Description
Book SynopsisIt is intended that the book will be a practical guide to provide any reader with the basic information to help them understand what is necessary in order to produce a good barrier coated web or to improve the quality of any existing barrier product.
After providing an introduction, where the terminology is outlined and some of the science is given (keeping the mathematics to a minimum), including barrier testing methods, the vacuum deposition process will be described. In theory a thin layer of metal or glass-like material should be enough to convert any polymer film into a perfect barrier material. The reality is that all barrier coatings have their performance limited by the defects in the coating. This book looks at the whole process from the source materials through to the post deposition handling of the coated material. This holistic view of the vacuum coating process provides a description of the common sources of defects and includes the possible methods of limiting t
Table of Contents
Biography
Acknowledgements
Preface
1 Introduction 1
1.1 Packaging 5
1.1.1 Opaque Barrier 6
1.1.2 Transparent Barrier 8
1.2 Markets 10
References 16
2 Terminology 19
2.1 Hansen Solubility Parameter 29
2.2 Permeability Models 33
2.3 Barrier Improvement Factor 39
2.4 Tortuous Path Model 40
2.5 Terminology Summary 44
References 45
3 Measurements 51
3.1 Permeation Measurements 52
3.2 Durability Testing 60
3.3 Adhesion 65
3.4 Pinholes 67
3.5 Surface Energy 69
3.6 Coefficient of Friction 74
3.7 Coating Thickness 76
3.8 Coating Conductivity or Resistivity 79
3.9 Transmittance, Reflectance and Ellipseometry 80
3.10 Standard Test Methods 81
3.10.1 Permeability Tests 81
3.10.2 Other Mechanical or Optical Performance Tests 82
References 83
4 Materials 89
References 100
5 Packaging Materials Calculations 103
5.1 Demonstration Calculations 108
References 112
6 Substrates, Surfaces, Quality and Defects 115
6.1 Substrates 115
6.1.1 Oligomers 120
6.1.2 Additives 121
6.1.3 Contamination 126
6.1.4 Surface Quality 132
6.2 Substrate Cleaning 134
6.3 Substrate Plasma Treatments 139
6.4 Wetting and Adhesion 149
6.5 Subbing or Planarisation Layers and Over-Coatings 157
References 161
7 Vacuum Deposition Processing 171
7.1 Nucleation, Growth and Modification 171
7.2 Managing the Substrate Heat Load 185
7.3 Web Winding in Vacuum 205
7.4 Troubleshooting 222
References 224
8 Vacuum Deposition 231
8.1 Resistance Heated Evaporation 232
8.2 Plasma Enhanced Chemical Vapour Deposition (PECVD) 249
8.3 Electron Beam Evaporation Sources 251
8.4 Induction Heated Evaporation Source 254
8.5 Magnetron Sputter Deposition Sources 255
8.6 Atomic Layer Deposition (ALD) 265
8.7 Other Deposition Processes 271
References 272
9 Summary 285
9.1 Cleanliness 285
9.2 Substrates 286
9.3 Coatings 287
9.4 Over Coatings 288
9.5 Multilayers 288
9.6 Conclusion 288
