Curable Composition for Superstrate Coating
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Solution Overview
Problem
Inkjet Adaptive Planarization (IAP) requires superstrates with high flatness and super-hydrophobic, super-oleophobic surfaces, but existing perfluorinated polymer coatings are costly, difficult to handle, and have limited solubility in non-fluorinated solvents, posing challenges in filtering and processing.
Innovation Solution
A curable composition comprising a first alkyl-acrylate polymer (AAP1) and a second alkyl-acrylate polymer (AAP2) with a weight ratio of at least 2:1, along with a thermal acid generator and solvent, forms a solid polymeric layer that is cost-effective, easily processable, and provides high hydrophobicity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If perfluorinated polymer coatings are used to achieve super-hydrophobic and super-oleophobic surfaces, then the required surface properties are improved, but material costs increase and handling becomes difficult
Solution Approach 1:
The patent introduces an intermediate layer comprising a fluorine-free polymer as a mediator between the substrate and the perfluorinated polymer coating. This intermediate layer facilitates easier handling and application while maintaining the super-hydrophobic and super-oleophobic properties of the upper perfluorinated layer, thus resolving the contradiction between achieving desired surface properties and ease of handling.
Solution Approach 2:
The coating system is segmented into multiple functional layers: a fluorine-free polymer intermediate layer and a perfluorinated polymer top layer. Each layer performs specific functions - the intermediate layer provides ease of handling and adhesion, while the top layer provides the required super-hydrophobic and super-oleophobic properties, thereby resolving the contradiction through functional separation.
2Reliability
If perfluorinated polymers are used to achieve super-hydrophobic surfaces, then the required surface properties are improved, but solubility in non-fluorinated solvents deteriorates
Solution Approach 1:
The coating system is divided into two segments with different solubility characteristics: the fluorine-free polymer intermediate layer is soluble in non-fluorinated solvents, while the perfluorinated polymer top layer provides the super-hydrophobic properties. This segmentation allows the system to achieve both good solubility in non-fluorinated solvents and the required surface properties.
Solution Approach 2:
The fluorine-free polymer intermediate layer acts as an intermediary that is soluble in non-fluorinated solvents, enabling easy processing and application. This intermediate layer allows the system to maintain compatibility with non-fluorinated solvents while still achieving super-hydrophobic surface properties through the upper perfluorinated layer.
3Manufacturing precision
If perfluorinated polymer coatings are applied to achieve high flatness, then the required surface properties are improved, but filtering difficulty increases at small pore sizes
Solution Approach 1:
The coating system is segmented into a fluorine-free polymer intermediate layer and a perfluorinated polymer top layer. The fluorine-free polymer intermediate layer has better filtering characteristics at small pore sizes (10 nm and below) compared to pure perfluorinated polymer coatings, while still enabling the formation of a flat surface when combined with the perfluorinated top layer.
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 composition enables the formation of a cost-efficient, easily handled, and highly hydrophobic polymeric layer with excellent water contact angles, replacing expensive fluoropolymer coatings and simplifying the handling and processing of superstrates.
Implementation Method 1
a thermal acid generator
Implementation Method 2
a curable composition comprising a first alkyl-acrylate polymer (AAP1) consisting essentially of the elements carbon, hydrogen, and oxygen; a second alkyl-acrylate polymer (AAP2) consisting essentially of the elements carbon, hydrogen, oxygen, and fluorine
Implementation Method 3
the solid polymeric layer has a water contact angle of at least 95°
Data Source
AI summary
A curable composition can comprise a first alkyl-acrylate polymer (AAP1) consisting essentially of the elements carbon, hydrogen, and oxygen; a second alkyl-acrylate polymer (AAP2) consisting essentially of the elements carbon, hydrogen, oxygen, and fluorine; a thermal acid generator; and a solvent, wherein a weight percent ratio of AAP1 to AAP2 is at least 2:1. The curable composition can be used for coating a superstrate blank to form a coated superstrate having excellent hydrophobic surface properties.