Sequential Vacuum Coating of Glass Optical and ETC Layers
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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 and equipment, leading to increased yield losses, contamination, and higher product costs due to additional handling steps, as well as poor scratch resistance in touch applications.
Innovation Solution
A process that vacuum deposits both optical and ETC coatings sequentially onto a glass substrate using the same apparatus, without breaking vacuum, involving an optical coating chamber and an ETC coating chamber, with the substrate being transferred vertically between chambers, and post-treatment at controlled temperatures to facilitate cross-linking of ETC molecules.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If separate manufacturing runs and equipment are used for applying AR and ETC coatings, then each coating can be applied with specialized equipment, but yield losses increase, contamination occurs, and manufacturing costs increase due to additional handling steps
Solution Approach 1:
The patent combines the AR coating and ETC coating processes into a single manufacturing run using a dual-chamber vacuum deposition apparatus. The substrate is transferred from the first chamber (where AR coating is applied) to the second chamber (where ETC coating is applied) without breaking vacuum, eliminating the need for separate manufacturing runs and reducing handling steps that cause yield losses and contamination.
Solution Approach 2:
The patent maintains continuous vacuum conditions throughout the entire coating process by transferring the substrate between chambers without breaking vacuum. This continuous action prevents contamination that would occur during atmospheric exposure and eliminates the need to re-establish vacuum between coating steps, thereby improving manufacturing efficiency and yield.
2Ease of manufacture
If separate manufacturing runs are used for AR and ETC coating, then each coating process can be optimized independently, but extra handling steps increase contamination risk and yield losses
Solution Approach 1:
The substrate is transferred between the first and second chambers without breaking vacuum, maintaining continuous protective conditions. This eliminates exposure to atmospheric contamination during transfer and between coating steps, ensuring product cleanliness while still allowing independent optimization of each coating process within their respective chambers.
Solution Approach 2:
The vacuum environment acts as an intermediary protective medium during substrate transfer between chambers. By maintaining vacuum conditions throughout the transfer process, the system protects the coated substrate from atmospheric contamination while allowing the substrate to move between the AR coating chamber and ETC coating chamber.
3Quantity of substance
If ETC coating is applied over optical coating in conventional 2-step process, then both coatings are present on the glass, but the final coating becomes easily scratched in touch applications
Solution Approach 1:
The patent applies ion assistance during the ETC coating deposition process, changing the physical and chemical parameters of the coating formation. This ion assistance modifies the coating structure to enhance cross-linking and improve abrasion resistance, making the final coating much more resistant to scratching in touch applications while maintaining complete coverage.
4Adaptability or versatility
If AR coating is applied first followed by ETC coating in separate runs, then both coating functions are achieved, but manufacturing costs increase due to additional handling and equipment requirements
Solution Approach 1:
The patent merges the AR coating and ETC coating processes into a single integrated manufacturing run using a dual-chamber vacuum deposition apparatus. This eliminates the need for separate manufacturing runs and reduces equipment requirements, thereby lowering manufacturing costs while maintaining both antireflection and easy-to-clean coating functions on the glass substrate.
Solution Approach 2:
The vacuum deposition apparatus is designed with multi-functionality, capable of applying both AR coating and ETC coating within the same system. The first chamber is configured for AR coating deposition while the second chamber is configured for ETC coating deposition, allowing the single apparatus to perform multiple coating functions that previously required separate equipment and processes.
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 abrasion resistance by over 10 times compared to conventional 2-step coating processes, and improves the reliability of the final product by eliminating extra handling steps and contamination, while maintaining optical performance.
Implementation Method 1
A process for vacuum depositing without breaking vacuum an optical coating and an easy-to-clean (ETC) coating onto a glass substrate
Implementation Method 2
The glass article may be post-treated at a temperature from about 60° C. to about 200° C. for a period of time, for example, from about 5 minutes to about 60 minutes, in air or humid environment to facilitate cross-linking between ETC molecules
Data Source
AI summary
A process in which both an optical coating, for example, an AR coating, and an ETC coating are deposited on a glass substrate article, in sequential steps, with the optical coating being deposited first and the ETC coating being deposited second, using the same apparatus and without exposing the article to the atmosphere at any time during the application of the optical coating and ETC coating.