Siloxane and Diamond-like Carbon Coating for Plastic Lens Abrasion
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Solution Overview
Problem
Current lenses for mobile devices, particularly glass and plastic lenses, face challenges in fracture resistance and three-dimensional shaping while maintaining adequate scratch and abrasion resistance, with glass lenses lacking in three-dimensional effects and plastic lenses having poor abrasion resistance despite hard coatings.
Innovation Solution
A multi-layer coating system comprising siloxane and diamond-like nano-composite (DLN) layers applied to a plastic substrate, with the siloxane-organic interpenetrating network (IPN) layers providing intermediate hardness and the DLN layer offering superior hardness, enhancing abrasion and scratch resistance comparable to glass lenses.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If glass lenses are used, then scratch resistance is improved, but fracture resistance deteriorates
Solution Approach 1:
The patent applies a multi-layer composite coating system on plastic lenses, combining siloxane IPN layers with diamond-like carbon (DLC) and diamond-like nano-composite (DLN) layers. This composite structure provides scratch resistance comparable to glass while maintaining the inherent fracture resistance of plastic substrates.
2Shape
If plastic lenses are used, then three-dimensional shaping capability is improved, but abrasion resistance deteriorates
Solution Approach 1:
The patent employs a composite coating system where siloxane IPN layers provide adhesion and intermediate properties, while DLC and DLN layers provide superior hardness and abrasion resistance. This enables plastic lenses to achieve glass-like scratch resistance while maintaining three-dimensional shaping capabilities.
Solution Approach 2:
The coating system applies different material properties to different layers: the siloxane IPN layer provides flexibility and adhesion closer to the plastic substrate, while the harder DLC and DLN layers provide abrasion resistance at the outer surface, creating a gradient of properties that optimizes both shaping and protection.
3Object-affected harmful factors
If hard coating is applied to plastic lens, then scratch resistance is improved, but overall scratch resistance remains inferior to glass lens
Solution Approach 1:
The patent uses a multi-layer composite coating combining siloxane IPN, DLC, and DLN materials. The DLN layer specifically provides nano-composite structure that enhances hardness and abrasion resistance beyond conventional single-layer coatings, closing the performance gap with glass lenses.
Solution Approach 2:
The siloxane IPN layer serves as an intermediary between the plastic substrate and the hard DLC/DLN layers, providing optimal adhesion and stress distribution that prevents coating failure while enabling the transmission of protective properties from the hard outer layers.
4Strength
If very hard coating is applied directly to plastic substrate, then hardness is improved, but coating fails prematurely
Solution Approach 1:
The siloxane IPN layer acts as an intermediary between the plastic substrate and the very hard DLC/DLN coating layers. This intermediate layer provides gradual transition in mechanical properties, ensuring strong adhesion and preventing premature coating failure due to stress concentration or poor bonding.
Solution Approach 2:
The coating system creates a gradient in mechanical properties through different layers, with the siloxane IPN layer providing intermediate hardness and flexibility, transitioning to the high hardness of DLC and DLN layers at the surface. This parameter gradient prevents stress concentration and improves coating longevity.
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 coating system significantly improves abrasion resistance and scratch resistance of plastic lenses, achieving comparable performance to glass lenses while allowing for three-dimensional shaping and flexible forms, with minimal dents on impact and improved protection against cracks and fractures.
Implementation Method 1
siloxane-organic interpenetrating network (IPN) layers providing intermediate hardness
Implementation Method 2
DLN layer offering superior hardness
Implementation Method 3
diamond-like nano-composite (DLN) layers
Data Source
AI summary
An abrasion resistant coating is applied to a display of a mobile device. In an embodiment, the coating includes a first layer including siloxane; a second layer including siloxane, wherein the second layer has opposing sides and a hardness greater than the first layer; and a third layer including an amorphous carbon selected from a diamond-like carbon and a diamond-like nano-composite. The first layer and third layer are positioned on opposing sides of the second layer. The third layer has a hardness greater than the second layer.