Gas Barrier Laminate Interface Carbon Gradient
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Solution Overview
Problem
Current gas barrier films, especially those used in liquid crystal and organic electroluminescence displays, face challenges with moisture and oxygen permeability, adhesiveness, flexibility, and environmental resistance, particularly when exposed to severe conditions, necessitating a material with enhanced gas barrier ability and durability.
Innovation Solution
A gas barrier laminate is developed with a substrate having alternating layers of polymer and gas barrier layers, where the average carbon content at the interface between these layers is strategically varied to improve adhesiveness and resistance, using a plasma CVD method under atmospheric pressure to form the polymer and gas barrier layers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a thin layer of metal oxide is vapor deposited on a plastic film substrate to improve gas barrier ability, then moisture barrier ability is improved (about 1 g/m2/day), but the gas barrier ability is still insufficient for high definition display applications requiring less than 0.1 g/m2/day
Solution Approach 1:
The gas barrier function is segmented into multiple thin layers (organic layer and inorganic layer) rather than relying on a single thick layer. This multilayer structure provides superior gas barrier performance (less than 0.1 g/m2/day) compared to single-layer approaches, enabling high definition display applications.
Solution Approach 2:
The patent uses composite materials combining organic polymer layers and inorganic metal oxide layers. This composite structure leverages the advantages of both material types - the flexibility and adhesion of organic materials combined with the excellent barrier properties of inorganic materials - to achieve the required gas barrier ability.
2Reliability
If multiple uniform layers of polymer and gas barrier are alternatively piled to improve gas barrier ability, then barrier performance is enhanced, but adhesiveness between layers deteriorates and flexibility is reduced
Solution Approach 1:
The patent applies local quality by creating layers with different compositions and properties at different positions. The organic layers and inorganic layers have distinct characteristics optimized for their specific functions, with intermediate layers providing graded transitions that improve interfacial adhesion while maintaining overall barrier performance.
Solution Approach 2:
Intermediate layers are introduced between the organic and inorganic layers to act as mediators. These intermediate layers improve the adhesiveness between the dissimilar materials, preventing delamination while maintaining the gas barrier function of the overall structure.
3Reliability
If a multilayered structure with uniform composition layers is used to achieve high gas barrier ability, then barrier performance is improved, but environmental resistance and bending resistivity deteriorate under severe storage conditions
Solution Approach 1:
The patent changes the compositional parameters of the layers, creating a non-uniform structure with varying organic-inorganic ratios across different layers. This parameter variation enhances environmental resistance and bending resistivity by distributing stress and preventing crack propagation, while maintaining superior gas barrier performance.
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 laminate achieves high gas barrier ability, improved adhesiveness, excellent bending resistance, and enhanced environmental resistance, maintaining performance even after prolonged storage under severe conditions, as demonstrated by reduced steam and oxygen permeability and maintained adhesiveness.
Implementation Method 1
using a plasma CVD method under atmospheric pressure to form the polymer and gas barrier layers
Data Source
AI summary
A gas barrier laminate comprising a substrate having thereon at least a gas barrier layer and a polymer layer, wherein at least one polymer layer is provided adjacent to at least one gas barrier layer; and an average carbon content of the polymer layer at a contact interface between the gas barrier layer is lower than an average carbon content in the polymer layer.