In the last few years plasma pre-treatment has been established as a powerful tool to increase the quality in vacuum web coating whereas, the effect of web pre-treatment under atmospheric conditions is declining due to several reasons, glow discharge assisted in line–in vacuo pre-treatment is much more reliable. Two tools for plasma pre-treatment are presented here. Both are easily scalable as to comply with the needs of large area web coating with a typical coating width of over 2 m, and they operate in a pressure range that is compatible with sputtering and evaporation processes taking place in the same vacuum system. The effect of the glow discharge on polymeric web depends on electron temperature (typically a few electron volts), electron density (ranging typically from 10 −9 to 10 −11 cm −3), ion energy, and chemical composition. The mentioned electron density range is indispensable to meet the demands of satisfactory production speeds, in particular with evaporation. By means of the so-called Treatmag ®, an abnormal glow discharge enhanced by a closed loop tunnel shaped magnetic field is generated in the 10 −2 mbar pressure range. This tool is widely used for the improvement of metallic coatings on polymeric web. The ion energies typically range well below 70 eV. Indeed, water vapor and oxygen permeation rates through OPP have been quartered respectively, third. The so-called RF hollow anode described herein next is comprising a capacitively coupled, asymmetric 13.56 MHz radio frequency glow discharge driven in a hollow life electrode, operated in the 10 −2 mbar pressure range. The easily scaleable RF hollow anode is dedicated to the dynamic pre-treatment or coating of either dielectric or metal web (or rigid sheet), and can be used in conjunction either with sputtering or, at line speeds of typical 5–10 m/s, with evaporation processes. The RF hollow anode renders ion fluxes of up to 1 mA/cm 2 at energies between 100 and several hundred electron volts. So far it complements the Treatmag ®, which yields ions with considerably lower energies. The adhesion improvement by the RF hollow anode we attribute to a pronounced increase of the cross-link density (amorphization) in the near surface region of in-plane oriented polymeric web commonly used. Ex situ XPS spectra taken 3 days after venting from PET samples treated at high web speeds are given. It is mentioned that the industrial application of the RF hollow anode is based on the surface modification as yielded in-situ/in-vacuo almost immediately after treatment. In case the RF hollow anode is operated with hydrocarbon, silane or other gases, it can also be employed for thin base-coatings or top-coatings on web material.
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