Plasma Hard Coating on Plastic Substrate with Adhesion Base Layer
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Solution Overview
Problem
Transparent hard coatings on plastic substrates face issues with adhesion and optical properties when deposited directly, requiring an intermediate layer to enhance adhesion and optics.
Innovation Solution
A coated substrate configuration with a soft layer, a hard basecoat, and a plasma-enhanced chemical vapor deposited hard coating, where the soft layer includes UV absorbers and stabilizers, and the hard basecoat provides improved adhesion and stress accommodation, while the hard coating offers superior durability and abrasion resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a hard coating is deposited directly on a bare plastic substrate, then the coating provides abrasion resistance and weatherability, but the adhesion of the hard coating to the substrate is limited
Solution Approach 1:
A base layer is introduced between the plastic substrate and the hard coating to serve as an intermediary that enhances adhesion. The base layer comprises a polymer matrix with UV absorbers and stabilizers, creating a chemically active surface that bonds effectively to both the substrate and the hard coating, thereby resolving the adhesion problem without requiring complex surface treatment processes.
Solution Approach 2:
The solution employs a composite structure consisting of multiple layers with different material properties. The base layer combines polymer matrices with UV absorbers and stabilizers to create a material that provides both adhesion enhancement and optical property improvement, while the hard coating layer provides protective functions. This composite approach allows each layer to be optimized for its specific function.
2Reliability
If a base layer is included between the substrate and the hard coating to improve adhesion, then the adhesion and optical properties are improved, but the number of layers and process complexity increases
Solution Approach 1:
The base layer is designed to perform multiple functions simultaneously: it provides adhesion enhancement between the substrate and hard coating, improves optical properties by managing UV radiation, and offers corrosion resistance. By consolidating these functions into a single layer with a carefully selected polymer matrix and additives, the design avoids the need for multiple separate layers, thereby reducing overall system complexity while maintaining reliability.
3Duration of action of stationary object
If multiple layers with different hardness levels are used, then the durability and crack resistance are improved, but the manufacturing process becomes more complex
Solution Approach 1:
The coating system employs local quality by assigning different hardness levels to different layers based on their specific functions. The base layer has a softer, more flexible composition that accommodates substrate expansion and contraction, while the hard coating layer provides superior abrasion and corrosion resistance. This gradient in material properties optimizes both durability and resistance to cracking, while the modular layering approach simplifies the deposition process compared to creating a fully integrated complex structure.
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 configuration significantly improves the adhesion, durability, and weatherability of the coated substrate, reducing the likelihood of cracking and degradation of the hard coating, and enhances the overall mechanical and environmental durability.
Implementation Method 1
Plasma enhanced chemical vapor deposition may be used to deposit the hard coating
Implementation Method 2
The third layer may include a plasma enhanced chemical vapor deposited coating
Implementation Method 3
an additive selected from the group consisting of an ultraviolet light (UV) absorber, a UV stabilizer, and a mixture thereof
Data Source
AI summary
A coated substrate includes: a substrate and a first layer on at least a portion of the substrate, the first layer including a polymer selected from the group consisting of an acrylic, an epoxy, a polyurethane, a copolymer thereof, and a mixture thereof, and an additive selected from the group consisting of an ultraviolet light (UV) absorber, a UV stabilizer, and a mixture thereof. The coated substrate further includes a second layer on at least a portion of the first layer, and a third layer on at least a portion of the second layer. A method of forming a coated substrate includes: forming a first layer on at least a portion of a substrate; forming a second layer on at least portion of the first layer; and forming a third layer by plasma enhanced chemical vapor deposition on at least a portion of the second layer.