Easy-to-Clean Optical Coating with Adhesion Layer

Solution Overview

Problem

Lubricous optical coatings on substrates are susceptible to abrasion damage, which degrades their durability and leads to flaking, oxidation, and reduced mechanical strength, compromising their protective and optical properties.

Innovation Solution

A coated article comprising a substrate with an optical coating that includes an optical stack, an adhesion coating with an alumina and silica layer, and an easy-to-clean coating, where the adhesion coating is positioned between the optical stack and the easy-to-clean coating, enhancing mechanical durability and resistance to abrasion.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of operation

If a lubricous optical coating is applied to provide a smooth feel and optical characteristics, then the surface quality and user experience are improved, but the coating becomes more susceptible to abrasion damage and reduces mechanical durability

Engineering Contradiction:

Improvesurface smoothnessVSAvoidabrasion resistance

Core Design Contradiction:

Ease of operationVSReliability

Solution Approach 1:

The coating system is segmented into multiple functional layers: a hard undercoating layer (alumina, silica, or diamond-like carbon) providing abrasion resistance, and a separate lubricous top coating layer providing smoothness. This segmentation allows each layer to optimize its specific function without compromising the other.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The invention uses composite material structure combining a hard inorganic undercoating (alumina, silica, or diamond-like carbon) with an organic lubricous coating layer. This composite structure integrates the advantages of both material types: hardness and abrasion resistance from the inorganic layer, and lubricity from the organic layer.

Inventive Principle:

Principle #40Composite materials

2Strength

If a lubricous coating is applied to reduce checking and improve strength, then the mechanical properties are enhanced, but the coating becomes more vulnerable to abrasion damage and oxidation over time

Engineering Contradiction:

Improvescratch resistanceVSAvoidabrasion damage susceptibility

Core Design Contradiction:

StrengthVSObject-affected harmful factors

Solution Approach 1:

The coating system is segmented into multiple functional layers: a hard undercoating layer (alumina, silica, or diamond-like carbon) providing abrasion resistance, and a separate lubricous top coating layer providing smoothness. This segmentation allows each layer to optimize its specific function without compromising the other.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The hard undercoating layer acts as an intermediary protective barrier between the substrate and the lubricous top coating, shielding the lubricous material from direct abrasion exposure while allowing it to maintain its lubricity function.

Inventive Principle:

Principle #24Intermediary (Mediator)

3Ease of manufacture

If a single-layer lubricous coating is used to achieve easy cleaning properties, then the manufacturing process is simplified, but the coating suffers from poor adhesion and reduced durability

Engineering Contradiction:

Improvecoating process simplicityVSAvoidcoating adhesion

Core Design Contradiction:

Ease of manufactureVSReliability

Solution Approach 1:

The coating system is segmented into multiple functional layers: a hard undercoating layer (alumina, silica, or diamond-like carbon) providing abrasion resistance, and a separate lubricous top coating layer providing smoothness. This segmentation allows each layer to optimize its specific function without compromising the other.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The invention uses composite material structure combining a hard inorganic undercoating (alumina, silica, or diamond-like carbon) with an organic lubricous coating layer. This composite structure integrates the advantages of both material types: hardness and abrasion resistance from the inorganic layer, and lubricity from the organic layer.

Inventive Principle:

Principle #40Composite materials

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 solution provides improved mechanical durability and resistance to abrasion, maintaining the optical properties and lubricous feel of the coating, as evidenced by increased hardness and retention of water contact angle after abrasion testing.

Implementation Method 1

A coated article may comprise a substrate and an optical coating deposited on the substrate

Methodology Applied

Scientific EffectPhysical vapor deposition: Physical Vapour Deposition

Data Source

PatentUS10578777B2Coated articles that include easy-to-clean coatings

Publication Date: 2020.03.03 CORNING INC

AI summary

According to one or more embodiments disclosed herein, a coated article may include a substrate and an optical coating. The optical coating may be disposed on a major surface of the substrate and may form an air-side surface. The optical coating may include an optical stack, an adhesion coating, and an easy-to-clean coating. The adhesion coating may comprise an alumina layer and a silica layer. The present disclosure is also directed to methods for depositing optical coatings on substrates and to consumer electronic products which include the coated articles.