Sapphire Thin Film Coated Substrate for Scratch and Shatter Resistance
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Solution Overview
Problem
The high fabrication cost and long fabrication time of sapphire screens due to their hardness and difficulty in cutting and polishing, combined with their weight and reduced shatter resistance, limit their widespread use in devices like smartphones and tablets.
Innovation Solution
A method to deposit a sapphire thin film onto softer substrates like quartz or glass, which involves a deposition process followed by annealing at specific temperatures, resulting in a sapphire-coated substrate that is scratch-resistant, shatter-resistant, and lighter than pure sapphire, while maintaining high transparency and reduced fragmentation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If pure sapphire substrate is used, then scratch resistance is improved, but shatter resistance deteriorates and weight increases
Solution Approach 1:
The patent applies composite materials by combining sapphire thin film (for scratch resistance) with a softer substrate material (for shatter resistance). This creates a hybrid structure where each material contributes its advantageous properties, resolving the contradiction between scratch resistance and shatter resistance that exists in pure sapphire substrates.
Solution Approach 2:
The patent applies local quality by creating a layered structure where the sapphire coating is applied only to the surface layer that requires scratch resistance, while the bulk substrate maintains its toughness and shatter resistance. This localized application of hard material solves the contradiction by confining the hard material to where it is most needed.
2Object-affected harmful factors
If pure sapphire substrate is used, then scratch resistance is improved, but fabrication cost and fabrication time increase
Solution Approach 1:
The patent applies flexible shells and thin films by using a thin sapphire coating layer instead of a thick or bulk sapphire substrate. This thin film approach maintains the scratch resistance benefits of sapphire while dramatically reducing material costs, fabrication time, and processing complexity associated with manufacturing large-area bulk sapphire substrates.
Solution Approach 2:
The patent applies cheap short-living objects by replacing expensive bulk sapphire substrates with a thin sapphire coating on a cheaper substrate. The thin coating uses far less expensive material while achieving the same protective function, making the overall device more cost-effective to manufacture.
3Object-affected harmful factors
If pure sapphire substrate is used, then hardness is improved, but weight increases
Solution Approach 1:
The patent applies flexible shells and thin films by using a thin sapphire coating layer that provides the necessary hardness and scratch resistance with minimal thickness. This thin film approach significantly reduces the weight compared to using a thick or bulk sapphire substrate while maintaining the protective hardness function.
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 method achieves a hardness comparable to pure sapphire with reduced weight and fabrication costs, offering improved mechanical performance and optical clarity, making it suitable for use in electronic devices without the drawbacks of pure sapphire.
Implementation Method 1
at least one deposition process wherein sapphire is deposited on to at least one substrate to form a sapphire coated substrate
Implementation Method 2
at least one anneal process wherein said sapphire coated substrate is annealed under an annealing temperature ranging between 500° C. and 2040° C. for an effective duration of time
Data Source
AI summary
A method to deposit a layer of harder thin film substrate onto a softer substrate. In particular, the present invention provides a method to deposit a layer of sapphire thin film on to a softer substrate e.g. quartz, fused silica, silicon and (toughen) glass. This combination is better than pure sapphire substrate.