Film coated with glass barrier layer with metal dopant

BACKGROUND OF THE INVENTION
This invention relates to polymeric films having improved barrier properties towards oxygen and other materials.
Flexible polymer films have been used extensively in the packaging of food, electronic and medical products. It is desirable in many applications to have a good barrier to oxygen and/or water vapor. However, most polymer based barrier resins such as ethylene vinyl alcohol copolymer ("EVOH") or polyvinylidene chloride ("PVDC"), although exhibiting good barriers to oxygen or moisture, do so only under ideal conditions. Although EVOH can be an excellent oxygen barrier, it looses its barrier property at moderate to high relative humidity. Thus this material is not widely usable in applications involving high water vapor content, such as moist foods. Although PVDC exhibits good moisture and oxygen barrier properties, it is not suitable for many applications, has an undesirable yellow color, and is difficult if not impossible to recycle. Other proposed alternatives to provide oxygen and water vapor barriers include laminations of aluminum foil and aluminum metallized film. Although these exhibit good barrier properties, they are completely opaque, cannot be recycled, and cannot be readily used for food packaging destined for use in a microwave oven.
U.S. Pat. No. 4,702,963 discloses packaging film in which an adhesion layer is first vacuum deposited on a flexible polymer substrate, followed by vacuum deposition of a barrier layer, to confer retortability to the packaging film. The adhesion layer can consist of Cr, which is preferred, co-deposited mixtures of Cr and SiO having at least 20% by weight Cr, among others. The barrier layer is preferably silicon monoxide or silicon dioxide. When silicon dioxide is used, it may be mixed with glass modifiers such as oxides of Mg, Ba, and Ca, or with fluoride of alkaline earth metals, e.g. MgF.sub.2. The glass modifiers serve to alter the color appearance of the overall coating. For example, a chromium/SiO composite film is disclosed to produce a coating with a yellowish appearance, while a neutral gray appearance is disclosed to result from the mixture of SiO.sub.2 with glass modifiers.
Japanese patent application 60-244540 discloses a laminate comprising the formation on the surface of a plastic film a transparent thin layer of one or more materials selected from metals, metal oxides, or glass by means of a dry plating method, providing a laminate with good barrier properties. Suitable metals include aluminum, silicon, iron, gold, silver, copper, chromium, nickel, tin, titanium, and magnesium. Suitable oxides may be the oxides of these metals (such as silicon oxide, which can be mixtures of silicon monoxide and silicon dioxide), and glass. A mixed evaporation or multilayer evaporation may be performed.
Japanese patent application 61-47244 discloses a laminate of a plastic film or sheet on the surface of which has been formed a transparent thin layer by dry plating one or more of the materials selected from metals, oxides of the metals, and glass. Suitable metals include aluminum, silicon, titanium, tin, iron, gold, silver, copper, chromium, nickel, magnesium, or the like. The oxides are those of these metals, or glass. These metals and metal oxides may be evaporated in a mixed state to form a layer or evaporated to form a multilayer. The laminate is said to have excellent gas-barrier performance.
U.S. Pat. No. 4,528,234 discloses a transparent laminate comprising a transparent plastic resin film substrate, a thin layer of at least one metal such as aluminum, tin, iron, zinc, or magnesium formed on the substrate by vacuum deposition, and a carboxyl group-containing polyolefin (e.g. ionomer)
layer formed on the metal layer by lamination. Optionally an additional layer of silicon oxide or titanium oxide may be present. Oxygen and moisture impermeability are said to be improved.
U.S. Pat. No. 3,442,686 discloses a composite film structure suitable as a packaging film consisting of a flexible transparent organic base sheet, e.g. PET film, having a top coating of a polymer such as polyethylene and an intermediate, gas barrier, glassy coating of an inorganic material such as a silicon oxide. Other inorganic compositions which are useful include lead chloride, silver chloride, calcium silicate, and crushed "Alundum" (Al.sub.2 O.sub.3 with SiO.sub.2 binder).
Japanese patent application 62-158677 discloses a transparent laminate wrapping material where a thin single or mixed metal oxide layer is an intermediate layer in a laminate structure. The laminate is said to have excellent gaseous oxygen and water vapor barrier properties. Silicon oxide and aluminum oxide-silicon oxide mixtures are effective.
Japanese patent application 62-156943 discloses a vapor-deposited layer built-in type multilayered gas-barrier film or sheet having two or more vapor-deposited layers of metals or metal compounds formed at one or more laminate interfaces of a multilayered synthetic resin film or sheet, having good gas barrier characteristics. Suitable metals include aluminum, zinc, copper, platinum, indium, tin, gold, silver, and silicon. A suitable metal compound is silicon oxide.
Chahroudi, "Glassy Barriers from Electron Beam Web Coaters," paper presented at Annual Technical Meeting of Society of Vacuum Coaters, discloses barriers of silicon oxide or SiO.sub.2. Oxides of Mg, Ca, Ba, B, Al, In, Ge, Sn, Zn, Ti, Zr, Ce, and MgF.sub.2 are disclosed as modifiers or replacements for silica.
Sakamaki, "Vapor Coating with Silicon Dioxide," discloses barrier properties of film with a thin layer of ceramic such as SiO.sub.x, in particular silicon oxide.
U.S. Pat. No. 3,522,080 discloses a process for hardening the surface of a synthetic material such as a lacquer film, which includes vapor deposition of layers of silicon oxide (SiO.sub.x derived from SiO.sub.2) onto the surface. The silicon oxide can contain 1.5 to 5 percent oxide of chromium, zinc, zirconium, or antimony.
U.K. patent application 2 197 881 discloses a heat resistant vessel made of a thermoplastic polyester resin by forming an inorganic coating layer comprising a silicon compound or a metal oxide-containing silicon compound on a surface of the polyester resin. The inorganic coating layer is obtainable from colloidal polysiloxane compounds. The coating material may further contain additives such as an inorganic filler of e.g. titanium oxide, zirconium silicate, nickel, copper oxide, manganese oxide, alumina, etc.
In certain of the above references, coatings of silicon monoxide (SiO), silicon dioxide (SiO.sub.2), or combinations thereof with a variety of metal oxides have been disclosed. There has been lacking, however, teaching as to the type and quantity of metal or metal oxide required to provide coatings of SiO.sub.2 with improved barrier properties. It has now been observed that combinations of SiO.sub.2 with many metals or metal oxides in fact do not provide improved barrier performance or alternatively reduce the optical transparency of films coated therewith to an objectionable extent. Furthermore, much of the prior art focuses on SiO as the primary barrier layer. The use of SiO is not practical for many packaging applications because it is quite expensive and exhibits an objectionable yellow color. The present invention, in contrast, overcomes these shortcomings by providing an inexpensive inorganic coating with good barrier performance and good light and microwave transparency, suitable for packaging applications.
SUMMARY OF THE INVENTION
The present invention provides a structure having superior barrier properties, comprising a polymeric substrate and a glassy coating of silicon dioxide doped with at least one metal selected from the group consisting of antimony, aluminum, chromium, cobalt, copper, indium, iron, lead, manganese, tin, titanium, tungsten, zinc, and zirconium, said coating and metal dopant contained therein being present in an amount which provides an oxygen transmission value through the coated film structure of at most about 5 mL/day-m.sup.2 -atm. Preferably the amount of metal dopant is sufficient to provide an oxygen permeation value for the glassy coating of at most about 3000.times.10.sup.-6 mL-mm/day-m.sup.2 -atm. The structure may be a film and may comprise one or more layers of a multiple layer structure.
The invention further provides a process for imparting barrier properties to a polymeric substrate, comprising the steps of selecting a polymeric substrate and vacuum depositing onto the substrate a glassy coating prepared from silicon dioxide and at least one metal selected from the group consisting of antimony, aluminum, chromium, cobalt, copper, indium, iron, lead, manganese, tin, titanium, tungsten, zinc, and zirconium, wherein the amount of said glassy coating and the amount of metal contained therein is suitable to provide an oxygen transmission value through said film structure of at most about 5 mL/day-m.sup.2 -atm.
The present invention further provides a similar structure and process in which the dopant is lithium borate.

DETAILED DESCRIPTION OF THE INVENTION
The barrier films of the present inventions are polymeric substrates such as films, coated directly or indirectly with specially selected glass coatings. The polymeric substrates include any having suitable physical and thermal properties for the particular packaging application at hand. The minimum requirement is that they have sufficient thermal and physical properties to withstand the conditions of application of the glass coating, described in more detail below, and exhibit sufficient adhesion to the class coating. Examples of suitable substrates include those prepared from polyamides, including amorphous and semicrystalline polyamides, polycarbonates, polyethers, polyketones, polyester ethers, and polyesters, which are preferred.
Examples of polyester resins include polyethylene naphthalate and most preferably polyethylene terephthalate ("PET"). Examples of semicrystalline polyamides include polycaprolactam (nylon 6) and condensation polymers of dicarboxylic acids and diamines, such as polyhexamethylene adipamide (nylon 6,6) etc. Examples of amorphous polyamides include hexamethylenediamine isophthalamide, hexamethylenediamine isophthalamide/terephthalamide terpolymer, having iso/terephthalic moiety ratios of 100/0 to 60/40, mixtures of 2,2,4- and 2,4,4-trimethylhexamethylenediamine terephthalamide, copolymers of hexamethylene diamine and 2-methylpentamethylenediame with iso- or terephthalic acids, or mixtures of these acids. Polyamides based on hexamethylenediamine iso/terephthalamide containing high levels of terephthalic acid moiety may also be useful particularly when a second diamine such as 2-methyldiaminopentane is incorporated to produce a processible amorphous polymer. Typically a substrate, especially a film, will have been oriented, optionally followed by heat setting so as to provide dimensional and thermal stability.
It is preferred that the substrate has a high surface smoothness. In particular when the substrate is polyethylene terephthalate it is preferred that the substrate have a smoothness such that the average height of roughness is less than about 50 nanometers, and most preferably less than about 10 nanometers, as measured on a WYKO.TM. optical profilometer, Model TOPO-3D from WYKO Co., Tuscon, Ariz. Most ordinary PET films have a relatively large degree of surface roughness because of the presence of various internal anti-block and slip additives which are necessary to improve handling properties. An oriented PET film without such additives will have a very smooth surface but cannot generally be handled, i.e., wound and rewound, without introducing excessive wrinkling. However, a practical film with preferred smoothness can be prepared by selectively treating only one surface with a selected antiblock agent, leaving the other surface untreated and smooth. Application of such an agent to at least one surface of a film is described in U.S. Pat. No. 3,808,027, the disclosure of which is incorporated herein by reference. A preferred commercially available substrate is Mylar.RTM. polyester film, type D, which has a surface roughness of 2-7 nm. It is believed that films with this superior level of smoothness provide better adhesion of the glass coating to the film, leading in certain instances to improved barrier properties and improved stability under retort conditions. It is preferred that the glassy coating be applied to the smooth side of such film.
A layer of doped glass is applied to the substrate. This layer can be applied directly to the substrate, or it can be applied indirectly, i.e., atop one or more intermediate layers which are themselves located on the substrate. One such intermediate layer, for example, can be silicon oxide, which is described in more detail below. The doped glass coating should be thick enough to adequately improve the barrier properties of the substrate, but not so thick as to seriously degrade transparency of the substrate or to result in loss of durability or flexibility of the glass, when the substrate is a film. Typically coatings of about 20 to about 500 nm are suitable, depending on the effectiveness of the particular glass composition. A thickness of about 50 to about 350 nm is preferred, although for some compositions a thickness of about 200 to 400 nm is desirable; for particularly effective compositions, a coating of 50 to 100 nm is quite adequate.
The doped glass coating is based on silicon dioxide. The actual stoichiometry of the glass in this layer may vary from the nominal oxygen-silicon ratio of 2:1 of SiO.sub.2, for example, due to reactions which may occur during the vacuum deposition process. The glass coating is generally applied to the substrate in a batch or continuous process by any of a variety of conventional vacuum methods. The portion of the substrate to be coated is positioned either by a continuous process or batch process in a chamber within which a vacuum is drawn. A source of silicon dioxide and dopant metal (in either different sources or comixed in a single source, either as a powder, a metal wire, or vitrified into a silica glass) is placed in the vacuum chamber and vaporized by heating with an electron beam or a resistance or induction heated furnace, or by sputtering or reactive sputtering by an ion beam or a magnetron source, or the like. The silicon dioxide, along with the dopant metal, condenses to form the desired coating. The thickness of the coating is determined by the residence time of the substrate in the chamber, the amount of oxide target present in the chamber relative to the area of the substrate, and/or the energy delivered to the source per unit area of the source. When the resin substrate is in the form of a film, the film may be made inaccessible to the vacuum deposition on one surface thereof so that only the opposite surface receives the vacuum deposited layers. When the resin substrate is in the form of a container, the entire container can be positioned within the vacuum chamber. The surface of the resin substrate facing the source receives the vacuum deposited coatings. The substrate can be repositioned and the coating operations repeated to cover additional surfaces, such as the opposite side, of the substrate.
Sufficient vacuum is drawn within the vacuum chamber that the mean free path of the silicon dioxide and dopant molecules is sufficient to reach and therefore enable deposition of the glassy layer on the resin substrate. The vacuum used in the experiments described in the Examples herein generally falls within the range of about 1 to 100 microtorr (760 torr =1 atm). One skilled in the art will know how to select the proper vacuum for a given vacuum deposition process, including its conditions of operation.
The dopant can be incorporated into the SiO.sub.2 layer either by evaporating a single source of a physical or fused mixture of the dopant and SiO.sub.2, or by co-depositing the dopant and the SiO.sub.2 from two or more sources simultaneously. In both cases, the dopant can be in a metallic form or in the form of an oxide, silicide, silicate, halide, or carbonate, and the like. In the case of depositing from a single source, the proportion of the dopant present in the deposited SiO.sub.2 layer may vary from the composition of the source. Such proportion can be determined for a particular source composition and conditions of vacuum deposition and can be adjusted to the proportion desired by adjustment of the source composition. In case of either deposition method, the composition of the coating can be determined by analysis of atomic absorption using inductively coupled plasma (ICP), which is a conventional analysis procedure. This analysis primarily detects the elemental metal in the SiO.sub.2. Therefore, the weight percents of dopant disclosed herein are based on the elemental metal of the metal dopant. Thus decomposition products, e.g. CO.sub.2 from carbonates, which do not become part of the SiO.sub.2 layer are not included in weight percents of dopant in that layer. The weight percents of dopant disclosed herein refer to the composition of the SiO.sub.2 layer unless otherwise indicated. These same weight percents may, however, be present in the source(s) for vacuum deposition (co-deposition), and as previously described, the resultant composition of the SiO.sub.2 layer for the vacuum deposition conditions used can then be determined, and the source composition can be adjusted in subsequent runs to obtain the final composition desired. More often, the source composition will be adjusted to provide the barrier properties desired for the multilayer structure rather than analyzing the SiO.sub.2 layer for its dopant content.
The silicon dioxide coating of the present invention is "doped," as described above, with a high level of at least one of a select group of metals. The term "doping" is used herein to describe a deposition with silicon dioxide of a relatively high level of metal, typically 0.5 to about 25 weight percent, as measured in the source, or about 0.5 to about 30 weight percent as measured as metal in the glass coating itself. (It is understood that the term "doped" or "doping" previously has been used in the art to refer to lower levels of metal additive, typically well below 1%. This is not what is meant by "doped" in the context of the present invention.)
The oxidation state of the metal as it resides in the coating matrix of silicon dioxide is not necessarily clearly understood or well defined. Thus if an elemental metal is used as the source for the dopant, the deposited metal atoms or particles may interact with the oxygen atoms of the matrix to form a partially or completely oxidized material.
Alternatively, if an oxide of the metal is used as the source, it is not necessarily known nor is it necessarily important whether the metal is deposited into the glassy matrix as the oxide or as the elemental metal. It appears that either the elemental metal or an oxide of the metal or certain other metal compounds, regardless of oxidation state can be suitably used as the source of the dopant metal for the present invention. Such possibilities and equivalents thereof are included within the scope of the present invention when terms such as "metal dopant" or the like are used. The selection of an appropriate source for metal dopant will be within the abilities of one skilled in the art and will be determined by such factors as relative cost and ease of handling. In many cases the metal oxide or especially the elemental metal will be preferred.
Suitable metal dopants for the present invention include antimony, aluminum, chromium, cobalt, copper, indium, iron, lead, manganese, tin, titanium, tungsten, zinc, and zirconium. Preferred metals include chromium, manganese, zinc, and most preferably copper and tin. When one or more of these metals are present, the barrier property of the glass coating and of the structure as a whole is greatly improved. Surprisingly it has been found that many other metals do not show this sort of improvement. Among the metals that are not particularly effective at comparable levels are calcium, vanadium, lithium, nickel, molybdenum, gold, germanium, and selenium. Sulfur is similarly not effective. It is surprising that these elements appear in the same regions of the periodic table with the metals that are effective. The chemical phenomenon that distinguishes between these groups of metals is not understood. It is noted that the metals which form a part of the present invention are generally located to the right of Column II of the Periodic Table, that is, to the right of the alkali metals and the alkaline earth metals.
When a metal dopant from the metals of the present invention is used in the layer of silicon dioxide, the improvement in barrier properties can be dramatic. One customary measurement of barrier properties of a film is its oxygen transmission rate ("OTR", ASTM D-3985-81(1988)) expressed as mL oxygen passage/m.sup.2 -day-atmosphere. A film of ordinary untreated PET, 23 micrometers thick, typically has an OTR of 75-90; that of a 12 micrometer film is typically 150-180. Addition of a 300 nm coating of SiO.sub.2 reduces the OTR somewhat, to about 10-80. Addition of one or more of the metals of the present invention can routinely reduce the OTR to less than 5. In copper, the most preferred case, addition of even 1 percent to the SiO.sub.2 (measured in the source) can reduce the OTR to as low as 0.5, while use of 5-10 percent copper can result in values as low as 0.3. Use of tin, which is also preferred, provides values nearly as low.
The effectiveness of the barrier properties depends not only on the type of metal involved but also, of course, on the thickness of the glass layer. The effect of total glass thickness can be factored out by focusing on the oxygen permeation value ("OPV," mL-mm,M.sup.2 -day-atm), which provides a measure of the inherent barrier properties of the glass. A coating of SiO.sub.2 alone exhibits an OPV on the order of 0.1 or higher. The coatings of the present invention exhibit OPV of typically 3.times.10.sup.-3 or lower, and in the best cases as low as 1.times.10.sup.-4 or better.
The OTR or OPV of a particular film or composition is not a simple linear function of dopant concentration. For each metal dopant there appears to be a certain minimum concentration required to achieve a significant improvement, a concentration range, varying somewhat with the metal but generally within about 0.5 to about 30 weight percent (calculated as elemental metal in total glass layer), where the invention is effective, and a region of higher metal concentration within which the effectiveness diminishes or the optical transparency of the film is adversely affected.
It has further been found that in one embodiment of the present invention, the appearance and resistance of the coated structure to retort conditions is improved when a thin underlayer of SiO is applied to the substrate. Further details of this embodiment are set forth in copending U.S. application Ser. No. 07/513,354 now U.S. Pat. No. 5,085,904 the disclosure of which is incorporated herein by reference.
In addition to the above described layers, an additional protective layer can be added. Such a layer can be selected from any plastic resin that adheres to the SiO.sub.2 layer or that adheres via an intervening adhesive layer. Examples of protective layers include a layer of polyester (adhered to the SiO.sub.2 layer via an adhesive), polyamides, acrylonitrile copolymers, polyvinylidene chloride, polyethylene, polypropylene, ethylene vinyl acetate copolymer, ethylene/acrylic or methacrylic acid copolymer and ionomer. The protective layer can be applied to the SiO.sub.2 layer by conventional processes such as adhesive or thermal laminating or extrusion coating simultaneous with extrusion of the intervening adhesive, if any. The protective layer can also be provided by solvent or dispersion coating onto the SiO.sub.2 layer, using multiple coatings if thickness greater than achievable by single coating is desired. The thickness of the protective layer will generally be about 0.5 to 100 micrometers, preferably 10 to 25 micrometers (0.020 to 0.025 mm).
Films and structures of the present invention are useful as a wide variety of packaging, from rigid to semi-rigid containers to packaging film where barrier properties towards oxygen and other materials are desired. The particular use will dictate the choice and shape of the resin substrate. For packaging films, the resin substrate will be in the form of a film having, for example, a thickness of 10 to 150 micrometers, often 12 to 50 or preferably 15 to 25 micrometers.
EXAMPLES 1-136
Silicon dioxide was mixed with a dopant material and loaded into the hearth (crucible) of an electron beam evaporator of the single crucible bent beam source type as sold by a variety of manufacturers including Denton Vacuum of Cherry Hill, NJ. A thin film was formed from this mixture onto the smoother surface of a 23 micrometer (92 gauge) PET film (Mylar.RTM. type D) by electron beam evaporation from the mixture. The accelerator voltage was continuously adjusted to sweep the beam across the material in the source crucible to give uniform erosion of the crucible's contents. The filament current (and hence the beam current) was adjusted to provide a high deposition rate, resulting in a relatively high background pressure of about 1.3.times.10.sup.-2 Pa (about 1.times.10.sup.-4 torr). This pressure was not so high as to cause premature arc-over of the electron beam gun. The thickness of the deposit was monitored by a calibrated oscillating quartz crystal monitor such as manufactured by Veeco Instruments Inc., Plainview, N.Y. The film (unless another grade is reported) had an average (RA) surface roughness of 2-7 nanometers. The coated film's oxygen transmission rate was measured using an "Ox-Tran 1000.TM." oxygen permeation device manufactured by Modern Control Inc. of Minneapolis, Minn. All data in Table I were obtained at 30.degree. C. at 80% relative humidity, using 100% oxygen at 1 atmosphere pressure (about 101 kPa). The results are reported in the Tables as oxygen transmission rate (mL/m.sup.2 -day-atm). In addition the results are reported as oxygen permeation value (mL-mm/m.sup.2 -day-atm) by subtracting the (minimal) barrier properties of the uncoated film and dividing the result by the thickness of the glass coating.
The results for the first Examples, Table I, Examples 1-11, illustrate the poor barrier properties of PET film treated with a layer of undoped silicon dioxide.
TABLE I______________________________________Ex..sup.a Dopant Thickness, nm OTR OPV .times. 10.sup.6______________________________________C1 none 325 23.6 12054C2 " 300 84.3 >100000C3 " 301 76.4 >100000C4 " 303 77.1 >100000C5 " 314 7.1 2517C6 " 315 62.1 >100000C7 " 323 51.6 83026C8 " 355 10.1 4238.sup. C9.sup.b " -- 161.5 -- .sup. C10.sup.b " -- 72.4 -- .sup. C11.sup.b " -- 28.1 --______________________________________ .sup.a Examples designated "C" are included for comparative purposes. .sup.b PET film having a surface roughness of 26-33 nm and a thickness of 12 micrometers. -- indicates value not measured.
The results in the next series of Examples, Table II, Examples 12-57, illustrate many of the metal dopants which are not a part of the present invention. Most of these dopants do not provide significant improvements in barrier properties in the concentration ranges examined, although a few do show improvement (e.g. MgF.sub.2, MgO, BaO, disclosed in U.S. Pat. No. 4,702,963 along with CaO which does not show adequate activity). For reasons which are not fully understood, low levels of lithium borate, Li.sub.2 B.sub.4 O.sub.7, seem to be effective and are thus considered to be included within the scope of the present invention.
TABLE II______________________________________Ex..sup.a Dopant, % Thickness, nm OTR OPV .times. 10.sup.6______________________________________C12 Ag 10 301 8.5 2944C13 AgO 10 300 5.9 1944C14 BaO 10 307 2.6 828C15 BaO 30 315 7.7 2743C16 B.sub.2 O.sub.3 3 326 80.3 >100000C17 B.sub.2 O.sub.3 10 213 77.2 >100000C18 B.sub.2 O.sub.3 10 327 83.4 >100000C19 Ca(BO.sub.2).sub.2 10 290 74.7 >100000C20 Ca(BO.sub.2).sub.2 10 303 35.5 23832C21 Ca(BO.sub.2).sub.2 25 239 82.5 >100000C22 Ca(BO.sub.2).sub.2 50 230 73.2 >100000C23 CaO 10 301 6.0 1985C24 CaO 30 265 12.3 4042C25 K.sub.2 O 10 308 27.0 14319C26 Li 3 -- 80.6 --27 Li.sub.2 B.sub.4 O.sub.7 1 307 2.5 79728 Li.sub.2 B.sub.4 O.sub.7 2 301 2.4 756C29 Li.sub.2 B.sub.4 O.sub.7 7 301 41.5 34897C30 LiF 1 301 30.1 17002C31 LiF 4 300 50.4 68597C32 MgCl.sub.2 2 301 51.7 78306C33 MgCl.sub.2 10 246 19.0 6639C34 MgCl.sub.2 10 246 23.3 8955C35 MgF.sub.2 1 303 20.6 9185C36 MgF.sub.2 2 299 1.1 320C37 MgF.sub.2 5 105 4.0 449C38 MgF.sub.2 5 201 2.2 455C39 MgF.sub.2 5 303 1.1 334C40 MgF.sub.2 10 297 1.1 328C41 MgF.sub.2 10 308 1.1 340C42 MgF.sub.2 15 306 2.2 713C43 MgF.sub.2 30 -- 10.2 --C44 MgO 5 304 1.9 602C45 MgO 10 302 5.4 1766C46 MgO 35 215 1.6 341C47 MgO 35 306 1.6 486C48 Na.sub.2 B.sub.4 O.sub.7 4 321 29.9 17889C49 Na.sub.2 B.sub.4 O.sub.7 10 -- 57.2 --C50 Na.sub.2 B.sub.4 O.sub.7 10 265 66.0 >100000C51 Na.sub.2 SO.sub.4 5 302 60.2 >100000C52 Na.sub.2 SO.sub.4 20 304 70.3 >100000C53 Na + Al.sup.a 301 73.1 >100000C54 Mo 10 302 72.7 >100000C55 Ni 10 299 55.8 >100000C56 Si 10 304 3.3 1073C57 Si 20 307 1.5 463______________________________________ .sup.a A fused glass; exact composition unknown.
The next series of Examples, Table III, Examples 58-67, show certain metal compound dopants (AlF.sub.3, CuCO.sub.3, CuF.sub.2, Cu.sub.5 Si, and WO.sub.2) which are effective only at comparatively higher concentrations in the source, e.g., about 20%. It is believed that these materials evaporate at a slower rate than does SiO.sub.2, resulting in lower actual concentrations in the films. Yet it is believed that when a sufficient amount of metal is deposited in the glass coating, the results nevertheless show significant improvement in barrier properties.
TABLE III______________________________________Ex. Dopant, % Thickness, nm OTR OPV .times. 10.sup.6______________________________________C58 AlF.sub.3 2 302 19.5 844559 AlF.sub.3 10 313 2.9 961C60 CuCO.sub.3 -- 5 302 15.3 6038 Cu(OH).sub.261 CuCO.sub.3 20 300 1.6 491C62 CuF.sub.2 5 273 9.8 3152C63 Cu.sub.5 Si 5 308 78.9 >10000064 Cu.sub.5 Si 20 302 1.9 58865 Cu.sub.5 Si 20 302 0.9 275C66 WO.sub.2 5 286 79.9 >10000067 WO.sub.3 20 123 4.1 537______________________________________
The last series of Examples, in Table IV, Examples 68-136, illustrate the results using metal dopants of the present invention. Concentrations of metal within the effective concentration ranges provide marked improvements in barrier properties. (In some of the examples using copper, the metal was added to the source material in the form of a wire; in other examples, as a powder. No consistent differences in the results were observed.)
TABLE IV__________________________________________________________________________Ex. Dopant, % Thickness, nm OTR OPV .times. 10.sup.6__________________________________________________________________________68 Al 2 303 1.9 59569 Al 10 303 1.3 40370 Al 10 311 1.6 49471 Al 15 312 4.5 1496C72.sup.a Al 30 321 14.3 587573 Co 10 214 0.9 19674 Cr 10 303 1.3 40875 Cr 20 302 1.9 60376 Cr 30 300 0.7 20777 Cr 30 302 1.3 387C78 Cu 1 300 8.1 2793C79.sup.a Cu 1 300 124.0 >10000080 Cu 1 301 0.5 16081 Cu 2 26 3.7 10282 Cu 2 52 4.9 27683 Cu 2 301 0.7 19884 Cu 3 303 4.1 133485.sup.b Cu 5 -- 0.7 --C86 Cu 5 28 11.4 38887 Cu 5 51 2.1 10988 Cu 5 100 0.9 9089 Cu 5 301 0.5 16090 Cu 5 301 1.0 30891 Cu 5 303 0.3 8092.sup.c Cu 5 305 2.6 82993.sup.d Cu 5 300 2.5 77094.sup.e Cu 5 295 2.2 658C95.sup.f Cu 5 300 7.6 242896.sup.g Cu 5 298 5.1 171297.sup.h Cu 5 300 0.9 27198.sup.h Cu 5 302 1.8 56799.sup.i Cu 5 301 1.5 527100 Cu 5 301 0.9 289C101 Cu 5 303 60.3 >100000C102 Cu 10 26 7.6 225103 Cu 10 28 2.9 84104 Cu 10 51 2.9 155105 Cu 10 102 3.3 360106 Cu 10 117 2.1 257107 Cu 10 301 0.3 94108 Cu 10 301 0.5 155109 Cu 15 100 1.3 136110 Cu 20 301 2.3 726111 Cu 30 300 0.6 188C112 Cu,B.sup.k 5 302 74.1 >100000113 Cu(NO.sub.3).sub.2 5 253 3.5 933114 Fe 5 302 1.4 421115 Fe 10 304 3.6 1174116 In 5 302 1.6 509117 In 20 309 1.5 476118 Mn 10 302 0.6 189119 Pb 10 330 1.5 497120 Pb 20 309 1.7 526121 Sb 5 190 5.8 1093122 Sn 5 302 1.2 358123 Sn 5 304 1.1 335124.sup.j Sn 5 130 1.6 256(est.)125 Sn 10 150 3.3 524126 Sn 20 303 1.0 296127 Sn 30 54 6.2 373C128.sup.a Sn 30 54 146.8 >100000C129.sup.a 316 stainless 10 305 5.3 1767 steel.sup.1130 TiO.sub.2 10 300 3.8 1200131 Zn 10 65 6.2 448132 Zn 10 257 1.4 375133 Zn 10 296 5.9 1913134 Zn 20 304 2.2 688135 ZnO 10 308 1.8 555 Zn 5136 301 3.9 1262 Cu 2__________________________________________________________________________ .sup.a Borderline example; results subject to scatter. .sup.b PET film "Melinex Type 442," surface roughness 10-18 nm. Coating thickness not measured. .sup.c PET film having a surface roughness of 10-18 nm and a thickness of 14 micrometers. .sup.d PET film having a surface roughness of 26-33 nm and a thickness of 12 micrometers. .sup.e PET film having a surface roughness of greater than 26 nm and a thickness of 23 micrometers. .sup.f Polyester film having a surface roughness of 41-49 nm and a thickness of 12 micrometers. .sup.g Laminate of the coated film to a layer of uncoated 12 micrometer PET, using copolyester adhesive sheet. .sup.h Laminate of the coated film to a layer of PET having a coating of heat sealable polyester copolymer, using copolyester adhesive sheet. .sup.i Laminate of the coated film to a layer of PET coated with PVDC, using copolyester adhesive sheet. .sup.j Substrate film poly(ethylene2,6-napthalene dicarboxylate with 30 n undercoating of SiO. .sup.k Fused silica glass containing Cu and B. .sup.l 18% Cr, 11% Ni, 2.5% Mo, <0.1% C, remainder Fe.
EXAMPLES 137-175
In the previous Tables the amount of dopant is listed as the amount present in the source in the hearth of the evaporator. The actual amount present in the glass coating was independently measured for some samples by atomic absorption. About 2-2.5 g of the sample is weighed accurately and charred with concentrated sulfuric acid, then dissolved by addition of concentrated nitric acid (aqua regia) and concentrated hydrofluoric acid and heating. The solution is diluted to 100 mL and analyzed by an Applied Research Laboratories 34000 simultaneous inductively coupled plasma analyzer or a Perkin Elmer 6500 (sequential) inductively coupled plasma analyzer. The amounts of the reported elements are calculated assuming that the dopant is the elemental metal and the matrix is SiO.sub.2 (m.w. 60). The results are shown in Table V.
TABLE V______________________________________ ThicknessEx. Dopant nm Source % Coating %______________________________________C137 Ag 303 10.0 0.1C138 B.sub.2 O.sub.3 300 10.0 0.7C139 MgF.sub.2 302 5.0 0.6C140 MgF.sub.2 301 10.0 1.0C141 Mo 301 10.0 13.4C142 Na.sub.2 B.sub.7 O.sub.4 302 10.0 {2.1 Na} {1.3 B}C143 Ni 300 10.0 16.3144 Al 302 5.0 3.8145 Al 312 10.0 4.0146 Al 303 10.0 <1.8147 Fe 298 5.0 7.4148 Fe 304 10.0 13.5149 Cr 301 2.0 3.2150 Cr 301 5.0 8.8151 Cr 298 5.0 7.7152 Cr 304 10.0 14.6153 Cr 301 10.0 14.1154 Cu 147 5.0 10.5155 Cu 299 5.0 0.0156 Cu 300 5.0 1.5157 Cu 307 5.0 8.7158 Cu 310 5.0 7.4159 Cu 152 10.0 15.8160 Cu 299 10.0 8.7161 Cu 303 10.0 6.2162 Cu 305 10.0 21.2163 Cu 276 10.0 17.1164 Cu 301 20.0 30.2165 Cu 153 20.0 29.8166 Mn 302 10.0 12.9167 Sn 301 2.0 8.8168 Sn 152 5.0 12.2169 Sn 304 5.0 24.3170 Sn 302 5.0 17.5171 Sn 301 5.0 12.0172 Sn 271 5.0 8.8173 Sn 153 10.0 14.6174 Sn 306 10.0 24.7175 Sn 285 10.0 26.4______________________________________
The considerable scatter in the analysis of the coating composition is believed to arise from several sources including inaccuracies in the atomic absorption technique and the use of a laboratory evaporation method which uses a powder mixture of the components which may be less reproducible than desired. However correlations can be obtained which indicate actual coating compositions with a calculable uncertainty. The results relating to the metals included in the present invention all indicate a higher concentration of the dopant metal in the coatings than in the source, with the possible exception of aluminum and silver. These trends are believed to be related to the relative vapor pressures of the metals compared with silicon dioxide. In particular the amount of copper or chromium in the glassy coating is about 1.4-1.5 times the amount in the source; the amount of tin in the coating is about 2.4-2.5 times the amount in the source. Metal compound dopants, for example some metal oxides, which may have lower vapor pressures than the elemental metals, may exhibit different correlations from those seen for the elemental metals. This phenomenon would explain the behavior of the examples in Table III, which require higher concentrations in the source to be effective. However, differences in vapor pressure cannot explain the ineffectiveness of such metals as nickel or molybdenum, which do appear in the coatings in amounts comparable to those for e.g. copper.
EXAMPLES 176-209
The Examples in Table VI show the effect of increasing dopant levels on visible light transmission of films prepared according to the procedure of Examples 1-136 using a batch "bell-jar" process. The visible light absorbance (from which transmission is calculated) was measured using a Hewlett-Packard 8452A diode-array UV-vis spectrophotometer, having a bandwidth of 2 nm, wavelength reproducibility of .+-.0.05 nm, and stability of <0.002 absorbance units. The device measures the entire UV and visible absorbance spectrum simultaneously without scanning. The zero absorbance level was defined using air as the blank. For each film the absorbance spectrum from 360 to 740 nm was measured and stored on disk. The absorbances at 400 and 550 nm are reported. It is observed that percent transmission decreases with increasing dopant level; preferred films are those which retain at least about 70 percent transmission at 550 nm. Iron, chromium, and tin appear to be preferred in minimizing loss of optical transmission. Iron appears particularly suitable in this regard and actually appears to enhance the optical transmission.
TABLE VI______________________________________ % TransmissionEx. Dopant, % Thickness (nm) 400 nm 550 nm______________________________________C176 (no coating) 85.01 88.71C177.sup.a (no coating) 69.25 77.34C178 none -- 323 81.85 83.18C179 none 303 75.68 83.56C180 MgF.sub.2 5 201 88.10 88.10181 MgF.sub.2 5 306 88.98 90.19182 MgF.sub.2 10 301 86.90 92.17C183.sup.b SF.sub.6 5 306 86.60 87.70184 Al 5 304 76.21 80.91185 Al 15 312 38.90 75.86186 Al 30 321 1.45 28.18187 Cr 5 304 84.96 88.73188 Cr 10 152 82.45 82.42189 Cr 10 303 85.62 90.07190 Cr 20 76 81.16 83.67191 Cr 20 153 70.89 78.76192 Cr 20 302 12.30 31.62193 Cu 5 300 59.57 71.94194 Cu 5 301 73.79 81.66195 Cu 10 117 64.12 72.44196 Cu 10 311 51.71 71.94197 Cu 20 78 84.96 88.73198 Cu 20 155 50.05 61.44199 Cu 20 301 25.59 39.81200 Cu 20 302 53.48 65.80201 Fe 5 302 87.90 89.41202 Fe 10 304 82.99 89.54203 Mn 10 302 78.16 83.95204 Pb 10 330 26.61 41.88205 Sn 5 302 85.11 88.72206 Sn 10 150 82.70 85.51207 Sn 10 311 84.45 85.29208 Sn 20 76 86.50 90.16209 Sn 20 303 25.94 36.31______________________________________ .sup.a Commodity PET film with internal slip additive, 24 micrometers thick. .sup.b Coating prepared from lead glass about 70% Pb.

Number	Name	Date
3442686	Jones	May 1969
3522080	Dietzel et al.	Jul 1970
3808027	Anderson et al.	Apr 1974
4312915	Fan	Jan 1982
4528234	Kaibo et al.	Jul 1985
4552791	Hahn	Nov 1985
4702963	Phillips et al.	Oct 1987

Number	Date	Country
61-47244	Mar 1986	JPX
60-244540	Dec 1986	JPX
62-156943	Jul 1987	JPX
62-158677	Jul 1987	JPX
2197881	Jun 1988	GBX

Film coated with glass barrier layer with metal dopant

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