Rough-Structure Coated Substrate for Low Reflectance and Transmittance
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Solution Overview
Problem
Conventional automotive lens coatings achieve reflectance levels above 1%, failing to meet the need for low-transmittance and low-reflectance substrates.
Innovation Solution
A coated substrate design featuring a light-transmissible substrate with an optical film layer and a rough structure layer, where the rough structure layer is formed between the substrate and the optical film layer, achieving adjusted reflectance and transmittance levels below the base values, with reflectance less than 1.5% and transmittance less than 0.1%, respectively.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If a conventional optical film is coated on a substrate, then the coated substrate has low transmittance characteristic, but the reflectance cannot be achieved to be less than 1%
Solution Approach 1:
The coating structure is segmented into multiple layers: an optical film layer and a rough structure layer. The rough structure layer is further divided into multiple sub-layers with different roughness values, allowing independent optimization of each layer's contribution to reflectance reduction
Solution Approach 2:
Different regions of the coating structure have different local properties. The rough structure layer has varying roughness values at different depths, with the first sub-layer having a first roughness value and the second sub-layer having a second roughness value different from the first, creating localized quality variations that optimize overall reflectance
Solution Approach 3:
The coating combines different material structures: a smooth optical film layer and a rough structure layer with controlled roughness. This composite structure integrates the optical properties of the film with the light-scattering properties of the rough structure to achieve superior reflectance reduction
2Object-affected harmful factors
If a rough structure layer is formed between the substrate and optical film layer, then the adjusted average reflectance is reduced below the base average reflectance, but the manufacturing process complexity increases
Solution Approach 1:
The rough structure layer is segmented into multiple sub-layers, each with controlled roughness characteristics. This segmentation allows the complex rough structure to be built systematically through sequential deposition processes, making the manufacturing more controllable despite the increased structural complexity
Solution Approach 2:
The roughness parameter is changed and controlled at different stages of rough structure layer formation. By adjusting the roughness value of each sub-layer during the coating process, the manufacturing process can achieve the desired optical performance while managing process complexity through parameter optimization
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 results in a coated substrate with reflectance of less than 0.4% at 0° and 0.6% at 40°, significantly reducing reflectance across various angles, while maintaining low transmittance, thus achieving the desired low-transmittance and low-reflectance characteristics.
Implementation Method 1
a rough structure layer, formed between the upper surface of the light-transmissible substrate and the optical film layer such that the coated substrate has an adjusted average reflectance and an adjusted transmittance
Data Source
AI summary
Disclosed is a coated substrate, comprising: a light-transmissible substrate; an optical film layer, disposed on an upper surface of the light-transmissible substrate to provide a base average reflectance and a base transmittance for light incident to the light-transmissible substrate; and a rough structure layer, formed between the upper surface of the light-transmissible substrate and the optical film layer such that the coated substrate has an adjusted average reflectance and an adjusted transmittance for light incident to the light-transmissible substrate, wherein the base average reflectance is less than 1.5%, the base transmittance is less than 0.1%, the adjusted average reflectance is less than the base average reflectance, and the adjusted transmittance is not greater than the base transmittance.