The background of this project was the use of radiation heated evaporation sources with high directed characteristics in large area vacuum coating on flexible substrates (vacuum web coating). Objectives were to improve the technology for existing products (metallised films) in terms of efficiency and to allow for alternative ways to produce new types of products on an easier way (transparent barrier films, other specific types of layers).
As major result of the project, good prospects can be seen for an alternative production technology for transparent barrier materials, especially for packaging purposes.
Coating with meltable metals
The targeted directional characteristics of the coating process could be shown for a number of different source configurations. Different characteristics, from strongly forward peaked to a "tophat" type of directional characteristic can be established and adapted to the desired application case. The problem of the required long lifetime of such a kind of sources (more than 100 hours of operation) was, however, only achieved for one type of sources.
Coating with oxides and sublimable metals
Here, the applicability in large scale equipment could be shown. Evaporation sources developed in the project can be retrofitted into standard vacuum web coating equipment. The equipment can be operated at web speeds (up to 8 m/s) that are in the same order of magnitude as in the widely used Aluminium metallisation by boat sources or as in other techniques presently used for oxide coating. Therefore, this technology is suitable for web coating companies to extend their product range into the area of transparent barrier films for packaging purposes.
For this product area, the performance of the system - source plus coating material - showed to yield good functional results in several cases. On coated PET film, laminated with PE, good barrier properties for oxygen (down to 0,25 cm³/m² d bar), water vapour (down to 0,23 g/m²d) and flavour substances (improvements over PET film by factor 70) could be obtained. The films have a high transparency over the visible spectral region which gives them a nearly colourless appearance, as required by many end users.
Also sublimable metals such as Chromium can be deposited by this technique.