Gas Barrier Laminate Primer Layer Modulus for Winding Stability
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Solution Overview
Problem
Gas barrier films used in displays and solar cells face deterioration in gas barrier capability when exposed to high temperatures and humidity, and exhibit poor winding capabilities due to issues like cracking and winding failure.
Innovation Solution
A gas barrier laminate is developed with a primer layer and a gas barrier layer sequentially stacked on a base, where the primer layer has a modulus of elasticity at 90°C of 1.6 GPa or more and the coefficient of static friction between the laminate surfaces is 0.35 to 0.8, enhancing durability and winding capabilities.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If a gas barrier layer is stacked on a transparent plastic film to reduce thickness and weight, then flexibility and weight are improved, but gas barrier capability deteriorates due to thermal shrinkage of the base film under high temperature and humidity
Solution Approach 1:
A primer layer is introduced as an intermediary between the base film and the gas barrier layer. This primer layer has a modulus of elasticity of 1.6 GPa or more at 90°C, which provides mechanical support to prevent thermal shrinkage of the base film and maintains the gas barrier capability of the overlaid inorganic layer under high temperature and humidity conditions.
Solution Approach 2:
The invention uses a composite structure consisting of a base film, a primer layer with specific mechanical properties, and an inorganic gas barrier layer. This composite material system combines the flexibility of the plastic base film with the dimensional stability of the rigid primer layer and the gas barrier properties of the inorganic layer, resolving the contradiction between weight reduction and gas barrier reliability.
2Ease of operation
If the gas barrier layer is made flexible to improve winding capability, then flexibility is improved, but gas barrier capability deteriorates due to cure shrinkage under high temperature and humidity
Solution Approach 1:
The primer layer serves as a mediator that compensates for the cure shrinkage of the flexible gas barrier layer. By providing mechanical support with its high modulus of elasticity, the primer layer prevents the gas barrier layer from shrinking excessively during curing, thereby maintaining gas barrier capability while allowing the overall structure to remain flexible for winding operations.
3Productivity
If a long gas barrier film is produced using roll-to-roll method, then productivity is improved, but winding failure occurs due to blocking or wrinkles
Solution Approach 1:
The invention changes the mechanical parameter of the laminate by introducing a primer layer with a modulus of elasticity of 1.6 GPa or more at 90°C. This parameter change improves the dimensional stability and surface flatness of the laminate, preventing blocking and wrinkles during winding, thereby enabling successful roll-to-roll production of long gas barrier films with high productivity.
Data Source
Figure 1
AI summary
The present invention provides: a gas barrier laminate comprising a base, a primer layer, and a gas barrier layer, the primer layer and the gas barrier layer being sequentially stacked on at least one side of the base, the primer layer having a modulus of elasticity at 90°C of 1.6 GPa or more, and a coefficient of static friction between a surface of one side of the gas barrier laminate and a surface of the other side of the gas barrier laminate being 0.35 to 0.8; a method for producing the gas barrier laminate; an electronic device member comprising the gas barrier laminate; and an electronic device.