Inorganic–organic hybrid coatings by sol–gel process are very suitable for fighting corrosion. Inorganic sols in hybrid coatings not only increase adhesion by forming chemical bonds between metals and hybrid coatings, but also improve comprehensive performances of polymer in the coatings. Different organic polymers or organic functionalities are introduced into gel network to achieve tailored properties, such as hydrophobic properties, increasing cross-linking density, etc. As for corrosion protection of metals organic components of hybrid coatings are selected to repel water and form dense thick films and reduce coating porosity. The factors, such as the ratio of inorganic and organic components, cure temperature, pigments in hybrid coatings, need to be optimized for attaining hybrid films with the maximum corrosion resistance. Electro-deposition technique offers relatively thick homogeneous defect-free hybrid coatings in comparison to dip or spin coating techniques. Green cerium ions and non-ionizable organic inhibitors are more developed in hybrid coatings nowadays than other corrosion inhibitors. Long-term corrosion resistance techniques of inhibitors are discussed. The inhibitors entrapped in the nanocontainers are doped in hybrid films to prolong release of the inhibitors to damaged zones, which is discussed in detail. Among all the nanocontainers of corrosion inhibitors the prospective techniques which show superior corrosion protection are cyclodextrin/organic inhibitor inclusion complexes and layer by layer assembly of organic corrosion inhibitors in nanocontainers. Super-hydrophobic property of hybrid coatings derives from low surface tension and surface roughness of hybrid coatings, which endues the films with excellent corrosion protection for metals, but the durable property of super-hydrophobic coatings needs to be improved for industrial application. An ideal multiple model of hybrid coatings for superior anti-corrosion of metals proposed is a combination of super-hydrophobic hybrid coatings and underlying hybrid coatings doped with sustained release of corrosion inhibitors on metal substrates.

Inorganic–organic sol gel hybrid coatings for corrosion protection of metals

The present invention relates to a method of fabricating a transparent gas barrier film by using plasma surface treatment and a transparent gas barrier film fabricated according to such method which has an organic/inorganic gradient interface structure at the interface between an organic/inorganic hybrid layer and an inorganic layer. Since the method of the present invention is capable of fabricating a gas barrier film by plasma surface treatment instead of deposition under high vacuum, it can mass-produce a transparent gas barrier film with excellent gas barrier properties in an economical and simple manner. Further, since the transparent gas barrier film fabricated according to the method of the present invention shows excellent gas barrier properties and is free of crack formation and layer-peeling phenomenon, it can be effectively used in the manufacture of a variety of display panels.

Method for fabrication of transparent gas barrier film using plasma surface treatment and transparent gas barrier film fabricated thereby

Thin film encapsulation of flexible organic light-emitting diodes (FOLEDs) with a moisture barrier, incorporating a silica nanoparticle-embedded sol–gel organic–inorganic hybrid nanocomposite (S–H nanocomposite) and Al2O3 were demonstrated, and their reliability and mechanical characteristics were assessed. The bending stress of the multi-layer structure for both the case of moisture barriers and encapsulated FOLEDs was investigated based on nonlinear finite-element analysis (FEA). To minimize the bending stress at the desired region, the neutral axis (NA) position could be strategically adjusted by the introduction of a buffer layer of UV-curable cycloaliphatic epoxy hybrid materials (hybrimer), synthesized via a sol–gel reaction. The optimized multi-layer structure, proposed as a result of FEA was validated by related experiments. Regarding the bending characteristics of the moisture barrier structure, the water vapor transmission rate (WVTR) of the hybrimer-coated moisture barrier was much lower than that of a non-coated sample, as a result of calcium corrosion tests after bending. The structure of encapsulated FOLEDs, which are coated by the hybrimer achieved an almost identical performance to that of non-bending samples in spite of 30 days exposure to 30 °C and 90% R.H. after a bending test with a radius of 1 cm. During this period, the occurrence of dark spots caused by moisture penetration was effectively suppressed. Collectively, these results suggest that the bending characteristics of hybrimer-coated multi-layer structures are remarkably improved with the theoretical prediction of the NA position.

Reliable thin-film encapsulation of flexible OLEDs and enhancing their bending characteristics through mechanical analysis

The present invention relates to light weight composite materials which comprise a metallic layer and a polymeric layer, the polymeric layer containing a filled thermoplastic polymer which includes a thermoplastic polymer and a metallic fiber. The composite materials of the present invention may be formed using conventional stamping equipment at ambient temperatures. Composite materials of the present invention may also be capable of being welded to other metal materials using a resistance welding process such as resistance spot welding.

Formable light weight composites

Plasma electrolytic oxidation (PEO) is widely used to improve the corrosion resistance and protection of magnesium and its alloys by the formation of ceramic oxide layers. However, this anodization processes generate porous and rough layers with poor tribological properties. In order to improve corrosion protection and tribological capabilities, three different post-treatments (novel sol–gel coating, polytetrafluoroethylene and acrylate-ethylene copolymer with nanoparticles) have been used as sealing agents on PEO anodized AZ91D magnesium alloys. Characterization of unsealed and sealed systems was made by Fourier transform IR (FTIR), scanning electron microscope (SEM) and energy dispersive X-ray spectrometry (EDX) in order to know the chemical structure, morphology and composition of PEO/coating systems. Corrosion resistance was evaluated by electrochemical measurements (open circuit potential and electrochemical impedance spectroscopy) in 5 wt.% NaCl solution at room temperature and by accelerated neutral salt spray test. Tribological properties were obtained using a ball-on-disk test. According to results, post-treatments have improved the corrosion protection performance of PEO systems. However, while internal physical interlocking of pores seemed to be crucial to enhance corrosion protection using polytetrafluoroethylene and sol–gel post-treatments, the formation of an external top layer was the main cause of the improvement of the barrier properties for acrylate–ethylene copolymer post-treatment. On the other hand, despite that tribological performance was mainly governed by the PEO coating, the formation of a top layer on the surface and its chemical composition can significantly reduce the friction coefficient.

Effect of different post-treatments on the corrosion resistance and tribological properties of AZ91D magnesium alloy coated PEO

Permeation analysis of ultra-thin hybrid organic/inorganic gas barrier coatings on polymers

Aminosilane solutions with pH equal to 8 and to 11 were applied and cured on SiO2 coated poly(ethylene terephthalate) (PET) films. The permeability of the silane-silica hybrid coating on PET was reduced twofold compared to that of the SiO2/PET film, at solution concentrations as low as 1%wt., irrespective of the pH. This concentration level led to a dense silane monolayer crosslinked to the silica surface. The oxygen transport mechanisms in the hybrid coatings were determined based on the thermally activated rate theory. Permeation experiments were also performed under tensile loading, and the critical strain for loss of barrier performance was found to be improved by a factor of two, only in case of basic pH. The defect population and morphology of the hybrid coating subjected to hydrothermal aging were analyzed using a reactive ion etching method and atomic force microscopy, respectively. These experiments confirmed the defect healing action of the aminosilane at low concentrations in solution, through the formation of a densely crosslinked polysiloxane layer at the silane-silica interface for both pH8 and pH11. The influence of the silane treatment was emphasized in case of basic pH due to the dissolution of superficial oxide layers.

Durability of aminosilane-silica hybrid gas-barrier coatings on polymers

Ultra-thin (10–500 nm) photo-polymerized γ-methacryloxypropyltriethoxysilane (MPMS) and vinyltrimethoxysilane (VTS) layers applied to SiO2 coatings on polyethylene terephthalate films improved the oxygen barrier performance of the oxide coated films by more than two-fold, and the coating strain to failure from 1.5% to beyond 5%, depending on the processing conditions. The oxygen transmission rate of composite films was measured under tensile strain. The chemical conversion of both MPMS and VTS with two different photoinitiators was studied by means of photo-calorimetry experiments, with attention paid to the influence of temperature, UV-light intensity and photoinitiator concentration. The conversion data were analyzed using an nth-order kinetic model, including an Arrhenius dependence of the temperature and a power-law dependence of the light intensity on the reaction rate. The improvement in mechanical integrity of the silane/silica barrier coating, with a toughness as high as 80 J/m2 was found to be controlled by the conversion state of the silane.

/pdf/supertough-uv-curable-silane-silica-gas-barrier-coatings-on-56odpwpfxd.pdf

Supertough UV-curable silane/silica gas barrier coatings on polymers

The invention relates to a composite article comprising at least one metal reinforcement element embedded in a polymer material. An adhesion promoting layer is interposed between the metal reinforcement element and the polymer material. The adhesion promoting layer comprises an organofunctional silane and a hyperbranched polymer. The invention further relates to a method of manufacturing a composite article and to the use of a composite article as metal reinforced article.

Composite article comprising a metal reinforcement element embedded in a thermoplastic polymer material

The aim of this study is to develop coatings on polymer substrates with a combined increase in oxygen barrier performance and toughness, based on SiOx coatings modified with multifunctional organo-silane polymers of controlled polarity and reactivity. As a first step, the formation mechanism of the amino-silane/SiOx interphase was determined using various analytical techniques (DSC, FTIR, ICP, AFM, XPS and XRF). Then the resulting oxygen permeability and cohesive properties of the nanocomposite barrier coating were investigated by means of tensile tests carried out in-situ in a scanning electron microscope and a permeation cell, respectively. It was found that the results and their analysis led to a better understanding of the role of the interfacial and/or interphasial properties in both the mechanical and permeation behavior of such nanocomposites.

The role of the amino-organosilane/SiOx interphase in the barrier and mechanical performance of nanocomposites

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