Half Mirror Plating via Selective Masking and Thickness Control

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Solution Overview

Problem

Existing methods for producing half mirrors face challenges in controlling transmittance and manufacturability, particularly due to difficulties in accurately controlling film thickness across the entire surface of a transparent plate.

Innovation Solution

A method involving selective plating on a transparent plate, where a masking step forms a lattice-shaped transmission region and reflection region, allowing for precise control of transmittance by adjusting the width and pitch of these regions, and including a plating step where only the reflection region is coated with a metal material, followed by a plating removing step to expose the masking material, simplifying the manufacturing process.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If the transmittance is set by controlling the film thickness of the plating, then the transmittance can be adjusted, but there is a difficulty in controlling film thickness and a decrease in manufacturability

Engineering Contradiction:
Improvetransmittance controlVSAvoidmanufacturability
Core Design Contradiction:
Manufacturing precisionVSEase of manufacture

Solution Approach 1:

The patent divides the transparent plate surface into multiple regions with different plating thicknesses or plating materials. By segmenting the plating process into different zones (first plating layer in certain regions, second plating layer in other regions), the patent achieves precise control over transmittance in different areas without requiring uniform film thickness control across the entire surface, thereby improving manufacturability.

Inventive Principle:
Principle #1Segmentation

Solution Approach 2:

The patent applies different plating characteristics (thickness, material composition) to different regions of the transparent plate based on local requirements. The first plating layer is applied in regions requiring specific optical properties, while the second plating layer is applied in other regions, allowing each region to have optimized local quality for its intended function, thus avoiding the need for precise global film thickness control.

Inventive Principle:
Principle #3Local quality

2Reliability

If plating is performed on the entire surface of the transparent plate, then complete coverage is achieved, but the complexity of film thickness control increases

Engineering Contradiction:
Improveplating coverageVSAvoidfilm thickness control complexity
Core Design Contradiction:
ReliabilityVSDevice complexity

Solution Approach 1:

The patent segments the plating process into multiple stages and regions. Instead of applying a single uniform plating layer across the entire surface, the patent performs plating in different regions sequentially or simultaneously with different parameters, reducing the complexity of controlling film thickness across the whole surface while ensuring reliable coverage in each segment.

Inventive Principle:
Principle #1Segmentation

Solution Approach 2:

The patent applies plating selectively to certain regions rather than uniformly across the entire surface. By performing partial plating actions in specific zones where needed, the patent achieves sufficient coverage for functional requirements without the complexity of controlling film thickness over the complete surface area.

Inventive Principle:
Principle #16Partial or excessive action

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

This approach enables easy setting of transmittance and improves manufacturability by reducing the complexity of film thickness control, allowing for efficient production of half mirrors with predetermined transmittance values and enhancing the expression of depth in lighting applications.

Implementation Method 1

a first plating 8a having a first plating thickness ta1 which is not less than a thickness of the masking material 7 is vapor-deposited

Methodology Applied
Scientific EffectVapor deposition: Physical Vapour Deposition

Data Source

PatentUS11624860B2Light body
Publication Date: 2023.04.11 HONDA MOTOR CO LTD
  • US11624860B2 patent drawing
  • US11624860B2 patent drawing
  • US11624860B2 patent drawing

AI summary

A method for producing a half mirror includes forming a reflection region by which light is reflected and a transmission region through which the light is transmitted on a surface of a transparent plate Only the reflection region is coated with a plating. The coating includes a masking step of coating a position of the transparent plate corresponding to the transmission region with a masking material, a plating step of coating the entire surface which includes the transmission region which has been coated with the masking material and the reflection region with the plating, a plating removing step of removing the plating to a depth in which the masking material is exposed after the plating step, and a masking material removing step of removing the masking material after the plating removing step.