Optical Member Curved Surface Antireflection Hydrothermal Aluminum
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Solution Overview
Problem
Existing optical members with fine concave-convex surfaces struggle with antireflection on substrates with partially curved surfaces, as conventional methods like liquid-phase film forming are incompatible and result in poor adhesion and coating properties, especially when trying to deposit aluminum or alumina without breaking vacuum.
Innovation Solution
An optical member with a substrate having a partially curved surface, featuring a concave-convex structure formed by hydrothermal treatment of a gas-phase deposited aluminum or aluminum compound layer, and a dielectric layer deposited between the substrate and the concave-convex structure, allowing for controlled film thickness and high adhesion without vacuum breakage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If liquid-phase film forming method is used to form fine concavity and convexity, then the antireflection effect is achieved, but the method is incompatible with conventional oxide thin film lamination and requires additional steps
Solution Approach 1:
The patent combines the formation of the fine concave-convex structure and the oxide thin film deposition into a single integrated process using sol-gel method. The sol-gel solution is applied to form the concave-convex structure, and then the oxide thin film is deposited over it in the same manufacturing sequence, eliminating the need for separate liquid-phase film forming steps and making it compatible with conventional oxide thin film lamination processes
2Shape
If liquid-phase film forming method is used, then fine concave-convex structure is formed, but film adhesion and coating properties on concave structures are poor
Solution Approach 1:
The patent changes the physical and chemical parameters of the film formation process by using sol-gel method with controlled hydrolysis and condensation reactions. By adjusting parameters such as solution composition, pH, temperature, and drying conditions, the method achieves excellent film adhesion on concave surfaces while maintaining the desired fine concave-convex structure
3Adaptability or versatility
If substrate with curved surface is used, then optical application is enabled, but antireflection effect on entire surface is difficult to achieve
Solution Approach 1:
The sol-gel method employed in the patent is universally applicable to various substrate geometries including flat, curved, and complex three-dimensional surfaces. The solution can uniformly coat the entire surface regardless of curvature, and the subsequent heat treatment process works effectively on all surface types, enabling consistent antireflection performance across the entire substrate surface
4Shape
If conventional methods are used for curved substrates, then substrate fabrication is possible, but film thickness control is difficult
Solution Approach 1:
The patent achieves precise film thickness control by carefully controlling the sol-gel process parameters including solution concentration, deposition conditions, drying temperature, and heat treatment conditions. These parameter changes enable uniform and controllable film thickness even on curved substrates with varying surface geometries
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 effective antireflection across the entire or specific parts of the substrate surface, even with curved substrates, while ensuring high film adhesion and controlled thickness, and allows for gas-phase deposition of aluminum or alumina without vacuum interruption, enhancing the optical member's performance and manufacturing efficiency.
Implementation Method 1
a concave-convex structure at an outermost surface, the concave-convex structure being prepared by hydrothermal treatment of a layer formed by gas-phase deposition of at least one of simple aluminum and a compound containing aluminum on the substrate
Implementation Method 2
the concave-convex structure being prepared by hydrothermal treatment of a layer formed by gas-phase deposition
Data Source
AI summary
Provided is an optical member, including: a substrate having an at least partially curved surface; a concave-convex structure at an outermost surface, the concave-convex structure being prepared by hydrothermal treatment of a layer formed by gas-phase deposition of at least one of simple aluminum and a compound containing aluminum on the substrate; and a dielectric layer formed by gas-phase deposition between the substrate and the concave-convex structure.