CN104070744A - 复合膜及其制造方法 - Google Patents
复合膜及其制造方法 Download PDFInfo
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- CN104070744A CN104070744A CN201310158492.2A CN201310158492A CN104070744A CN 104070744 A CN104070744 A CN 104070744A CN 201310158492 A CN201310158492 A CN 201310158492A CN 104070744 A CN104070744 A CN 104070744A
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- film
- hydrophobic polymer
- gas barrier
- composite membrane
- inorganic gas
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- 229920001600 hydrophobic polymer Polymers 0.000 claims abstract description 69
- 230000004888 barrier function Effects 0.000 claims abstract description 61
- 229910001872 inorganic gas Inorganic materials 0.000 claims abstract description 54
- QVGXLLKOCUKJST-UHFFFAOYSA-N atomic oxygen Chemical compound [O] QVGXLLKOCUKJST-UHFFFAOYSA-N 0.000 claims abstract description 33
- 239000001301 oxygen Substances 0.000 claims abstract description 33
- 229910052760 oxygen Inorganic materials 0.000 claims abstract description 33
- 239000010408 film Substances 0.000 claims description 149
- 239000010410 layer Substances 0.000 claims description 66
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- FPYJFEHAWHCUMM-UHFFFAOYSA-N maleic anhydride Chemical compound O=C1OC(=O)C=C1 FPYJFEHAWHCUMM-UHFFFAOYSA-N 0.000 claims description 11
- 229920001155 polypropylene Polymers 0.000 claims description 11
- PNEYBMLMFCGWSK-UHFFFAOYSA-N Alumina Chemical compound [O-2].[O-2].[O-2].[Al+3].[Al+3] PNEYBMLMFCGWSK-UHFFFAOYSA-N 0.000 claims description 10
- CSNNHWWHGAXBCP-UHFFFAOYSA-L Magnesium sulfate Chemical compound [Mg+2].[O-][S+2]([O-])([O-])[O-] CSNNHWWHGAXBCP-UHFFFAOYSA-L 0.000 claims description 10
- OSGAYBCDTDRGGQ-UHFFFAOYSA-L calcium sulfate Chemical compound [Ca+2].[O-]S([O-])(=O)=O OSGAYBCDTDRGGQ-UHFFFAOYSA-L 0.000 claims description 10
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- BRPQOXSCLDDYGP-UHFFFAOYSA-N calcium oxide Chemical compound [O-2].[Ca+2] BRPQOXSCLDDYGP-UHFFFAOYSA-N 0.000 claims description 7
- 239000000292 calcium oxide Substances 0.000 claims description 7
- ODINCKMPIJJUCX-UHFFFAOYSA-N calcium oxide Inorganic materials [Ca]=O ODINCKMPIJJUCX-UHFFFAOYSA-N 0.000 claims description 7
- VYPSYNLAJGMNEJ-UHFFFAOYSA-N Silicium dioxide Chemical compound O=[Si]=O VYPSYNLAJGMNEJ-UHFFFAOYSA-N 0.000 claims description 6
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- 229910001628 calcium chloride Inorganic materials 0.000 claims description 5
- AXCZMVOFGPJBDE-UHFFFAOYSA-L calcium dihydroxide Chemical compound [OH-].[OH-].[Ca+2] AXCZMVOFGPJBDE-UHFFFAOYSA-L 0.000 claims description 5
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- UHESRSKEBRADOO-UHFFFAOYSA-N ethyl carbamate;prop-2-enoic acid Chemical compound OC(=O)C=C.CCOC(N)=O UHESRSKEBRADOO-UHFFFAOYSA-N 0.000 claims description 5
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- KCTAWXVAICEBSD-UHFFFAOYSA-N prop-2-enoyloxy prop-2-eneperoxoate Chemical compound C=CC(=O)OOOC(=O)C=C KCTAWXVAICEBSD-UHFFFAOYSA-N 0.000 claims description 5
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- NWAIGJYBQQYSPW-UHFFFAOYSA-N azanylidyneindigane Chemical compound [In]#N NWAIGJYBQQYSPW-UHFFFAOYSA-N 0.000 claims description 3
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- 238000001704 evaporation Methods 0.000 claims description 3
- 229910000449 hafnium oxide Inorganic materials 0.000 claims description 3
- WIHZLLGSGQNAGK-UHFFFAOYSA-N hafnium(4+);oxygen(2-) Chemical compound [O-2].[O-2].[Hf+4] WIHZLLGSGQNAGK-UHFFFAOYSA-N 0.000 claims description 3
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- 239000010409 thin film Substances 0.000 claims description 3
- 239000011787 zinc oxide Substances 0.000 claims description 3
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 abstract description 23
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- 239000004715 ethylene vinyl alcohol Substances 0.000 description 9
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- VGGSQFUCUMXWEO-UHFFFAOYSA-N Ethene Chemical compound C=C VGGSQFUCUMXWEO-UHFFFAOYSA-N 0.000 description 6
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- 239000002274 desiccant Substances 0.000 description 2
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- RZXDTJIXPSCHCI-UHFFFAOYSA-N hexa-1,5-diene-2,5-diol Chemical compound OC(=C)CCC(O)=C RZXDTJIXPSCHCI-UHFFFAOYSA-N 0.000 description 2
- 230000002209 hydrophobic effect Effects 0.000 description 2
- 125000002887 hydroxy group Chemical group [H]O* 0.000 description 2
- 239000010954 inorganic particle Substances 0.000 description 2
- 229920001911 maleic anhydride grafted polypropylene Polymers 0.000 description 2
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- 238000012360 testing method Methods 0.000 description 2
- 238000002834 transmittance Methods 0.000 description 2
- JLTRXTDYQLMHGR-UHFFFAOYSA-N trimethylaluminium Chemical compound C[Al](C)C JLTRXTDYQLMHGR-UHFFFAOYSA-N 0.000 description 2
- MYMOFIZGZYHOMD-UHFFFAOYSA-N Dioxygen Chemical compound O=O MYMOFIZGZYHOMD-UHFFFAOYSA-N 0.000 description 1
- 239000000853 adhesive Substances 0.000 description 1
- 230000001070 adhesive effect Effects 0.000 description 1
- 229910052782 aluminium Inorganic materials 0.000 description 1
- 210000002469 basement membrane Anatomy 0.000 description 1
- 230000009286 beneficial effect Effects 0.000 description 1
- 125000002915 carbonyl group Chemical group [*:2]C([*:1])=O 0.000 description 1
- 239000011248 coating agent Substances 0.000 description 1
- 238000001816 cooling Methods 0.000 description 1
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- 230000009931 harmful effect Effects 0.000 description 1
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- 238000005286 illumination Methods 0.000 description 1
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- 230000007246 mechanism Effects 0.000 description 1
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Abstract
本发明公开一种复合膜及其制造方法。复合膜包括一有机多层膜以及二无机阻气层。有机多层膜包括一疏水性高分子膜及二亲水性高分子膜,二亲水性高分子膜分别形成于疏水性高分子膜的相对二表面上。二无机阻气层分别形成于二亲水性高分子膜上。本发明的复合膜及其制造方法,可使该复合膜具有良好的整体阻水氧效果。
Description
技术领域
本发明涉及一种复合膜及其制造方法,且特别涉及一种具有低水氧穿透率的复合膜及其制造方法。
背景技术
近年来由于市场对于消费性电子产品的可移植性及其额外具备的可挠性的兴趣及重视,软性电子产品的开发受到了广泛的关注。软性电子产品具有轻、薄的优点,且由于其可服贴于弯曲表面的性质,将使现有光电元件在能源、显示、照明等领域有更广泛及崭新的应用。
软性电子元件一般以塑料或金属薄片为基材,其中塑料基材相较于金属基材具有质轻、透明及可挠度较高的优点,有机会成为软性基材的主流。
然而,塑料基材对水气、氧气的阻障效果不佳,使得光电组件中的作用层及低功函数电极易与空气中的水、氧反应而造成元件劣化,成为了软性电子产品发展上的主要限制。因此,开发具透明性、可挠特性的阻水、氧基膜,已成为软性电子产品发展的关键。
发明内容
本发明的目的在于提供一种复合膜及其制造方法,使该复合膜具有良好的整体阻水氧效果。
为实现上述目的,本发明的一实施例提出一种复合膜。复合膜包括一有机多层膜以及二无机阻气(gas barrier)层。有机多层膜包括一疏水性(hydrophobic)高分子膜及二亲水性(hydrophilic)高分子膜,二亲水性高分子膜分别形成于疏水性高分子膜的相对二表面上。二无机阻气层分别形成于二亲水性高分子膜上。
其中,该疏水性高分子膜直接接触该亲水性高分子膜。
其中,该疏水性高分子膜的材质包括一接枝(grafted)疏水性高分子。
其中,该接枝疏水性高分子的接枝率为0.5~8%。
其中,该疏水性高分子膜的材质包括聚丙烯接枝马来酸酐(maleic anhydridegrafted polypropylene,PP-g-MA)、聚丙烯接枝甲基丙烯酸缩水甘油酯(glycidylmethacrylate grafted polypropylene,PP-g-GMA)、乙烯-丙烯共聚物接枝马来酸酐(maleic anhydride grafted ethylene-propylene copolymer)和乙烯-丙烯共聚物接枝甲基丙烯酸缩水甘油酯(glycidyl methacrylate grafted ethylene-propylenecopolymer)的至少其中之一或任两者的组合。
其中,该亲水性高分子膜的材质分别包括乙烯共聚物、丙烯共聚物、乙烯-乙烯醇共聚物(ethylene vinyl alcohol,EVOH)、聚酰胺(polyamide)、丙烯腈-甲基丙烯酸甲酯共聚物(acrylonitrile-methyl methacrylate copolymer)和苯乙烯-丙烯腈共聚物(styrene-acrylonitrile copolymer)的至少其中之一或任两者的组合。
其中,该无机阻气层分别直接接触该亲水性高分子膜。
其中,该无机阻气层的材质分别包括氧化铝、氧化锌、氧化锆、氧化铪、氧化硅和氮化铟的至少其中之一或任两者的组合。
其中,更包括二保护层,分别形成于该二无机阻气层上。
其中,该保护层的材质分别包括聚氨酯丙烯酸酯(urethane acrylate)、环氧丙烯酸酯(epoxy acrylate)、聚丙烯酸酯(polyacrylate)和聚酯(polyester)的至少其中之一或任两者的组合。
其中,更包括一吸湿剂(desiccant)混合于该疏水性高分子膜中。
其中,该吸湿剂的材质包括氧化钙、氢氧化钙、氯化钙、硫酸钙和硫酸镁的至少其中之一或任两者的组合。
其中,该吸湿剂为氧化钙、氢氧化钙、氯化钙、硫酸钙和硫酸镁的至少其中之一或任两者的组合混合于聚乙烯、聚丙烯或乙烯-醋酸乙烯共聚物中所形成的一母粒(masterbatch)。
其中,该疏水性高分子膜、该亲水性高分子膜及该无机阻气层由一种以上相同或不同的透明材料所制成,该复合膜的水蒸气穿透率小于0.1g/m2-day,该复合膜的氧气穿透率小于0.01cc/m2-day-atm。
本发明的另一实施例提出一种复合膜的制造方法。复合膜的制造方法包括:以共押出工艺(coextrusion process)形成一有机多层膜,包括形成一疏水性高分子膜及分别形成二亲水性高分子膜于疏水性高分子膜的相对二表面上;以及分别形成二无机阻气层于二亲水性高分子膜上。
其中,该疏水性高分子膜的材质包括一接枝疏水性高分子。
其中,更包括:分别形成二保护层于该二无机阻气层上。
其中,更包括:混合一吸湿剂于该疏水性高分子膜中。
其中,以热蒸镀工艺、溅镀工艺、化学气相沉积或原子层沉积法(atomic layerdeposition,ALD)形成该无机阻气层于该亲水性高分子膜上。
其中,该无机阻气层分别直接接触该亲水性高分子膜。
其中,该疏水性高分子膜、该亲水性高分子膜及该无机阻气层由一种以上相同或不同的透明材料所制成。
其中,更包括:设置该复合膜于一软性电子装置、一薄膜太阳能电池或一有机太阳能电池中作为一基材或一封装膜。
本发明的复合膜及其制造方法,借由亲水性高分子膜形成于疏水性高分子膜相对的二表面上以形成有机多层膜、及无机阻气层形成于亲水性高分子膜上的配置,可使有机多层膜同时提供良好的水、氧阻障性质,并增进无机阻气层于有机多层膜上的附着性、降低其缺陷密度,进而提供良好的整体阻水氧效果。
以下结合附图和具体实施例对本发明进行详细描述,但不作为对本发明的限定。
附图说明
图1为本发明一实施例的复合膜的示意图。
图2A至图2C为本发明一实施例的一种复合膜的制造方法示意图。
其中,附图标记:
100:复合膜
110:有机多层膜
111:疏水性高分子膜
111a、111b:表面
113、115:亲水性高分子膜
120、130:无机阻气层
140、150:保护层
具体实施方式
本发明的实施例中的复合膜,借由亲水性高分子膜形成于疏水性高分子膜相对的二表面上以形成有机多层膜、及无机阻气层形成于亲水性高分子膜上的配置,可使有机多层膜同时提供良好的水、氧阻障性质,并增进无机阻气层于有机多层膜上的附着性、降低其缺陷密度,进而提供良好的整体阻水氧效果。以下参照所附图式详细叙述本发明内容的实施例。图式中相同的标号用以标示相同或类似的部分。需注意的是,图式已简化以利清楚说明实施例的内容,实施例所提出的细部结构仅为举例说明之用,并非对本发明欲保护的范围做限制。本领域技术人员当可依据实际实施态样的需要对该结构加以修饰或变化。
图1绘示本发明内容的一实施例的复合膜100的示意图。请参照图1。复合膜100包括有机多层膜(organic multilayer film)110以及二无机阻气(barrier)层120和130。有机多层膜110包括疏水性(hydrophobic)高分子膜111及二亲水性(hydrophilic)高分子膜113和115,亲水性高分子膜113和115分别形成于疏水性高分子膜111的相对的二表面111a和111b上。无机阻气层120和130分别形成于亲水性高分子膜113和115上。
一实施例中,疏水性高分子膜111的厚度介于10~200微米(μm),较佳介于50~150微米;亲水性高分子膜113和115的厚度介于1~20微米,较佳介于5~10微米。
一实施例中,疏水性高分子膜111的材质包括一接枝(grafted)疏水性高分子。接枝疏水性高分子相较于未接枝疏水性高分子具有较高极性,可使得疏水性高分子膜111和亲水性高分子膜113和115之间具有较佳接着性(adhesion)。如此一来,如图1所示,疏水性高分子膜111直接接触亲水性高分子膜113和115,中间不需要额外的黏着层。举例来说,接枝疏水性高分子可以是其接枝官能基本身具有高极性,或者是接枝后使整体高分子的极性提高。
一实施例中,接枝疏水性高分子的接枝率介于0.5~8%。此比例为关键,接枝率低于0.5%时,高分子整体极性太低,疏水性高分子膜111和亲水性高分子膜113和115之间的接着性不佳;接枝率高于8%时,疏水性高分子的分子量会过低,导致无法成膜。
实施例中,疏水性高分子膜111具有良好的水气阻绝效果,亲水性高分子膜113和115具有良好的氧气阻绝效果。此两者可共同提供良好的阻水氧效果。实施例中,疏水性高分子膜111及亲水性高分子膜113和115均具有高透明性,其由一种以上相同或不同的透明材料所制成。
实施例中,疏水性高分子膜111的材质包括聚丙烯接枝马来酸酐(maleicanhydride grafted polypropylene,PP-g-MA)、聚丙烯接枝甲基丙烯酸缩水甘油酯(glycidyl methacrylate grafted polypropylene,PP-g-GMA)、乙烯-丙烯共聚物接枝马来酸酐(maleic anhydride grafted ethylene-propylene copolymer)和乙烯-丙烯共聚物接枝甲基丙烯酸缩水甘油酯(glycidyl methacrylate graftedethylene-propylene copolymer)的至少其中之一或任两者的组合。
实施例中,亲水性高分子膜113和115的材质独立地分别包括乙烯共聚物、丙烯共聚物、乙烯-乙烯醇共聚物(ethylene vinyl alcohol,EVOH)、聚酰胺(polyamide)、丙烯腈-甲基丙烯酸甲酯共聚物(acrylonitrile-methyl methacrylatecopolymer)和苯乙烯-丙烯腈共聚物(styrene-acrylonitrile copolymer)的至少其中之一或任两者的组合。
实施例中,复合膜100更包括一吸湿剂(desiccant)混合于疏水性高分子膜111中。一实施例中,吸湿剂占疏水性高分子膜111的重量百分比介于1~5wt%。吸湿剂的存在可额外提供水气阻障的机制,也可避免在后续加工时,高分子材料内含的水分导致微气泡的产生而对有机多层膜110的质量有不良影响。
一实施例中,吸湿剂的材质包括氧化钙、氢氧化钙、氯化钙、硫酸钙和硫酸镁的至少其中之一或任两者的组合的无机粉体,或者上述材料的无机粉体混合于聚乙烯、聚丙烯或乙烯-醋酸乙烯共聚物中所形成的母粒(masterbatch)。一实施例中,母粒中,无机物的重量百分比介于60~80wt%。吸湿剂必需存在于疏水性高分子膜111中。吸湿剂若是添加到亲水性高分子膜113和115中,可能会影响到其膜层表面粗糙度,而对于后续无机阻气层的形成有不良的影响。
实施例中,如图1所示,无机阻气层120和130分别直接接触亲水性高分子膜113和115,中间不需要额外的黏着层。实施例中,亲水性高分子膜113和115包覆在疏水性高分子膜111的外层表面,无机阻气层120和130直接形成于亲水性高分子膜113和115的亲水性表面上。亲水性高分子膜113和115的表面结构具有极性官能基,例如是羟基(OH group)、氰基(CN group)、羰基(COgroup)和/或氨基(NHx group),对于无机阻气层120和130在镀膜过程中所使用的亲水性前驱物(例如是金属错合物)吸附能力较佳,因此不但无须对亲水性高分子膜113和115的表面进行额外的化学性或物理性的表面处理便可以形成无机阻气层120和130于其上,同时可以有效降低无机阻气层120和130的缺陷,并提高其阻水氧效果。换句话说,无机阻气层120和130与亲水性高分子膜113和115(相较于与疏水性高分子膜111)之间具有较佳的接着性。因此,亲水性高分子膜113和115包覆在疏水性高分子膜111的表面的有机多层膜110本身不仅具有良好阻水氧效果,搭配形成于其上的无机阻气层120和130,更可提高其接着性,因此能提供更佳的整体阻水氧效果。
实施例中,无机阻气层120和130为透明金属氧化物层,均具有高透明性,其由一种以上相同或不同的透明材料所制成。无机阻气层120和130的材质独立地分别包括氧化铝、氧化锌、氧化锆、氧化铪、氧化硅和氮化铟的至少其中之一或任两者的组合。
实施例中,如图1所示,复合膜100更可包括二保护层140和150,保护层140和150分别形成于无机阻气层120和130上。保护层140和150与无机阻气层120和130之间具有良好的附着性,且保护层140和150具有耐刮及可挠的特性,可提供物理性保护,保护无机阻气层120和130的表面不被刮伤或破裂,同时也有助于防止无机阻气层120和130与空气中的水气与氧气反应而劣化。
实施例中,保护层140和150的材质独立地分别包括聚氨酯丙烯酸酯(urethane acrylate)、环氧丙烯酸酯(epoxy acrylate)、聚丙烯酸酯(polyacrylate)和聚酯(polyester)的至少其中之一或任两者的组合。一实施例中,保护层140和150的厚度介于1~8微米,较佳介于1~5微米。
以下提出实施例的一种复合膜100的制造方法,然该步骤仅为举例说明,并非用以限缩本发明。本领域技术人员当可依据实际实施态样的需要对该步骤加以修饰或变化。请参照图2A至图2C。图2A至图2C绘示依照本发明的一实施例的一种复合膜100的制造方法示意图。
请参照图2A,形成有机多层膜110。形成有机多层膜110的制造方法包括:形成疏水性高分子膜111,以及分别形成二亲水性高分子膜113和115于疏水性高分子膜111的相对二表面111a和111b上。
一实施例中,以共押出工艺(coextrusion process)形成有机多层膜110,熔融押出的温度介于220~240℃。相较于一般以贴合工艺制作多层膜结构的方式,共押出工艺是一体成形在一个步骤直接形成多层结构的有机多层膜110,可使得多层结构紧密结合而无须额外的黏着层,且具有简化工艺及降低成本的优点。
一实施例中,例如是将亲水性高分子膜的原料及疏水性高分子膜的原料各自注入单螺杆押出机(single screw extruder)中,经T型模头熔融共押出,经由铸膜轮(casting drum)冷却得到亲水性高分子膜113/疏水性高分子膜111/亲水性高分子膜115的结构,即为有机多层膜110。押出机的操作温度例如介于220℃至240℃之间,铸膜轮的温度介于15℃至40℃之间。吸湿剂可以在共押出工艺中导入疏水性高分子膜111。
实施例中,疏水性高分子膜111的材质包括一接枝疏水性高分子,有助于提高疏水性高分子膜111与亲水性高分子膜113和115之间的接着性。实施例中,形成疏水性高分子膜111时,亦可于疏水性高分子膜111中混入吸湿剂,可提高阻水氧的效果,亦可避免后续融熔共押出加工时,高分子材料内含的水分导致微气泡的产生,进而提升共押出的有机多层膜110的品质。
一实施例中,亲水性高分子膜113和115的材质例如包括乙烯-乙烯醇共聚物(EVOH),乙烯占整体共聚物的莫耳百分比介于32~48mol%,如此一来,有机多层膜110具有良好阻氧气效果且易于加工成膜。此比例为关键,乙烯的莫耳百分比低于约32mol%时,不易加工成膜;乙烯的重量百分比高于约48mol%时,虽利于加工成膜,但阻氧气特性会大幅下降。
接着,请参照图2B,分别形成二无机阻气层120和130于亲水性高分子膜113和115上。
实施例中,如图2B所示,无机阻气层120和130例如是分别直接接触亲水性高分子膜113和115。由于亲水性高分子膜113和115可降低无机阻气层120和130在镀膜时的缺陷密度,增进其接着性,因此可在有机多层膜110原先的水氧阻障性质外,借由无机阻气层的镀制大大提升整体阻水氧效果。
实施例中,例如是以热蒸镀工艺、溅镀工艺、化学气相沉积或原子层沉积法(atomic layer deposition,ALD)形成无机阻气层120和130于亲水性高分子膜113和115上。
一实施例中,例如以原子层沉积法形成无机阻气层120和130,可选用的前驱物例如是三甲基铝及水,利用原子层沉积机台在反应温度介于100~150℃下沉积无机阻气层120和130,形成的无机阻气层120和130大约具有120~200层原子层的厚度,较佳具有180~200层原子层的厚度,因此具有良好的挠屈性且不易龟裂。此外,相较于物理气相沉积,以原子层沉积法制作而成的结构较致密且缺陷也较少,具超低针孔密度,因此具有较佳的阻水氧效果。
接着,请参照图2C,分别形成二保护层140和150于二无机阻气层120和130上。
形成保护层140和150的制造方法例如包括:涂布光固化型保护层胶材于无机阻气层120和130的表面,以及以紫外光照射光固化型保护层胶材使其发生交联反应而固化成保护层140和150。至此,形成如图2C(图1)所示的复合膜100。
以下就实施例作进一步说明。以下实施例中列出复合膜的材质、结构配置及特性。然而以下实施例仅为例示说明,而不应被解释为本发明实施的限制。
实施例1:疏水性高分子膜111的材质选用聚丙烯接枝马来酸酐(PP-g-MA),亲水性高分子膜113和115的材质选用乙烯-乙烯醇共聚物(EVOH),以共押出工艺形成具有EVOH/PP-g-MA/EVOH的有机多层膜。其中,亲水性高分子膜113和115(乙烯-乙烯醇共聚物(EVOH))的厚度为15微米,乙烯含量为38mol%,疏水性高分子膜111(聚丙烯接枝马来酸酐(PP-g-MA))的厚度为110微米。接着,以三甲基铝(trimethyl aluminum)及水作为前驱物,于120℃下以原子层沉积机台进行200层原子层的氧化铝沉积,形成无机阻气层。接着,以线棒及涂布机台分别于上、下无机阻气层表面涂覆压克力系光固化胶材,并以紫外光曝光机固化胶材而形成保护层。制作完成的复合膜以ASTM F1249测试方法下测定水气穿透率(water vapor transmission rate,WVTR),以ASTM D3985测试方法测定氧气穿透率(oxygen transmission rate,OTR),并量测全光谱穿透度(fullwavelength optical transmittance,测试方法:ASTM D1003)。
其中,“ASTM F1249测试方法”、“ASTM D3985测试方法”和“测试方法ASTM D1003”是ASTM(American Society for Testing and Materials)美国材料试验协会提供的标准测定方法。其各个代码为标号,各标号的实际操作方法中英文名称如下:
D3985:利用库伦检测器量测塑胶薄膜及薄板的氧气穿透速率的试验方法(Standard test method for oxygen gas transmission rate through plastic film andsheeting using a coulometric sensor);F1249:利用调制红外线检测器量测塑胶薄膜及薄板的水蒸气穿透率的试验方法(Standard test method for water vaportransmission rate through plastic film and sheeting using a modulated infraredsensor);D1003:量测透明高分子雾度及光穿透度的试验方法(Standard testmethod for haze and luminous transmittance of transparent plastic)。
实施例2:制作方法与实施例1基本上相同,其差异在于本实施例的乙烯含量为44mol%。亦对制作完成的复合膜进行水气穿透率、氧气穿透率及全光谱穿透度的量测。
实施例3:制作方法与实施例1基本上相同,其差异在于本实施例的在疏水性高分子膜111(聚丙烯接枝马来酸酐,PP-g-MA)中混入吸湿剂,吸湿剂选用为80wt%氧化钙与20wt%聚乙烯的共混母粒,添加于疏水性高分子膜111中,使氧化钙的比率为4wt%。亦对制作完成的复合膜进行水气穿透率、氧气穿透率及全光谱穿透度的量测。
实施例4:制作方法与实施例3基本上相同,其差异在于本实施例的乙烯含量为44mol%。亦对制作完成的复合膜进行水气穿透率、氧气穿透率及全光谱穿透度的量测。
表1
由表1中可看出,实施例1~4的复合膜的氧气穿透率均小于0.01cc/m2-day-atm,水气穿透率均小于0.088g/m2-day,且全光谱穿透度均高于81.45%。由此可看出,本发明的实施例中的复合膜均具有良好的阻水氧功效且具有高光穿透的特性。
本发明的实施例的复合膜为具有有机膜及无机膜的复合膜,具有高透明度、可挠性及高阻水氧能力,可以应用于软性电子装置、薄膜太阳能电池或有机太阳能电池的基材或封装膜。并且,本发明的实施例的复合膜不需经过精密的工艺控制直接沉积在应用元件上,而可以采用包覆或贴合方式进行封装,因此应用简单便利。
当然,本发明还可有其它多种实施例,在不背离本发明精神及其实质的情况下,熟悉本领域的技术人员可根据本发明作出各种相应的改变和变形,但这些相应的改变和变形都应属于本发明权利要求的保护范围。
Claims (22)
1.一种复合膜,其特征在于,包括:
一有机多层膜,包括:
一疏水性高分子膜;及
二亲水性高分子膜,分别形成于该疏水性高分子膜的相对二表面上;以及
二无机阻气层,分别形成于该二亲水性高分子膜上。
2.根据权利要求1所述的复合膜,其特征在于,该疏水性高分子膜直接接触该亲水性高分子膜。
3.根据权利要求1所述的复合膜,其特征在于,该疏水性高分子膜的材质包括一接枝疏水性高分子。
4.根据权利要求3所述的复合膜,其特征在于,该接枝疏水性高分子的接枝率为0.5~8%。
5.根据权利要求1所述的复合膜,其特征在于,该疏水性高分子膜的材质包括聚丙烯接枝马来酸酐、聚丙烯接枝甲基丙烯酸缩水甘油酯、乙烯-丙烯共聚物接枝马来酸酐和乙烯-丙烯共聚物接枝甲基丙烯酸缩水甘油酯的至少其中之一或任两者的组合。
6.根据权利要求1所述的复合膜,其特征在于,该亲水性高分子膜的材质分别包括乙烯共聚物、丙烯共聚物、乙烯-乙烯醇共聚物、聚酰胺、丙烯腈-甲基丙烯酸甲酯共聚物和苯乙烯-丙烯腈共聚物的至少其中之一或任两者的组合。
7.根据权利要求1所述的复合膜,其特征在于,该无机阻气层分别直接接触该亲水性高分子膜。
8.根据权利要求1所述的复合膜,其特征在于,该无机阻气层的材质分别包括氧化铝、氧化锌、氧化锆、氧化铪、氧化硅和氮化铟的至少其中之一或任两者的组合。
9.根据权利要求1所述的复合膜,其特征在于,更包括二保护层,分别形成于该二无机阻气层上。
10.根据权利要求9所述的复合膜,其特征在于,该保护层的材质分别包括聚氨酯丙烯酸酯、环氧丙烯酸酯、聚丙烯酸酯和聚酯的至少其中之一或任两者的组合。
11.根据权利要求1所述的复合膜,其特征在于,更包括一吸湿剂混合于该疏水性高分子膜中。
12.根据权利要求11所述的复合膜,其特征在于,该吸湿剂的材质包括氧化钙、氢氧化钙、氯化钙、硫酸钙和硫酸镁的至少其中之一或任两者的组合。
13.根据权利要求11所述的复合膜,其特征在于,该吸湿剂为氧化钙、氢氧化钙、氯化钙、硫酸钙和硫酸镁的至少其中之一或任两者的组合混合于聚乙烯、聚丙烯或乙烯-醋酸乙烯共聚物中所形成的一母粒。
14.根据权利要求1所述的复合膜,其特征在于,该疏水性高分子膜、该亲水性高分子膜及该无机阻气层由一种以上相同或不同的透明材料所制成,该复合膜的水蒸气穿透率小于0.1g/m2-day,该复合膜的氧气穿透率小于0.01cc/m2-day-atm。
15.一种复合膜的制造方法,其特征在于,包括:
以共押出工艺形成一有机多层膜,包括:
形成一疏水性高分子膜;及
分别形成二亲水性高分子膜于该疏水性高分子膜的相对二表面上;以及
分别形成二无机阻气层于该二亲水性高分子膜上。
16.根据权利要求15所述的复合膜的制造方法,其特征在于,该疏水性高分子膜的材质包括一接枝疏水性高分子。
17.根据权利要求15所述的复合膜的制造方法,其特征在于,更包括:
分别形成二保护层于该二无机阻气层上。
18.根据权利要求15所述的复合膜的制造方法,其特征在于,更包括:
混合一吸湿剂于该疏水性高分子膜中。
19.根据权利要求15所述的复合膜的制造方法,其特征在于,以热蒸镀工艺、溅镀工艺、化学气相沉积或原子层沉积法形成该无机阻气层于该亲水性高分子膜上。
20.根据权利要求15所述的复合膜的制造方法,其特征在于,该无机阻气层分别直接接触该亲水性高分子膜。
21.根据权利要求15所述的复合膜的制造方法,其特征在于,该疏水性高分子膜、该亲水性高分子膜及该无机阻气层由一种以上相同或不同的透明材料所制成。
22.根据权利要求15所述的复合膜的制造方法,其特征在于,更包括:
设置该复合膜于一软性电子装置、一薄膜太阳能电池或一有机太阳能电池中作为一基材或一封装膜。
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