Recent Advances in Gas Barrier Thin Films via Layer-by-Layer Assembly of Polymers and Platelets

Layer‐by‐layer (LbL) assembly has emerged as the leading non‐vacuum technology for the fabrication of transparent, super gas barrier films. The super gas barrier performance of LbL deposited films has been demonstrated in numerous studies, with a variety of polyelectrolytes, to rival that of metal and metal oxide‐based barrier films. This Feature Article is a mini‐review of LbL‐based multilayer thin films with a ‘nanobrick wall’ microstructure comprising polymeric mortar and nano­platelet bricks that impart high gas barrier to otherwise permeable polymer substrates. These transparent, water‐based thin films exhibit oxygen transmission rates below 5 × 10‐3 cm3 m‐2 day‐1 atm‐1 and lower permeability than any other barrier material reported. In an effort to put this technology in the proper context, incumbent technologies such as metallized plastics, metal oxides, and flake‐filled polymers are briefly reviewed. This Feature Article reviews multilayer thin films, deposited layer‐by‐layer to produce a ‘nanobrick wall’ structure that imparts high gas barrier to permeable polymer substrates. These transparent, water‐based thin films exhibit a lower permeability than any other barrier thin film material.