Foldable Photopatternable Siloxane Hard Coatings With Abrasion Resistance
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Solution Overview
Problem
Existing hard coating technologies for plastics used in flexible electronics fail to provide adequate abrasion resistance, flexibility, and photopatternability, while existing siloxane resins are difficult to process into flexible and foldable coatings.
Innovation Solution
A layered structure comprising a substrate and a siloxane polymer layer is developed, achieved by depositing a composition of at least three different silane monomers, including a bi-silane with an active group for cross-linking, which are partially hydrolyzed and polymerized to form a cross-linked siloxane polymer layer, allowing the structure to be bent without breaking and exhibiting high surface hardness and adhesion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If organic hard coating materials (acryl, urethane, melamine) are used to provide flexibility and moldability, then flexibility and ease of processing are improved, but surface hardness and abrasion resistance deteriorate
Solution Approach 1:
The patent uses organic-inorganic hybrid materials combining siloxane resin (inorganic) with organic functional groups. The siloxane backbone provides surface hardness and abrasion resistance, while organic functional groups (epoxy, alicyclic epoxy, vinyl, acrylate, methacrylate) provide flexibility and moldability. This composite structure resolves the contradiction by integrating benefits of both material types at molecular level.
Solution Approach 2:
The patent modifies the chemical composition parameters of the siloxane resin by incorporating specific functional groups with defined molecular structures. By controlling the types and ratios of functional groups (epoxy, vinyl, acrylate, etc.), the material achieves optimal balance between surface hardness and flexibility for flexible electronic devices.
2Strength
If silicon-based inorganic materials are used to provide high surface hardness and transparency, then surface hardness and optical properties are improved, but flexibility and moldability deteriorate
Solution Approach 1:
The patent creates organic-inorganic hybrid siloxane materials where the inorganic siloxane backbone (Si-O-Si structure) provides surface hardness and transparency, while organic functional groups attached to silicon atoms provide flexibility. This molecular-level composite structure allows the material to exhibit both inorganic hardness and organic flexibility simultaneously.
Solution Approach 2:
The patent changes the chemical structure parameters of siloxane resin by introducing flexible organic functional groups (epoxy, vinyl, acrylate, methacrylate) with specific molecular configurations. These parameter changes enable the rigid siloxane backbone to gain flexibility while maintaining surface hardness, making it suitable for foldable flexible electronic devices.
3Strength
If conventional siloxane resins are used to achieve high surface hardness, then abrasion resistance is improved, but processability into flexible and foldable coatings deteriorates
Solution Approach 1:
The patent modifies the molecular weight, functional group composition, and cross-linking density parameters of siloxane resin to optimize processability. By controlling these parameters, the resin achieves appropriate viscosity for coating application and forms flexible films that can be folded without cracking, while maintaining high abrasion resistance through the siloxane backbone structure.
Solution Approach 2:
The patent introduces different functional groups at different molecular locations within the siloxane structure. The siloxane backbone provides local hardness for abrasion resistance, while peripheral organic functional groups provide local flexibility and processability. This spatial differentiation of material properties resolves the contradiction between hardness and processability.
4Illumination intensity
If transparent plastics (PET, PI, PC, PMMA) are used to provide high light transmittance and suitable refractive index, then optical properties are improved, but abrasion resistance deteriorates
Solution Approach 1:
The patent creates organic-inorganic hybrid siloxane coatings that can be applied on transparent plastic substrates. The siloxane coating layer provides abrasion resistance while maintaining high light transmittance due to its optical transparency. This composite structure protects the underlying transparent plastic without compromising its optical properties.
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 siloxane polymer layer achieves a thickness of 1 to 50 μm, capable of bending without breaking, with a surface hardness greater than 3H and excellent adhesion, providing scratch and abrasion resistance, suitable for flexible electronic devices.
Implementation Method 1
at least partially hydrolyzed and polymerized
Implementation Method 2
hydrolyzed and polymerized to form a cross-linked siloxane polymer layer
Implementation Method 3
cross-linking the siloxane polymer chains so as to achieve a cross-linked siloxane polymer layer
Data Source
AI summary
A layered structure comprising a substrate layer; and a layer of a siloxane polymer on the substrate layer, the layered structure being capable of being bent about a mandrel having a radius of curvature without breaking. The layer of the siloxane polymer has a thickness of 1 to 50 μm, in particular about 5 to 20 μm, and it is obtained by depositing on the substrate a composition comprising at least three different silane monomers, including at least one bi-silane; at least one of the silane monomers having an active group capable of achieving cross-linking to adjacent siloxane polymer; at least partially hydrolyzing the silane monomers to form siloxane polymer chains; and cross-linking the siloxane polymer chains so as to achieve a cross-linked siloxane polymer layer on the substrate.