Plasma polymer coatings for chemical resistance of plastic packaging
Conventional multilayer packaging is difficult to recycle, while mono material packagings offer only limited protection against aggressive chemicals. As part of the DFG-funded ChemShield project, novel coating systems are being developed for PE-HD containers that are resistant even to strong alkalis and acids.
The project is based on plasma polymer coatings using plasma enhanced chemical vapour deposition (PECVD). These are to be augmented by plasma enhanced atomic layer deposition (PEALD) processes. The aim is to combine the defect-prone PECVD layers with virtually defect-free, chemically homogeneous PEALD layers to create a stable barrier that can prevent damage mechanisms such as chemical decomposition and physical infiltration.
The first step involves refining the PECVD coatings for PE-HD. In order to reduce defects, PEALD coatings will be investigated and integrated in a second step. The coatings will be analysed and optimised in electrochemical tests. The resistance of the new coatings to aggressive chemicals will then be investigated using caustic soda and hydrochloric acid as examples.
The combination of PECVD and PEALD not only allows the production of highly cross-linked, pore-free multilayer systems, but also enables the targeted control of interfacial chemistry, which will be employed to develop a better understanding of damage mechanisms. The project thus lays the foundation for the development of fully recyclable and chemically resistant packaging.
© IKVProject data and funding
We would like to thank the DFG for funding the project (funding reference DA 488/7-1) and the project partners for their cooperation.
Project start: 01.07.2025
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