Title of Invention

METHOD AND DEVICE FOR THE INTERNAL PLASMA TREATMENT OF HOLLOW BODIES

Abstract The invention relates to a method for the plasma treatment of workpieces, especially hollow-bodied workpieces. According to this method, an area of treatment in a reactor chamber is at least partially evacuated, a process gas is introduced into the area of treatment, especially into the hollow body of the workpiece, and a plasma is ignited in the process gas introduced into the area of treatment using electromagnetic energy radiated into it. The invention is characterized in that the process gas, during plasma treatment, flows through the area of treatment between opposite ends of the area.
Full Text Method and Device for the Internal Plasma Treatment of
Hollow Bodies
Description
The invention relates in general to the internal plasma
treatment of substrates in the form of hollow bodies,
particularly substrates with small diameters, such as
typical pharmaceutical packaging.
EP 1 206 389 Bl discloses a method and a device for the
sterile packaging of substances in plastic containers. A
plasma treatment is carried out in this case, for example
plasma sterilization, in which the plasma is excited
selectively as a function of position and/or time in
various zones of the walls of the container. The method and
the device are intended to make it possible to carry out
aseptic packaging, and even pyrogen-free packaging in the
case of pharmaceutical products, of liquids in plastic
containers such as ampoules, bottles or vials, and to
combine this with further processing steps.
EP 1 251 190 Al describes a method for the uniform coating
of hollow bodies, wherein one open end of the hollow body
is hermetically sealed by a lid, the hollow body is placed
in a plasma-induced CVD reactor, a vacuum is applied to the
hollow body, a coating temperature is set up and the
plasma-induced coating is carried out.
Furthermore, DE 196 29 877 CI discloses a CVD method and a
device for the internal coating of hollow bodies, in which

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the coating quality can already be predicted during
production. A pulsed plasma method is used, in which the
plasma is ignited by a chronological sequence of ignition
pulses, and the time correlation of the light pulses of an
oxygen plasma, as well as the intensity of at least one
emission line of the coating gas, are measured and
evaluated both during the heating phase and during the
coating phase.
DE 196 34 795 C2 describes a plasma CVD system having an
array of microwave plasma electrodes and a control circuit.
Two neighboring plasma electrodes are respectively exposed
by the control circuit to microwave pulses at different
times, the duration of the pulse being short compared with
the duration of a pulse conventionally used for pulsed
plasma CVD methods.
DE 44 3 8 3 59 C2 discloses a plastic container with a
barrier coating, the barrier coating consisting of a layer
stack with sequentially arranged barrier layers of
inorganic material consisting of one or more inorganic
oxides, nitrides or oxynitrides or a mixture thereof, and
an organic polymer material. The layer stack in this case
contains at least two barrier layers made of the inorganic
material. The layers are preferably deposited by means of
plasma polymerization.
It is an object of the invention to improve the plasma
treatment of small and/or elongate hollow bodies with
narrow cross sections. The coating of such workpieces in
the form of hollow bodies is a technical challenge which
has to date been resolved only unsatisfactorily.

3
This object is directly achieved in an extremely
surprisingly simple way by the subject-matter of the
independent claims. Advantageous configurations and
refinements of the invention are specified in the dependent
claims.
Accordingly, the invention provides a method for the plasma
treatment of workpieces, particularly workpieces in the
form of hollow bodies, in which a treatment zone in a
reactor chamber is at least partially evacuated, a process
gas is introduced into the treatment zone, for instance the
cavity of the workpiece, and a plasma is ignited by means
of injected electromagnetic energy in the process gas
introduced into the treatment zone, wherein the process gas
flows through the treatment zone between opposite ends of
the zone during the plasma treatment.
A corresponding device for the plasma treatment of
workpieces, which is in particular adapted to carry out the
method as defined above, comprises a reactor chamber, a
treatment zone in the reactor chamber, an instrument for at
least partially evacuating the treatment zone in the
reactor chamber, an instrument for injecting
electromagnetic energy into the treatment zone in order to
generate a plasma in the process gas introduced in the
treatment zone and an instrument for introducing process
gas into the treatment zone, wherein the instrument for
introducing process gas and the instrument for evacuating
the treatment zone are arranged so that the process gas
flows through the treatment zone between opposite ends of
the zone during operation. The evacuation instrument is
also used to discharge the process gas.

4
Workpieces which have dielectric properties at least in a
local zone are preferably treated by the invention. The
effect achieved by this is that the electromagnetic
radiation cannot be shielded by conductive surfaces of the
workpiece.
The plasma treatment may be carried out exclusively on the
inside or exclusively on the outside of the workpiece of
the hollow body. Two-sided plasma treatment, i.e. both on
the inside and on the outside of the hollow body, may
likewise be carried out. The plasma treatments may also
advantageously be different on the inside and the outside
of the hollow body, or affect the surfaces in different
ways. This is possible, for example, by introducing
different process gases into the surroundings and into the
cavity.
The invention particularly advantageously allows the plasma
treatment of small workpieces, which may furthermore be
highly elongate. Thus, according to a refinement of the
invention, workpieces may be treated which are shaped
cylindrically or quasi-cylindrically and have a maximum
external diameter of between 1 mm and 50 mm, preferably
between 3 mm and 3 0 mm, preferably from 5 mm to 2 0 mm and a
height of from 10 mm to 200 mm, preferably from 30 mm to
150 mm, particularly preferably from 50 mm to 100 mm.
According to another refinement of the invention,
cylindrically or quasi-cylindrically shaped workpieces with
a maximum internal diameter of between 1 mm and 50 mm,
preferably between 2 mm and 29 mm, particularly preferably
from 4 mm to 20 mm and a height of from 10 mm to 200 mm,
preferably from 30 mm to 150 mm, particularly preferably

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from 50 mm to 100 mm and a wall thickness of from 0.2 mm to
10 mm, preferably from 0.3 mm to-8 mm, particularly
preferably from 2 mm to 5 mm are plasma-treated. In
particular, such workpieces may be treated along their
entire length or at least the entire length of the cavity
of the workpieces.
The workpieces may comprise a second cylindrical or quasi-
cylindrical, for example slightly conical appendage with a
smaller diameter and a shorter length, which are preferably
20% less than the maximum diameter and the height. Such an
appendage may for example be the connection element for the
cannula, for example a Luer cone or a nozzle of a syringe
body. This second cylindrical or quasi-cylindrical
appendage with a smaller diameter and a shorter length may
have a preferably narrow, cannula-like internal diameter of
between 0.01 and 15 mm, particularly preferably between
0.05 and 4 mm. Workpieces with such geometries, which thus
comprise different sections with very different diameters,
may for the first time be treated satisfactorily by the
through-flow principle according to the invention.
Accordingly, the invention is in particular also suitable
for small workpieces with a volume in the range of 0.1 -
100 ml, preferably in the range of 0.2 - 40 ml,
particularly preferably 0.5 - 20 ml.
It has been found that by means of the through-flow
principle according to the invention, coatings can be
deposited very uniformly on all the surfaces, in particular
internally. If barrier coatings are deposited, it is
thereby possible to ensure that a barrier effect is
achieved surface-wide. In the case of a cylindrical or
quasi-cylindrical workpiece with a first cylindrical or

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quasi-cylindrical surface and a cylindrical or quasi-
cylindrical appendage with a second cylindrical or quasi-
cylindrical surface, at least one thin layer with a layer
thickness D1 may thus be applied on the first cylindrical
or quasi-cylindrical surface and the layer may be applied
with a thickness D2 on the second quasi-cylindrical
surface, the relation 0.2 D2/D1 being satisfied for the ratio of the thicknesses Dl and D2.
For syringes in which the cylindrical or quasi-cylindrical
appendage represents the nozzle or the luer cone, a coating
with a sufficient barrier effect can thereby also be
deposited inside the nozzle.
It is likewise possible to deposit a scratch protection
layer by means of the through-flow reactor according to the
invention. This may be deposited internally and/or in
particular externally.
Another embodiment of the invention provides a method for
the plasma treatment of workpieces in the form of hollow
bodies, in which the cavity of the workpiece is at least
partially evacuated, a process gas is introduced into the
cavity of the workpiece, and a plasma is ignited by means
of injected electromagnetic energy in the process gas
introduced into the cavity, the workpiece in the form of a
hollow body furthermore comprising at least one opening
leading into the cavity at a first end of the workpiece and
the cavity being evacuated through this opening, wherein
the process gas is put into the cavity at a position which
lies at least half the longitudinal extent of the cavity
away from the opening at the first end of the workpiece.

7
To this end a device according to the invention for the
plasma treatment of workpieces in the form of hollow
bodies, which is suitable in particular for carrying out
the method, comprises a holder in a reactor chamber for at
least one workpiece in the form of a hollow body with a
connection instrument to connect an evacuation instrument,
for at least partially evacuating the cavity of the
workpiece, to an opening leading into the cavity at a first
end of the workpiece, an instrument for injecting
electromagnetic energy into the cavity in order to ignite a
plasma in process gas which can be introduced in the
cavity, and an instrument for introducing process gas at a
position in the cavity which lies at least 2/3 of the
longitudinal extent of the cavity away from the opening at
the first end of the workpiece.
The process gas is therefore respectively put in
essentially opposite to the opening of the cavity which is
used for the evacuation. The process gas thus flows through
at least the majority of the cavity in a directed movement.
This configuration has proven particularly advantageous for
achieving a uniform plasma treatment on the inner surface
of the workpiece.
It is even more advantageous for the process gas to be put
into the cavity by means of a suitably designed instrument
at a position which lies at least 2/3, more desirably 3/4,
preferably 9/10, particularly preferably 95/100 of the
longitudinal extent of the cavity away from the opening at
the first end of the workpiece.

8
To this end the process gas may be put into the cavity-
through a cannula, the opening of which lies at least 2/3,
more desirably at least 3/4, preferably 9/10, particularly
preferably 95/100 of the longitudinal extent of the cavity
away from the opening at the first end of the workpiece.
Dielectric material, in particular ceramic, is preferably
used for the cannula.
In order to be able to plasma-treat the surface of elongate
and/or small workpieces with narrow cross sections
uniformly, the invention also provides a method and a
device in which a treatment zone in a reactor chamber is at
least partially evacuated by means of an evacuation
instrument, a process gas is introduced into the treatment
zone, particularly into the cavity of the workpiece, and a
plasma is ignited by means of injected electromagnetic
energy in the process gas introduced into the treatment
zone, wherein the process gas is put into the treatment
zone through at least one cannula, the internal opening
diameter of which is between 0.1 and 5.0 mm, preferably
between 0.2 mm and 3.0 mm, particularly preferably between
0.3 mm and 2.0 mm and the wall thickness of which is
between 0.05 mm and 3.0 mm, preferably between 0.1 mm and
2.0 mm, particularly preferably between 0.15 mm and 1.0 mm.
According to another particularly preferred embodiment of
the invention, the workpiece is evacuated through an
opening at a first end and the process gas is introduced
through another opening at a second end of the workpiece,
which lies opposite the first end. The openings may also
have different cross sections in this case. This achieves
flow of the process gas through in a direction between the
two openings. In order to achieve particularly homogeneous

9
deposition, according to a refinement, the electromagnetic
energy may additionally be input in the axial direction,
particularly preferably axisymmetrically to the workpiece.
By means of the invention, a continuous directed gas flow
is achieved which flows through the zone of the reactor in
which the plasma is ignited, in particular through the
cavity to be treated. In contrast to this, dead zones in
which there is scarcely any flow may be formed in
previously known coating devices when filling with the
process gas. This becomes commensurately more critical as
the cross sections to be coated are narrower. Exchange of
the process gas is thereby at least retarded in these
zones, which inter alia may have a detrimental effect on
the coatings being applied.
Irrespective of whether the process gas is fed in through a
cannula or through a second opening of the workpiece, in a
preferred refinement of the invention an axisymmetric flow
of the process gas through the cavity of the workpiece is
established in order to achieve uniform coating. In general
it is favorable, especially for the preferred small
dimensions of the workpieces, for the electromagnetic
energy to be input into the cavity or the surroundings of
the workpiece in the axial direction of the workpiece,
particularly preferably axisymmetrically. This allows a
maximally homogeneous field distribution in the region of
the workpiece surface to be coated, and therefore more
homogeneous coating. In the case of syringe bodies, the
input is therefore preferably carried out axisymmetrically
with its cylinder axis.

10
The plasma treatment may in particular comprise plasma
coating, and furthermore plasma activation, plasma
pretreatment, plasma cleaning, plasma immersion or plasma
modification. Furthermore, a plurality i.e. at least two of
these treatment steps may advantageously be carried out by
means of the method according to the invention, or the
corresponding device.
A layer which contains at least one of the substances SiOx,
SiOxCy, SiOxNy, SiNy, TiOx, AlxOyNz, A1XNZ, AlxOy, CxHy,
CxFy, TiNx may be deposited by the plasma treatment. The
layer thicknesses are preferably greater than 5 nanometers,
in particular greater than 20 nanometers, particularly
preferably greater than 50 nanometers.
The method according to the invention, or the corresponding
device according to the invention, may furthermore be
integrated into a production and/or treatment line. Thus,
the plasma treatment can already achieve advantageous
properties on the workpiece within the process line, which
are directly manifested within the subsequent process line
for example by obviating further treatment steps or by a
better achievable yield, for example a sterile or scratch-
resistant surface. The invention is suitable in particular
for the various types of pharmaceutical packaging. For
instance, the cavity of the workpiece may also particularly
advantageously be sterilized during the plasma treatment.
The plasma treatment may also serve the sole purpose of
sterilization in this case. If the cavities of the
workpieces are sterilized, then in an advantageous
refinement of the invention the plasma treatment may also
be followed by further processing steps in a sterile

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environment. These may extend up to the form of the
workpieces ready for dispatch or--sale, for example filling
the workpieces with medicaments and/or sterilely packaging
them.
For such integration of the method according to the
invention into a production line to produce packaged
pharmaceutical products, a production or treatment line may
for example contain the following steps: production of the
workpiece (for example injection molding, blow molding, hot
molding, for example in the hot molding of raw glass),
cleaning the workpiece, plasma treatment, siliconizing,
filling, sterilizing, packaging. In another advantageous
embodiment of the invention, additional sterilization may
also be obviated if the sterilization achieved by the
plasma treatment is already sufficient and the subsequent
steps take place in a sterile environment.
The plasma treatment according to the invention offers an
advantage even before use of the product (i.e. for example
before use of a prefilled syringe or opening the
packaging), particularly preferably already within the
industrial manufacturing line, since inter alia at least
one of the properties: storage stability of the product
with which the packaging is filled, sterility or scratch
resistance, can be improved.
In particular for the plasma treatment of pharmaceutical
containers as well, it has proven advantageous to generate
a pulsed plasma for the plasma treatment. To this end, the
instrument for injecting electromagnetic energy into the
cavity comprises an instrument for generating pulsed
electromagnetic energy. Using a pulsed plasma, process

12
waste gases can be discharged in the pulse pauses. In this
way, for example during plasma coating, it is possible to
prevent sizeable particles of the coating material from
being formed in the plasma and being able to deposit on the
surface of the cavity of the workpiece. Substantially
higher peak powers can furthermore be used compared with a
continuous plasma, which in turn accelerates or
substantially improves the sterilization.
Particularly for small pharmaceutical packaging with narrow
cross sections, it has surprisingly been found that uniform
coating is not necessarily achieved only when the
electromagnetic energy can penetrate through the cavity
with minimal impediment. Rather, it has been found that at
least local shielding may be provided, which encloses the
workpiece and locally shields zones of the cavity of the
workpiece against injected electromagnetic energy. The
shielding can prevent a particularly hot plasma from being
formed locally in the cavity, which may detrimentally
affect the coating and in particular the workpiece.
In order to improve the product properties of
pharmaceutical packaging in particular, at least one
barrier layer is particularly preferably deposited by the
plasma treatment. Such a barrier layer may be a barrier
against ingress or egress of gases such as oxygen, hydrogen
or C02. It is furthermore possible to deposit at least one
barrier layer which has a barrier effect against
constituents from the workpiece, for example initial or
byproduct or final compounds from the production of the
workpiece. For instance, a suitable barrier layer may
prevent or at least retard the migration of substances from
the substrate. The ion leaching of glasses or the

13
dissolving of substances from polymers, for example from
plastic containers, may also be avoided or retarded. At
least one barrier layer with a chemical barrier effect may
furthermore be deposited.
A preferred embodiment of the invention relates to a device
and a method for the internal plasma treatment of syringe
bodies. Owing to their generally elongate cylindrical shape
and the attached Luer cone or nozzle, onto which the
cannula is fitted, these are difficult to coat. By means of
the invention, in which the process gas essentially flows
in an axial direction through the syringe body, it is
however possible to achieve good, uniform results in the
plasma treatment.
Owing to the very narrow cross sections of syringes,
especially in the region of the Luer cone or the nozzle,
(internal) coating of syringes is a technical challenge
which has not been resolved by the prior art to date.
Ignition of a plasma in the narrow cross section, and
uniform coating, have not yet been achieved by conventional
coating technology owing to the narrow cross sections.
Particularly in embodiments of syringes with asymmetric
cross sections, for example with a geometry in which the
mid-axes of the nozzle and the cylinder body are mutually
offset laterally, the technical challenge is particularly
great.
It is in this case particularly expedient for the cavity of
the syringe to be evacuated through its plunger opening. To
this end, a device according to this embodiment of the
invention accordingly comprises a connection instrument to

14
connect an evacuation instrument onto the plunger opening
of the syringe.
In order to achieve an inventive flow of the process gas
through in the axial direction, it is furthermore
particularly advantageous for the process gas to be
delivered through the Luer cone on the opposite side from
the plunger opening, or through the nozzle. The reverse
configuration is nevertheless also possible, in which case
the process gas is accordingly delivered through the
plunger opening of the syringe body.
It may furthermore be expedient to carry out external
coating of the workpiece. To this end, a device which is
adapted for external coating of workpieces accordingly
comprises an instrument for at least partially evacuating
the surroundings of a workpiece in the reactor chamber.
Like internal coating, the external coating may also be
carried out by plasma coating. In this case, an instrument
is provided for introducing process gas into the vicinity
of the workpiece in the reactor chamber. Other coating
methods, in particular PVD methods, for instance sputtering
or evaporation coating, may nevertheless also be used.
Possible functional layers are for example scratch
protection layers, or hard material layers. Such functional
layers are advantageous for example in the case of very
scratch-sensitive cyclo-olefinic polymers and copolymers.
Absorbent or reflective coatings for particular
wavelengths, preferably in the IR, visible or UV ranges,
may furthermore be deposited. Inter alia, these may also
have a decorative effect.

15
Many substrates, in particular plastics, age under exposure
to ultraviolet light. Applying a selective reflection layer
against UV irradiation or a UV absorber layer on the outer
surface of the substrate makes it possible to prevent
degradation of the substrate. A further applied scratch
protection layer may protect the optical functional layer
and the substrate against scratching. In a refinement of
the invention, a UV reflecting and/or absorbing layer,
which protects the content of the workpiece or the
workpiece per se against degradation by ultraviolet light,
may accordingly be deposited internally and/or externally.
According to another refinement of the invention, a
coloring layer, preferably a blue-colored layer is
deposited. Pharmaceutical products are often radiation-
sterilized, for example with gamma radiation. Owing to the
irradiation, the substrate (for example plastic or glass)
changes its color impression. For example, plastics often
experience yellowish discoloration under gamma irradiation.
According to the prior art a dye, for example a blue dye,
is therefore added to the plastic in order to compensate
for this discoloration by a green hue which is acceptable
on the market. According to the invention, this dye may be
at least partially or entirely replaced by an optional
functional layer, for example a layer design which causes a
blue color impression, so as to similarly compensate for
the yellow color impression after irradiation and
discoloration of the plastic, or so that the color
perception becomes much less than in the case of dyed
plastics.

16
In order inter alia to obtain a more attractive appearance,
a mirroring or blooming layer may furthermore be deposited.
Like a coloring layer which reflects UV or infrared light,
such a layer may also be deposited as a multilayer
dielectric interference layer system.
The invention may very advantageously be used to treat a
plastic surface of the workpiece, preferably a plastic
workpiece. Plastics are being used more and more for
pharmaceutical packaging, although in respect of various
properties plastics are inferior for example compared with
glass. For instance, the barrier properties of plastic are
not comparable with glass, and plastics are more difficult
to print on or coat with other plastics. These
disadvantages may however be compensated for by suitable
plasma treatments, in particular the deposition of suitable
coatings or activation of the surfaces. Plastic surfaces of
workpieces, which contain at least one of the following
materials, are preferably treated: polycyclic hydrocarbons,
for example cyclic polymers or copolymers, preferably
cyclopolyolefinic copolymers or polymers, particularly
preferably COC, preferably Topas® or COP (cyclo-olefinic
polymer), in particular Zeonor®, polycarbonates, preferably
autoclavable polycarbonates such as Apec® or particularly
preferably Makrolon®, polyesters such as polyethylene
terephthalate (PET) or PETG (glycol-modified PET
copolyester), polystyrene, polyethylene such as MDPE
(medium density polyethylene), but in particular HDPE (high
density polyethylene) or LDPE (low density polyethylene),
polypropylene and oriented polypropylene (o-PP), or
biaxially oriented polypropylene (BOPP), polymethyl
methacrylate, PES (polyether sulfone), polyethylene
naphthalate (PEN), SAN (styrene-acrylonitrile copolymer),

17
polymers containing fluorine, preferably
polychlorotrif luoroethylenes (PCT-FE) , particularly
preferably Aclar®, EVOH, polyamide, preferably Nylon6®,
PVC, PVDC (polyvinylidene chloride), PMMI, PA, ABS, MABS,
PMP, PSI.
Glass workpieces or glass surfaces of workpieces may also
be plasma-treated by the invention. Glasses containing
alkali metals, alkaline-earth metals or aluminum are
preferred in this case, preferably borosilicate glasses,
for instance Fiolax glass, and metallurgical glass, for
example soda-lime glass. Besides glass workpieces, it is
also possible to plasma-treat glass-ceramic or ceramic
workpieces.
The device according to the invention is preferably adapted
so that it can be integrated into a production line. In
particular, the device may be operated at least partially
in a sterile environment. In a further configuration, the
device comprises a plurality of coating locations. These
may be configured in a mobile fashion, so that the
workpieces are inserted into reactors at a delivery
position, the reactors are transported on a transport path
to an extraction position and extracted there, the
workpieces being plasma-treated between the delivery and
extraction positions. Accordingly, a device for this
configuration of the invention comprises reactors mobile
along a transport path for the plasma treatment of
workpieces, a delivery position for delivering the
workpieces to the reactors, an extraction position for
extracting the workpieces from the reactors, and a plasma
treatment instrument between the delivery and extraction
positions having an instrument for injecting

18
electromagnetic energy into the cavity. The device is
preferably configured as a rotary machine or as a linear
machine. In the case of a rotary machine, the reactors are
conveyed on a revolving transport path, for example on a
carousel, while in the case of a linear machine the
reactors are transported in a straight line between the
delivery and extraction positions.
In order to be able to carry out simultaneous plasma
treatment of a plurality of workpieces, in such a
multilocation treatment device it has proven highly
advantageous for the plurality of coating locations
respectively to comprise separate energy sources for the
provision of electromagnetic energy. It is also favorable
for the device to comprise separate antechambers for the
coating locations, which are connected to the coating zones
and are joined to a common vacuum generation instrument,
preferably through a further chamber, in which case
instruments for exciting the process gas, which are
respectively attached to separate second energy sources,
are respectively arranged in the antechambers.
In order to inject electromagnetic energy into the process
gas, according to another configuration of the invention
the instrument for injecting electromagnetic energy
comprises at least one of the instruments:
- a coaxial cable,
- a waveguide, preferably a rectangular waveguide,
- a slot for injection into a coating reactor,
- an antenna, which can be inserted into the cavity of a
workpiece,
- a combination of the instruments above, preferably a

19
rectangular waveguide and a coaxial cable connected thereto
on the output side.
Since the field distribution is often critical,
particularly in the case of workpieces with a narrow cross
section of the cavity, it is furthermore recommendable to
provide tuning elements for optimizing the injection.
Accordingly, the instrument for injecting electromagnetic
energy furthermore preferably comprises at least one of the
tuning elements: a stub tuner (3-pin tuner), a short-
circuit slider, displaceable components which modify the
electromagnetic field distribution.
The aforementioned tuning elements and injection
instruments are suitable in particular for microwave
sources as energy sources for generating the plasma in the
process gas. Besides a microwave source, it is nevertheless
also possible to use a high-frequency source (HF source) or
radiofrequency source (RF source). Microwaves are in this
case intended to be understood as electromagnetic waves
with a frequency above 1 GHz. For high-frequency sources
(HF source) or radiofrequency sources (RF source),
electrodes may be used to inject electromagnetic energy
into the cavity, in which case energy is injected by
applying an (alternating) current to the electrodes.
Impedance matching instruments, for example a matchbox with
a control circuit and variable impedances (capacitors or
inductors) may also be provided for HF or RF sources.
Inter alia carrier or reaction gases, such as carrier gases
containing oxygen or nitrogen or containing hydrogen,
preferably from the group oxygen, ozone, nitrogen, ammonia,
nitrogen oxides, hydrogen, may be used as process gases.

20
In order to deposit coatings, the following process gas
components are preferably used:
inorganic or organic silicon compounds, preferably HMDSO or
HMDSN, or TMDSO or TMCTS or TEOS or TMS or SiCl4, SiH4 or
tetraisocyanatosilane,
organic or inorganic aluminum compounds, preferably
aluminum chloride,
organotitanium compounds, preferably TIPT,
inorganic titanium compounds, preferably TiCl4,
hydrocarbons, preferably acetylene, methane, propane,
butane,
fluorine compounds, preferably fluorinated hydrocarbons,
noble gases such as argon, helium, xenon, krypton.
A device according to the invention in this case preferably
comprises a gas supply instrument having at least two
containers for different gases, the mixture of which is
used for the plasma treatment.
In order to avoid ignition of a plasma in the feed lines to
the reactor chamber, according to a refinement of the
invention a shield for the electromagnetic energy is
provided to decouple the feed line of the reactor chamber
to the evacuation instrument.
In a preferred configuration, the device furthermore
comprises an antechamber before the reactor space, the
evacuation instrument being connected to the antechamber.
With such an antechamber, the device can be adapted rapidly
for different workpieces to be coated by mounting
respectively adapted holding instruments on the
antechamber.

21
The device may for example comprise an antechamber or
subspace before the reactor space as a component of the
delivery line. This will then be at least partially
decoupled from the reactor space by the shielding. The
decoupling is carried out for example using an electrically
conductive separating piece. Inter alia a grid or a metal
body with gas inlets is possible for this.
Decoupling means in particular that no energy for the
production/coating process employed reaches the subspace
before the reactor space, or only so little energy that a
plasma cannot be ignited there by the energy source.
Decoupling of the gas source may likewise be carried out.
The gas is discharged into the reactor space, to and
through the antechamber or subspace or otherwise configured
feed lines to the evacuation instrument. After ignition of
the plasma in the cavity of the workpiece, the substance
concentration of the starting gas in the subspace is then
significantly reduced, so that a plasma can no longer be
ignited in the feed lines, particularly in the antechamber.
In general, a combination of shielding the electromagnetic
energy and the gas decrease in the feed lines is used so
that coating can primarily take place only in the reactor
space, i.e. the subspace is coated not at all or
significantly less than the workpiece.
It has surprisingly been found that reliable ignition of
the plasma is achievable by such an ignition instrument,
which is not in fact arranged in the region of the plasma
thereby ignited. Such an ignition instrument may generally
also be used in other reactor types and methods for the
plasma treatment of workpieces. Accordingly, the invention

22
also provides a method for the plasma treatment of
workpieces in which at least one zone of a reactor chamber
is at least partially evacuated, a process gas is
introduced into the zone and a plasma is generated by means
of injected electromagnetic energy in the vicinity of at
least a part of the surface of the workpiece in the process
gas being introduced, the plasma being ignited by
excitation of gas in a space separate from the reactor
chamber while the electromagnetic energy for generating the
plasma is injected into the process gas being introduced.
Accordingly, the invention also provides a method for the
plasma treatment of workpieces in which at least one zone
of a reactor chamber is at least partially evacuated, a
process gas is introduced into the zone and a plasma is
generated by means of injected electromagnetic energy in
the vicinity of at least a part of the surface of the
-workpiece in the process gas being introduced, the plasma
being ignited by excitation of gas in a space separate from
the reactor chamber. In particular, the plasma may be
ignited by excitation of gas in a space separate from the
reactor chamber while the electromagnetic energy for
generating the plasma is injected into the process gas
being introduced, in which case the excitation leads to the
formation of energetic species in the form of excited
particles and energetic radiation and assists the ignition
of the plasma.
A corresponding device, in particular for carrying out this
method, accordingly comprises a reactor chamber for
receiving a workpiece to be coated, an instrument for at
least partially evacuating at least one zone of the reactor
chamber, an instrument for injecting electromagnetic energy

23
into the reactor chamber as well as a space separate from
the reactor chamber, and an instrument for igniting the
plasma in the reactor chamber, the ignition instrument
comprising an instrument for exciting gas in the space
separate from the reactor chamber.
A glow discharge is preferably ignited in the separate
space in order to ignite the plasma. By means of an
instrument for generating a glow discharge in the space
separate from the reactor space, gas can be highly excited
in a particularly straightforward way. In order to ignite
such a glow discharge, for example, an ignition electrode
may be provided to which a high voltage is preferably
applied as a DC or AC voltage. The voltage is applied
either before the plasma treatment, or at the latest at the
start of the coating, and it leads to ignition of the glow
discharge. This glow discharge on its own does not yet
however ignite a plasma in the reactor; rather, excited
species are provided in the zone in which the plasma is
intended to be ignited. This may be done both by ions,
electrons, excited neutral particles diffusing from the
glow discharge, and by photoionization due to UV light
which results from the glow discharge. Easier ignition of
the plasma is facilitated owing to the free charge
carriers.
Only by applying the energy from the energy source, for
instance a microwave source, does ignition of the plasma
take place. In a refinement of the invention, the glow
discharge may be controlled by a preferably optical
monitoring instrument.

24
The glow discharge is in this case preferably ignited by
one of the following parameters:
i) a high voltage in the range of 0.1 kV - 100 kV
ii) an alternating current with a frequency of 0.2 kHz -
100 MHz, preferably 1 kHz - 100 kHz
iii) an rms alternating current in the range of 0.01 mA -
2A, preferably in the range of from 0.1 mA to 500 mA.
The separate space is particularly preferably connected to
the reactor chamber by vacuum technology. This space may in
particular be an antechamber as described above, through
which the reactor chamber is connected to the evacuation
instrument. For separation, shielding may be provided which
prevents microwaves from entering the antechamber and/or
the feed lines to the evacuation instrument.
Roots pumps and rotary disk pumps are preferably used as
components of the evacuation instrument, and also
turbomolecular, oil diffusion or cryo pumps for lower
pressures to be achieved, for instance for PVD coatings.
In order to control the plasma treatment process, in a
refinement of the invention and the light emission of the
antechamber and/or the treatment chamber may be measured.
To this end a photodiode may respectively be used. A
wavelength filter may be used to filter out certain
characteristic emission lines of the plasma or of a glow
charge for igniting the plasma. When workpieces in the form
of hollow bodies are being treated, then the interior of
the workpiece and its surroundings in the reactor chamber
may be monitored separately in the reactor chamber.
Particularly for small workpieces, such as typical
pharmaceutical packaging, a compact arrangement may also be

25
selected in which the light emitted by the plasma is sent
through a glass fiber or a glass fiber bundle to an optical
detector.
Particularly for the treatment of small workpieces, for
example pharmaceutical products such as syringe bodies,
vials, blood sampling tubes or carpules, a particularly
compact arrangement may furthermore be achieved when the
instrument for injecting electromagnetic energy into the
reactor chamber comprises a coaxial cable, the coaxial
cable comprising an axially extending channel through which
the process gas can be delivered. At the same time,
therefore, the electromagnetic energy can be delivered
through the coaxial cable and process gas can be delivered
through its inner conductor. Additional arrangement of a
gas delivery may be obviated in this way. In an alternative
refinement of the invention, the electromagnetic energy may
also be injected through a coaxial cable and the treatment
zone may be evacuated through the coaxial cable. In another
configuration another ignition instrument, particularly an
ignition electrode for generating a glow discharge, may
also be provided in the channel through the inner
conductor. It is particularly preferable to arrange the
coaxial cable in the axial direction of the workpiece to be
treated, so that the coaxial cable extends in the axial
direction of the workpiece. In the case of a cylindrical or
quasi-cylindrical workpiece, for instance a syringe body,
the coaxial cable therefore preferably extends in a
direction along the mid-axis of the cylinder of the syringe
body. In this way, a maximally symmetrical field
distribution is accordingly achieved in or on the syringe
body.

26
A filler body may furthermore be provided, which at least
partially fills a cavity of a workpiece to be treated. By
at least partially filling a cavity of a workpiece to be
treated with a filler body, the temperature distribution on
the workpiece can be kept more uniform during and after the
plasma treatment, compared with a plasma treatment without
such a filler body. The filler body may at the same time be
a fixing and/or vacuum sealing element for a further cavity
of the workpiece. In some syringe bodies, for example,
there is an edge which encloses the Luer cone or the nozzle
and forms a cavity. Under certain circumstances, an
undesirable plasma may also be formed in this cavity. This
effect can be prevented by such a filler body. In
particular, to this end the filler body may be designed to
absorb or reflect high-frequency electromagnetic energy.
The filler body in this case preferably prevents ignition
of a plasma in the immediate vicinity of the filled zone.
Inter alia polymer, ceramic or metallic materials are
suitable for the filler body - optionally in combination.
At the same time, the filler body may seal the cylinder of
the syringe body as a further cavity and/or fix the
workpiece, so that the filler body acts as a sealing or
fixing element. In particular, such a filler body may be
integrated into a coaxial inner conductor. The filler body
need not be a separate part in this case, and it may also
be formed at least partially by a section of the inner
conductor material. Inter alia rigid polymers, for example
PTFE, POM or polycarbonate are suitable as plastics for the
filler body. If the filler body is also intended to act as
a sealing element, then elastomers such as silicone,
bromobutyl elastomer or polyisoprene-bromobutyl elastomer,

27
may in particular also be used in addition or as an
alternative.
Surprisingly, it could furthermore be shown that the plasma
deposition of functional layers on pharmaceutical packaging
with a narrow cross section, for example syringe bodies,
vials, blood sampling tubes or carpules, could be achieved
with very low average powers. In particular, such
containers could be coated in a pulsed plasma with average
powers of at most 3 00 watts, or even at most 10 0 watts.
As an alternative or in addition, the workpiece may also be
cooled by a gas flow during the plasma treatment. If
internal coating is carried out, for example, the workpiece
may be cooled externally by a gas flow - in the simplest
case a flow of air at atmospheric pressure. Also in the
case of external coating, cooling may likewise be carried
out by passing a gas flow through the cavity of the
workpiece.
The invention will be explained in more detail below with
the aid of exemplary embodiments and with reference to the
appended drawings. References which are the same in the
drawings denote parts which are identical or similar.
Fig. 1 shows a schematic cross-sectional view of an
example of a through-flow reactor according to
the invention.
Figs 2 and 3 show alternative arrangements to the through-
flow reactor shown in Fig. 1,

28
Fig. 4 shows a through-flow reactor for external
coating,
Figs 5 to 7 show variants of the reactor represented in
Fig. 4,
Fig. 8 shows a variant of the examples shown in Fig.
1 or 3 with electrodes for feeding in the
electromagnetic energy,
Fig. 9 shows a variant of the reactor shown in Fig. 8
for external coating,
Figs 10a, 10b show two exemplary embodiments of reverse
flow reactors.
Figs 11 - 15 show details of coaxial inner conductors for
delivering electromagnetic energy,
Fig. 16 shows an exemplary embodiment of a
multilocation coating system,
Figs 17 to 19 show SIMS intensity-sputter time profiles for
the elements/molecules C, 02, Si and for the
C8 chain of the coated COC syringe, coated
with a 2-layer system comprising an adhesion
promoter layer and a barrier layer. The
profile shape corresponds to the sequence:
inorganic barrier layer, adhesion promoter
layer containing carbon, polymer substrate
(cyclo-olefinic copolymer).

29
In what follows, a through-flow reactor is intended to mean
a device according to the invention in which a treatment
zone is at least partially evacuated in a reactor chamber,
a process gas is introduced into the cavity of the
workpiece and a plasma is ignited by means of injected
electromagnetic energy in the process gas introduced into
the treatment zone, the process gas flowing through the
treatment zone between opposite ends of the zone during the
plasma treatment.
In the context of the invention, a reverse flow reactor is
furthermore intended to mean a reactor in which the process
gas is put in not at a further opening, opposite to the
opening at the first end connected to the vacuum system,
but inside the cavity to be coated. In this case, however,
the position at which the gas flows in preferably lies at
least 2/3 of the longitudinal extent of the cavity away
from the opening at the first end of the workpiece. The
process gas is in this case preferably put in using a
cannula inserted into the cavity.
Fig. 1 shows a schematic cross section of a through-flow
reactor 1, which is designed for the internal coating of
workpieces in the form of hollow bodies. In particular, the
reactor 1 is adapted for the coating of pharmaceutical
packaging, for instance syringe bodies or carpules. To this
end, Fig. 1 shows a syringe body 10 arranged in the reactor
chamber 2 of the reactor 1. The syringe body 10 comprises a
cylinder 11, which opens into a plunger opening 12 and
encloses a cylindrical cavity 13. At the opposite end of
the cylinder 11 from the plunger opening, it is provided
with a cover element 14 having a second cylindrical or
quasi-cylindrical, for example slightly conical appendage

30
with a smaller diameter and a shorter length in the form of
a Luer cone 15 with a second opening 16. When the syringe
is being used, the cannula is fitted onto the Luer cone 15.
The length and height of the Luer cone 15 are preferably at
least 20% less than the maximum diameter and the height of
the syringe body 10. The Luer cone 15 has a narrow,
cannula-like inner diameter of between 0.01 and 15 mm,
particularly preferably between 0.05 and 4 mm.
The device 1 represented in Fig. 1 is designed in
particular for the internal plasma treatment of such
syringe bodies 10. The material of the syringe body 10 at
least locally has dielectric properties in this case. The
syringe body is shaped cylindrically or guasi-
cylindrically, and typically has a maximum outer diameter
of between 1 mm and 50 mm, preferably between 3 mm and 3 0
mm, and a height of from 10 mm to 2 00 mm, preferably from
30 mm to 150 mm.
In this example, the electromagnetic energy for generating
a plasma is delivered by means of a coaxial cable. Fig. 1
showing only the inner conductor 2 0 of the coaxial cable.
Using the inner conductor 20 and a sealing element 22
attached thereto, the syringe body 10 is both fixed and
sealed off from the surrounding regions of the reactor
chamber 2. In this embodiment of the invention, in
particular, the electromagnetic energy is delivered through
the coaxial cable and the process gas is delivered through
an axially extending channel 24 in the inner conductor 20
of the coaxial cable.
The inner conductor 2 0 furthermore presses the syringe body
10 onto a further sealing element 25, which encloses an

31
opening 27 in a separating plate 26. By means of the
separating plate 26, the reactor:chamber 2 is separated
from an antechamber 28 connected to an evacuation
instrument (not shown). The sealing element 25 around the
opening 2 7 in the base plate in this case accordingly forms
a connection instrument to connect an evacuation
instrument, for at least partially evacuating the cavity 13
of the workpiece 10, onto the plunger opening of the
syringe.
As can be seen from Fig. 1 the cavity of the syringe body
10 is evacuated through an opening at a first end - here
accordingly the plunger opening 12 - and the process gas is
introduced through a further opening, i.e. the opening 16
in the Luer cone 15 - at a second end of the syringe body
10, which lies opposite the first end. During the coating,
the process gas therefore flows through the cavity 13 in an
axial direction along its entire length. Owing to the
axisymmetric arrangement of the Luer cone 15, the cylinder
wall and the plunger opening, an axisymmetric flow of the
process gas takes place through the cavity 13 of the
syringe body 10.
The plasma in the treatment zone, i.e. here the cavity 13,
is furthermore ignited by means of an ignition instrument.
The ignition instrument comprises an instrument for
exciting gas in the antechamber 28 separated from the
reactor chamber. In particular, the ignition instrument is
in this case an ignition electrode 29 arranged in the
antechamber 28, by which a glow discharge is ignited and
gas contained in the antechamber is thereby excited.
Ignition in the coating zone i.e. here the interior of the
syringe body 10, can however take place only if

32
electromagnetic energy, for example microwaves with a
frequency of 2.45 GHz, is simultaneously injected through
the coaxial cable. Astonishingly, ignition by the glow
discharge burning in the antechamber 28 takes place even
though the antechamber 2 8 and the reactor chamber are
separated from each other by the separating wall 26, and
the gas flow travels in the opposite direction owing to the
evacuation. Another shield 3 0 for the electromagnetic
energy is furthermore provided to decouple the feed line of
the reactor chamber 2 to the evacuation instrument, which
suppresses entry of the electromagnetic waves into the
antechamber 28 in order to avoid ignition of a plasma in
this region. Ignition by means of the glow discharge is
unaffected, or at least not substantially affected, even by
such shielding. A monitoring instrument 23 may
advantageously be used to check whether a glow discharge
has been ignited. It may for example comprise one or more
photodiodes, which optically record the light of the glow
discharge.
Figs 2 and 3 represent alternative arrangements of a
through-flow reactor 1 as shown in Fig. 1.
In the example represented in Fig. 2, the process gas is
likewise delivered through the Luer cone 15, i.e. the
narrower of the two openings 12, 16. The connection
instrument for connecting the treatment zone in this
embodiment of the invention, here likewise the interior 13
of the syringe body 10, comprises a connection element 31
connected to the inner conductor 20 of a coaxial cable and
having a sealing element 25, which seals the plunger
opening 12 of the syringe body 10 off from the rest of the
reactor space 2. The process gas is accordingly not

33
delivered through the coaxial cable in this case, rather it
is discharged, and the interior of the syringe is
evacuated, through this.
In the example represented in Fig. 3, the electromagnetic
energy is fed through with a waveguide 33, preferably a
rectangular waveguide and a gap 34 opening into the reactor
space 2, instead of a coaxial cable. A dielectric tube
seals the inner part of the reactor chamber 2 with the
syringe body 10 off from the outer part, while the
electromagnetic waves emerging from the gap 34 can pass
through the tube 36. Instead of or in addition to the
dielectric tube 36, it is also possible to use a dielectric
window in the gap 34. The injection of electromagnetic
waves takes place not in the axial direction of the syringe
body 10 here, but instead laterally. An HF or RF source is
preferably used in conjunction with the waveguide.
The Luer cone 15 of the syringe body 10 is connected
hermetically by a connection element 31 and a sealing
element 22 to a gas supply. In other regards, the structure
with an antechamber 28 connected to an evacuation
instrument, an ignition electrode 29 and a shield 30, is
similar to the example represented in Fig. 1.
Fig. 4 shows a variant of a through-flow reactor 1 for the
external coating of workpieces. Here again a syringe body
10 is represented as a workpiece to be coated, although
other types of workpieces, even workpieces not in the form
of hollow bodies, may also be plasma-treated, in particular
plasma-coated by such an arrangement. For the external
coating, the syringe body is sealed off both at the plunger
opening and at the Luer cone by sealing elements 42 and 44,

34
respectively, from the rest of the reactor space 2 which in
this case constitutes the treatment zone. In particular,
the cavity 13 of the syringe body 10 may remain at
atmospheric pressure during a plasma treatment, while the
surrounding reactor space 2 is evacuated through the
evacuation instrument connected to the antechamber 28.
In this example, the antechamber 2 8 is separated from the
reactor space 2 not by a separating wall, but only by a
shield 30.
The process gas is introduced into the treatment zone via
two or more supply channels 3 8 with gas distributors 3 9
connected thereto, and it is sucked through the shield 3 0
and the antechamber 28 by the evacuation instrument. The
electromagnetic energy is delivered from the same direction
as the process gas in this example. A dielectric window 4 0
seals the reactor chamber 2 hermetically, but transparently
for the electromagnetic waves being introduced. In this
example as well, the process gas flows through the
treatment zone between two opposite ends.
Fig. 5 shows a variant of the example represented in Fig.
4. In this variant, the process gas for an external
treatment, for example external coating of the workpiece,
is delivered laterally. To this end lateral openings 46 are
formed in the reactor chamber 2, and they are provided with
shields 4 8 against entry of the electromagnetic waves into
the gas delivery system. As an alternative or in addition,
the shields may also act as gas distributors.
The variant represented in Fig. 6 is again designed as a
through-flow reactor. The gas delivery and the vacuum

35
system with an antechamber 2 8 and a shield 3 0 correspond to
the example represented in Fig. 4. In contrast to the
example shown in Fig. 4, however, microwave energy is
delivered through a coaxial cable 19 with an inner
conductor 20 and an outer conductor 21. The syringe body is
connected hermetically by means of a sealing element 25 to
the waveguide 19 by the plunger opening 12. An antenna 50,
which is inserted into the cavity 13 of the syringe body
10, is connected to the inner conductor 2 0 of the waveguide
19. The antenna 50 ensures better introduction and more
homogeneous distribution of the electromagnetic fields.
Fig. 7 shows a reactor 1, which is designed both for
internal and for external coating of the syringe body 10.
The internal coating is carried out in this case with a
process gas flowing through between opposite ends of the
inner treatment zone, i.e. the cavity 13 of the syringe
body. In particular, the Luer cone 15 of the syringe body
10 is filled with the process gas for the internal coating
through a connection element 31 with a supply channel and a
sealing element 22, and it is sucked out again at the
opposite end, i.e. the plunger opening 12. To this end the
plunger opening 12 is connected by a sealing element 25 to
a tube 52, which extends through the antechamber 28 and is
connected to a first evacuation instrument "Vacuum 1". In
order to suppress entry of the electromagnetic fields into
the tube, a separate shield 32 is arranged in the tube.
The gas delivery and discharge for the process gas for an
external treatment, introduced into the surroundings of the
syringe in the reactor space, and the delivery of
electromagnetic energy through a vacuum-tight window 4 0

36
which is transparent for RF, HF or microwaves, correspond
here to the example shown in Fig. 5.
Fig. 8 shows a variant of a through-flow reactor similar to
the examples shown in Fig. 1 or 3. Process gas flows in the
axial direction through cavity 13 of the syringe body 10
between the Luer cone 15 and the plunger opening 12, as in
the examples shown in Fig. 1 or 3. Instead of injecting the
electromagnetic energy through coaxial cables or waveguides
as in the example shown in Fig. 8, however, an
electromagnetic field is generated between two electrodes
56, 58 which are connected to a high-frequency generator
54. One or more other tuning elements 6 0 may be provided in
addition. The reactor chamber may, as in this example, be
formed by the cavity 13 of the syringe body 10 itself.
Fig. 9 shows a variant of the arrangement shown in Fig. 8
which is adapted for external coating of workpieces, such
as the syringe body 10 depicted. This variant is also
designed as a through-flow reactor, the process gas being
introduced into the treatment zone on one side of the
reactor chamber 2 through two or more supply channels 38
with gas distributors 39 connected thereto, and it is
sucked out again through openings arranged in the opposite
separating plate between the reactor chamber 2 and the
antechamber 28. The side walls of the reactor chamber are
formed by a dielectric tube 36, or may alternatively
comprise dielectric wall elements, so that the high-
frequency field radiated by the electrodes 56, 58 can
penetrate through the reactor space 2. The cavity 13 of the
syringe is sealed by sealing elements 42, 44 and may be
kept at atmospheric pressure while the treatment zone, i.e.

37
the regions of the reactor chamber 2 which enclose the
syringe body 10, is evacuated.
Figs 10a and 10b show two variants of reverse flow
reactors. The reactor shown in Fig. 10a is similar in
structure to the through-flow reactor shown in Fig. 1. In
contrast to the example shown in Fig. 1, however, the
process gas is not introduced into the cavity 13 through
the Luer cone 15. Rather, the Luer cone is sealed off from
the rest of the reactor chamber 2 by a sealing element in
this example. The delivery of process gas takes place
through a cannula 64 here, which penetrates through the
plunger opening 12 into the cavity 13. The cannula
protrudes into the syringe body by at least 3/4, preferably
9/10, particularly preferably 95/100 of the longitudinal
extent of the cavity 13.
Regions of the cavity 13 are also locally shielded at least
partially against the injected electromagnetic energy by
means of a metal shield enclosing the base of the syringe
body with the plunger opening. This prevents a particularly
hot-burning plasma, which may damage the syringe body 10,
from being able to form locally at this position. This
measure may of course also be used in the other embodiments
represented in the figures.
The example shown in Fig. 10b represents a reactor which is
adapted for internal and external coating of syringe bodies
10. The reactor resembles the example shown in Fig. 7 in
its structure, the process gas for the internal treatment
being delivered through a cannula 64 protruding into the
cavity 13 in the example shown in Fig. 10b.

38
Fig. 15 shows details of a reactor with delivery of
electromagnetic energy through a coaxial cable. The outer
conductor is not represented for the sake of simplicity.
The inner conductor 2 0 comprises an axially extending
channel 70, through which process gas can be introduced via
the opening 16 into the cavity or interior 13 of the
syringe body 10. In order to establish a hermetic
connection to the opening 16 of the Luer cone 15, an
internal sealing element 72 sealing the channel 70 is
provided. This, like the other sealing elements, is
preferably made of flexible material, in particular
elastomer material such as silicone rubber, bromobutyl
elastomer or polyisoprene-bromobutyl elastomer.
Such a coaxial cable may then be used for example for the
reactor represented in Fig. 1. The treatment zone may
nevertheless also be evacuable through the coaxial cable,
in which case the axially extending channel 70 will be
connected to an evacuation instrument.
In this example, the syringe body 10 also comprises a
further cavity 80 which is formed between an edge 82
encircling the cover element 14 of the syringe body and the
Luer cone 15. This cavity can be pumped out only with
difficulty. An undesirable plasma may therefore also be
formed in this cavity 80 when electromagnetic waves are
injected for the plasma coating. In order to avoid this,
the inner conductor 2 0 comprises an integrated filler body
84 which is inserted into the cavity 80 when fitting the
inner conductor 2 0 and fixing the syringe body 10, and at
least partially fills it. The filler body 84 may for
example be made of a dielectric material such as plastic,

39
or polymers, or ceramic or even metallic material, in order
to absorb or reflect high-frequency electromagnetic energy
and thus prevent ignition of a plasma in the immediate
vicinity of the filled zone. The filler body 84 makes the
temperature distribution on the workpiece more uniform
during and after the plasma treatment, compared with a
plasma treatment without such a filler body.
The inner conductor 2 0 furthermore comprises another collar
86, which encloses the cylinder 11 of the syringe body 10
along a part of its axial length. This collar acts as
shielding, in order to shield regions of the cavity of the
workpiece locally against injected electromagnetic energy.
This prevents too hot a plasma from burning in the narrow
Luer cone 15, which may damage the workpiece.
In the variant represented in Fig. 12, the filler body 84
simultaneously forms a sealing element for sealing off the
cavity 13 and hermetically connecting to the channel 70.
The filler body 84 is preferably made of elastomer material
in this case, in particular silicone rubber, bromobutyl
elastomer or polyisoprene-bromobutyl elastomer.
In the further variant shown in Fig. 13, a separate sealing
element 74 is provided similarly as in the example
represented in Fig. 11. In contrast to the example
represented in Fig. 11, however, the annular sealing
element 74 is in this case placed not on the Luer cone 15
but on the circumferential edge 82.
The filler body 84 is not a separate part in the variant
shown in Fig. 14, rather it is formed by a section of the
inner conductor material itself.

40
Fig. 15 shows an exemplary embodiment of the coating with a
reverse flow reactor, such as is represented for example in
Fig. 10a. The cannula for delivering the process gas is not
represented in this example for the sake of simplicity.
The inner conductor comprises a cavity 88, which is formed
by a collar 86 as in the previous examples. The syringe
body 10 is inserted with the Luer cone 15 into the cavity,
so that the collar 86 partially encloses the cylinder 11
and partially shields the region of the cavity 13 in the
Luer cone 15. The opening 16 in the Luer cone 15 is sealed
by a sealing element 44 as in the example shown in Fig.
10a. Filling of the cavity 80 may be obviated in this
example, since the environment of the syringe body 10
remains at atmospheric pressure and it is evacuated only
internally.
Fig. 16 shows an exemplary embodiment of a device according
to the invention designed as a multilocation coating
system. A multilocation coating system, such as is
represented as an example in Fig. 16, may be adapted for
simultaneously coating a plurality of workpieces. The
example shown in Fig. 16 comprises in particular four
reactors 100, although two or more reactors may for example
also be used. The reactors are preferably designed as
through-flow reactors. The system comprises a supply source
100 with a control instrument for providing a fluid or
fluid mixture, preferably of two different fluids, or
process gas mixtures. In this way, for example, an adhesion
promoter coating and a barrier coating may sequentially be
deposited by means of plasma coating. The gases or gas
mixtures provided by the supply source 110 may be

41
introduced separately into the reactors 100 through the
valves 112 on the reactors. In-order to provide the fluid
mixtures, the supply instrument comprises a plurality of
gas containers 95 which are connected by mass flow
regulators 97 to two control valves 99. The reactors 100
with the coating locations respectively comprise separate
energy sources 101. This prevents cross-contamination
during the simultaneous coating. A separate antechamber 2 8
with an ignition instrument (not shown) is furthermore
provided for each reactor 100. The ignition instrument is
preferably an ignition electrode as represented in Fig. 1.
The ignition instruments are in turn likewise equipped with
respectively separate energy sources for exciting the glow
discharge in the respective antechambers. This also
prevents cross-contamination between the reactors. The
antechambers 28, and therefore also the reactors 100, are
connected together through a further chamber 105 to a
vacuum generation instrument, which reduces the equipment
outlay without causing cross-contamination during
simultaneous coating. A regulating instrument 92 regulates
the pump power of the instrument 90. In order to monitor
the evacuation and the process gas decrease, pressure
meters 93 are provided in the common chamber 105 and in the
feed line to the vacuum generation instrument 90.
The invention will be further explained below with the aid
of exemplary embodiments of coating methods.
In the exemplary embodiments presented below, a glow
discharge, which does not yet lead to layer deposition on
the substrate, is initially ignited in a subspace. Only by
injecting high-frequency energy into the coating chamber is
the plasma ignited in the coating reactor by means of this

42
glow discharge. In said examples, a current in the range of
5 mA - 50 mA and a frequency in the range of 10 - 2 5 kHz
are used for the glow discharge. The glow discharge is
current-regulated'. The high voltage used lies between 0.5 -
2 kV.
Exemplary Embodiment la: PECVD method, internal coating
with through-flow reactor
A syringe made of COC (cyclic olefinic copolymer), 1 ml
volume with a cylinder height of 54 mm and a cylinder inner
diameter of 6.5 mm, a total height of 64.5 mm and a Luer
cone according to DIN 594 with a length of 10 mm and with
an internal opening diameter of 2 mm is put in the reactor
described in Fig. 1 with the large cross section downward
and the narrow cross section (Luer cone) upward. The
syringe initially rests on the sealing surface on the lower
side of the reactor. The upper side of the reactor is
subsequently lowered, and the syringe is hermetically
sealed on the upper side when the reactor is closed. The
counterpressure ensures that the syringe also rests
hermetically on the lower side. The interior of the syringe
is subsequently evacuated until a base pressure is reached. The exterior remains at atmospheric pressure
throughout the treatment process. While the connection to
the vacuum at the lower side is maintained, the gas inlet
valve is opened and a first gas mixture of oxygen and
hexamethyldisiloxane with an HMDSO flow rate of 3.4 seem
and an oxygen flow rate of 16.6 seem at a pressure of 0.55
mbar is introduced through the side with the narrow cross
section, i.e. at the Luer cone of the syringe. In this
through-flow operation, a continuous flow is set up in
which the gas flows parallel to the symmetry axis from the

43
narrow cross section to the wide cross section. A glow
discharge is ignited in the subspace by means of the
ignition device, although this does not yet lead to layer
deposition on the inside of the syringe. A plasma is not
ignited in the interior of the syringe until the time at
which pulsed microwave energy is input into the reactor
space from the microwave source with a frequency of 2.45
GHz and an average pulse power of 57 watts through the
waveguide, while no plasma is ignited externally owing to
the atmospheric pressure.
During the process, the syringe is coated internally with a
first adhesion promoter layer for a first coating time of
1.0 s and with an average layer thickness of 40 nm. Toward
the end of the first coating, the microwave energy is
turned off. This is followed by a gas change phase, during
which a second gas mixture of hexamethyldisiloxane (HMDSO)
and oxygen with an HMDSO flow rate of 0.2 seem and an
oxygen flow rate of 39.8 seem at a pressure of 0.8 mbar is
fed into the interior of the syringe.
As soon as pulsed microwave energy is introduced into the
reactor space from the microwave source with a frequency of
2.45 GHz and with an average microwave power of 3 0.8 W
through the waveguide, a plasma is ignited internally in
the syringe and a second inorganic barrier layer is applied
for a second coating time of 55.4 s and with an average
layer thickness of 30 nm. Toward the end of the coating
process, the microwave energy is turned off and the supply
of process gas is terminated. In a cooling phase, the
coating is terminated and the syringe is cooled to room
temperature. After re-evacuation, a 3rd inorganic barrier
layer is subsequently applied with the same process

44
parameters and the same average layer thickness of 3 0 run,
so that the total average barrier thickness is 6 0 nm.
Toward the end of the process, the interior of the syringe
is flushed to atmospheric pressure.
The coated syringes exhibit an oxygen permeation of 0.0018
cm3/(Pckg d 0.21 bar) at 23°C and 50% rel. humidity, while
uncoated syringes have an oxygen permeation of 0.0074
cm3/(Pckg d 0.21 bar), so that the barrier improvement for
oxygen is better than a factor of 4.
Exemplary Embodiment lb: Through-flow reactor, coating of
the Luer cone:
A 1 ml COC syringe is coated internally in the through-flow
reactor similarly as in Example la.
Step 1:
A first gas mixture of oxygen and hexamethyldisiloxane with
an HMDSO flow rate of 3.4 seem and an oxygen flow rate of
16.6 seem at a pressure of 0.55 mbar is introduced at the
Luer cone of the syringe. A glow discharge is ignited in
the subspace by means of the ignition device, although this
does not yet lead to layer deposition on the inside of the
syringe. A plasma is not ignited in the interior of the
syringe until the time at which pulsed microwave energy is
input into the reactor space from the microwave source with
a frequency of 2.45 GHz and an average pulse power of 57
watts through the waveguide, while no plasma is ignited
externally owing to the atmospheric pressure. During the
process, the syringe is coated internally with a first
adhesion promoter layer for a first coating time of 0.9 s.

45
Toward the end of the first coating, the microwave energy-
is turned off.
Step 2:
This is followed by a gas change phase, during which a
second gas mixture of hexamethyldisiloxane (HMDSO) and
oxygen with an HMDSO flow rate of 0.6 seem and an oxygen
flow rate of 3 9.4 seem at a pressure of 0.15 mbar is fed
into the interior of the syringe. As soon as pulsed
microwave energy is introduced into the reactor space from
the microwave source with a frequency of 2.45 GHz and with
an average microwave power of 3 0.8 W through the waveguide,
a plasma is ignited internally in the syringe and a second
inorganic barrier layer is applied for a second coating
time of 47 s.
Toward the end of the coating process, the microwave energy
is turned off and the supply of process gas is terminated.
In a cooling phase, the syringe body is flushed internally
with nitrogen and subsequently re-evacuated. Step 2 is
subsequently repeated while maintaining the same coating
time. Toward the end of the process, the interior of the
syringe is flushed to atmospheric pressure.
By means of secondary ion mass spectrometry (SIMS) depth
profiling, the syringe body coated in this way was examined
at 3 positions. To this end, Figs 17 to 19 show the SIMS
intensity-sputter time profiles at three different
positions of the coated syringe body. Fig. 17 shows such a
profile in the region of the large-diameter opening
("Position 15 mm"), Fig. 18 shows such a profile in the
region of the middle of the syringe cylinder ("Position 40
mm") and Fig. 19 shows such a profile in the narrow channel

46
of the Luer cone of the syringe ("Position 59 mm"). The
profiles for the elements/compounds C, Si, 02 and the C8
chain are represented. The junction of the layer system
with the substrate can be seen with the aid of the
intensity drop in the Si and 0 sputter time profiles. The
different shapes for the C and C8 sputter time profiles are
due to the adhesion promoter layer containing carbon.
Based on the data of the depth profilings as represented in
Figs 17 to 19, the relative local layer thickness of the
overall system is determined. To this end the sputter time
x in which the Si or O SIMS-sputter time profiles in the
layer have fallen to half intensity is determined. The
relative, normalized layer thickness drel is given by the
ratio of the times xx and xref which are found:
drei = Di /D„£ = TiA^,
where D1 and Dref correspond to the absolute local layer
thicknesses. The "Position 40 mm" was selected as a
reference position in this case.
The following are obtained as relative thicknesses:

Position Relative thickness drel
(%)
15 mm (opening) 60
4 0 mm (middle) 100
59 mm (Luer cone) 93
In particular, these analyses reveal that the narrow Luer
channel of the syringe can be coated internally and that a
very good layer uniformity is achieved in the through-flow
reactor: the thickness difference between the Luer cone (59

47
mm) and the middle of the cylinder (40 mm) is only
93%/l00%.
Exemplary Embodiment lc: PECVD method, internal coating
with through-flow reactor, multiple alternating layers
i) Layer System I:
A syringe made of COC (cyclic olefinic copolymer), 1 ml
volume with a cylinder height of 54 mm and a cylinder inner
diameter of 6.5 mm, a total height of 64.5 mm and a Luer
cone according to DIN 594 with a length of 10 mm and with
an internal opening diameter of 2 mm is put in the reactor
described in Fig. 1 with the large cross section downward
and the narrow cross section (Luer cone) upward. The
syringe initially rests on the sealing surface on the lower
side of the reactor. The upper side of the reactor is
subsequently lowered, and the syringe is hermetically
sealed on the upper side when the reactor is closed. The
counterpressure ensures that the syringe also rests
hermetically on the lower side.
Step 1) The interior of the syringe is subsequently
evacuated until a base pressure exterior remains at atmospheric pressure throughout the
treatment process. While the connection to the vacuum at
the lower side is maintained, the gas inlet valve is opened
and a first gas mixture of oxygen and hexamethyldisiloxane
with an HMDSO flow rate of 3.4 seem and an oxygen flow rate
of 16.6 seem at a pressure of 0.55 mbar is introduced
through the side with the narrow cross section, i.e. at the
Luer cone of the syringe. A glow discharge is ignited in
the subspace by means of the ignition device, although this
does not yet lead to layer deposition on the inside of the

48
syringe. A plasma is not ignited in the interior of the
syringe until the time at which pulsed microwave energy is
input into the reactor space from the microwave source with
a frequency of 2.45 GHz and an average microwave power of
57 watts through the waveguide, while no plasma is ignited
externally owing to the atmospheric pressure.
During the process, the syringe is coated externally with a
first adhesion promoter layer with an average layer
thickness of 40 nm. Toward the end of the first coating,
the microwave energy is turned off.
Step 2:
This is followed by a gas change phase, during which a
second gas mixture of hexamethyldisiloxane (HMDSO) and
oxygen with an HMDSO flow rate of 0.6 seem and an oxygen
flow rate of 39.4 seem at a pressure of 0.15 mbar is fed
into the interior of the syringe.
As soon as pulsed microwave energy is introduced into the
reactor space from the microwave source with a frequency of
2.45 GHz and with an average microwave power of 3 0.8 W
through the waveguide, a plasma is ignited internally in
the syringe and a second inorganic barrier layer is applied
with an average layer thickness of 100 nm. Toward the end
of the coating process, the microwave energy is turned off
and the supply of process gas is terminated.
The 2-layer system produced as described above (40 nm/100
nm) exhibits the following properties:
The coated syringes exhibit an oxygen permeation of 0.0004
cm3/(Pckg d 0.21 bar) at 23°C and 50% rel. humidity, while
uncoated syringes have an oxygen permeation of 0.0074

49
cm3/(Pckg d 0.21 bar), so that the barrier improvement for
oxygen is a factor of 20.
Measurements of the water vapor permeation at 38°C, 90%
relative humidity, reveal that the coated syringes have a
water vapor permeation of 0.05 mg/(Pckg. d) , while uncoated
syringes have a water vapor permeation of 0.11 mg/(Pckg.
d) , so that the barrier improvement for water vapor is a
factor of 2.
ii) Layer System II, 6-level Multilayer
(40 nm / 100 nm / 40 nm / 100 nm / 40 run / 100 nm) :
The layers are applied similarly as for layer system I,
although steps 1) and 2) are repeated a further two times
so that an alternating layer system of 3 organic and 3
inorganic layers is applied overall.
The coated syringes exhibit an oxygen permeation of 0.00011
cm3/(Pckg d 0.21 bar) at 23°C and 50% rel. humidity, while
uncoated syringes have an oxygen permeation of 0.0074
cm3/(Pckg d 0.21 bar), so that the barrier improvement for
oxygen is a factor of 70. Consequently, the oxygen barrier
is improved substantially more highly by the multilayer
coating with 6 layers of layer system II other than with
layer system I, which consists of 2 layers.
Measurements of the water vapor permeation at 38°C, 90%
relative humidity, reveal that the coated syringes have a
water vapor permeation of 0.041 mg/(Pckg. d). Conversely,
uncoated syringes have a water vapor permeation of 0.11

50
mg/(Pckg. d) so that the barrier improvement for water
vapor is a factor of 2.7.
Exemplary Embodiment Id: PECVD method, internal coating
with through-flow reactor, low flow rate, higher water
vapor barrier
A syringe made of COC (cyclic olefinic copolymer), 1 ml
volume with a cylinder height of 54 mm and a cylinder inner
diameter of 6.5 mm, a total height of 64.5 mm and a Luer
cone according to DIN 594 with a length of 10 mm and with
an internal opening diameter of 2 mm is put in the reactor
described in Fig. 1 with the large cross section downward
and the narrow cross section (Luer cone) upward. The
syringe initially rests on the sealing surface on the lower
side of the reactor. The upper side of the reactor is
subsequently lowered, and the syringe is hermetically
sealed on the upper side when the reactor is closed. The
counterpressure ensures that the syringe also rests
hermetically on the lower side.
Step 1: The interior of the syringe is subsequently
evacuated until a base pressure exterior remains at atmospheric pressure throughout the
treatment process. While the connection to the vacuum at
the lower side is maintained, the gas inlet valve is opened
and a first gas mixture of oxygen and hexamethyldisiloxane
with an HMDSO flow rate of 3.4 seem and an oxygen flow rate
of 16.6 seem at a pressure of 0.55 mbar is introduced
through the side with the narrow cross section, i.e. at the
Luer cone of the syringe. A glow discharge is ignited in
the subspace by means of the ignition device, although this
does not yet lead to layer deposition on the inside of the

51
syringe. A plasma is not ignited in the interior of the
syringe until the time at which pulsed microwave energy is
input into the reactor space from the microwave source with
a frequency of 2.45 GHz and an average pulse power of 57
watts through the waveguide, while no plasma is ignited
externally owing to the atmospheric pressure. During the
process, the syringe is coated externally with a first
adhesion promoter layer with an average layer thickness of
40 nm. Toward the end of the first coating, the microwave
energy is turned off.
Step 2:
This is followed by a gas change phase, during which a
second gas mixture of hexamethyldisiloxane (HMDSO) and
oxygen with an HMDSO flow rate of 0.3 seem and an oxygen
flow rate of 19.7 seem at a pressure of 0.15 mbar is fed
into the interior of the syringe.
As soon as pulsed microwave energy is introduced into the
reactor space from the microwave source with a frequency of
2.45 GHz and with an average microwave power of 30.8 W
through the waveguide, a plasma is ignited internally in
the syringe and a second inorganic barrier layer is applied
with an average layer thickness of 100 nm for a second
coating time of 245.4 s. Toward the end of the coating
process, the microwave energy is turned off and the supply
of process gas is terminated.
Step 3 :
A third gas mixture of oxygen and hexamethyldisiloxane with
an HMDSO flow rate of 14 seem and an oxygen flow rate of 6
seem at a pressure of 0.55 mbar is introduced. A glow
discharge is ignited in the subspace by means of the

52
ignition device, although this does not yet lead to layer
deposition on the inside of the syringe. A plasma is not
ignited in the interior of the syringe until the time at
which pulsed microwave energy is input into the reactor
space from the microwave source with a frequency of 2.45
GHz and an average pulse power of 57 watts through the
waveguide, while no plasma is ignited externally owing to
the atmospheric pressure.
During the process, the syringe is coated internally with a
third organosilicon layer with an average layer thickness
of 100 nm. Toward the end of the first coating, the
microwave energy is turned off.
The coated syringes exhibit an oxygen permeation of 0.0016
cm3/(Pckg d 0.21 bar) at 23°C and 50% rel. humidity, while
uncoated syringes have an oxygen permeation of 0.0074
cm3/(Pckg d 0.21 bar), so that the barrier improvement for
oxygen is a factor of 4.8.
Measurements of the water vapor permeation at 38°C, 90%
relative humidity, reveal that the coated syringes have a
water vapor permeation of 0.02 mg/(Pckg. d). Conversely,
uncoated syringes have a water vapor permeation of 0.11
mg/(Pckg. d) so that the barrier improvement for water
vapor is a factor of 5.5.
As a further reference, syringes were coated just as in
this exemplary embodiment but the second inorganic barrier
layer is deposited with a total flow rate of 40 seem in
Step 2 while maintaining the same HMDSO concentration and
while maintaining the layer thickness. At 38°C, 90%

53
relative humidity, the water vapor permeation of this layer
is 0.05 mg/(Pckg. d). The water vapor barrier is therefore
significantly inferior than in the case of the barrier
coating with the smaller total flow rate of 2 0 seem in the
second process step.
Exemplary Embodiment le: PECVD method, production of a
tetramethyldisiloxane (TMDSO) barrier, adhesion promoter
and a third layer by means of hexamethyldisiloxane (HMDSO):
A syringe made of COC (cyclic olefinic copolymer), 1 ml
volume with a cylinder height of 54 mm and a cylinder inner
diameter of 6.5 mm, a total height of 64.5 mm and a Luer
cone according to DIN 594 with a length of 10 mm and with
an internal opening diameter of 2 mm is put in the reactor
described in Fig. 1 with the large cross section downward
and the narrow cross section (Luer cone) upward. The
syringe initially rests on the sealing surface on the lower
side of the reactor. The upper side of the reactor is
subsequently lowered, and the syringe is hermetically
sealed on the upper side when the reactor is closed. The
counterpressure ensures that the syringe also rests
hermetically on the lower side.
Step 1: The interior of the syringe is subsequently
evacuated until a base pressure exterior remains at atmospheric pressure throughout the
treatment process. While the connection to the vacuum at
the lower side is maintained, the gas inlet valve is opened
and a first gas mixture of oxygen and hexamethyldisiloxane
with an HMDSO flow rate of 3.4 seem and an oxygen flow rate
of 16.6 seem at a pressure of 0.55 mbar is introduced
through the side with the narrow cross section, i.e. at the

54
Luer cone of the syringe. A glow discharge is ignited in
the subspace by means of the ignition device, although this
does not yet lead to layer deposition on the inside of the
syringe. A plasma is not ignited in the interior of the
syringe until the time at which pulsed microwave energy is
input into the reactor space from the microwave source with
a frequency of 2.45 GHz and an average pulse power of 57
watts through the waveguide, while no plasma is ignited
externally owing to the atmospheric pressure.
During the process, the syringe is coated externally with a
first adhesion promoter layer with an average layer
thickness of 40 run. Toward the end of the first coating,
the microwave energy is turned off.
Step 2:
This is followed by a gas change phase, during which a
second gas mixture of tetramethyldisiloxane (TMDSO) and
oxygen with a TMDSO flow rate of 0.6 seem and an oxygen
flow rate of 3 9.4 seem at a pressure of 0.15 mbar is fed
into the interior of the syringe.
As soon as pulsed microwave energy is introduced into the
reactor space from the microwave source with a frequency of
2.45 GHz and with an average microwave power of 30.8 W
through the waveguide, a plasma is ignited internally in
the syringe and a second inorganic barrier layer is applied
with an average layer thickness of 100 run for a second
coating time of 133.7 s. Toward the end of the coating
process, the microwave energy is turned off and the supply
of process gas is terminated.

55
Step 3 :
A third gas mixture of oxygen and hexamethyldisiloxane with
an HMDSO flow rate of 14 seem and an oxygen flow rate of 6
seem at a pressure of 0.55 mbar is introduced. A glow
discharge is ignited in the subspace by means of the
ignition device, although this does not yet lead to layer
deposition on the inside of the syringe. A plasma is not
ignited in the interior of the syringe until the time at
which pulsed microwave energy is input into the reactor
space from the microwave source with a frequency of 2.45
GHz and an average pulse power of 57 watts through the
waveguide, while no plasma is ignited externally owing to
the atmospheric pressure. During the process, the syringe
is coated internally with a third organosilicon layer with
an average layer thickness of 100 nm. Toward the end of the
first coating, the microwave energy is turned off.
The coated syringes exhibit an oxygen permeation of 0.0017
cm3/(Pckg d 0.21 bar) at 23°C and 50% rel. humidity, while
uncoated syringes have an oxygen permeation of 0.0074
cm^/(Pckg d 0.21 bar), so that the barrier improvement for
oxygen is a factor of 4.5.
At 38°C, 90% relative humidity, the coated syringes exhibit
a water vapor permeation of 0.03 mg/(Pckg. d), while
uncoated syringes have a water vapor permeation of 0.11
mg/(Pckg. d) so that the barrier improvement for water
vapor is a factor of 3.4.
Exemplary Embodiment If: PECVD method, production of all
layers from tetramethyldisiloxane (TMDSO), barrier process
with shorter process time:

56
A syringe made of COC (cyclic olefinic copolymer), 1 ml
volume with a cylinder height of 54 mm and a cylinder inner
diameter of 6.5 mm, a total height of 64.5 mm and a Luer
cone according to DIN 594 with a length of 10 mm and with
an internal opening diameter of 2 mm is put in the reactor
described in Fig. 1 with the large cross section downward
and the narrow cross section (Luer cone) upward. The
syringe initially rests on the sealing surface on the lower
side of the reactor. The upper side of the reactor is
subsequently lowered, and the syringe is hermetically
sealed on the upper side when the reactor is closed. The
counterpressure ensures that the syringe also rests
hermetically on the lower side.
Step 1: The interior of the syringe is subsequently
evacuated until a base pressure exterior remains at atmospheric pressure throughout the
treatment process. While the connection to the vacuum at
the lower side is maintained, the gas inlet valve is opened
and a first gas mixture of oxygen and tetramethyldisiloxane
with a TMDSO flow rate of 3.4 seem and an oxygen flow rate
of 16.6 seem at a pressure of 0.55 mbar is introduced
through the side with the narrow cross section, i.e. at the
Luer cone of the syringe. A glow discharge is ignited in
the subspace by means of the ignition device, although this
does not yet lead to layer deposition on the inside of the
syringe. A plasma is not ignited in the interior of the
syringe until the time at which pulsed microwave energy is
input into the reactor space from the microwave source with
a frequency of 2.45 GHz and an average pulse power of 57
watts through the waveguide, while no plasma is ignited
externally owing to the atmospheric pressure.

57
During the process, the syringe is coated externally with a
first adhesion promoter layer with an average layer
thickness of 40 rim within a coating time of 0.8 s. Toward
the end of the first coating, the microwave energy is
turned off.
Step 2:
This is followed by a gas change phase, during which a
second gas mixture of tetramethyldisiloxane (TMDSO) and
oxygen with a TMDSO flow rate of 1.6 seem and an oxygen
flow rate of 78.4 seem at a pressure of 0.15 mbar is fed
into the interior of the syringe.
As soon as pulsed microwave energy is introduced into the
reactor space from the microwave source with a frequency of
2.45 GHz and with an average microwave power of 59.3 W
through the waveguide, a plasma is ignited internally in
the syringe and a second inorganic barrier layer is applied
with an average layer thickness of 100 run for a second
coating time of 3 6.7 s. Toward the end of the coating
process, the microwave energy is turned off and the supply
of process gas is terminated.
Step 3:
A third gas mixture of oxygen and tetramethyldisiloxane
with a TMDSO flow rate of 14 seem and an oxygen flow rate
of 6 seem at a pressure of 0.55 mbar is introduced. A glow
discharge is ignited in the subspace by means of the
ignition device, although this does not yet lead to layer
deposition on the inside of the syringe. A plasma is not
ignited in the interior of the syringe until the time at
which pulsed microwave energy is input into the reactor

58
space from the microwave source with a frequency of 2.45
GHz and an average pulse power of 57 watts through the
waveguide, while no plasma is ignited externally owing to
the atmospheric pressure.
During the process, the syringe is coated internally with a
third organosilicon with an average layer thickness of 100
nm. Toward the end of the first coating, the microwave
energy is turned off.
The coated syringes exhibit an oxygen permeation of 0.0015
cm3/(Pckg d 0.21 bar) at 23°C and 50% rel. humidity, while
uncoated syringes have an oxygen permeation of 0.0074
cm3/(Pckg d 0.21 bar), so that the barrier improvement for
oxygen is a factor > 5.
Exemplary Embodiment 2: Through-flow reactor, internal
coating with lower average power
A syringe is coated internally in the through-flow reactor
similarly as in Example 1. The same adhesion promoter layer
is applied. On the other hand, however, a second barrier
layer is subsequently deposited with a much lower microwave
power:
After having applied the 40 nm thick adhesion promoter
layer, a second gas mixture of hexamethyldisiloxane and
oxygen with an HMDSO flow rate of 0.2 seem and an oxygen
flow rate of 9.8 seem at a pressure of 0.15 is fed into the
interior of the syringe in a gas change phase.
As soon as pulsed microwave energy is introduced into the
reactor space from the microwave source with a frequency of

59
2.45 GHz and with an average microwave power of 15.7 W
through the waveguide, a plasma is ignited internally in
the syringe and a second inorganic barrier layer is applied
for a second coating time of 138.9 s and with an average
layer thickness of 60 nm. Toward the end of the coating
process, the microwave energy is turned off, the supply of
process gas is terminated and the interior of the syringe
is flushed to atmospheric pressure.
The coated syringes exhibit an oxygen permeation of 0.002 0
cm3/(Pckg d 0.21 bar) at 23°C and 50% rel. humidity, while
uncoated syringes have an oxygen permeation of 0.0074
cm3/(Pckg d 0.21 bar), so that the barrier improvement for
oxygen is better than a factor of 3.5.
Exemplary Embodiment 3: Through-flow reactor, barrier
coating of a glass syringe
A Fiolax glass syringe, 1 ml volume, is introduced into the
reactor described in Fig. 2 with the large cross section
upward and the narrow cross section (Luer cone) downward.
The syringe initially rests on the sealing surface on the
lower side of the reactor. The upper side of the reactor is
subsequently lowered, and the syringe is hermetically
sealed on the upper side when the reactor is closed. The
counterpressure ensures that the syringe also rests
hermetically on the lower side. The interior of the syringe
is subsequently evacuated until a base pressure is reached. The exterior remains at atmospheric pressure
throughout the treatment process.

60
While the connection to the vacuum at the lower side is
maintained, the gas inlet valve is opened and a first gas
of oxygen with an oxygen flow rate of 4 0 seem at a pressure
of 2.5 mbar is introduced through the side with the narrow
cross section, i.e. at the Luer cone of the syringe. In
this through-flow operation, a continuous flow is set up in
which the gas flows parallel to the symmetry axis from the
narrow cross section to the wide cross section.
A glow discharge is ignited in the subspace by means of the
ignition device, although this does not yet lead to layer
deposition on the inside of the syringe. A plasma is not
ignited in the interior of the syringe until the time at
which pulsed microwave energy is input into the reactor
space from the microwave source with a frequency of 2.45
GHz and an average pulse power of 167 watts through the
waveguide, while no plasma is ignited externally owing to
the atmospheric pressure. During the process, the syringe
is heated internally to a temperature of 250°C for a
treatment time of 19 s.
Toward the end of the heating process, the microwave energy
is turned off. This is followed by a gas change phase,
during which a second gas mixture of hexamethyldisiloxane
and oxygen with an HMDSO flow rate of 1.2 seem and an
oxygen flow rate of 40 seem at a pressure of 2.5 mbar is
fed into the interior of the syringe. Before the start of
the coating, the syringe is at a temperature of 205°C.
As soon as pulsed microwave energy is introduced into the
reactor space from the microwave source with a frequency of
2.45 GHz and with an average microwave power of 167 W
through the waveguide, a plasma is ignited internally in

61
the syringe and a second inorganic barrier layer is applied
for a coating time of 13 s and with an average layer
thickness of 100 nm. Toward the end of the coating process,
the microwave energy is turned off and the supply of
process gas is terminated. Toward the end of the process,
the interior of the syringe is flushed to atmospheric
pressure.
The coated syringes are filled with 0.1 mol HCl and
autoclaved at 121°C for 6 hours. After the autoclaving, the
sodium leaching is measured. Compared with uhcoated glass
syringes, the sodium leaching is reduced significantly and
is less than 0.3 ppm.
Exemplary Embodiment 4a: Reverse flow reactor syringe
coating
A syringe body made of COC (cyclic olefinic copolymer),
1 ml volume with a cylinder height of 54 mm and a cylinder
inner diameter of 6.5 mm, a total height of 64.5 mm and a
Luer cone according to DIN 594 with a length of 10 mm and
with an internal opening diameter of 2 mm is put in the
reactor described in Fig. 10a with the large cross section
downward and the narrow cross section (Luer cone) upward.
The syringe initially rests on the sealing surface on the
lower side of the reactor and a gas feed (supply channel)
consisting of stainless steel, with an outer diameter of 2
mm, an inner diameter of 1.5 mm, projects into the syringe
with a penetration depth of 34.5 mm. The syringe is
hermetically closed with sealing material on the side with
the narrow cross section (Luer cone). The upper side of the
reactor is subsequently lowered, and a mechanical
counterpressure ensures that the syringe rests hermetically

62
on the lower side. The interior of the syringe is
subsequently evacuated until a base pressure reached. The exterior remains at atmospheric pressure
throughout the treatment process. While the connection to
the vacuum at the lower side is maintained, the gas inlet
valve is opened and a first gas mixture of oxygen and
hexamethyldisiloxane with an HMDSO flow rate of 3.4 seem
and an oxygen flow rate of 16.6 seem at a pressure of 0.4
mbar is introduced through the gas feed. A continuous flow
is thereby set up. A glow discharge is ignited in the
subspace by means of the ignition device, although this
does not yet lead to layer deposition on the inside of the
syringe. A plasma is not ignited in the interior of the
syringe until the time at which pulsed microwave energy is
input into the reactor space from the microwave source with
a frequency of 2.45 GHz and an average pulse power of 57 W
through the waveguide, while no plasma is ignited
externally owing to the atmospheric pressure. During the
process, the syringe is coated internally with a first
adhesion promoter layer for a first coating time of 1.2 s
and with an average layer thickness of 4 0 nm. Toward the
end of the first coating, the microwave energy is turned
off. This is followed by a gas change phase, during which a
second gas mixture of hexamethyldisiloxane and oxygen with
an HMDSO flow rate of 0.44 seem and an oxygen flow rate of
39.6 seem at a pressure of 0.4 mbar is fed into the
interior of the syringe. As soon as pulsed microwave energy
is introduced into the reactor space from the microwave
source with a frequency of 2.45 GHz and with an average
microwave power of 84.9 W through the waveguide, a plasma
is ignited internally in the syringe and a second inorganic
barrier layer is applied for a second coating time of 15.3
s and with an average layer thickness of 2 0 nm. Toward the

63
end of the coating process, the microwave energy is turned
off and the supply of process gas is terminated. The
substrate is subsequently cooled in a cooling phase, and
the coating process for the barrier layer is repeated three
times after evacuation, the same process parameters being
used and equally thick barrier layers being deposited as in
Step 2. The overall barrier thickness of the 3 successively
applied barrier layers 60 run. Toward the end of the
process, the interior of the syringe is flushed to
atmospheric pressure.
The coated syringes exhibit an oxygen permeation of 0.0033
cm3/(Pckg d 0.21 bar) at 23°C and 50% rel. humidity, while
uncoated syringes have an oxygen permeation of 0.0074
cm3/(Pckg d 0.21 bar), so that the barrier improvement for
oxygen is better than a factor of 2.5.
Exemplary Embodiment 4b: Reverse flow reactor, syringe
coating
A syringe body made of COC (cyclic olefinic copolymer),
1 ml volume with a cylinder height of 54 mm and a cylinder
inner diameter of 6.5 mm, a total height of 64.5 mm and a
Luer cone according to DIN 594 with a length of 10 mm and
with an internal opening diameter of 2 mm is put in the
reactor described in Fig. 10a with the large cross section
downward and the narrow cross section (Luer cone) upward.
The syringe initially rests on the sealing surface on the
lower side of the reactor and a gas feed (supply channel)
consisting of stainless steel, with an outer diameter of 2
mm, an inner diameter of 1.5 mm, projects into the syringe
with a penetration depth of 17.5 mm. The syringe is

64
hermetically closed with sealing material on the side with
the narrow cross section (Luer cone) . The upper side of the
reactor is subsequently lowered, and a mechanical
counterpressure ensures that the syringe rests hermetically
on the lower side. The interior of the syringe is
subsequently evacuated until a base pressure reached. The exterior remains at atmospheric pressure
throughout the treatment process. While the connection to
the vacuum at the lower side is maintained, the gas inlet
valve is opened and a first gas mixture of oxygen and
hexamethyldisiloxane with an HMDSO flow rate of 3.4 seem
and an oxygen flow rate of 16.6 seem at a pressure of 0.4
mbar is introduced through the gas feed. A continuous flow
is thereby set up. A glow discharge is ignited in the
subspace by means of the ignition device, although this
does not yet lead to layer deposition on the inside of the
syringe. A plasma is not ignited in the interior of the
syringe until the time at which pulsed microwave energy is
input into the reactor space from the microwave source with
a frequency of 2.45 GHz and an average pulse power of 57 W
through the waveguide, while no plasma is ignited
externally owing to the atmospheric pressure. During the
process, the syringe is coated internally with a first
adhesion promoter layer for a first coating time of 2.1 s
and with an average layer thickness of 4 0 nm. Toward the
end of the first coating, the microwave energy is turned
off. This is followed by a gas change phase, during which a
second gas mixture of hexamethyldisiloxane and oxygen with
an HMDSO flow rate of 0.38 seem and an oxygen flow rate of
24.6 seem at a pressure of 0.4 mbar is fed into the
interior of the syringe. As soon as pulsed microwave energy
is introduced into the reactor space from the microwave
source with a frequency of 2.4 5 GHz and with an average

65
microwave power of 214 W through the waveguide, a plasma is
ignited internally in the syringe and a second inorganic
barrier layer is applied for a second coating time of 3 s
and with an average layer thickness of 6.4 run. Toward the
end of the coating process, the microwave energy is turned
off and the supply of process gas is terminated. The
substrate is subsequently cooled in a cooling phase, and
the coating process for the barrier layer is repeated ten
times after evacuation, the same process parameters being
used and equally thick barrier layers being deposited as in
Step 2. The overall barrier thickness of the 11
successively applied barrier layers is 70 nm. Toward the
end of the process, the interior of the syringe is flushed
to atmospheric pressure.
The coated syringes exhibit an oxygen permeation of 0.0012
cm3/(Pckg d 0.21 bar) at 23°C and 50% rel. humidity, while
uncoated syringes have an oxygen permeation of 0.0074
cm3/(Pckg d 0.21 bar), so that the barrier improvement for
oxygen is better than a factor of 6.
Exemplary Embodiment 5: Reverse flow reactor, coating of
vials
A vial made of COC (cyclic olefinic copolymer), 12 ml
volume, is put in the reactor described in Fig. 10a. The
vial initially rests on the sealing surface on the lower
side of the reactor and a gas feed made of metal projects
into the vial. The upper side of the reactor is
subsequently lowered, and the interior of the vial is
subsequently evacuated until a base pressure reached. The outer region of the reactor chamber,

66
surrounding the vial, remains at atmospheric pressure
throughout the treatment process.
While the connection to the vacuum at the lower side is
maintained, the gas inlet valve is opened and a first gas
mixture of oxygen and hexamethyldisiloxane with an HMDSO
flow rate of 4.25 seem and an oxygen flow rate of 20.75
seem at a pressure of 0.4 mbar is introduced through the
gas feed. A continuous flow is thereby set up, in which the
gas is distributed axisymmetrically. A glow discharge is
ignited in the subspace by means of the ignition device,
although this does not yet lead to layer deposition on the
inside of the vial. A plasma is not ignited in the interior
of the vial until the time at which pulsed microwave energy
is input into the reactor space from the microwave source
with a frequency of 2.45 GHz and an average pulse power of
57 W through the waveguide, while no plasma is ignited
externally owing to the atmospheric pressure.
During the process, the vial is coated internally with a
first adhesion promoter layer for a first coating time of
0.4 s and with an average layer thickness of 2 0 nm. Toward
the end of the first coating, the microwave energy is
turned off. This is followed by a gas change phase, during
which a second gas mixture of hexamethyldisiloxane and
oxygen with an HMDSO flow rate of 0.75 seem and an oxygen
flow rate of 50 seem at a pressure of 0.4 mbar is fed into
the interior of the vial.
As soon as pulsed microwave energy is introduced into the
reactor space from the microwave source with a frequency of
2.45 GHz and with an average microwave power of 214 W
through the waveguide, a plasma is ignited internally in

67
the vial and a second inorganic barrier layer is applied
for a second coating time of 34 s and with a layer
thickness of 100 ran. Toward the end of the coating process,
the microwave energy is turned off, the supply of process
gas is terminated and the interior of the vial is flushed
to atmospheric pressure.
The coated vials exhibit an oxygen permeation of 0.001
cm3/(Pckg d 0.21 bar) at 23°C and 50% rel. humidity, while
uncoated vials have an oxygen permeation of 0.0283
cm3/(Pckg d 0.21 bar). The resolution limit of the
permeation measuring instrument is reached, so that the
barrier improvement improved for oxygen is better than a
factor of 28.
At 38°C, 90% relative humidity, coated vials exhibit a
water vapor permeation of 0.16 mg/(Pckg. d), while uncoated
vials have a water vapor permeation of 0.3 mg/(Pckg. d).
The barrier improvement achieved for water vapor is
therefore a factor of 1.9.
Storage stability:
During a storage test, the vials were filled with i)
distilled water and ii) 0.1 molar hydrochloric acid and
stored for 1 week at 60 °C. After emptying and drying, the
oxygen permeation was again measured at 23°C and 50% rel.
humidity. After the storage test, in both cases i) and ii)
the oxygen permeation was still at the resolution limit of
0.001 cm3 / (Pckg d 0.21 bar). An oxygen barrier
improvement by a factor of more than 28 therefore still
remains.

68
Exemplary Embodiment 6: Internal coating of syringe with
barrier layer, outer coating with scratch protection layer
a) A COC syringe, 1 ml volume, is coated in a reactor
corresponding to Fig. 7. The syringe is first coated
internally with an adhesion promoter layer and a barrier
layer using "Vacuum 1" and delivery of the process gas
through "Gas 1" according to Exemplary Embodiment 1. After
flushing the interior of the syringe to atmospheric
pressure, the reactor exterior is evacuated through "Vacuum
2" to a base pressure hexamethyldisiloxane and oxygen is subsequently delivered
into the exterior through the gas distributor device "Gas
2", while sustaining the continuous gas flow through
"Vacuum 2". Pulsed microwave energy with a frequency of
2.45 GHz is subsequently input into the reactor space using
the microwave source, and a plasma is now ignited in the
exterior. A 100 nm thick scratch protection layer is
applied on the outer wall of the substrate.
b) A COC syringe, 12 ml volume, is coated in a reactor
corresponding to Fig. 10b. The syringe is first coated
internally with an adhesion promoter layer and a barrier
layer using "Vacuum 1" and delivery of process gas through
"Gas 1" according to Exemplary Embodiment 4. After flushing
the interior of the syringe to atmospheric pressure, the
reactor exterior is evacuated through "Vacuum 2" to a base
pressure oxygen is subsequently delivered into the exterior through
the gas distributor device "Gas 2", while sustaining the
continuous gas flow through "Vacuum 2".

69
Pulsed microwave energy with, a frequency of 2.45 GHz is
subsequently input into the reactor space using the
microwave source, and a plasma is now ignited in the
exterior. A 100 nm thick scratch protection layer is
applied on the outer wall of the substrate.
Exemplary Embodiment 7a: Barrier layer of amorphous carbon
on organosilicon bonding layer, deposition on a COC syringe
A syringe made of COC (cyclic olefinic copolymer), 1 ml
volume with a cylinder height of 54 mm and a cylinder inner
diameter of 6.5 mm, a total height of 64.5 mm and a Luer
cone according to DIN 594 with a length of 10 mm and with
an internal opening diameter of 2 mm is put in the reactor
described in Fig. 1 with the large cross section downward
and the narrow cross section (Luer cone) upward. The
syringe initially rests on the sealing surface on the lower
side of the reactor. The upper side of the reactor is
subsequently lowered, and the syringe is hermetically
sealed on the upper side when the reactor is closed. The
counterpressure ensures that the syringe also rests
hermetically on the lower side. The interior of the syringe
is subsequently evacuated until a base pressure is reached. The exterior remains at atmospheric pressure
throughout the treatment process.
Step 1: While the connection to the vacuum at the lower
side is maintained, the gas inlet valve is opened and a
first gas mixture of oxygen and hexamethyldisiloxane with
an HMDSO flow rate of 3.4 seem and an oxygen flow rate of
16.6 seem at a pressure of 0.55 mbar is introduced through
the side with the narrow cross section, i.e. at the Luer
cone of the syringe. A glow discharge is ignited in the

70
subspace by means of the ignition device, although this
does not yet lead to layer deposition on the inside of the
syringe. A plasma is not ignited in the interior of the
syringe until the time at which pulsed microwave energy is
input into the reactor space from the microwave source with
a frequency of 2.45 GHz and an average pulse power of 57
watts through the waveguide, while no plasma is ignited
externally owing to the atmospheric pressure.
During the process, the syringe is coated internally with a
first organosilicon adhesion promoter layer with an average
layer thickness of 4 0 nm. Toward the end of the first
coating, the microwave energy is turned off.
Step 2: Next, acetylene gas at a pressure of 0.2 mbar and
with a flow rate of 4 0 seem is fed in during a gas change
phase. A glow discharge is ignited in the subspace by means
of the ignition device, although this does not yet lead to
layer deposition on the inside of the syringe. A plasma is
not ignited in the interior of the syringe- until the time
at which pulsed microwave energy is input into the reactor
space from the microwave source with a frequency of 2.45
GHz and an average microwave power of 3 0.8 W through the
waveguide, while no plasma is ignited externally owing to
the atmospheric pressure. During the process, the syringe
is coated internally with a barrier layer of amorphous
carbon for a coating time of 10 s. Toward the end of the
coating process, the microwave energy is turned off, the
supply of process gas is terminated and the interior of the
syringe is flushed to atmospheric pressure.
Compared with the uncoated substrate, a barrier improvement
is achieved for oxygen:

71
The coated syringes exhibit an oxygen permeation of 0.007
cm3/(Pckg d 0.21 bar) at 23°C and 50% rel. humidity, while
uncoated syringes have an oxygen permeation of 0.008
cm-V (Pckg d 0.21 bar) . The barrier improvement for oxygen
is a factor of 1.2.
Exemplary Embodiment 7b: Barrier layer of amorphous carbon
on organosilicon bonding layer, deposition on CQC vials:
A vial made of COC (cyclic olefinic copolymer), 12 ml
volume, is put in the reactor described in Fig. 10a. The
vial initially rests on the sealing surface on the lower
side of the reactor and a gas feed made of metal projects
into the vial. The upper side of the reactor is
subsequently lowered, and the interior of the vial is
subsequently evacuated until a base pressure reached. The outer region of the reactor chamber,
surrounding the vial, remains at atmospheric pressure
throughout the treatment process.
Step 1: While the connection to the vacuum at the lower
side is maintained, the gas inlet valve is opened and a
first gas mixture of oxygen and hexamethyldisiloxane with
an HMDSO flow rate of 4.25 seem and an oxygen flow rate of
20.75 seem at a pressure of 0.4 mbar is introduced through
the gas feed. A glow discharge is ignited in the
antechamber by means of the ignition device, although this
does not yet lead to layer deposition on the inside of the
syringe. A plasma is not ignited in the interior of the
vial until the time at which pulsed microwave energy is
input into the reactor space from the microwave source with
a frequency of 2.45 GHz and an average pulse power of 57 W

72
through the waveguide, while no plasma is ignited
externally owing to the atmospheric pressure.
During the process, the vial is coated internally with a
first adhesion promoter layer for a first coating time of
0.5 s and with a thickness of 2 0 run. Toward the end of the
first coating, the microwave energy is turned off.
Step 2: Next, acetylene gas at a pressure of 0.2 mbar and
with a flow rate of 80 seem is fed in during a gas change
phase. A glow discharge is ignited in the subspace by means
of the ignition device, although this does not yet lead to
layer deposition on the inside of the vial. A plasma is not
ignited in the interior of the vial until the time at which
pulsed microwave energy is input into the reactor space
from the microwave source with a frequency of 2.45 GHz and
an average microwave power of 72.7 W through the waveguide,
while no plasma is ignited externally owing to the
atmospheric pressure. During the process, the vial is
coated internally with a barrier layer of amorphous carbon
for a coating time of 10 s. Toward the end of the coating
process, the microwave energy is turned off, the supply of
process gas is terminated and the interior of the vial is
flushed to atmospheric pressure.
The coated vials exhibit an oxygen permeation of 0.0006
cm3/(Pckg d 0.21 bar) at 23°C and 50% rel. humidity, while
uncoated vials have an oxygen permeation of 0.0283
cm3/(Pckg d 0.21 bar), so that the barrier improvement
achieved for oxygen is better than a factor of 40. This
high barrier improvement could be detected by a high-
resolution permeation measurement method in this case.

73
At 38°C, 90% relative humidity, coated vials exhibit a
water vapor permeation of 0.23 mg/(Pckg. d), while uncoated
vials have a water vapor permeation of 0.4 mg/(Pckg. d).
The barrier improvement achieved for water vapor is
therefore a factor of 1.8.
Exemplary Embodiment 7c: Barrier layer of amorphous carbon
on organosilicon bonding layer, deposition on COC vials
A vial made of COC (cyclic olefinic copolymer), 12 ml
volume, is put in the reactor described in Fig. 10a. The
vial initially rests on the sealing surface on the lower
side of the reactor and a gas feed made of metal projects
into the vial. The upper side of the reactor is
subsequently lowered, and the interior of the vial is
subsequently evacuated until a base pressure reached. The outer region of the reactor chamber,
surrounding the vial, remains at atmospheric pressure
throughout the treatment process.
Step 1: Next, acetylene gas at a pressure of 0.2 mbar and
with a flow rate of 50 seem is fed in during a gas change
phase. A glow discharge is ignited in the subspace by means
of the ignition device, although this does not yet lead to
layer deposition on the inside of the vial. A plasma is not
ignited in the interior of the vial until the time at which
pulsed microwave energy is input into the reactor space
from the microwave source with a frequency of 2.45 GHz and
an average microwave power of 214 W through the waveguide,
while no plasma is ignited externally owing to the
atmospheric pressure. During the process, the vial is
coated internally with a barrier layer of amorphous carbon

74
for a coating time of 30 s. Toward the end of the coating
process, the microwave energy is turned off, the supply of
process gas is terminated and the interior of the vial is
flushed to atmospheric pressure.
The coated vials exhibit an oxygen permeation of 0.0008
cm3/(Pckg d 0.21 bar) at 23°C and 50% rel. humidity, while
uncoated vials have an oxygen permeation of 0.0283
cm3/(Pckg d 0.21 bar), so that the barrier improvement
achieved for oxygen is better than a factor of 30. This
high barrier improvement could be detected by a high-
resolution permeation measurement method in this case.
At 38°C, 90% relative humidity, coated vials exhibit a
water vapor permeation of 0.22 mg/(Pckg. d), while uncoated
vials have a water vapor permeation of 0.4 mg/(Pckg. d).
The barrier improvement achieved for water vapor is
therefore a factor of 1.8.
Exemplary Embodiment 8: External coating with barrier layer
A syringe made of COC (cyclic olefinic copolymer), 1 ml
volume with a cylinder height of 54 mm and a cylinder inner
diameter of 6.5 mm, a total height of 64.5 mm and a Luer
cone according to DIN 594 with a length of 10 mm and with
an internal opening diameter of 2 mm is put in the reactor
described in Fig. 4 with the large cross section downward
and the narrow cross section (Luer cone) upward. The
syringe is sealed hermetically at both openings: the
syringe initially rests on the sealing surface on the lower
side of the reactor and is sealed from the vacuum at the

75
bottom. On the upper side, the narrow cross section (Luer
cone) is covered and is also vacuum-tight.
The exterior of the syringe is subsequently evacuated until
a base pressure remains at atmospheric pressure throughout the treatment
process. While the connection to the vacuum at the lower
side is maintained, the gas inlet valve is opened and a
first gas mixture of oxygen and hexamethyldisiloxane with
an HMDSO flow rate of 3.4 seem and an oxygen flow rate of
16.6 seem at a pressure of 0.55 mbar is introduced through
the gas distributor device. In this through-flow operation,
a continuous flow is set up in which the gas flows parallel
to the symmetry axis. A glow discharge is ignited in the
subspace by means of the ignition device, although this
does not yet lead to layer deposition on the inside of the
syringe. A plasma is not ignited in the exterior of the
reactor until the time at which pulsed microwave energy is
input into the reactor space from the microwave source with
a frequency of 2.45 GHz and an average microwave power of
57 watts through the waveguide, while no plasma is ignited
internally owing to the atmospheric pressure. During the
process, the syringe is coated externally with a first
adhesion promoter layer for a first coating time of 1.1 s
and with a thickness of 4 0 nm. Toward the end of the first
coating, the microwave energy is turned off. This is
followed by a gas change phase, during which a second gas
mixture of hexamethyldisiloxane and oxygen with an HMDSO
flow rate of 0.8 seem and an oxygen flow rate of 39.2 seem
at a pressure of 0.8 mbar is fed into the exterior of the
reactor. As soon as pulsed microwave energy is introduced
into the reactor space from the microwave source with a
frequency of 2.45 GHz and with an average microwave power

76
of 7 6.9 W through the waveguide, a plasma is ignited in the
exterior and a second inorganic barrier layer is applied
for a second coating time of 15.7 s and with a thickness of
15 run. Toward the end of the coating process, the microwave
energy is turned off and the supply of process gas is
terminated. The substrate is subsequently cooled in a
cooling phase, and the coating process for the barrier
layer is repeated four times after evacuation, the same
process parameters being used and equally thick barrier
layer is being deposited as in Step 2. The overall barrier
thickness of the four successively applied barrier layers
is 60 nm. Toward the end of the process, the interior of
the syringe is flushed to atmospheric pressure. Compared
with the uncoated syringe, the coated syringe has a barrier
improvement for oxygen.
Exemplary Embodiment 9: Internal coating with decorative
layer (layer with selective reflection in the visible
spectral range)
A syringe made of COC (cyclic olefinic copolymer), 1 ml
volume with a cylinder height of 54 mm and a cylinder inner
diameter of 6.5 mm, a total height of 64.5 mm and a Luer
cone according to DIN 594 with a length of 10 mm and with
an internal opening diameter of 2 mm is put in the reactor
described in Fig. 1 with the large cross section downward
and the narrow cross section (Luer cone) upward. The
syringe initially rests on the sealing surface on the lower
side of the reactor. The upper side of the reactor is
subsequently lowered, and the syringe is hermetically
sealed on the upper side when the reactor is closed. The
counterpressure ensures that the syringe also rests
hermetically on the lower side. The interior of the syringe

77
is subsequently evacuated until a base pressure is reached.
The exterior remains at atmospheric pressure throughout the
treatment process.
Step 1: Deposition of a high refractive index layer
While the connection to the vacuum at the lower side is
maintained, the gas inlet valve is opened and a first gas
mixture of titanium chloride and oxygen with a TiCl4 flow
rate of 0.2 seem and an oxygen flow rate of 19.8 seem at a
pressure of 0,2 mbar is fed into the interior of the
syringe through the side with the narrow cross section,
i.e. at the Luer cone of the syringe. As soon as pulsed
microwave energy is introduced into the reactor space from
the microwave source with a frequency of 2.45 GHz and with
an average microwave power of 90 W through the waveguide, a
plasma is ignited internally in the syringe and a first
high refractive index layer is applied for a first coating
time of 27 s and with a thickness of 3 0 nm.
Step 2: Deposition of a low refractive index layer
This is followed by a gas change phase, during which a
second gas mixture of hexamethyldisiloxane and oxygen with
an HMDSO flow rate of 0.2 seem and an oxygen flow rate of
9.8 seem at a pressure of 0.15 mbar is fed into the
interior of the syringe. As soon as pulsed microwave energy
is introduced into the reactor space from the microwave
source with a frequency of 2.45 GHz and with an average
microwave power of 15.7 W through the waveguide, a plasma
is ignited internally in the syringe and a second inorganic
barrier layer is applied for a second coating time of 93 s
with an average layer thickness of 40 nm.

78
Steps 1 and 2 are repeated 8 times, the layer thicknesses
and the coating times being adapted for the layer design.
Toward the end of the coating process, the microwave energy
is turned off, the supply of process gas is terminated and
the interior of the syringe is flushed to atmospheric
pressure.
A decorative effect is achieved by the alternating layer
system of high and low refractive index layers: the layer
reflects the incident light selectively (i.e. wavelength-
dependently). The layer design is adapted so that the layer
system has a bluish effect.
Furthermore, owing to the additional barrier effect of the
titanium oxide layer, the barrier improvement for oxygen is
significantly better than in Exemplary Embodiment 2.
Exemplary Embodiment 10: Mirroring
The layers are applied similarly as in Exemplary Embodiment
9. 12 layers are used, however, and the design is adapted
so that the visible light spectrum is reflected
selectively.
Exemplary Embodiment 11: Layer with selective reflection in
the infrared wavelength range
The layers are applied similarly as in Exemplary Embodiment
10. 14 layers are used, however, and the design is adapted
so that light of the infrared wavelength range is reflected
selectively.

79
Exemplary Embodiment 12: Layer with selective reflection in
the infrared wavelength range
The layers are applied similarly as in Exemplary Embodiment
10. 14 layers are used, however, and the design is adapted
so that light of the infrared wavelength range is reflected
selectively.
Exemplary Embodiment 13: External coating with a UV
reflection layer and scratch protection layer
The UV reflection layer is a layer with selective
reflection in the ultraviolet wavelength range.
The layers are deposited similarly as in Exemplary
Embodiment 8, and the layer sequence is similar to
Exemplary Embodiment 9. 16 layers are used, however, and
the design is adapted so that light of the ultraviolet
wavelength range is reflected selectively. A 100 nm thick
scratch protection layer is additionally applied as a final
layer, with a coating process similar to Exemplary
Embodiment 6.
Exemplary Embodiment 14: External coating with decorative
layer
Similar to Exemplary Embodiment 9 and with the reactor
corresponding to Exemplary Embodiment 8 and similarly to
the method according to Exemplary Embodiment 9, a
decorative layer is applied on the outside.
It is clear to the person skilled in the art that the
invention is not restricted to the exemplary embodiments
described above, rather it may be modified in a wide
variety of ways. In particular, the features of the
individual exemplary embodiments may also be combined with
one another.

Patent Claims
1. A method for the plasma treatment of workpieces in the
form of hollow bodies, in which a treatment zone in a
reactor chamber is at least partially evacuated, a
process gas is introduced into the treatment zone,
particularly into the cavity of the workpiece, and a
plasma is ignited by means of injected electromagnetic
energy in the process gas introduced into the treatment
zone, wherein the process gas flows through the treatment
zone between opposite ends of the zone during the plasma
treatment, the workpiece comprising a first cylindrical
or quasi-cylindrical surface and a cylindrical or quasi-
cylindrical appendage with a smaller diameter and a
shorter length and a second cylindrical or quasi-
cylindrical surface, the diameter and the height of the
appendage being less than the maximum diameter and the
height by at least 20%, preferably by 50%.
2 The method as claimed in claim 1, wherein the plasma
treatment is carried out exclusively on the inside of the
hollow body.
3. The method as claimed in one of claims 1 and 2, wherein
the plasma treatment is carried out exclusively on the
outside of the hollow body.
4. The method as claimed in one of claims 1 to 3, wherein
the plasma treatment is carried out both on the inside
and on the outside of the hollow body, and wherein the
plasma treatments on the inside and the outside of the

2
hollow body are preferably different or affect the
surfaces in different ways.
5. The method as claimed in one of the preceding claims,
wherein the workpiece
i) is shaped cylindrically or quasi-cylindrically and
has a maximum external diameter of between 1 mm and 50
mm, preferably between 3 mm and 30 mm, particularly
preferably from 5 mm to 20 mm and a height of from 10 mm
to 200 mm, preferably from 30 mm to 150 mm, particularly
preferably from 50 mm to 100 mm, or
ii) has a maximum internal diameter of between 1 mm and
50 mm, preferably between 2 mm and 29 mm, particularly
preferably from 4 mm to 20 mm and a height of from 10 mm
to 200 mm, preferably from 30 mm to 150 mm, particularly
preferably from 50 mm to 100 mm and a wall thickness of
from 0.2 mm to 10 mm, preferably from 0.3 mm to 8 mm,
particularly preferably from 2 mm to 5 mm, or
iii) wherein the workpiece comprises a second
cylindrical or quasi-cylindrical appendage with a smaller
diameter and a shorter length, which has a preferably
narrow, cannula-like internal diameter of between 0.01 and
15 mm, particularly preferably between 0.05 and 4 mm, or
iv) has a volume in the range of 0.1 - 100 ml,
preferably in the range of 0.2 - 40 ml, particularly
preferably 0.5 - .2 0 ml.
6. The method as claimed in one of the preceding claims,
wherein the workpiece is shaped cylindrically or quasi-
cylindrically with a first cylindrical or quasi-
cylindrical surface and comprises a cylindrical or quasi-
cylindrical appendage with a second cylindrical or quasi-
cylindrical surface, at least one thin layer with a layer
thickness Dl being applied on the first cylindrical or
quasi-cylindrical surface and the layer being applied

3
with a thickness D2 on the second quasi-cylindrical
surface, the relation 0.2 D2/D1 being satisfied for the ratio of the thicknesses Dl and
D2.
7. The method as claimed in one of the preceding claims,
wherein the process gas is put into the treatment zone
through at least one cannula, the internal opening
diameter of which is between 0.1 and 5.0 mm, preferably
between 0.2 mm and 3.0 mm, particularly preferably
between 0.3 mm and 2.0 mm and the wall thickness of which
is between 0.05 mm and 3.0 mm, preferably between 0.1 mm
and 2.0 mm, particularly preferably between 0.15 mm and
1.0 mm.
8. The method as claimed in one of the preceding claims,
wherein the workpiece is evacuated through an opening at
a first end and the process gas is introduced through
another opening at a second end of the workpiece, which
lies opposite the first end, and wherein electromagnetic
energy is input in the axial direction, particularly
preferably axisymmetrically to the workpiece.
9. The method as claimed in one of the preceding claims,
wherein syringe bodies are plasma-treated internally.

10. The method as claimed in claim 9, wherein the cavity of
the syringe is evacuated through its plunger opening.
11. The method as claimed in claim 9 or 10, wherein the
process gas is delivered through the Luer cone of the
syringe body.

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12. The method as claimed in claim 9 or 10, wherein the
process gas is delivered through the plunger opening of
the syringe body.
13. The method as claimed in one of the preceding claims,
wherein the plasma treatment comprises at least one, and
preferably two of the steps plasma coating, plasma
activation, plasma pretreatment, plasma cleaning, plasma
immersion, plasma modification, plasma sterilization.
14. The method as claimed in one of the preceding claims,
wherein the plasma treatment is used to deposit at least
one layer which
i) has a barrier effect against gases, or
ii) has a barrier effect against constituents from the
workpiece, for example initial or byproduct or final
compounds from the production of the workpiece, or
wherein
iii) a barrier layer with a chemical barrier effect, or
iv) a scratch protection layer is deposited, or
v) a UV-reflecting or UV-absorbing layer is deposited,
or
vi) a coloring layer, preferably a blue-colored layer is
deposited, or
vii) a mirroring or blooming layer is deposited.
15. The method as claimed in one of the preceding claims,
wherein a plastic surface of the workpiece, which
contains at least one of the following materials, is
treated:
polycyclic hydrocarbons, for example cyclic polymers or
copolymers, preferably a cyclopolyolefinic copolymers or
polymers, particularly preferably COC, Topas or COP,
polycarbonates, preferably autoclavable polycarbonates,
polyethylene terephthalate (PET) or PETG, polystyrene,

5
polyethylene such as MDPE, but in particular HDPE or
LDPE, polypropylene and oriented polypropylene (o-PP), or
biaxially oriented polypropylene (BOPP), polymethyl
methacrylate, PES, polyethylene naphthalate (PEN), SAN,
polymers containing fluorine, preferably
polychlorotrifluoroethylenes (PCTFE), EVOH, polyamide,
PVC, PVDC, PMMI, PA, ABS-, MABS, PMP, PES, PSI.
16. The method as claimed in claims 1 to 14, wherein a
glass, glass-ceramic or ceramic workpiece is plasma-
treated.
17. The method as claimed in one of the preceding claims,
wherein the electromagnetic energy is injected into the
cavity by means of electrodes.
18. The method as claimed in one of the preceding claims,
wherein an axisymmetric flow of the process gas through
the cavity of the workpiece is produced, and wherein
electromagnetic energy is input in the axial direction,
particularly preferably axisymmetrically into the
workpiece.
19. The method as claimed in one of the preceding claims,
wherein at least one zone of a reactor chamber is at
least partially evacuated, a process gas is introduced
into the zone and a plasma is generated by means of
injected electromagnetic energy in the vicinity of at
least a part of the surface of the workpiece in the
process gas being introduced, the plasma being ignited by
excitation of gas in a space of the device separate from
the reactor chamber while the electromagnetic energy for
generating the plasma is injected into the process gas
being introduced.

6
20. The method for the plasma treatment of workpieces as
claimed in claim 19, wherein the plasma is ignited by
excitation of gas in a space separate from the reactor
chamber while the electromagnetic energy for generating
the plasma is injected into the process gas being
introduced, and energetic species or radiation such as
i) excited electrons
ii) excited ions
iii) excited neutral particles
iv) ultraviolet radiation
are formed during the excitation and the ignition of the
plasma is assisted by them.
21. The method as. claimed in claim 19 or 20, wherein the
plasma is ignited in the environment by means of a glow
discharge in the separate space, and wherein the glow
discharge is preferably ignited by one of the following
parameters:
i) a high voltage in the range of 0.1 kV - 100 kV
ii) an alternating current with a frequency of 0.2 kHz -
100 MHz, preferably 1 kHz - 100 kHz
iii) an rms alternating current in the range of 0.01 mA -
2A, preferably in the range of from 0.1 mA to 500 mA.
22. The method as claimed in one of the preceding claims,
wherein the electromagnetic energy is delivered through a
coaxial cable and process gas is delivered through the
inner conductor of the coaxial cable.
23. The method as claimed in one of the preceding claims,
wherein the electromagnetic energy is injected through a
coaxial cable preferably in the axial direction and the
treatment zone is evacuated through the coaxial cable.

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24. The method as claimed in one of the preceding claims,
wherein a functional layer is deposited by means of
plasma deposition on pharmaceutical packaging, in
particular a syringe body, a vial, a blood sampling tube
or a carpule, preferably with an average power of at
least 300 watts, particularly preferably at most 100
watts.
25. The method as claimed in one of the preceding claims,
wherein a layer, which contains at least one of the
substances SiOx, SiOxCy, SiOxNy, SiNy, TiOx, AlxOyNz,
AlxNz, AlxOy, CxHy, CxFy, TiNx, is deposited by the
plasma treatment.
26. The method as claimed in one of the preceding claims,
wherein a cavity of a workpiece to be treated is filled
at least partially with a filler body and the temperature
distribution on the workpiece is thereby rendered more
uniform during and after the plasma treatment.
27. A device for the plasma treatment of workpieces in the
form of hollow bodies, adapted to carry out the method as
claimed in one of the preceding claims, comprising a
reactor chamber, a treatment zone in the reactor chamber,
an instrument for at least partially evacuating the
treatment zone in the reactor chamber, an instrument for
injecting electromagnetic energy into the treatment zone
in order to generate a plasma and an instrument for
introducing process gas into the treatment zone, wherein
the instrument for introducing process gas and the
instrument for evacuating the treatment zone are arranged
so that the process gas flows through the treatment zone
between opposite ends of the zone during operation, with
a workpiece which comprises a first cylindrical or quasi-

8
cylindrical surface and a cylindrical or quasi-
cylindrical appendage with a smaller diameter and a
shorter length and a second cylindrical or quasi-
cylindrical surface, the diameter and the height of the
appendage being less than the maximum diameter and the
height by at least 20%, preferably by 50%.
28. The device as claimed in claim 25, wherein the
instrument for introducing process gas into the treatment
zone comprises at least one cannula, the opening diameter
of which is between 0.1 and 5.0 mm, preferably between
0.2 mm and 3.0 mm, particularly preferably between 0.3 mm
and 2.0 mm and the wall thickness of which is between
0.05 mm and 3.0 mm, preferably between 0.1 mm and 2.0 mm,
particularly preferably between 0.15 mm and 1.0 mm.
29. The device as claimed in one of the two preceding
claims, wherein the instrument for introducing process
gas comprises an instrument for introducing the process
gas through a further opening as a second end of the
workpiece, which lies opposite the first end.
30. The device as claimed in one of claims 27 to 29,
adapted for the internal plasma treatment of syringe
bodies.
31. The device as claimed in claim 30, which comprises a
connection instrument to connect an evacuation
instrument, for at least partially evacuating the cavity
of the syringe body, onto the plunger opening of the
syringe.
32. The device as claimed in claim 30 or 31, which
comprises an instrument for introducing the process gas

9
through the Luer cone of the syringe body.
33. The device as claimed in one of claims 27 to 32, which
comprises at least one local shield that encloses the
workpiece and locally shields zones of the cavity of the
workpiece against injected electromagnetic energy.
34. The device as claimed in one of claims 27 to 33,
adapted for the external coating of workpieces, having an
instrument for at least partially evacuating the
surroundings of a workpiece in the reactor chamber.
35. The device as claimed in one of claims 27 to 34, which
comprises reactors movable along a transport path, a
delivery position for delivering the workpieces to the
reactors, an extraction position for extracting the
workpieces from the reactors, and an instrument for
plasma treatment between the delivery and extraction
positions having an instrument for injecting
electromagnetic energy into the cavity.
36. The device as claimed in the preceding claim, wherein
the plurality of coating locations respectively comprise
separate energy sources for providing electromagnetic
energy, as well as separate antechambers which are
connected to the coating zones and to a common vacuum
generation instrument preferably through a further
chamber, and instruments for exciting the process gas,
which are respectively connected to separate second
energy sources, are respectively arranged in the
antechambers.
37. The device as claimed in one of claims 27 to 36, which
comprises a shield for the electromagnetic energy to
decouple the feed line of the reactor chamber to the

10
evacuation instrument.
38. The device as claimed in one of claims 27 to 37, which
comprises an antechamber before the reactor space, the
evacuation instrument being connected to the antechamber.
39. A device for the plasma treatment of workpieces, as
claimed in one of claims 27 to 38, having a reactor
chamber for receiving a workpiece to be coated, an
instrument for at least partially evacuating at least one
zone of the reactor chamber, an instrument for injecting
electromagnetic energy into the reactor chamber as well
as a space separate from the reactor chamber, and an
instrument for igniting the plasma in the reactor
chamber, the ignition instrument comprising an instrument
for exciting gas in the space separate from the reactor
chamber.
40. The device as claimed in claim 39, wherein the ignition
instrument comprises an instrument for generating a glow
discharge in the space separate from the reactor chamber.
41. The device as claimed in claim 40, which comprises a
preferably optical monitoring instrument for the glow
discharge.
42. The device as claimed in one of claims 27 to 41,
wherein the instrument for injecting electromagnetic
energy into the reactor chamber comprises a coaxial
cable, the coaxial cable comprising an axially extending
channel through which the process gas can be delivered.
43. The device as claimed in one of claims 27 to 42,
wherein the instrument for injecting electromagnetic
energy into the reactor chamber comprises a coaxial

11
cable, the treatment zone being evacuable through the
coaxial cable.
44. The device as claimed in claim 43, wherein an ignition
instrument, in particular an ignition electrode, is
provided for generating a glow discharge in the channel
through the inner conductor of the coaxial cable.
45. The device as claimed in one of claims 27 to 44, which
comprises a filler body that at least partially fills a
cavity of a workpiece.
46. The device as claimed in claim 45, wherein the filler
body absorbs or reflects high-frequency electromagnetic
energy.
47. The device as claimed in claim 45 or 46, wherein the
filler body prevents ignition of a plasma in the
immediate vicinity of the filled zone.
48. The device as claimed in one of claims 43 to 45,
wherein the filler body is integrated into a coaxial
inner conductor.

The invention relates to a method for the plasma treatment
of workpieces, particularly workpieces in the form of
hollow bodies, in which a treatment zone in a reactor
chamber is at least partially evacuated, a process gas is
introduced into the treatment zone, particularly into the
cavity of the workpiece, and a plasma is ignited by means
of injected electromagnetic energy in the process gas
introduced into the treatment zone, wherein the process gas
flows through the treatment zone between opposite ends of
the zone during the plasma treatment.

Documents:

http://ipindiaonline.gov.in/patentsearch/GrantedSearch/viewdoc.aspx?id=3P6bjSCG1qgVZ3xzGMgw5g==&loc=wDBSZCsAt7zoiVrqcFJsRw==


Patent Number 268371
Indian Patent Application Number 636/KOLNP/2008
PG Journal Number 35/2015
Publication Date 28-Aug-2015
Grant Date 27-Aug-2015
Date of Filing 13-Feb-2008
Name of Patentee SCHOTT AG
Applicant Address HATTENBERGSTRASSE 10, 55122 NAINZ
Inventors:
# Inventor's Name Inventor's Address
1 BICKER, MATTHIAS ULMENSTRASSE 18, 55126 MAINZ
2 LOHMEYER, MANFRED AN DER LEHNSWEIDE 49, 55299 NACKENHEIM
3 HORMES, ROBERT IM GRUN 26, 79379 MULLHEIM
PCT International Classification Number H01J 37/32
PCT International Application Number PCT/EP2006/008302
PCT International Filing date 2006-08-24
PCT Conventions:
# PCT Application Number Date of Convention Priority Country
1 10 2005 040 266.6 2005-08-24 Germany