Gas barrier properties and periodically fractured surface of thin DLC films coated on flexible polymer substrates

Thin DLC films coated on polymer surfaces are attracting considerable attention due to their wide applications and their interesting surface properties. When DLC films were coated on polymers, the resulting DLC-polymer composites are highly functionalized materials, some of which presenting dramatically improved gas barrier properties. In this paper, we will introduce several commonly used polymers including polyethylene terephthalate (PET), polyethylene (PE) and polypropylene (PP) for semi-crystalline polymers, and polymethyl methacyrlate (PMMA) for an amorphous polymer. The polymers were coated with thin DLC films and the gas barrier properties of the resulting DLC-polymer composites were investigated. Some of the DLC-polymer composites dramatically improved their gas barrier properties while they presented horizontal crack lines and vertical micro-buckling lines on the DLC surface when stretched to a certain strain. The gas barrier properties of the DLC-polymer composites with fractured DLC surface were also studied. It was found that the gas barrier property of the polymer substrates with lower residual strains was less damaged, when the substrates were mechanically deformed, than that of the polymer substrates with higher residual strains. When the number of the cracks increases, the strain imposed on each crack decreases, since the overall deformation is almost equally distributed to each crack while the crack spacing of each crack becomes shorter. Thus, it was found that the degradation of the gas barrier property after mechanical deformation is dependent on the residual strain of the polymers and the number of cracks on DLC films.