Multilayer Composite Coating for Low-Temperature Dip Coating
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Solution Overview
Problem
Current antireflective coatings are not cost-effective for complex curved substrates, require high-temperature sintering that can damage plastic substrates, or are expensive due to chemical vapor deposition methods, and lack low-temperature thermally curable compositions suitable for dip coating applications.
Innovation Solution
A multilayered composite article with an abrasion-resistant layer having a high refractive index and an antireflection layer with a low refractive index, comprising inorganic oxide nanoparticles and a fluorosilane polymer, respectively, which can be thermally cured at relatively low temperatures and applied using dip coating methods.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If high-temperature sintering is used to create antireflective coatings, then the coating achieves good antireflective properties, but the substrate may be damaged due to the high temperature
Solution Approach 1:
The patent changes the curing temperature parameter from high-temperature sintering to low-temperature thermal curing, enabling the coating process to be compatible with plastic substrates that cannot withstand high temperatures while still achieving functional curing of the antireflective coating
Solution Approach 2:
The patent uses a composite coating system consisting of an abrasion-resistant inorganic layer and an organic antireflective layer, where the inorganic layer provides thermal stability and the organic layer provides antireflective properties, allowing low-temperature curing without compromising overall coating performance
2Reliability
If chemical vapor deposition is used to apply antireflective coatings, then the coating achieves good antireflective properties, but the manufacturing cost increases significantly
Solution Approach 1:
The patent replaces expensive chemical vapor deposition equipment and processes with simpler, more cost-effective dip-coating or spray-coating methods, using inexpensive organic coating materials that can be applied and cured in standard manufacturing equipment
Solution Approach 2:
The patent substitutes the complex mechanical and chemical vapor deposition system with a simpler liquid coating application system, replacing CVD equipment with standard coating applicators and using liquid precursor solutions instead of vapor-phase reactants
3Device complexity
If a single-layer coating is used, then the manufacturing process is simplified, but the coating cannot simultaneously provide both abrasion resistance and antireflective properties
Solution Approach 1:
The patent divides the coating system into two distinct functional layers: an abrasion-resistant inorganic layer and an organic antireflective layer, allowing each layer to optimize its specific function while working together as an integrated coating system
Solution Approach 2:
The patent assigns different material properties to different layers: the inorganic layer has high hardness and abrasion resistance, while the organic layer has low refractive index for antireflective properties, with each layer locally optimized for its specific function
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 a cost-effective, abrasion-resistant, antireflective, and easy-to-clean coating suitable for complex substrates, maintaining durability and optical properties while being compatible with low-temperature processing.
Implementation Method 1
an antireflection layer adjacent to the abrasion-resistant layer opposite the substrate, wherein the antireflection layer has an index of refraction less than 1.48
Implementation Method 2
an abrasion-resistant layer adjacent to the substrate, wherein the abrasion-resistant layer has an index of refraction greater than 1.55, wherein the abrasion-resistant layer comprises inorganic oxide nanoparticles
Data Source
AI summary
Described herein is composite article comprising a substrate; and on at least one face of the substrate a multilayered coating disposed thereon. The multilayered coating comprises (i) an abrasion-resistant layer adjacent to the substrate, wherein the abrasion-resistant layer comprises inorganic oxide nanoparticles and a polymer binder; and (ii) an antireflection layer adjacent to the abrasion-resistant layer opposite the substrate, wherein the antireflection layer comprises a fluorosilane polymer, wherein the fluorosilane polymer comprises: at least one monomeric unit A represented by the formula (I) wherein R1 represents H or methyl, L1 represents a covalent bond or a divalent aliphatic group having from 1 to 10 carbon atoms, each Y1 independently represents a hydrocarbyl group having from 1 to 6 carbon atoms, each Y2 independently represents a hydrolyzable group, g is 0, 1, or 2; and at least one divalent monomeric unit B represented by the formula (I) wherein R2, R3, and R4 represent H, methyl, trifluoromethyl, or F, wherein at least one of R2, R3, and R4 is F, Rf1 represents a covalent bond or a divalent group selected from the group consisting of —(CF2O)a—, —(CF2CF2O)b—, —(CF2CF2CF2O)c—, —(CF2CF2CF2CF2O)d—, —(CF2CF(CF3)O)e—, and combinations thereof, wherein a, b, c, d, and e represent integers in the range of from 0 to 130, and wherein 1≤a+b+c+d+e≤130, and Rf2 is a perfluoroalkyl group.