Coated Substrates With Magnetron-Sputtered Oxide Topcoats
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Solution Overview
Problem
Existing functional coatings, particularly those comprising magnetron sputtered dielectric layers, are susceptible to chemical and mechanical damage during production, transport, storage, and handling, limiting their use in contact with the external environment due to insufficient mechanical, chemical, and corrosion resistance.
Innovation Solution
A coated substrate with a magnetron sputtered topcoat of a mixed metal oxide comprising SiOx, TiOy, and ZrOz, where x, y, z range from 1.8 to 2.2, with specific atomic percentages of silicon, titanium, and zirconium, and a thickness of 0.1 to 10 nm, providing enhanced mechanical and chemical durability without impacting the underlying coating's optical properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a functional coating is applied to a substrate, then optical properties are achieved, but mechanical and chemical resistance deteriorates
Solution Approach 1:
The patent applies a composite topcoat structure consisting of multiple layers with different compositions and functions. The first topcoat layer contains silicon oxide and titanium oxide for base protection, while the second topcoat layer contains zirconium oxide and titanium oxide for enhanced abrasion resistance. This multi-layer composite structure provides both mechanical durability and chemical resistance without compromising the underlying functional coating's optical properties.
2Strength
If a protective topcoat is added to enhance mechanical durability, then abrasion resistance improves, but the production process complexity increases
Solution Approach 1:
The patent combines the protective function and the decorative/optical function into an integrated coating system. The topcoat layers are designed to work together with the underlying functional coating, where the first topcoat layer (silicon oxide and titanium oxide) provides base protection and the second topcoat layer (zirconium oxide and titanium oxide) enhances abrasion resistance. This merged structure eliminates the need for separate protective treatments while maintaining optical properties.
3Strength
If a thick protective layer is applied to improve mechanical resistance, then durability against abrasion improves, but the optical properties of the underlying coating are compromised
Solution Approach 1:
The patent applies local quality by creating a gradient structure in the topcoat layers. The first topcoat layer contains silicon oxide and titanium oxide providing base protection, while the second topcoat layer contains zirconium oxide and titanium oxide specifically for enhanced abrasion resistance at the outermost surface. This localized functional distribution ensures that the protective properties are concentrated where needed while maintaining the optical properties of the underlying functional coating.
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 topcoat significantly enhances mechanical durability against abrasion and chemical resistance, maintaining the optical properties of the functional coating, even under heat treatment, while being compatible with existing production lines.
Implementation Method 1
a magnetron sputtered topcoat of a mixed metal oxide comprising at least SiOx, TiOy, and ZrOz
Data Source
AI summary
The present invention relates to coated substrate comprising a transparent substrate having two major opposing first and second surfaces, wherein at least one surface is provided with a functional coating, characterized in that the transparent substrate is provided, above and in contact with the functional coating, with a magnetron sputtered topcoat of a mixed metal oxide comprising at least SiOx, TiOy, and ZrOz wherein x, y, z range from 1.8 to 2.2, wherein the topcoat comprises from 10 to 65 at% silicon, from 8 to 38 at% titanium, from 25 to 80 at% zirconium, for a total of 100 at% of the metals, and wherein the topcoat has a thickness from 0.1 to 10 nm, to methods to provide for said coated substrates and to uses thereof.