Siloxane Coating for Mobile Display Lens Abrasion
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Solution Overview
Problem
Current display lenses, particularly those made of plastic, suffer from poor abrasion resistance and fracture resistance, while glass lenses have limited three-dimensional shaping capabilities and poor fracture resistance, and advanced coatings like DLC fail prematurely on plastic substrates.
Innovation Solution
A multi-layer coating system comprising a siloxane-organic interpenetrating network (IPN) and a diamond-like nano-composite (DLN) layer is applied to a plastic substrate, with the siloxane IPN layer having a thickness of at least 20 microns and a hardness intermediate between the plastic substrate and the DLN layer, providing superior abrasion and scratch resistance comparable to glass lenses.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If a hard coating is applied to a plastic lens to improve abrasion resistance, then scratch resistance is improved, but the coating fails prematurely due to poor adhesion
Solution Approach 1:
The patent introduces a siloxane-organic interpenetrating network layer as an intermediary between the plastic substrate and the diamond-like nano-composite coating. This intermediate layer has intermediate hardness between the soft plastic substrate and the hard DLC coating, creating a gradient that improves adhesion and prevents premature coating failure while maintaining scratch resistance.
Solution Approach 2:
The patent changes the hardness parameter progressively through multiple layers: the plastic substrate has low hardness, the siloxane-organic IPN layer has intermediate hardness, and the DLC top coating has high hardness. This gradient in hardness parameters resolves the adhesion problem by avoiding abrupt transitions between soft and hard materials.
2Object-affected harmful factors
If glass lenses are used to achieve good scratch resistance, then abrasion resistance is improved, but fracture resistance is poor
Solution Approach 1:
The patent creates a composite structure combining plastic substrate with siloxane-organic IPN layer and diamond-like nano-composite coating. This composite material system achieves glass-like scratch resistance from the DLC layer while maintaining the inherent fracture resistance and flexibility of the plastic substrate.
3Object-affected harmful factors
If a thick hard coating is applied to a plastic lens to improve abrasion resistance, then scratch resistance is improved, but the overall structure becomes more prone to cracking
Solution Approach 1:
The patent applies a gradient hardness parameter through multiple layers, with the siloxane-organic IPN layer having intermediate hardness between the soft plastic substrate and the hard DLC coating. This gradual transition in hardness prevents stress concentration and cracking that would occur with a single thick hard coating.
Solution Approach 2:
The patent segments the protective coating into multiple functional layers: the siloxane-organic IPN layer provides adhesion and stress buffering, while the DLC top layer provides scratch resistance. This segmentation allows each layer to optimize its function without compromising the overall structure.
Data Source
AI summary
Hard coatings are applied to a lens assembly. In an embodiment, the coated lens assembly (140) includes a first layer (106B) including siloxane; a second layer (106A) including siloxane, wherein the second layer has opposing sides and a hardness greater than the first layer; and a third layer (104) including an amorphous carbon selected from a diamond-like carbon and a diamond-like nano-composite. The first layer (106B) and third layer (104) are positioned on opposing sides of the second layer (106A). The third layer (104) has a hardness greater than the second layer (106A).