Silane Primer and Fluorinated Coating for Adhesion
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Solution Overview
Problem
Existing water/oil repellent technologies face challenges in achieving effective adhesion to various substrates and maintaining antistatic properties, particularly due to the non-adhesive nature of fluorinated compounds and the susceptibility of water repellent films to static buildup.
Innovation Solution
A water/oil repellent member is created by forming a primer layer composed of an organosilicon compound with multiple silanol groups and a water/oil repellent layer from a cured hydrolyzable fluorinated compound, using a wet or dry coating process, which provides improved abrasion resistance and antistatic properties without requiring vacuum or high-temperature processes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If fluorinated compounds are used as water/oil repellent agent, then water/oil repellent properties are achieved, but adhesion to substrates deteriorates due to very low surface free energy
Solution Approach 1:
The patent introduces a silane-based primer layer as an intermediary between the substrate and the fluorinated water/oil repellent layer. This primer layer contains silane groups that can bond to the substrate and fluorinated groups that can bond to the water/oil repellent agent, thus mediating the adhesion problem between the non-adhesive fluorinated compound and the substrate.
Solution Approach 2:
The patent creates a composite structure consisting of multiple layers: a substrate, a silane-based primer layer, and a fluorinated water/oil repellent layer. This composite material approach allows each layer to perform its specific function - the primer provides adhesion while the fluorinated layer provides water/oil repellency, resolving the adhesion issue of pure fluorinated compounds.
2Reliability
If water repellent films are formed, then water/oil repellent properties are achieved, but antistatic properties deteriorate due to static buildup
Solution Approach 1:
The patent modifies the surface resistivity parameter of the water/oil repellent layer by controlling the thickness and composition of the fluorinated layer. By optimizing these parameters, the layer maintains water/oil repellency while achieving acceptable antistatic properties, reducing static buildup without sacrificing the primary water/oil repellent function.
3Strength
If dry process like evaporation or sputtering is used to deposit SiO2 primer layer, then adhesion is improved, but productivity and production cost worsen due to vacuum requirement and massive unit necessity
Solution Approach 1:
The patent replaces the mechanical vacuum-based deposition processes (evaporation, sputtering) with a chemical solution-based coating method. The silane-based primer layer is applied through chemical reactions with moisture in the air, eliminating the need for vacuum equipment and massive units, thus improving productivity while maintaining adhesion.
Solution Approach 2:
The patent uses a consumable silane-based primer layer solution that can be easily applied and cured, replacing expensive and complex vacuum deposition equipment. This approach uses inexpensive materials and simple coating processes to achieve the same adhesion effect, significantly improving productivity and reducing production costs.
4Ease of manufacture
If polysilazane solution is used to deposit primer layer by wet process, then vacuum process is eliminated, but productivity and cost worsen due to high-temperature heating or humidifying over long term
Solution Approach 1:
The patent changes the curing conditions by using silane-based compounds that can cure at lower temperatures and shorter times compared to polysilazane. This parameter change in the chemical composition allows the primer layer to be applied and cured under milder conditions, improving productivity while maintaining ease of manufacture.
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 achieves a water/oil repellent surface with surface resistivity up to 1.0×10^11 Ω/sq, enhancing antistatic and antifouling properties on various substrates, including electronic devices and eyeglass lenses, while maintaining visibility and appearance by preventing static buildup and staining.
Implementation Method 1
a primer layer which is composed mainly of an organosilicon compound having a plurality of silanol groups in the molecule
Implementation Method 2
an organosilicon compound having a plurality of silanol groups in the molecule
Implementation Method 3
a water/oil repellent layer which is composed mainly of a cured product of a hydrolyzable fluorinated compound
Implementation Method 4
cured product of a hydrolyzable fluorinated compound
Implementation Method 5
wet coating a solution containing an organosilicon compound having a plurality of silanol groups in the molecule and a solvent on at least one surface of a substrate
Implementation Method 6
drying the solvent to form and deposit a primer layer
Data Source
AI summary
This water-repellent, oil-repellent member is obtained via, inter alia, a method having: a step for wet-coating a substrate surface with a solution that contains a solvent and an organosilicon compound comprising multiple silanol groups in the molecule; a step for drying the solvent to form and laminate a primer layer on the substrate surface; a step for wet-coating the outer surface of the primer layer with a solution containing a hydrolyzable fluorine-containing compound and a solvent, and subsequently drying the solvent, or dry-coating the outer surface of the primer layer with a hydrolyzable fluorine-containing compound obtained by evaporating the solvent from the solution; and a step for curing the hydrolyzable fluorine-containing compound to form and laminate a water-repellent, oil-repellent layer on the outer surface of the primer layer. The water-repellent, oil-repellent member is obtained by providing, on various substrates: a primer layer of a specific thickness that contains, as a main component, an organosilicon compound having multiple silanol groups in the molecule; and, on the outer surface of the primer layer, a water-repellent, oil-repellent layer of a specific thickness that contains, as a main component, the cured hydrolyzable fluorine-containing compound. The water-repellent, oil-repellent member makes it possible for a water-repellent, oil-repellent coating exhibiting superior abrasion resistance and antistatic properties to be stably and straightforwardly formed on various substrates.