Multilayer Diamond Display System Scratch Resistance

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Solution Overview

Problem

Practical applications of diamond-based semiconductor devices for consumer electronic components, such as displays and lenses, are limited due to stringent design requirements like increased hardness and water resistance, which existing technologies have not adequately addressed.

Innovation Solution

A multilayer diamond display system is developed, comprising an optical grade silicon substrate, a transparent titanium dioxide layer, and a polycrystalline diamond layer, where the diamond layer is deposited on an optically transparent intermediate layer, with diamond grains sized between 2 nm and 1 micron, enhancing scratch resistance and optical transparency.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If diamond-based semiconductor devices are used for consumer electronic components, then hardness and scratch resistance are improved, but manufacturing complexity and design requirements increase

Engineering Contradiction:

ImprovehardnessVSAvoiddesign requirements

Core Design Contradiction:

StrengthVSDevice complexity

Solution Approach 1:

The patent applies composite materials by combining diamond layers with other materials (such as silicon substrates, transparent conductive oxides, and organic light-emitting layers) to create a multilayer structure that achieves both the desired hardness and scratch resistance while maintaining compatibility with existing consumer electronic component manufacturing processes. The diamond layer serves as a protective coating that enhances mechanical properties without requiring complete redesign of the underlying device architecture.

Inventive Principle:

Principle #40Composite materials

2Strength

If diamond layers are deposited on substrates, then scratch resistance is improved, but optical transparency may be compromised

Engineering Contradiction:

Improvescratch resistanceVSAvoidoptical transparency

Core Design Contradiction:

StrengthVSIllumination intensity

Solution Approach 1:

The patent applies parameter changes by carefully controlling diamond layer thickness (typically in the range of nanometers to a few micrometers), grain size (ultrananocrystalline to nanocrystalline ranges), and deposition conditions to optimize both scratch resistance and optical transparency. By adjusting these parameters, the diamond coating provides protective mechanical properties while maintaining sufficient light transmission for display applications.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent applies local quality by creating diamond coatings with spatially varying properties - such as gradient thickness or controlled grain size distribution - to achieve optimal balance between scratch resistance in high-stress areas and optical transparency in light-transmission areas, allowing different regions of the diamond layer to serve different functional requirements.

Inventive Principle:

Principle #3Local quality

3Temperature

If multilayer diamond structure is implemented, then thermal conductivity is improved, but manufacturing process complexity increases

Engineering Contradiction:

Improvethermal conductivityVSAvoidmanufacturing process complexity

Core Design Contradiction:

TemperatureVSEase of manufacture

Solution Approach 1:

The patent applies segmentation by dividing the diamond coating into multiple discrete layers with different thicknesses, grain sizes, or orientations, where each layer serves a specific thermal management function. This segmented approach allows optimization of thermal conductivity through the stack while using standardized deposition processes for each individual layer, making the manufacturing more manageable despite the multilayer complexity.

Inventive Principle:

Principle #1Segmentation

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 multilayer diamond display system achieves high transmittance and mechanical strength, meeting or exceeding the specifications of existing display glass, with improved thermal conductivity and reduced thermal budget, while maintaining optical clarity and durability.

Implementation Method 1

a polycrystalline diamond layer, wherein the transparent layer is between the substrate layer and the polycrystalline diamond layer

Methodology Applied

Scientific EffectPhysical Vapour Deposition: Physical Vapour Deposition

Implementation Method 2

forming a nanocrystalline diamond layer on the titanium dioxide layer

Methodology Applied

Scientific EffectChemical Vapour Deposition: Chemical Vapour Deposition

Data Source

PatentUS20230091473A1Multilayer Diamond Display System and Method

Publication Date: 2023.03.23 AKHAN SEMICONDUCTOR INC

AI summary

A multilayer diamond system includes an optically transparent substrate and an optically transparent intermediate layer deposited on the optically transparent substrate. A diamond layer is deposited on the optically transparent intermediate layer and formed from diamond having at least 50% of diamond grains sized between 2 nm and 500 nanometers.