# US 9,040,120 B2 · Inorganic nanocoating primed organic film > Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt - Number: US 9,040,120 B2 - Document ID: US9040120B2 - Status: Granted - Kind: B2 - Application number: 13/204,483 - Filed: 2011-08-05 - Published: 2013-02-07 - Granted: 2015-05-26 - Earliest claimed: 2011-08-05 - Assignees: Frito-Lay North America, Inc. - Applicants: Andrew Hunt; Yongdong Jiang; Kenneth Scott Laverdure; Anthony Robert Knoerzer - Inventors: Andrew Hunt; Yongdong Jiang; Kenneth Scott Laverdure; Anthony Robert Knoerzer - Web page: https://patentgrep.com/patent/US9040120B2 ## CPC - C23C 16/40: Oxides - C23C 14/02: Pretreatment of the material to be coated (C23C14/04 takes precedence) - C23C 16/02: Pretreatment of the material to be coated (C23C16/04 takes precedence) - C23C 16/0272: {Deposition of sub-layers, e.g. to promote the adhesion of the main coating} - C23C 16/401: {containing silicon} - C23C 16/402: {Silicon dioxide} - C23C 16/453: passing the reaction gases through burners or torches, e.g. atmospheric pressure CVD (C23C16/513 takes precedence; for flame or plasma spraying of coating material in the molten state C23C4/00) - C23C 16/50: using electric discharges {(generation and control of plasma in discharge tubes for surface treatment H01J37/32, H01J37/34)} - C23C: COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL (making metal-coated products by extrusion B21C23/22; covering with metal by connecting pre-existing layers to articles, see the relevant places, e.g. B21D39/00, B23K; metallising of glass C03C; metallising mortars, concrete, artificial stone, ceramics or natural stone C04B41/00; enamelling of, or applying a vitreous layer to, metals C23D; treating metal surfaces or coating of metals by electrolysis or electrophoresis C25D; single-crystal film growth C30B; by metallising textiles D06M11/83; decorating textiles by locally metallising D06Q1/04) ## Abstract An inorganic nanolayer surface coated polymer film product is disclosed with enhancements such as improved metallization capability, low cost, low polymer additives and modifiers, improved recyclability, and good web properties. Also method for priming a flexible film substrate to enhance the reactivity or wettability of the substrate for metallization is disclosed. A substrate film is coated with one or more nanolayers of a metal or metal oxide applied by CCVD and/or PECVD at open atmosphere. The deposited coating acts to enhance the surface energy of the film substrate and to and reduce the surface gauge variation of the substrate or supporting film, thereby enhancing the wettability of the film substrate for metallization and/or to improve the anti-block characteristics of the film. The deposited coatings may also act as a barrier layer for lowering the permeability of light, gas and vapor transmission through the substrate. ## Claims ### Claim 1 A method comprising: a) forming a coextruded organic film substrate by a co-extrusion process; b) depositing a first inorganic nanocoating layer directly on to a surface of the film substrate at open atmosphere to enhance the wettability of the film substrate for metallization, wherein the first inorganic nanocoating layer is silica, and wherein the inorganic nanocoating layer is deposited on to at least one surface of the film substrate prior to all winding and deposited in a process that is inline with the coextrusion process, wherein the inorganic nanocoating layer is less than 8 nm in average thickness; and wherein the surface roughness of the inorganic nanocoating layer is characterized by root mean square value of less than about 5 nm; and c) depositing a metal layer directly on the first inorganic nanocoating layer by a vacuum metallization process to produce a coated film substrate, wherein the metal layer is not a metal oxide layer, wherein the metal layer is aluminum, and wherein the metal layer has a thickness from about 5 to about 50 nm. ### Claim 2 (depends on 1) The method of claim 1 wherein the inorganic nanocoating layer is deposited on to at least one surface of the film substrate by combustion chemical vapor deposition. ### Claim 3 (depends on 1) The method of claim 1 wherein the inorganic nanocoating layer is deposited on to at least one surface of the film substrate by plasma enhanced chemical vapor deposition. ### Claim 4 (depends on 1) The method of claim 1 wherein the inorganic nanocoating layer is substantially deposited by redirection of a flame. ### Claim 5 (depends on 1) The method of claim 1 wherein the inorganic nanocoating layer is substantially deposited by electro-redirection of a plasma field. ### Claim 6 (depends on 1) The method of claim 1 wherein the film substrate is a cast, monoaxially, or biaxially oriented cast film. ### Claim 7 (depends on 1) The method of claim 1 wherein the film substrate is a blown film. ### Claim 8 (depends on 1) The method of claim 1 wherein the film substrate is a biaxial film. ### Claim 9 (depends on 1) The method of claim 1 wherein the film substrate is a bio-based polymer film. ### Claim 10 (depends on 1) The method of claim 1 wherein the film substrate comprises a core polymer layer selected from the group consisting of polyethylene, polypropylene, polystyrene, polylactic acid, polyethylene terephthalate, polyesters, and copolymers thereof and mixtures thereof. ### Claim 11 (depends on 1) The method of claim 1 wherein the coated film substrate has a moisture vapor transmission rate of 2.0 g/m2/day or less. ### Claim 12 (depends on 1) The method of claim 1 wherein the coated film substrate has an oxygen transmission rate of 10 cc/m2·day or less. ### Claim 13 (depends on 1) The method of claim 1 wherein at least one additional inorganic nanocoating layer is applied to form a transparent barrier layer. ### Claim 14 (depends on 1) The method of claim 1, wherein between the depositing a first inorganic nanocoating layer step and the depositing a metal layer step, the coated film substrate is wound. ### Claim 15 A method comprising: a) forming a coextruded organic film substrate by a co-extrusion process; b) depositing a first inorganic nanocoating layer directly on to a surface of the film substrate at open atmosphere to substantially inhibit blocking of the film substrate, wherein the first inorganic nanocoating layer is silica, and wherein the inorganic nanocoating layer is deposited on to at least one surface of the film substrate prior to all winding and deposited in a process that is inline with the coextrusion process, wherein the inorganic nanocoating layer is less than 8 nm in average thickness; and wherein the surface roughness of the inorganic nanocoating layer is characterized by a root mean square value of less than about 5 nm; and c) depositing a metal layer directly on the first inorganic nanocoating layer by a vacuum metallization process, wherein the metal layer is not a metal oxide layer, wherein the metal layer is aluminum, and wherein the metal layer has a thickness from about 5 to about 50 nm. ### Claim 16 (depends on 15) The method of claim 15 wherein the inorganic nanocoating layer is deposited on to at least one surface of the film substrate by combustion chemical vapor deposition. ### Claim 17 (depends on 15) The method of claim 15 wherein the inorganic nanocoating layer is substantially deposited on to at least one surface of the film substrate by plasma enhanced chemical vapor deposition. ### Claim 18 (depends on 15) The method of claim 15 wherein the inorganic nanocoating layer is substantially deposited by redirection of a flame. ### Claim 19 (depends on 15) The method of claim 15 wherein the inorganic nanocoating layer is substantially deposited by electro-redirection of a plasma field. ### Claim 20 (depends on 15) The method of claim 15 wherein the inorganic nanocoating layer is substantially deposited on to at least one surface of the film substrate prior to lamination. ### Claim 21 (depends on 15) The method of claim 15 wherein the film substrate is a cast, monoaxially, or biaxially oriented cast film. ### Claim 22 (depends on 15) The method of claim 15 wherein the film substrate is a blown film. ### Claim 23 (depends on 15) The method of claim 15 wherein the film substrate is a bio-based polymer film. ### Claim 24 (depends on 15) The method of claim 15 wherein the film substrate comprises a core polymer layer selected from the group consisting of polyethylene, polypropylene, polystyrene, polylactic acid, polyethylene terephthalate, polyesters, and copolymers thereof and mixtures thereof. ### Claim 25 (depends on 15) The method of claim 15, wherein between the depositing a first inorganic nanocoating layer step and the depositing a metal layer step, the coated film substrate is wound.