Gas Barrier Layer for Flexible Electronic Devices
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Solution Overview
Problem
Existing gas barrier plastic films used in displays and packaging are prone to deterioration when bent or rolled due to cracks in the metal oxide gas barrier layer, and existing methods for enhancing gas barrier capability, such as forming a polysilazane film, require thick layers to achieve sufficient performance.
Innovation Solution
A formed article comprising a base layer, a primer layer with a hydroxyl group-containing polymer, and a gas barrier layer formed of a material with specific oxygen, nitrogen, and silicon atom content rates, and a polysilazane compound layer that is ion-implanted using plasma ion implantation to achieve a robust gas barrier while maintaining transparency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a metal oxide gas barrier layer is stacked on a transparent plastic film by evaporation, ion plating, or sputtering, then the gas barrier capability is improved, but cracks occur when the substrate is rolled up or bent, causing deterioration of gas barrier capability
Solution Approach 1:
The invention changes the material composition parameters of the gas barrier layer by incorporating both inorganic particles (metal oxides) and organic polymer components. This composite composition allows the layer to maintain gas barrier capability while gaining flexibility and crack resistance through the polymer matrix that can accommodate bending and rolling without fracturing like pure inorganic layers.
Solution Approach 2:
The invention uses a composite material system combining inorganic metal oxide particles with organic polymer materials. The inorganic particles provide gas barrier properties while the organic polymer provides flexibility and mechanical integrity. This composite approach resolves the contradiction between achieving high gas barrier capability and maintaining structural integrity during bending or rolling operations.
2Reliability
If a polysilazane film is formed and subjected to plasma treatment to enhance gas barrier capability, then the gas barrier performance is improved, but a thick layer is required to achieve sufficient performance
Solution Approach 1:
The invention changes the compositional parameters by incorporating high-density inorganic metal oxide particles into the polymer matrix. These inorganic particles provide superior gas barrier properties per unit thickness compared to organic polymers alone, enabling achievement of sufficient gas barrier capability with a thinner overall layer thickness while maintaining flexibility.
Solution Approach 2:
The composite structure of inorganic metal oxide particles dispersed in an organic polymer matrix provides enhanced gas barrier capability at reduced thickness. The inorganic particles create tortuous paths for gas permeation, significantly improving barrier performance without requiring the thick layers needed for pure organic or inorganic coatings.
3Ease of operation
If a transparent plastic film is used as an electrode substrate instead of a glass plate, then thickness and weight are reduced and flexibility is improved, but water vapor and oxygen pass through more easily, causing deterioration of elements
Solution Approach 1:
The invention applies a composite gas barrier coating combining inorganic metal oxide particles with organic polymer materials on the flexible plastic film. This composite layer provides excellent gas barrier capability to prevent water vapor and oxygen permeation, while the underlying plastic film maintains its flexibility and lightweight characteristics, thus resolving the contradiction between flexibility and gas barrier performance.
Solution Approach 2:
The invention changes the functional parameters of the plastic film by adding a gas barrier coating layer with specific compositional parameters (inorganic/organic composite). This allows the substrate to simultaneously achieve low permeability to water vapor and oxygen while maintaining the inherent flexibility and light weight of the plastic film material.
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 an excellent gas barrier capability and transparency, suitable for applications in electronic devices like touch panels and solar cells, with a water vapor transmission rate less than 0.10 g/m2/day and total light transmittance of 90% or more, while being cost-effective and easy to produce.
Implementation Method 1
a gas barrier layer, the gas barrier layer being formed of a material that includes at least an oxygen atom and a silicon atom... exhibits an excellent gas barrier capability
Implementation Method 2
implanting ions into the polysilazane compound-containing layer
Data Source
AI summary
The present invention is a formed article sequentially comprising a base layer, a primer layer that includes a hydroxyl group-containing polymer, and a gas barrier layer, the gas barrier layer being formed of a material that includes at least an oxygen atom and a silicon atom, a surface layer part of the gas barrier layer having an oxygen atom content rate of 60 to 75%, a nitrogen atom content rate of 0 to 10%, and a silicon atom content rate of 25 to 35%, based on a total content rate of oxygen atoms, nitrogen atoms, and silicon atoms, and the surface layer part of the gas barrier layer having a film density of 2.4 to 4.0 g/cm3. According to the present invention, provided is a formed article, a method for producing the same, an electronic device member including the formed article, and an electronic device including the electronic device member, with an excellent gas barrier capability and excellent transparency.