Transparent Barrier Composition for Oxygen and Moisture Encapsulation
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Solution Overview
Problem
Existing electronic systems, particularly organic photovoltaic devices, suffer from rapid degradation due to exposure to oxygen and moisture, leading to performance loss and reliability issues, with current barrier materials facing challenges such as inter-layer delamination and requiring energy-intensive deposition processes incompatible with fiber-based devices.
Innovation Solution
A curable composition comprising ionic layered filler particles with a high aspect ratio, coated with an intercalating compound like alkylated polypyridine, embedded in a matrix, providing enhanced oxygen and moisture barrier properties while maintaining flexibility and optical transparency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multi-layered stacks of polymeric films with sputtered metal oxide layers are used to enhance barrier properties, then oxygen and moisture barrier properties are improved, but inter-layer delamination occurs due to fatigue or crack propagation
Solution Approach 1:
The patent employs composite materials by combining polymeric films with sputtered metal oxide layers in a multi-layered stack structure. This composite approach creates a tortuous path for moisture and oxygen molecules, enhancing barrier properties while the integration of multiple material types (polymeric and inorganic) provides complementary protection mechanisms that address both gas barrier needs and structural stability
Solution Approach 2:
The barrier system is segmented into multiple alternating layers of polymeric films and metal oxide layers. This segmentation creates a tortuous path that forces oxygen and moisture molecules to traverse through a complex, winding route rather than a straight line, significantly reducing permeation. Each layer segment provides specific protective functions, distributing the barrier stress across multiple interfaces
2Reliability
If vacuum based coating systems are used to deposit thin films of inorganic barrier materials, then barrier film deposition is achieved, but the process is energy-intensive, time-consuming, and incompatible with fiber-based devices
Solution Approach 1:
The patent replaces the vacuum-based mechanical deposition system with a solution-based coating process. Instead of using vacuum chambers and sputtering equipment to deposit inorganic barrier layers, the invention uses liquid precursor solutions that can be applied via dip-coating, spin-coating, or other solution-based methods. This substitution eliminates the need for vacuum infrastructure, reduces energy consumption, and enables processing of fiber-based devices that cannot withstand vacuum conditions
Solution Approach 2:
The deposition process parameters are fundamentally changed from vacuum-based physical vapor deposition to solution-based chemical deposition. The inorganic barrier layers are formed from liquid precursors that decompose or react to form the desired oxide structures at lower temperatures and atmospheric pressure, making the process compatible with temperature-sensitive and fiber-based electronic devices
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 composition significantly reduces water vapor and oxygen transmission, maintaining high optical transparency and flexibility, suitable for encapsulating electronic devices, including fiber-based systems, without the drawbacks of traditional barrier materials.
Implementation Method 1
the intercalating compound has a size sufficient to change the basal spacing of the ionic layered filler particles relative to the basal spacing of the ionic layered filler particles in the absence of the intercalating compound
Implementation Method 2
the composition significantly reduces water vapor and oxygen transmission
Data Source
AI summary
Disclosed herein is a curable composition with high optical transparency and good oxygen and moisture barrier properties, compositions for making the same, and methods of making and of using the same.