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Roll-to-Roll Technology on Pilot Scale for Transparent Ultra-High Multilayer barriers

: Fahlteich, J.; Schiller, N.; Miesbauer, O.; Kücükpinar-Niarchos, E.; Noller, K.; Weber, U.; Amberg-Schwab, S.; Boeffel, C.

Society of Vacuum Coaters -SVC-, Albuquerque/NM:
Society of Vacuum Coaters. 55th Annual SVC Technical Conference 2012 : April 28-May 3, 2012; Santa Clara, Calif.; Proceedings
Albuquerque: SVC, 2012
ISBN: 978-1-878068-32-3
ISBN: 1-878068-32-6
S. 711-716
Society of Vacuum Coaters (Annual Technical Conference) <55, 2012, Santa Clara/Calif.>
Fraunhofer FEP ()
Fraunhofer ISC ()
Fraunhofer IVV ()
Fraunhofer IAP ()

Thin transparent layers on polymer films are used to drastically
enhance the permeation barrier properties of polymer webs
while at the same time maintaining the flexibility and optical
transparency. Applications range from food packaging films to
encapsulation films for solar cells or flexible electronics. Very
low water vapor and oxygen transmission rates are required
for the encapsulation of flexible OPV devices and OLEDs.
This paper introduces a new technology for manufacturing
ultra-high permeation barrier films using a roll-to-roll coating
process. This multilayer barrier is based on reactively sputtered
oxide barrier layers and an interlayer of inorganic-organic
hybrid polymers (ORMOCER®s). The multilayer barrier is
compared to other high barrier technologies and evaluated
regarding barrier performance, optical transparency, surface
properties and reproducibility. The water vapor transmission
rate (WVTR) has been measured using different methods for
different sample sizes and test conditions. The measurement
limit of a MOCON Aquatran® system (5·10-4 g/(m²d)) has
been reached with a three layer stack at 38°C / 90% relative
humidity. The technology is now being used for a pilot production
of barrier films. Coated rolls with a width of 400 mm
and several 100 m in length can be provided for development
purposes. In addition to the barrier layers, further layers can
be applied to the polymer film to provide a mechanical protection,
a smoothing layer for further processing or transparent
conductive layers for e.g. manufacturing of flexible organic
solar cells or flexible OLEDs. Applications such as using the barrier film as either a substrate for organic electronic devices or for the encapsulation of such devices will be discussed.