Aluminum oxide barrier layers have been deposited onto BOPP and PET film substrates via reactiveevaporation of aluminum using an industrial ‘boat-type’ roll-to-roll metallizer. The effects of parameterssuch as treatment, surface chemistry, film additives, and surface roughness and topography on barrierlevels have been investigated. Additionally, coating adhesion, thickness and surface energy have beenassessed. Whilst good adhesion was achieved regardless of barrier properties, the plain film surfacecharacteristics and coating nucleation, growth and structure appeared to be the governing factors forbarrier performance.
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