principle #3Local quality

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

The solution provides a stable and printable composite layer with improved lamination strength and barrier properties, maintaining surface tension and resistance to processing and retort conditions, thus overcoming the limitations of prior art.

Implementation Method 1

vapour depositing the oligomeric organic compound on the metal or metal oxide layer while the film remains at reduced pressure

Methodology Applied

Scientific EffectVapour deposition: Physical Vapour Deposition

Implementation Method 2

the oligomeric compound is evaporated from an oligomeric or polymeric compound comprising a stabilizer

Methodology Applied

Scientific EffectEvaporation: Evaporation

Data Source

PatentEP3161179B1A process for preparation of a composite layer or a laminate, and product obtained therewith

Publication Date: 2019.04.24 KNOWFORT HOLDING BV

AI summary

The invention relates to a process for preparing a composite layer, by applying an oligomeric organic compound layer on a substrate with a metal or metal oxide layer by vapour deposition, comprising the steps of (a) providing a substrate layer, (b) applying a metal or metal oxide layer under reduced pressure on said substrate, and (c) vapour depositing the oligomeric organic compound on the metal or metal oxide layer while the film remains at reduced pressure, wherein the oligomeric compound is evaporated from an oligomeric or polymeric compound comprising a stabiliser, or wherein the oligomeric compound is amorphous, or has a high solubility in certain solvents.