Antibacterial Cover Window Patterning for Uniform, Durable Protection
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Solution Overview
Problem
Existing antibacterial films suffer from peeling off over time, non-uniform thickness, and decreased antibacterial performance, leading to poor uniformity and protection of the substrate.
Innovation Solution
A method of manufacturing an antibacterial cover window involving forming a mask pattern on a substrate, followed by an antibacterial layer, and then removing the mask pattern to create embossed or inlay antibacterial patterns, ensuring uniform distribution and strong bonding with the substrate.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If an antibacterial material is simply coated or jetted/sprayed onto the substrate surface, then the application process is simple and fast, but the thickness of the deposited material is non-uniform and the material peels off over time
Solution Approach 1:
The substrate surface is pre-treated with oxygen plasma before depositing the antibacterial material. This preliminary action activates the substrate surface, creating reactive groups that enhance adhesion and ensure uniform distribution of the antibacterial material, preventing peeling over time while maintaining efficient deposition
Solution Approach 2:
The conventional mechanical jetting or spraying method is replaced with atmospheric pressure plasma deposition. This substitution uses plasma chemistry rather than mechanical force to deposit the antibacterial material, achieving uniform thickness and strong adhesion without the non-uniformity and peeling issues associated with mechanical deposition
2Object-affected harmful factors
If an antibacterial film is coated on the substrate to protect the surface, then some protection is provided, but the film itself is gradually damaged over time and cannot permanently protect the product
Solution Approach 1:
The protective function and antibacterial function are merged into a single integrated layer. The antibacterial material is directly deposited onto the activated substrate surface, forming a unified structure where the antibacterial material itself provides both protection and antibacterial activity, eliminating the separate film that would peel and damage over time
Solution Approach 2:
Oxygen plasma treatment is applied as a preliminary action to activate the substrate surface before depositing the antibacterial material. This creates strong chemical bonds between the substrate and antibacterial material, ensuring the antibacterial layer remains intact and functional for extended periods, providing both protection and long-lasting antibacterial properties
3Reliability
If nanoparticles are coated on products to provide antibacterial properties, then antibacterial function is achieved, but the nanoparticles easily peel off with time and cannot perform antibacterial property after a certain period
Solution Approach 1:
Mechanical nanoparticle coating is replaced with plasma deposition of antibacterial material. The plasma process creates strong chemical adhesion between the antibacterial material and substrate, eliminating the peeling problem associated with mechanically applied nanoparticles while maintaining reliable antibacterial function over extended periods
Solution Approach 2:
Oxygen plasma treatment is performed as a preliminary action to activate the substrate surface, creating reactive groups that form strong bonds with the deposited antibacterial material. This preliminary activation ensures the antibacterial coating remains firmly attached and functional, preventing the peeling that occurs with conventional nanoparticle applications
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The method results in a cover window with long-lasting, uniform antibacterial properties and improved abrasion resistance, suitable for protective applications.
Implementation Method 1
a first step of preparing a substrate, a second step of forming a mask pattern on the substrate through a patterning process, a third step of forming an antibacterial layer on the substrate on which the mask pattern is formed, and a fourth step of removing the mask pattern
Implementation Method 2
a third step of forming an antibacterial layer on the substrate on which the mask pattern is formed
Data Source
AI summary
Disclosed is a method of manufacturing an antibacterial cover window. The method includes a first step of preparing a substrate, a second step of forming a mask pattern on the substrate through a patterning process, a third step of forming an antibacterial layer on the substrate on which the mask pattern is formed, and a fourth step of removing the mask pattern to obtain an antibacterial pattern formed on the substrate. Through the method, it is possible to produce a cover window with antibacterial patterns regularly and uniformly distributed over the entire area thereof. Thus, the cover window has long-lasting excellent antibacterial property over the entire area thereof.