Nano-structured Coating for Optical Displays and PV Modules
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Solution Overview
Problem
Current optical coatings for electronic displays and photovoltaic modules face challenges in achieving high light transmittance with low haze, chemical resistance, and ease of application, particularly due to the use of thick and hazy fluoropolymer coatings that are not suitable for portable devices.
Innovation Solution
A nano-structured polymeric coating with distinct particles of less than 300 nm in size, applied directly to an optically clear substrate, providing cross-linked particles that enhance light transmittance while maintaining chemical and scratch resistance, and can be formed using aqueous or solvent solutions for improved environmental and handling characteristics.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If thick fluoropolymer coatings are applied to improve chemical resistance, then chemical resistance is improved, but haze level increases and light transmittance decreases
Solution Approach 1:
The coating is segmented into distinct nano-sized particles (average size <300 nm) rather than forming a continuous thick film. This segmentation allows the coating to provide chemical resistance through particle presence while maintaining optical clarity because the particles are too small to significantly scatter visible light wavelengths
Solution Approach 2:
The particle size parameter is changed to be less than 300 nm, which is below the resolution limit of visible light scattering. This parameter change enables the coating to transition from being optically opaque (when thick and continuous) to optically clear (when nano-segmented), while still providing the desired chemical resistance
2Reliability
If conventional PVDF coatings are applied to improve durability, then chemical and scratch resistance are improved, but the coating becomes hazy and unsuitable for portable devices
Solution Approach 1:
The coating material is segmented into nano particles with average size less than 300 nm. This segmentation provides scratch resistance through the distributed particle structure while maintaining optical clarity because the particle dimensions are smaller than the wavelength of visible light, minimizing light scattering and haze
Solution Approach 2:
The coating exhibits different properties at different scales: at the nano-scale, particles provide localized protection against scratches and chemicals, while at the macro-scale (optical level), the coating remains transparent because the nano-structures are below the detection threshold of human vision and optical instruments
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 nano-structured coating achieves light transmittance greater than 93% with a haze level of less than 2%, offering improved optical clarity, chemical resistance, and ease of application, making it suitable for both electronic displays and photovoltaic modules.
Implementation Method 1
Moth-eye anti-reflective coatings, having a particulate structure have been applied to both inorganic and organic substrates by an etching process. The anti-reflective nano moth-eye structures have been developed at a small scale based on low pressure plasma or ion etching surface treatment
Implementation Method 2
The dried coating contains nano-structures that provide a very low haze level of less than 2 percent, and a light transmission improvement of at least 1% over the non-coated substrate
Data Source
AI summary
The invention relates to a thin, nano-structured coating that provides optical light efficiency enhancement. The dried coating contains nano-structures that provide a very low haze level of less than 2 percent, and a light transmission improvement of at least 1% over the non-coated substrate. For the nano-structured coating on an acrylic substrate the transmission is greater than 93 percent, and preferably greater than 94 percent. The coatings of the invention are especially useful for optical electronic displays and photovoltaic modules.