Copper-Doped Zirconium Oxide Coating for High-Temperature Scratch Resistance
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Solution Overview
Problem
Conventional scratch-resistant coatings, such as diamond-like carbon (DLC), are not capable of withstanding high-temperature heat treatments required for tempering or strengthening glass, as they oxidize and burn off, rendering them unsuitable for applications like vehicle windows and tempered glass articles.
Innovation Solution
A method involving a copper-doped zirconium oxide or nitride layer on a glass substrate, which undergoes heat treatment to transform into a copper-doped zirconium oxide layer, providing enhanced scratch and corrosion resistance while maintaining stability at high temperatures.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If diamond-like carbon (DLC) coating is applied to provide scratch resistance, then scratch resistance is improved, but the coating cannot withstand high-temperature heat treatment and oxidizes/burns off
Solution Approach 1:
The patent changes the material composition parameters by doping zirconium oxide with copper (1-50 atomic percent Cu) to create a coating that maintains structural integrity and scratch resistance at high temperatures up to 600°C, unlike conventional DLC coatings that decompose below 400°C
Solution Approach 2:
The patent creates a composite material system combining zirconium oxide as the base material with copper dopant, forming a chemically stable composite coating that provides both scratch resistance and thermal stability simultaneously
2Strength
If conventional coatings are used to protect glass substrates, then scratch resistance is provided, but corrosion resistance and chemical stability at high temperatures are insufficient
Solution Approach 1:
The patent modifies the chemical composition parameters by incorporating copper-doped zirconium oxide with specific stoichiometry (Zr1-xCuxOy where x=0.01-0.50) to achieve enhanced chemical stability and corrosion resistance while maintaining scratch resistance
Solution Approach 2:
The patent applies different functional properties to different aspects of the coating: copper doping provides corrosion resistance and chemical stability, while the zirconium oxide matrix provides scratch resistance and mechanical durability
3Strength
If heat treatment is applied to temper or strengthen glass substrates, then strength and durability are improved, but conventional protective coatings oxidize and burn off during the process
Solution Approach 1:
The copper-doped zirconium oxide coating creates a chemically inert environment that resists oxidation during heat treatment, allowing the coating to survive tempering processes at 580-600°C without burning off like conventional organic coatings
Solution Approach 2:
The patent replaces conventional short-lived organic coatings (DLC) that decompose at low temperatures with a thermally stable inorganic coating that can withstand high-temperature heat treatment processes
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 copper-doped zirconium oxide layer significantly improves scratch resistance and corrosion resistance, allowing for heat-treated glass articles that are more durable and resistant to thermal processes, with improved chemical stability and transmission properties.
Implementation Method 1
heat treating a glass substrate coated with at least a layer comprising zirconium (Zr) oxide and/or nitride doped with copper (Cu)
Implementation Method 2
Following heat treatment, the coated article includes a glass substrate supporting at least a layer comprising zirconium oxide doped with copper
Implementation Method 3
DLC may be used to generate energy during HT, e.g., due to its combustion during HT, for transforming at least another layer in the coating
Implementation Method 4
DLC tends to oxidize and burn off at temperatures of from approximately 350 degrees C (possibly from 380 to 400 degrees C) or higher
Data Source
Figure 1~2
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Figure 4
AI summary
In certain example embodiments, a coated article includes a copper-doped zirconium based layer before heat treatment (HT). The coated article is heat treated sufficiently to cause the copper-doped zirconium oxide and/or nitride based layer to result in a copper-doped zirconium oxide based layer that is scratch resistant and/or chemically durable. The doping of the layer with copper has been found to improve scratch resistance.