Optical Element Coating with Discontinuous Pressure and Layer Segmentation
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Solution Overview
Problem
Conventional optical elements with water-repellent films, while improving wear resistance, do not provide sufficient antiweatherability, especially when used in severe exterior conditions such as vehicle-mounted view cameras, lacking favorable light resistance.
Innovation Solution
A manufacturing method for an optical element involving a stack of layers with a silicon oxide-containing layer formed prior to a fluorine compound-containing layer, utilizing a discontinuous pressure condition to enhance both antiweatherability and abrasion resistance, where the fluorine compound-containing layer has a surface with bumps and dents for improved adherence and durability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a water-repellent film with fluorine atoms is formed on the optical element, then wear resistance is improved, but antiweatherability and light resistance deteriorate
Solution Approach 1:
The coating is divided into multiple functional layers: a base layer (silicon oxide-containing layer) providing antiweatherability and light resistance, and a top layer (fluorine compound-containing layer) providing wear resistance and water repellency. This segmentation allows each layer to perform its specific function without compromising the others.
Solution Approach 2:
The silicon oxide-containing layer is formed first as a preliminary step before forming the fluorine compound-containing layer. This preliminary action ensures that the base layer with good antiweatherability is established before applying the wear-resistant fluorine layer, preventing the fluorine layer from directly contacting the optical element surface.
2Adaptability or versatility
If a single-layer fluorine coating is applied, then water repellency is achieved, but both abrasion resistance and light resistance cannot be simultaneously improved
Solution Approach 1:
The invention uses a composite coating structure combining silicon oxide-containing layer and fluorine compound-containing layer. This composite material approach allows the coating to exhibit multiple properties: the silicon oxide layer contributes to hardness, abrasion resistance, and light resistance, while the fluorine layer provides water repellency and low friction.
3Ease of manufacture
If continuous pressure condition is used during layer formation, then manufacturing process is simplified, but surface quality and layer adhesion deteriorate
Solution Approach 1:
The pressure condition is made discontinuous during the coating formation process, with periodic variations in pressure during deposition. This periodic action helps control the deposition rate and improves layer uniformity, surface quality, and adhesion between layers, while still maintaining a relatively simple manufacturing process.
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 optical element achieves enhanced antiweatherability and abrasion resistance, maintaining performance under severe conditions with improved light resistance and durability, as demonstrated by tests showing improved contact angles and resistance to abrasion and environmental degradation.
Implementation Method 1
a multi-layers forming step for forming an optical multi-layered part of the stack covering of layers, and an outermost surface forming step for forming an outermost surface part of the stack covering of layers
Data Source
AI summary
There is provided a method for manufacturing an optical element comprising a base material, and a stack covering of layers formed on the base material. The method of the present disclosure comprises a multi-layers forming step for forming an optical multi-layered part of the stack covering, and an outermost surface forming step for forming an outermost surface part of the stack covering. A pressure condition for the formation of the stack covering is made discontinuous between the multi-layers forming step and the outermost surface forming step. In the outermost surface forming step, a silicon oxide-containing layer is formed prior to a formation of a fluorine compound-containing layer.