Sequential Optical and ETC Coating on Glass
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current processes for applying antireflection (AR) and easy-to-clean (ETC) coatings on glass articles require separate manufacturing runs and equipment, leading to increased yield losses, contamination, and higher product costs due to extra handling steps, which results in poor reliability and durability of the final product.
Innovation Solution
A process and apparatus that allow for the sequential application of optical and ETC coatings using the same equipment, utilizing a substrate carrier with magnets and adhesive material, and a coating apparatus with a vacuum chamber, plasma source, and e-beam sources to apply coatings uniformly without exposing them to air, enhancing abrasion resistance and reducing handling-related issues.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If separate equipment and manufacturing runs are used for applying AR and ETC coatings, then each coating can be applied with specialized equipment, but yield losses increase, contamination occurs, and handling-related issues arise
Solution Approach 1:
The patent combines the AR coating and ETC coating processes into a single integrated manufacturing run using one equipment system. The apparatus can sequentially apply both coatings without transferring the glass article between different equipment, eliminating handling steps and reducing contamination risks while maintaining the specialized coating application capabilities for both coating types.
Solution Approach 2:
The coating apparatus is designed with multi-functionality to perform both AR coating and ETC coating operations. The system includes multiple e-beam sources and thermal evaporation sources that can be configured to apply different coating materials (optical coatings and fluorinated ETC coatings) sequentially on the same glass article within a single vacuum chamber environment.
2Ease of manufacture
If multiple handling steps are introduced between AR and ETC coating procedures, then coating application can be completed, but contamination increases and product costs rise
Solution Approach 1:
By combining both coating procedures into a single continuous manufacturing run within one vacuum chamber, the patent eliminates the need to transfer glass articles between different equipment. This merging of processes prevents surface contamination that would occur during handling and transfer operations while still completing both AR and ETC coating applications.
3Manufacturing precision
If conventional 2-step coating process is used with separate equipment, then AR and ETC coatings can be applied, but extra handling increases yield losses and reduces product reliability
Solution Approach 1:
The patent merges the AR and ETC coating processes into a single integrated operation where both coatings are applied sequentially in the same vacuum chamber without transferring the glass article. This approach maintains the precision and quality of both coating applications while eliminating yield losses associated with handling and transfer between separate equipment.
4Manufacturing precision
If separate manufacturing runs are used for AR and ETC coatings, then each coating can be optimized independently, but additional cleaning steps are required and costs increase
Solution Approach 1:
The patent combines both coating processes into a single manufacturing run where AR and ETC coatings are applied sequentially in the same vacuum chamber. This merging maintains the ability to optimize each coating independently through controlled deposition parameters while eliminating the need for additional cleaning steps that would be required between separate manufacturing runs.
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 achieves improved abrasion resistance and durability of glass articles by applying coatings in a single, shadow-free process, reducing contamination and handling-related losses, and maintaining the optical performance of the coatings, with the ETC coating providing lubrication and enhanced scratch resistance.
Implementation Method 1
an e-beam source positioned in the vacuum chamber and oriented to direct an electron beam onto the optical coating material
Implementation Method 2
vaporizing the optical coating material
Implementation Method 3
a thermal evaporation source positioned in the vacuum chamber for vaporizing ETC coating material
Implementation Method 4
a plasma source positioned within the vacuum chamber and substantially vertically oriented to direct plasma onto an underside of the rotatable dome
Data Source
AI summary
This disclosure is directed to an improved process for making glass articles having optical coating and easy-to clean coating thereon, an apparatus for the process and a product made using the process. In particular, the disclosure is directed to a process in which the application of the optical coating and the easy-to-clean coating can be sequentially applied using a single apparatus. Using the combination of the coating apparatus and the substrate carrier described herein results in a glass article having both optical and easy-to-clean coating that have improved scratch resistance durability and optical performance, and in addition the resulting articles are “shadow free.”