Summary

Abstract:
To solve the increasing problem of safety and shelf-life of food and protection of sensitive display circuit elements a multi-functional barrier coating on plastic films is required. Improved coating performance is essential with regard to barrier properties (lower permeabilities for water and oxygen), anti-microbial activity, mechanical and optical properties. SOLPLAS will solve these problems by researching and developing a coating with a, novel, low cost, in-line, deposition technology, combining atmospheric plasma and electrostatic (nano-size) aerosol spraying.

Objectives:
The objectives of the SOLPLAS project are: I) Research on organic-inorganic nano-composite coatings with high performance which can be tailored towards different functionalities for different industrial sectors. II) Research on an unique atmospheric pressure based plasma assisted deposition technology which can produce these high quality coatings at low cost in an in-line production environment. III) Design new aerosol chemicals and formulations enabling the deposition of nano-composite coatings. IV) Process development directed towards two strategic application areas: "anti-microbial barrier layers" for active food packaging and "protective barrier layers" for plastic displays.

Description of the work:
The project consists of 7 Work Packages (WP). In WP1, an experimental set-up for carrying out Aerosol Assisted Atmospheric Plasma (AAAP) deposition experiments will be designed, constructed, tested and continuously optimised in function of performance. In WP2, the formulation and chemical synthesis of aerosol precursors will be initiated by selecting and pre-screening relevant classes of precursors. Based on these results a first series of precursors will be synthesised for use in the AAAP configuration. Before end of year 1 the AAAP experimental set-up will be operational and a feasibility study will (WP3) is started. Coatings will be deposited on a selected range of base film materials and carefully characterised. These new coatings will be validated with respect to state-of-the-art technology. Feedback from characterisation results will give input to new formulation and synthesis of precursors (WP2) and optimisation of AAAP equipment/ process control (WP1). At Mid-Term, the coating development work will converge towards the realisation of multifunctional coatings (WP4): "protective barrier layers + anti-microbial functionality". Thereafter, film samples will be tested in end-user applications (WP5): active food packaging and plastic displays. In addition to the preparation of a "Technology Implementation Plan" (discussing exploitation with respect to food packaging and plastic displays), the exploitation effort will focus on the preparation of blueprints for a pilot line + education and training of industrial partners. A continuous action (WP6: characterisation) throughout the whole project will be devoted to environmental testing, in particular regarding the use of aerosols, the exhaust from the AAAP reactor and waste issues related to the film products produced. WP7: Project management and exploitation plan.

Milestones and expected results:
Main result: performant barrier coatings for food and display applications. Main deliverables: an unique atmospheric plasma deposition process (AAAP), new aerosol precursors, validation test results for anti-microbial food packaging and plastic displays, blueprints for a pilot line of a scale sufficient for targeted customer evaluation. Main milestone at mid-term: operation of AAAP equipment demonstrated; deposition of nano-composite coatings demonstrated; exploitation prospects confirmed.