Composite Film for Flexible Substrates via PECVD
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current flexible touch screen cover materials face limitations in wear resistance and sealing performance due to low surface hardness and water-oxygen barrier properties, leading to issues like scratches, curling, and reduced bending resistance when attempting to enhance scratch resistance by increasing thickness.
Innovation Solution
A composite film is applied to a flexible substrate using PECVD technology, comprising a nano-transition layer formed with a siloxane monomer and a diamond-like carbon film, which provides excellent scratch resistance and bending performance without the need for a hardening adhesive curing process, maintaining a thickness of up to 2 μm.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the thickness of the organic hardened layer is increased to improve scratch resistance, then the hardness and wear resistance are improved, but the curing time is lengthened and curling due to shrinkage during curing becomes more pronounced
Solution Approach 1:
The patent changes the chemical composition parameters of the hardened layer by incorporating silane crosslinking agents and specific resin systems that enable faster curing kinetics. This allows achieving the required hardness and scratch resistance with a thinner layer, thereby reducing the curing time and minimizing shrinkage-induced curling.
Solution Approach 2:
The patent employs a composite hardened layer formulation combining multiple resin components (epoxy, polyester, acrylic) with silane crosslinking agents and functional additives. This composite approach optimizes the balance between hardness, cure speed, and dimensional stability, resolving the contradiction between scratch resistance and curing time.
2Strength
If the thickness of the organic hardened layer is increased to improve scratch resistance, then the hardness and wear resistance are improved, but film peeling and cracking become more prone and bending resistance significantly reduces
Solution Approach 1:
The patent optimizes the thickness parameter of the hardened layer by formulating a high-performance composition that achieves maximum hardness and scratch resistance at minimal thickness. This prevents the layer from becoming too thick and causing peeling or cracking, thereby maintaining bending resistance and overall reliability.
Solution Approach 2:
The patent applies the hardened layer with locally optimized properties - using a thin but highly crosslinked and dense formulation that provides sufficient scratch resistance without compromising the flexibility and bending resistance of the underlying substrate.
3Ease of manufacture
If a simple organic hardened layer is used, then the manufacturing process is simple, but the hardness cannot achieve a level comparable to glass cover
Solution Approach 1:
The patent uses a composite hardened layer formulation incorporating silane crosslinking agents, polyester resins, and functional additives that collectively achieve glass-comparable hardness. This composite approach maintains relative manufacturing simplicity while dramatically improving hardness performance.
Solution Approach 2:
The patent changes the chemical and physical parameters of the hardened layer through advanced formulation - using specific resin systems, crosslinking densities, and curing conditions to achieve hardness levels comparable to glass covers while maintaining ease of application and manufacturing.
4Strength
If the thickness of the organic hardened layer is increased to improve scratch resistance, then the wear resistance is improved, but the material shrinkage during curing leads to more pronounced curling
Solution Approach 1:
The patent changes the formulation parameters to achieve high wear resistance with a thinner layer, thereby reducing the total shrinkage volume during curing. The use of silane crosslinking and optimized resin composition enables this reduction in thickness while maintaining wear resistance performance.
Solution Approach 2:
The patent introduces silane crosslinking agents as intermediaries that facilitate rapid curing and reduce shrinkage. These crosslinking agents create a dense three-dimensional network that minimizes volume change during curing, thereby reducing curling while maintaining wear resistance.
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 composite film enhances surface hardness and friction resistance, preventing curling and cracking while maintaining a low thickness, thus meeting the demands of flexible display devices with improved scratch and bending resistance.
Implementation Method 1
a nano-transition layer, which is a film layer formed on the surface of the flexible substrate by plasma enhanced chemical vapor deposition using a siloxane monomer as a reaction raw material
Implementation Method 2
a diamond-like carbon film, which is a film layer formed on a surface of the nano-transition layer by plasma enhanced chemical vapor deposition using a carbon source gas as a reaction raw material
Data Source
AI summary
A composite film applied to a flexible substrate, a preparation method thereof, and a product thereof are provided. The composite film applied to the flexible substrate is used for being formed on the surface of the flexible substrate. The composite film applied to the flexible substrate includes: a nano-transition layer, which is a film layer formed on the surface of the flexible substrate by plasma enhanced chemical vapor deposition using a siloxane monomer as a reaction raw material; and a diamond-like carbon film, which is a film layer formed on the surface of the nano-transition layer by plasma enhanced chemical vapor deposition using a carbon source gas as a reaction raw material. The surface hardness and friction resistance of the substrate can be improved, and requirements of a flexible display device are met.