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Aluminum coatings applied to polymer films by physical vapor deposition should be defect-free for applications such as packaging and electronic devices. However, cracks can appear in the aluminum coating as the polymer film stretches, becoming manifest as an increase in resistance. We evaluated the effect of different aluminum thicknesses (10–85 nm), polymer films (polyethylene terephthalate or polypropylene), and corona doses (0–280 W∙min/m2) on the relative increase in resistance during stretching (strain = 0–100%). We found that the thickness of the aluminum coating was inversely related to the increase in resistance. Corona pretreatment led to an increase in surface energy (≤40 mN/m for polypropylene; ≤50 mN/m for polyethylene terephthalate) although high corona doses resulted in overtreatment, which limited the adhesion of aluminum to the substrate and led to a greater increase in resistance. Varying the coating thickness had a much greater effect than the corona pretreatment, suggesting that thicker aluminum coatings are more effective than corona pretreatment as a strategy to increase coating stability. The effect of aluminum thickness and strain on resistance was described using a fit function containing three fit factors.

Effect of Substrate Strain, Aluminum Thickness and Corona Pretreatment on the Electrical Resistance of Physical Vapor Deposited Aluminum Coatings