Sequential Optical and ETC Coating Apparatus
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Solution Overview
Problem
Current processes for applying antireflection (AR) and easy-to-clean (ETC) coatings on glass articles require separate manufacturing runs, leading to higher yield losses and increased costs due to extra handling, which can result in contamination and poor reliability of the final product.
Innovation Solution
A method and apparatus for sequentially applying optical and ETC coatings using the same apparatus, where a vacuum chamber with a magnetic rotatable dome allows for magnetically positioning a glass substrate, enabling the deposition of optical coatings followed by ETC coatings without exposing the optical coating to ambient atmosphere, utilizing a combination of e-beam and thermal evaporation sources within the same chamber.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If separate apparatuses are used for applying AR coating and ETC coating, then each coating can be applied with dedicated equipment, but manufacturing costs increase and productivity decreases due to separate manufacturing runs and extra handling
Solution Approach 1:
The patent combines the AR coating apparatus and ETC coating apparatus into a single integrated coating system. The apparatus includes a vacuum chamber that can sequentially receive both types of coatings without exposing the intermediate product to ambient atmosphere, thereby eliminating the need for separate manufacturing runs and reducing handling steps while maintaining product reliability
Solution Approach 2:
The coating apparatus is designed with multi-functionality to perform both AR coating and ETC coating operations. The system includes adjustable coating heads and process control mechanisms that can switch between different coating types, allowing a single apparatus to replace multiple dedicated equipment and improve manufacturing efficiency
2Manufacturing precision
If separate manufacturing runs are used for AR and ETC coatings, then each coating process can be optimized independently, but yield losses increase due to extra handling and contamination risks
Solution Approach 1:
The apparatus maintains a controlled atmosphere within the vacuum chamber during the transition between AR and ETC coating processes. This prevents contamination of the AR-coated surface before ETC coating application, eliminating yield losses associated with contamination while allowing independent optimization of each coating process
3Reliability
If AR coating is applied first followed by ETC coating in separate processes, then both coatings can be applied, but the final product has poor abrasion resistance due to contamination from extra handling
Solution Approach 1:
The vacuum chamber maintains a protected environment throughout the sequential coating process, preventing ambient contamination of the AR coating before ETC application. This ensures the final composite coating achieves optimal abrasion resistance by eliminating contamination from intermediate handling steps
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
This approach reduces manufacturing costs, enhances the reliability of the final product by minimizing contamination and improving abrasion resistance, with the ETC coating providing lubrication and increasing the durability of the glass and optical coatings, resulting in a shadow-free, optically functional surface.
Implementation Method 1
a magnetic rotatable dome allows for magnetically positioning a glass substrate
Implementation Method 2
utilizing a combination of e-beam and thermal evaporation sources within the same chamber
Implementation Method 3
thermal evaporation sources
Implementation Method 4
a vacuum chamber with a magnetic rotatable dome allows for magnetically positioning a glass substrate, enabling the deposition of optical coatings followed by ETC coatings without exposing the optical coating to ambient atmosphere
Implementation Method 5
the ETC coating providing lubrication and increasing the durability of the glass and optical coatings
Data Source
Figure 1A~1C
Figure 2~3A
Figure 3B~4B
AI summary
This disclosure is directed to an improved process for making glass articles having optical coating and easy-to clean coating thereon, an apparatus for the process and a product made using the process. In particular, the disclosure is directed to a process in which the application of the optical coating and the easy-to-clean coating can be sequentially applied using a single apparatus. Using the combination of the coating apparatus and the substrate carrier described herein results in a glass article having both optical and easy-to-clean coating that have improved scratch resistance durability and optical performance, and in addition the resulting articles are "shadow free."