Roll-to-Roll Vacuum Deposition of Barrier Coatings (eBook)

Charles Bishop left school at 16 to start an engineering apprenticeship completing it as a Toolmaker. Opting to return to education he took a degree in Materials Technology. Here the seeds of vacuum processing were sown in the form of a final year project working on bone implants. Moving to the Physics Department he went on to complete Masters and Doctorate degrees on different aspects of vacuum deposition. After a brief time as a post doctoral researcher he moved into industry for the next 15 years before setting up his own consultancy business in 1998. He is the author of the book Vacuum deposition onto webs, films and foils, 3rd edition and author or co-author of over 90 papers and 5 patents. He contributes a regular column in Converting Quarterly as well as technical articles. He was presented with a SVC Mentor Award in 2008. Currently he is the Editor of the Vacuum Web Coating blog that is accessed through www.convertingquarterly.com on behalf of AIMCAL as well as a regular lecturer at the AIMCAL Converting Schools and presenter of a number of Webinars also offered by AIMCAL.

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