Deposition of ultra-thin inorganic oxide coatings on packaging

Abstract

An apparatus and method for depositing an ultra-thin inorganic coating on to a packaging film substrate is disclosed. Flame pretreatment enhances the quality of the inorganic coating. Multiple coating layers may be deposited onto the substrate by passing the substrate over various one or more flame head configurations in either a stand-alone or in-line manufacturing environment.

We claim: 
     
         1 . A system for coating a packaging film substrate with an inorganic oxide layer comprising:
 at least one flame treatment flame head assembly supplied with no inorganic oxide precursor;   one or more deposition flame heads supplied with at least one inorganic oxide precursor placed in series on at least one deposition flame head assembly;   wherein said substrate passes through said flame treatment flame head assembly before said substrate passes through said deposition flame head assembly, and wherein said at least one flame treatment flame head assembly and said one or more deposition flame heads are at open atmosphere.   
     
     
         2 . The system of  claim 1  wherein said at least one flame treatment flame head assembly or said at least one deposition flame head assembly comprises multiple flame head assemblies oriented in parallel rows perpendicular to a substrate movement direction. 
     
     
         3 . The system of  claim 1  wherein said at least one flame treatment flame head assembly or said at least one deposition flame head assembly comprises a square or rectangular shaped flame head assembly. 
     
     
         4 . The system of  claim 1  wherein said at least one flame treatment flame head assembly or said at least one deposition flame head assembly comprises multiple flame heads assemblies oriented in rows parallel to a substrate movement direction. 
     
     
         5 . The system of  claim 1  wherein said at least one flame treatment flame head assembly or said at least one deposition flame head assembly comprises a curved flame head assembly. 
     
     
         6 . The system of  claim 1  wherein said at least one flame treatment flame head assembly or said at least one deposition flame head assembly is oriented at an angle relative to a surface of said substrate. 
     
     
         7 . The system of  claim 1  wherein said substrate passes through said flame head assemblies as it passes over a portion of said at least one chill roll. 
     
     
         8 . The system of  claim 1  wherein said inorganic precursors are fed into a flame fuel line of said deposition flame heads prior to being mixed with air from an air line and combusted at said flame heads. 
     
     
         9 . The system of  claim 1  wherein said inorganic precursors are fed into an air line of said deposition flame heads prior to being mixed with fuel from a fuel line and combusted at said flame heads. 
     
     
         10 . The system of  claim 1  wherein said inorganic precursors are fed into an air line and a fuel line of said deposition flame heads prior to being mixed and combusted at said flame heads. 
     
     
         11 . The system of  claim 1  wherein said inorganic precursors are mixed with an air/fuel mixture prior to being fed to said deposition flame heads. 
     
     
         12 . The system of  claim 1  wherein said inorganic precursors is injected into a flame produced by said deposition flame heads. 
     
     
         13 . The system of  claim 1  further comprising an air knife flame redirect.