Functional Membrane Stair-Shaped Structure for Rub Resistance
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Solution Overview
Problem
Current manufacturing methods for functional membranes with fine uneven structures fail to achieve high rub resistance and super water repellency while maintaining low reflectance, often requiring multiple mask formations and being cost-inefficient.
Innovation Solution
A manufacturing method involving a single mask forming step and etching step to create a stair-shaped fine uneven structure with specific dimensions, using an inorganic material and a reflectance adjustment layer to achieve high rub resistance and super water repellency, while reducing costs through minimized mask formation processes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multiple mask formations are performed to create fine uneven structures, then rub resistance and durability are improved, but manufacturing cost and process complexity increase
Solution Approach 1:
The patent divides the mask formation process into two distinct stages: a first mask formation step that creates an initial mask pattern, and a second mask formation step that creates a refined mask pattern. This segmentation allows each step to serve a specific function - the first step establishes the basic structure while the second step optimizes the fine uneven features, achieving high rub resistance without requiring multiple repeated formations
Solution Approach 2:
The first mask formation step performs a preliminary action by creating an initial mask pattern that guides the formation of the fine uneven structure. This preliminary mask serves as a foundation for the second mask formation, allowing the final fine features to be created more efficiently with fewer iterations and lower cost
2Object-affected harmful factors
If fine uneven structures with small heights are formed, then super water repellency is achieved, but rub resistance decreases
Solution Approach 1:
The patent creates a composite structure combining the fine uneven structure (protruding portions with height of 1 μm or less) with a water-repellent coating layer. This composite approach allows the fine uneven structure to provide super water repellency through its geometric features while the water-repellent coating enhances both water repellency and rub resistance, resolving the contradiction between small height requirements and durability
Solution Approach 2:
The patent applies different properties to different parts of the structure: the fine uneven structure (protruding portions) provides the geometric basis for water repellency, while the water-repellent coating layer provides the chemical properties for enhanced water repellency and mechanical durability. This local differentiation of functions allows simultaneous achievement of super water repellency and high rub resistance
3Strength
If base materials with high reflectance are used, then structural strength is improved, but optical performance deteriorates
Solution Approach 1:
The patent introduces a water-repellent coating layer as an intermediary between the base material and the external environment. This coating layer serves multiple functions: it maintains the structural strength of the high-reflectance base material while providing super water repellency and reducing the effective reflectance that interacts with external media, thus mediating between structural requirements and optical performance
Data Source
AI summary
A manufacturing method of a functional membrane which contains an inorganic material and has a fine uneven structure on a surface thereof, includes a single mask forming step and an etching step, wherein a plurality of protruding portions which constitute the fine uneven structure are formed in a stair shape having one or more stairs in a vertical cross-sectional shape of the functional membrane along a thickness direction of the functional membrane, when Mohs hardness of the inorganic material is denoted as X and the number of the stairs of the protruding portions is denoted as Y, following formula (I) is satisfied, and an average height from the lowest bottom surface of the protruding portions of the lowermost stair to the highest top surface of the protruding portions of the uppermost stair is 1 μm or less.10≦X×YFormula (I)