Method for manufacturing a barrier layer on a substrate and a multi-layer stack

A method for manufacturing a barrier layer (14) on a flexible substrate (6a, 6b), comprising depositing an inorganic layer on the substrate in a treatment space (5), the treatment space (5) being formed between at least two electrodes (2, 3) for generating an atmospheric pressure glow discharge plasma. The barrier layer (14) is characterized in that it is formed by three subsequent depositions of inorganic layers on the substrate (6a, 6b), each layer being at most 150 nm in thickness.

RELATED APPLICATION DATA

This application is a National Stage Application under 35 U.S.C. 371 of co-pending PCT application PCT/GB2011/051305 designating the United States and filed Jul. 12, 2011; which claims the benefit of GB patent application number 1012225.7 and filed Jul. 21, 2010 each of which are hereby incorporated by reference in their entireties.

TECHNICAL FIELD

The present invention relates to a method for manufacturing a barrier layer on a flexible substrate. In further aspects, a method is provided for manufacturing a multi-layer stack structure, the structure comprising in order a substrate-a barrier layer-an adhesive layer-a barrier layer-a substrate.

BACKGROUND ART

Photovoltaic (“PV”) modules are large-area optoelectronic devices that convert solar radiation directly into electrical energy. PV modules are made by interconnecting individually formed and separate solar cells, e.g., multi-crystalline or mono-crystalline silicon solar cells, and then mechanically supporting and protecting the solar cells against environmental degradation by integrating the cells into a laminated PV module. The laminated modules generally comprise a rigid and transparent protective front panel or sheet, and a rear panel or sheet which is typically called a back-sheet. Forming a sandwiched arrangement between the front panel and back-sheet are the interconnected solar cells and an encapsulant which is transparent to solar radiation. The front panel and back-sheet encapsulate the solar cell(s) and provide protection from environmental damage. The primary function of the back sheet is to provide the low water vapor transmission, UV and oxygen barrier properties and necessary to protect the silicon wafers (photocells) from degradation induced by reaction with water, oxygen or UV radiation. Because the silicon wafers are generally encapsulated in ethylene vinyl acetate (EVA) the back-sheet material should adhere well to EVA when the components are laminated together in a thermoforming process.

US2006/0166023 describes back-side protective sheets for PV battery module comprising a vapor-deposited film of an inorganic oxide in a vacuum chamber. The thickness of the vapor-deposited film of an inorganic oxide is described to be lower than 400 nm because of cracking of the film.

WO2009/099325 from applicant which is hereby incorporated by reference describes the manufacturing of a multi-layer stack especially for OLED devices with improved water vapour transmission ratio (WVTR) properties.

Documents WO 2008/147 184 and EP 2 226 832 A, both from applicant, disclose an atmospheric pressure plasma treatment apparatus and method.

JP 2003-171 770 A discloses an apparatus for creating an anti-reflective layer on a substrate, the apparatus comprising a plurality of discharge sections. However, JP 2003-171 770 does not disclose the conditions for creating an improved barrier layer.

WO 2009/031886 A by applicant also discloses an apparatus for plasma treatment having multiple treatment spaces. Again, the conditions for creating an improved barrier layer are not disclosed.

DISCLOSURE OF THE INVENTION

In the art of manufacturing and commercialization of flexible thin substrate material i.e. back sheets or front-sheets for PV cells or PV modules displaying good properties as barrier properties, good handling properties and being defect-free a more cost-effective and a simpler process is desired.

In a first aspect of the present invention, a method is provided for manufacturing a barrier layer, in particular a water vapour barrier layer, on a flexible substrate, comprising depositing an inorganic layer on the substrate in a treatment space, the treatment space being formed between at least two electrodes for generating an atmospheric pressure glow discharge plasma. The barrier layer is characterized in that it is formed by deposition of at least three inorganic layers after each other on the substrate, each of the deposited inorganic layers being at most 150 nm in thickness. All of the at least three subsequent inorganic layer depositions can take place in the same treatment space, or in two or more separate treatment spaces. For example, one treatment space per inorganic layer deposition may be provided. Each of the at least three inorganic layers can be formed of essentially the same material (for example, by using essentially the same precursor gas compositions in each of the treatment spaces). However, each of the at least three inorganic layers can be formed using two, three or more different materials (for example, by using various the precursor gas compositions in the different treatment spaces).

The present invention provides an effective, efficient and cheap process for manufacturing of a flexible multi-layer material with excellent web-handling property. Further the invention provides an excellent multilayer stack especially in use as back sheet or front sheet for PV-cells or PV-modules.

In a further embodiment, each layer deposited is thicker than 50 nm, e.g. thicker than 60 or 100 nm. This allows to efficiently reach a total thickness of the barrier layer which is sufficient to reach predetermined characteristics, such as WVTR.

In a specific embodiment the at least three subsequent layer depositions are being executed in separate treatment spaces. Operating conditions in each treatment space can then be optimized. In a further embodiment, two of the at least three subsequent layer depositions are being executed in the same treatment space. This provides for a very efficient total treatment, and may especially be used when treating a substrate in the form of a continuous web or film.

In a further embodiment, a gas atmosphere is provided in each treatment space, wherein the gas atmosphere comprises between 4 and 25% of oxygen, e.g. between 6 and 21% of oxygen. Using the present invention embodiments allows to provide for deposition rates of more than 50 nm/s, e.g. 200 nm/s, as a result of which a very efficient and cost effective manufacturing process can be obtained.

In an even further embodiment, the method further comprises manufacturing a multi-layer stack structure, the structure comprising in order a substrate-a barrier layer-an adhesive layer-a barrier layer-a substrate, by laminating two substrates with a barrier layer with an adhesive layer in between the facing surfaces of the barrier layers to obtain the multi-layer stack structure. By treating two substrates through at least three treatment spaces and subsequently laminating of the two substrates, a very efficient production process is obtained resulting in a multi-layer stack structure having good barrier properties. Also, a more uniform treatment of the substrates is achieved when using said three treatment spaces by two substrates simultaneously.

In a further embodiment, the method further comprises laminating two or more multi-layer stack structures with an additional adhesive layer in between. By further stacking multi-layer stack structures, the WVTR characteristics may be even further improved.

In a further embodiment, the two substrates are provided on a roll to obtain the multi-layer stack structure in a continuous process. E.g. the substrates are provided as sheets to obtain the multi-layer stack structure in a continuous process. For example, the substrates may be provided from two rolls with a predetermined width, and the laminated structure may be spooled on a receiving roll. This two roll-to-one roll process is very efficient for continuous manufacturing of the multi-layer stack structure, by adhering the two treated substrates with the treated surfaces facing each other by lamination into one roll using an adhesive.

In a further embodiment, the method comprising treating the two substrates through at least three treatment spaces simultaneously. This will result in even more uniform and efficient process of manufacturing. In an even further embodiment, the two substrates are treated in the same treatment spaces.

In a further aspect this invention relates to a protective back- or front sheet for a PV- (or solar) cell or module comprising such a multi-layer stack structure being flexible and moisture resistant and a PV battery module using the same. E.g. a roll of treated substrate for use in a roll-to-roll application prepared by the method according to any one of the present invention embodiments is provided, or a roll of a multi-layered structure for a PV back or front sheet application comprising a multi-layer stack structure. Furthermore, a device comprising a part of such a roll is provided, such as a PV-cell or PV-module, in which the treated substrate or multi-layer stack structure is used as a flexible protective back or front sheet.

In a further embodiment, the substrates are organic resin films. Examples of such organic resin films (of polymer materials) include, but are not limited to PEN (PolyEthylene Naphtalate), PET (PolyEthylene Teraphtalate), PC (PolyCarbonate), COP (Cyclic Olefin Polymer), COC (Cyclic Olefin CoPolymer), etc. Other embodiments use ethylene-vinyl acetate copolymer (EVA) or polyvinyl butyral (PVB) as substrates. The thickness of the substrates may be between 20 and 800 μm, e.g. 50 μm or 200 μm.

In a further embodiment, the step of treating the facing surfaces is executed with a duty cycle of at least 90% and another embodiment is having a duty cycle of 100%. This effectively reduces the formation of dust when depositing the inorganic layer on the substrates.

An atmospheric pressure glow discharge is generated in a further embodiment by applying electrical power from one or more (dynamic matched) power supplies connected to the two electrodes (or electrode couple) in said at least three treatment spaces.

DETAILED DESCRIPTION OF THE INVENTION

FIG. 1shows a schematic view of a simplified exemplary plasma apparatus10in which the present invention embodiments may be applied. The plasma apparatus10according to the present invention embodiments comprises at least three treatment spaces5,5′,5″, inFIG. 1shown as a single treatment space5for reasons of simplicity.

Each treatment space5may be a treatment chamber within an enclosure7(not shown inFIG. 1) or a treatment spaces5with an open structure (as shown inFIG. 1). Two curved electrodes2,3are provided, e.g. cylinder shaped electrodes2,3. In general the electrode couples or electrodes2,3are provided with a dielectric barrier in order to be able to generate and sustain a glow discharge at atmospheric pressure in the treatment space5.

Two substrates6a,6bare fed from two source rolls4through the treatment space5(e.g. for depositing a layer on the surface of the substrates6a,6b, or to treat the surface of the substrates6a,6bfor subsequent processing). Guiding or tensioning rollers8are provided to assure the substrates6a,6bare kept tightly on the surface of the electrodes2,3. In the system shown inFIG. 1, the resulting treated substrates6a′,6b′ are subsequently bonded together in a laminating system23, the laminating system23in this example comprising e.g. a glue dispenser20and two pressure rollers21,22. As a result, a laminated multi-layer stack structure12is provided. As an alternative, the treated substrates6a′,6b′ are stored (e.g. on a roll) as semi-product for further use on other processes.

InFIG. 2a, a schematic view is shown of a plasma apparatus10in which embodiments of the present invention can be performed. In this case, the plasma apparatus is provided with three separate treatment spaces5,5′,5″ in three distinct enclosures7,7′,7″. Each treatment space5,5′,5″ is provided by electrode pairs2,3;2′,3′;2″,3″ all in a manner similar to the one described with reference toFIG. 1. At specific locations, guiding rollers8are provided to properly guide the substrates6a,6bthrough the plasma apparatus10. Tensioning rollers9are provided to guide the treated substrates6a′,6b′ to a laminating apparatus23(and subsequently through an optional curing element24) in order to provide the multi-layer stack structure12.

In the example ofFIG. 2atwo substrates6a,6bare simultaneously fed through the same treatment spaces5,5′,5″ however this is not necessary.FIG. 2bshows an alternative set-up of the plasma apparatus10, in which a first substrate6ais treated twice in a separate treatment space5′″ (having an optional enclosure7′″ and electrode pairs2′″,3′″). A second substrate6bis treated consecutively in three treatment spaces5,5′,5″ similar to the embodiment ofFIG. 2a. A third treatment of the first substrate6ais executed simultaneously with the third treatment of the second substrate6bin treatment space5″.

A characterizing feature of the present invention embodiments is that each of the two substrates6a,6bare fed through at least three (same or different) treatment spaces5consecutively. In each treatment space5,5′,5″ etc, an inorganic layer is deposited with an inorganic barrier amount ranging from 5 nm to at most 150 nm in thickness. In a further exemplary embodiment the range of deposited inorganic layer is from 10 to 100 nm. Depositions of less than 5 nm will not result in barriers having a good water vapour transmission ratio (WVTR) property. Depositions of more than 150 nm are susceptible for defects, e.g. caused by dust.

As a result of the present method embodiments (leading the substrates6a,6bthrough at least three treatment spaces5) two treated substrates6a′,6b′ are provided having both a deposited inorganic layer from which as result from the three or more consecutive depositions the inorganic layer has a thickness commensurate with desired properties such as a minimum WVTR, e.g. a total thickness of the inorganic layer of 450 nm or above.

The electrodes2,3;2′,3′;2″,3″ may be mounted to allow rotation in operation, e.g. using a mounting shaft and/or bearing arrangements. The electrodes2,3;2′,3′;2″,3″ may be provided as a rolling electrode2,3;2′,3′;2″,3″ which is freely rotating or may be driven at certain angular speed using controller and drive units (which as such are known to the skilled person). As a further alternative, the electrodes2,3may be provided using an electrode-couple having a flat/rotary or rotary/flat or even a flat/flat configuration. The electrodes2,3may also be formed from multiple segments.

The substrates6a,6bmay be provided in the treatment spaces5from a respective roll4, allowing a continuous feed of the substrates6a,6bto the treatment space5using the guiding rollers8. Treated substrates6a′,6b′ leave the treatment spaces5,5′,5″ etc for further processing (e.g. using the laminating apparatus23and curing element24to provide the multi-layer stack structure12) or e.g. as semi-product for storage.

Treating the two substrates6a,6bin the at least three same treatment spaces5,5′,5″ simultaneously provides a much more uniform and effective plasma treatment as compared to the application of using separate treatment processes for each substrate6a,6bseparately.

The formation of a glow discharge plasma may be stimulated by controlling the displacement current (dynamic matching) using a plasma control unit11(seeFIG. 1) connected to the electrodes2,3;2′,3′;2″,3″ leading to a uniform activation of the surface of substrate6a,6bin the treatment space5. The plasma control unit11e.g. comprises a power supply and associated control circuitry as described in the pending international patent application PCT/NL2006/050209, and European patent applications EP-A-1381257, EP-A-1626613 of applicant, which are herein incorporated by reference.

In another embodiment each electrode couple can have its own power control unit11,11′,11″ to electrode couple2,3; electrode couple2′,3′; electrode couple2″,3″ respectively and each said power unit comprises a power supply and associated control circuitry as described in the pending international patent application PCT/NL2006/050209, and European patent applications EP-A-1381257, EP-A-1626613 of applicant, which are herein incorporated by reference.

The invention further relates to a method of manufacturing a multi-layer stack structure12providing a good barrier to water vapour and being defect-free. Furthermore, the invention relates to a defect-free protective (back) sheet (formed by a treated substrate6a′,6b′ or a multi-layer stack structure12) for PV-cells or PV battery modules having a thick deposited barrier providing excellent barrier properties such as against water vapour.

An atmospheric plasma apparatus10could not be used before until now for making thick barrier layers on a flexible substrate6a,6bwithout cracks, i.e. for instance having a barrier layer thickness of 450 nm, 600 nm, 700 nm or 1000 nm thick on a flexible substrate6a,6b. Surprisingly using this new method by providing two substrates6a,6bsimultaneously through at least three treatment spaces5,5′,5″, it was surprisingly found that it is possible to make defect-free inorganic barrier layers of e.g. 450 nm, 600 nm, 700 nm, 800 nm, 900 nm, 1000 nm on said flexible substrate6a,6bwithout cracking and also having good barrier properties. Such barrier properties were not obtained when the deposition was done via one treatment space (e.g. using an at least three times lower substrate line speed) and having enough strength. After a lamination step of the treated substrates6a,6ba multi-layer stack product12as a result is obtained which has very good barrier property and which can be perfectly handled in roll-shape.

In order to quantify water vapour transmission rates for barrier films the Mocon Aquatran is used (which uses a coloummetric cell (electrochemical cell) with a minimum detection limit of 5*10−4g/m2·day). This method provides a more sensitive and accurate permeability evaluation than the permeation measurement by using IR absorption (known to the person skilled in the art). Measurement conditions can be varied from 10-40° C. and also relative humidity usually from 60-90%.

In the treatment spaces5a combination of gasses may be introduced from one or more gas supply devices (not shown), including a pre-cursor material. The gas supply devices may be provided with storage, supply and mixing components as known to the skilled person. The purpose is to have the precursor decomposed in the treatment spaces5to a chemical compound or chemical element which is deposited on the surfaces of the two substrates6a,6b. It may be advantageous to have different precursors in each different treatment space5however in the case for a sheet as back sheet in PV-application it is preferred to have one precursor resulting in one and the same deposition composition.

In general the combination of gases comprises in the treatment spaces5besides the precursor an active gas like for example oxygen and a mixture of inert gases. In one embodiment this combination of gasses comprises oxygen as active gas in a range from 4 to 25%. In another embodiment said combination may use oxygen in a range of 6 to 21%. In another embodiment as gas mixture air is used.

The duty cycle, defined as the power on time divided by the sum of the power on and power of time of these pulsing examples is large, typically in the range of 90% or higher and is even more preferred 100%.

The power supply or supplies for each electrode couple2,3may have a power supply independent from other electrode couple(s) can be a power supply providing a wide range of frequencies. For example it can provide a low frequency (f=10-450 kHz) electrical signal during the on-time. It can also provide a high frequency electrical signal for example f=450 kHz-30 MHz. Also other frequencies can be provided like from 450 kHz-1 MHz or from 1 to 20 MHz and the like.

Good results are obtained in general with a precursor concentration from 2 to 500 ppm of the gas composition and for example an oxygen concentration of e.g. 0.01% of the gas phase, or more, e.g. 2%, but less than 25% for example 10%.

Although oxygen as a reactive gas in this invention has a many advantages also other reactive gases might be used like for example hydrogen, carbon dioxide, ammonia, oxides of nitrogen, and the like. It may be advantageous to a different gas compositions per treatment space.

In the present invention embodiments the plasma gas including the precursor to be deposited via atmospheric pressure glow discharge plasma is brought into contact with two resin substrates6a,6b(e.g. in the form of continuous rolls) synchronously. At least three treatment spaces5are being used as can be seen in the embodiment ofFIG. 2a. These steps will result in less consumption of precursor and/or carrier materials and as such to much more efficient application of plasma gas including precursor to be used onto the substrates6a,6b, which provides benefits from economical and commercialization point of view. The embodiments described with reference toFIGS. 1,2aand2babove are only illustrative for plasma gas contacting two rolls of resins (i.e. substrates6a,6b) synchronously, it may be understood that the method may include also the use of a remote plasma device and jetting the plasma gas including the precursor element to be deposited onto the two resin rolls6a,6bsynchronously. Further the use of atmospheric pressure glow discharge avoids the use of complex and expensive vacuum equipment which makes the process simpler and more cost-effective.

As a result of the deposition on each substrate6a,6ban inorganic barrier14is formed with a thickness of e.g. 450 nm or above. Such depositions on flexible substrates6a,6bhave not been described in literature without having cracks. This invention allows the deposited substrate6a′,6b′ to be used as half-product or intermediate product for photo-voltaic (PV) back-sheet or front-sheet applications.

It may be well understood that as a result of the use of at least three separate treatment spaces5precursor and gas mixture composition in each treatment space5may be varied and as such may result in varied depositions on the substrates6a,6b.

Each inorganic barrier layer14will display typically a water vapour transmission rate (WVTR) of about 0.005 g/m2·day before the lamination step of a further embodiment of this invention.

InFIGS. 2aandbthe lamination process is shown according an embodiment of this invention. The pair of inorganic barrier layers6a′,6b′ are suitably bonded or laminated together with an adhesive15on the inorganic barrier14side facing each other, using the laminating apparatus23. In the embodiment shown inFIG. 3a multi-layer stack structure12is obtained by first forming two substrates6a′,6b′ with an inorganic barrier layer14in the at least three treatment spaces5, similar to the embodiment ofFIG. 1. The treated substrates6a′,6b′ are then fed to two laminating rollers21,22(seeFIG. 1), and an adhesive material is applied the to inorganic layer side of substrates6a′,6b′ using an adhesive applicator20(seeFIG. 1). The laminating rollers21,22are arranged to provide heat or radiation to the adhesive material between the treated substrates6a′,6b′, in order to cure or modify the adhesive material to form an adhesive layer15.

As a result a multi layer stack structure12is obtained having an excellent barrier for water vapour. In one particular embodiment of this invention already excellent barrier properties were observed in the case when one [resin layer-inorganic]-layer stack combination6ais adhered to another one [inorganic-organic]-layer stack combination6busing an adhesive15between the two opposing face related inorganic barrier coatings14resulting in a multi layer stack structure12comprising the following layers as shown in cross section inFIG. 3a: i) organic resin (substrate6a); ii) an inorganic barrier14; iii) an adhesive15; iv) an inorganic barrier14and v) an organic resin (substrate6b). Also indicated are the semi-products6a′,6b′ each comprising a substrate6a,6band a barrier layer14.

In this particular embodiment the laminate structure may display a typical water vapour transmission rate (WVTR) of lower than 0.001 g/m2·day.

It may be well understood that as a result of the 2-rolls-to-1-roll operation as described above in relation toFIG. 3a, a further product multi-layer stack structure12can be prepared by using each produced multi-layer stack structure12as a starting substrate roll(s) in another separate 2 roll-to-1 roll operation step. The separate structures12are laminated using an additional adhesive layer16as shown in the cross sectional view ofFIG. 3b. As a result a thicker multi-stack layer structure12may be prepared comprising i) [organic resin-inorganic barrier-adhesive-inorganic barrier-organic resin layer-adhesive]nlayers and ii) [organic resin-inorganic barrier-adhesive-inorganic barrier-organic resin layer], layer where n is an integer larger than 0. As a result even better barrier properties may be observed for these types of multi-stack layer structures12.

Adhesives15,16that may be applied for bonding the inorganic barrier layers14include all suitable thermoplastic- and elasto-plastic polymers; polymers which are curable by radiation such as by ultraviolet or electron-beam, by heat, by chemical initiators or by combinations thereof; organic or organic-containing adhesives, such as acrylics, urethanes, epoxides, polyolefins, organosilicones and others; and products of plasma-polymerization, oligomerization, or curing of organic-, organosilicon and other organometallic compounds, either volatile or deposited by other means such as spraying, sputtering, casting or dip-coating.

The adhesive forms an adhesive layer15bonding the two opposing faces of inorganic barrier layers14in the embodiment ofFIG. 3aand an additional adhesive layer16bonding two substrates6a,6bof different multi-layer stack structures12in the embodiment ofFIG. 3b. The adhesive layer15,16may suitably have a thickness of 50 nm to 1000 μm, preferably from 100 nm to 100 μm.

Further in order to prevent ultraviolet deterioration ultraviolet absorbers or photo-stabilizers (such as hindered amine compounds) may be added to the adhesive.

The multi-layer stack structures12may be applied in several devices as under- or over-layer protection means. Possible use of these multi-layers is in protecting PV-cells or PV-battery modules by using these multi-layers enveloping the PV-battery cells or modules. A further possible embodiment is the use of the multi-layer stacks as protective sheet such as a back-sheets in PV-cells or PV-battery modules.

The multi-layer material (single or multiple multi-layer stack structures12) according to the invention may be used also in other types of devices, such as liquid crystal displays, which are known in prior art to require transparent materials impermeable to oxygen and water vapour.

EXAMPLES

All electrode couples2,3have been independently dynamically matched to an own power-supply. The power was continuously supplied to each unit (AC/800 W/200 kHz). As precursor in each treatment space5, 2 ppm TEOS was used.

The gas mixture in each treatment space contained a O2/N2-mixture and is respectively controlled on 10%/90% except for examples 8, 9, 10 and 11.

Example 8 used in each treatment space a O2/N2-mixture and is respectively controlled on 6%/94%.

Example 9 used in each treatment space a O2/N2-mixture and is respectively controlled on 1%/99%.

Example 10 and 11 used in each treatment space common air as gas-mixture. Further in each example conditions in the treatment spaces5were kept the same. As substrate6a,6bPET ST505 (Melinex) from DuPont Tejin Films (width 20 cm/thickness 100 μm) was used.

Comparative Example 1

Two barrier films14are deposited synchronously using the electrode set-up as shown inFIG. 1using an atmospheric pressure plasma device10and one treatment space5. On both sides of the substrates6a,6bfacing the plasma discharge a SiOx layer14of 450 nm is deposited. Samples are collected from both substrates which show visually cracks as defects. Further both sheets have a WVTR of typically of about 1 g/m2·day.

The substrates are brought together with the facing side to each other and laminated with a hydrophobic acrylate of 10 micron which was followed by UV-curing. The resulted multi-layer stack shows visually crack defects and has a WVTR of about 1 g/m2·day.

Comparative Example 2

Two barrier films14are deposited simultaneously using the set-up as shown inFIG. 1using an atmospheric pressure plasma device10and two subsequent treatment spaces resulting in two substrates having both a SiOx-barrier layer of 450 nm. Treatment space conditions were same as done in comparative example 1 however line speed of the substrates was 100% higher as in example 1.

The substrates are brought together with the facing side to each other and laminated with a hydrophobic acrylate of 10 micron which was followed by UV-curing. The resulted multi-layer stack shows visually tiny crack-defects and has a WVTR of about 0.6 g/m2·day.

Two barrier films14are deposited simultaneously using the set-up as shown inFIG. 2ausing an atmospheric pressure plasma device10and three subsequent treatment spaces resulting in two substrates having both a SiOx-barrier layer of 450 nm.

Treatment space conditions were same as in example 1 conditions however the line speed of the substrates was 200% higher as in example 1.

The substrates are brought together with the facing side to each other and laminated with a hydrophobic acrylate of 10 micron which was followed by UV-curing.

The resulted multi-layer stack shows no crack-defects and has a WVTR of 1.3*10−3g/m2·day.

Two barrier films14are deposited simultaneously using the set-up as shown inFIG. 2aexcept the substrates were fed using four subsequent treatment spaces using an atmospheric pressure plasma device10resulting in two substrates having both a SiOx-barrier layer of 450 nm.

Treatment space conditions were same as in example 1 conditions however the line speed of the substrates was 300% higher as in example 1.

The substrates are brought together with the facing side to each other and laminated with a hydrophobic acrylate of 10 micron which was followed by UV-curing.

The resulted multi-layer stack shows no crack-defects and has a WVTR of about 9.6*10−4g/m2·day.

Two barrier films14are deposited simultaneously using the set-up as shown inFIG. 2aexcept the substrates were fed using five subsequent treatment spaces using an atmospheric pressure plasma device10resulting in two substrates having both a SiOx-barrier layer of 450 nm.

Treatment space conditions were same as in example 1 conditions however the line speed of the substrates was 400% higher as in example 1.

The substrates are brought together with the facing side to each other and laminated with a hydrophobic acrylate of 10 micron which was followed by UV-curing. The resulted multi-layer stack shows no crack-defects and has a WVTR of about 7.4*10−4g/m2·day.

Two barrier films14are deposited simultaneously using the set-up as shown inFIG. 2aexcept the substrates were fed using six subsequent treatment spaces using an atmospheric pressure plasma device10resulting in two substrates having both a SiOx-barrier layer of 450 nm.

Treatment space conditions were same as in example 1 conditions however the line speed of the substrates was 500% higher as in example 1.

The substrates are brought together with the facing side to each other and laminated with a hydrophobic acrylate of 10 micron which was followed by UV-curing.

The resulted multi-layer stack shows no crack-defects and has a WVTR was found to be below the detection limit of the Mocon Aquatran which is below 5*10−4g/m2·day.

Two barrier films14are deposited simultaneously using the set-up as shown inFIG. 2aexcept the substrates were fed using four subsequent treatment spaces using an atmospheric pressure plasma device10resulting in two substrates having both a SiOx-barrier layer of 600 nm.

Treatment space conditions were same as in example 1 conditions however the line speed of the substrates was 300% higher as in example 1.

The substrates are brought together with the inorganic barrier facing side to each other and laminated with a hydrophobic acrylate of 10 micron which was followed by UV-curing.

The resulted multi-layer stack shows no crack-defects and has a WVTR of 9.6*10−4g/m2·day.

Two barrier films14are deposited simultaneously using the set-up as shown inFIG. 2aexcept the substrates were fed using four subsequent treatment spaces using an atmospheric pressure plasma device10resulting in two substrates having both a SiOx-barrier layer of 600 nm.

Treatment space conditions were same as in example 7 conditions except for the oxygen concentration in all treatment spaces which was controlled to be on 6%.

The substrates are brought together with the inorganic barrier facing side to each other and laminated with a hydrophobic acrylate of 10 micron which was followed by UV-curing.

The resulted multi-layer stack shows no crack-defects and has a WVTR of 1.3*10−3g/m2·day.

Comparative Example 9

Two barrier films14are deposited simultaneously using the set-up as shown inFIG. 2aexcept the substrates were fed using four subsequent treatment spaces using an atmospheric pressure plasma device10resulting in two substrates having both a SiOx-barrier layer of 600 nm.

Treatment space conditions were same as in example 7 conditions except for the oxygen concentration in all treatment spaces which was controlled to be on 2%.

The substrates are brought together with the inorganic barrier facing side to each other and laminated with a hydrophobic acrylate of 10 micron which was followed by UV-curing.

The resulted multi-layer stack shows some visual crack-defects and has a WVTR of 0.6 g/m2·day.

Two barrier films14are deposited simultaneously using the set-up as shown inFIG. 2aexcept the substrates were fed using six subsequent treatment spaces using an atmospheric pressure plasma device10resulting in two substrates having both a SiOx-barrier layer of 450 nm.

Treatment space conditions were same as in example 1 conditions however the line speed of the substrates was 500% higher as in example 1 and as gas mixture air was used.

The substrates are brought together with the facing side to each other and laminated with a hydrophobic acrylate of 10 micron which was followed by UV-curing. The resulted multi-layer stack shows no crack-defects and has a WVTR was found to be below the detection limit of the Mocon Aquatran which is below 5*10−4g/m2·day.

Two barrier films14are deposited simultaneously using the set-up as shown inFIG. 2aexcept the substrates were fed using nine subsequent treatment spaces using an atmospheric pressure plasma device10resulting in two substrates having both a SiOx-barrier layer of 450 nm.

Treatment space conditions were same as in example 1 conditions however the line speed of the substrates was 800% higher as in example 1 and as gas mixture air was used in the treatment spaces.

The substrates are brought together with the facing side to each other and laminated with a hydrophobic acrylate of 10 micron which was followed by UV-curing. The resulted multi-layer stack shows no crack-defects and has a WVTR was found to be below the detection limit of the Mocon Aquatran which is below 5*10−4g/m2·day.