Plastic Substrate Hardness via Ion Implantation
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Solution Overview
Problem
Existing plastic substrates for display devices lack sufficient hardness and abrasion resistance compared to glass, making them unsuitable for protecting display surfaces in mobile devices.
Innovation Solution
A plastic substrate is developed with a plastic support member and a first organic-inorganic hybrid layer, which includes a hybrid matrix with ions implanted at a specific depth and energy range to enhance hardness and abrasion resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If plastic materials are used as substitute for glass, then weight is reduced and breakage resistance is improved, but hardness and abrasion resistance deteriorate
Solution Approach 1:
The patent applies composite materials by combining organic-inorganic hybrid layers with plastic support members. The hybrid layers contain both organic components (such as silane-modified polymers) and inorganic components (such as metal oxides or ceramic particles), creating a composite structure that provides glass-like hardness and abrasion resistance while maintaining the lightweight and impact-resistant properties of plastic substrates.
Solution Approach 2:
The patent employs parameter changes by modifying the chemical composition and physical structure of the plastic substrate surface through ion implantation. Specific ions are implanted at controlled depths and concentrations to alter surface hardness, wear resistance, and other properties without changing the bulk material characteristics, thereby achieving glass-like surface properties while retaining plastic substrate advantages.
2Weight of moving object
If plastic materials are used as substitute for glass, then weight is reduced and breakage resistance is improved, but abrasion resistance deteriorates
Solution Approach 1:
The organic-inorganic hybrid layers incorporate inorganic particles or phases within the organic matrix, creating a composite structure where the inorganic components provide enhanced abrasion resistance. This composite approach allows the plastic substrate to maintain its lightweight properties while the surface layer resists wear and scratching similar to glass.
Solution Approach 2:
The patent applies local quality by treating only the surface layer of the plastic substrate with organic-inorganic hybrid materials. The surface layer (typically a few micrometers thick) is modified to have high hardness and abrasion resistance, while the bulk plastic material retains its inherent lightweight and impact-resistant properties. This localized modification resolves the contradiction between overall weight reduction and surface abrasion resistance.
3Strength
If ion implantation is performed to enhance hardness, then surface hardness is improved, but manufacturing complexity increases
Solution Approach 1:
The patent uses ion implantation to change the physical and chemical parameters of the plastic substrate surface. By controlling ion type, implantation energy, dose, and depth, the process achieves desired surface hardness and other properties. Although ion implantation adds a manufacturing step, the process is well-established in semiconductor and materials industries, allowing for standardized production with controlled complexity.
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 proposed solution significantly improves the hardness and abrasion resistance of the plastic substrate, making it a viable alternative to glass for display device windows while maintaining light transmittance.
Implementation Method 1
ions implanted into the first organic-inorganic hybrid matrix at a side opposite to a side adjacent the plastic support member
Data Source
AI summary
A plastic substrate includes: a plastic support member having light transmittance; and a first organic-inorganic hybrid layer on the plastic support member. The first organic-inorganic hybrid layer includes: a first organic-inorganic hybrid matrix; and ions implanted into the first organic-inorganic hybrid matrix at a side opposite to a side adjacent the plastic support member. An amount of the ions per unit area is in a range from about 2×1013/cm2 to about 2×1014/cm2.