Transparent Buffer Layer for Curved Glass Coating
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Solution Overview
Problem
Conventional coating methods on glass substrates often lead to stress accumulation and crack propagation when the glass is bent, resulting in reduced strength and non-uniform anti-reflective properties due to the deposition process's inability to maintain a consistent film thickness on curved surfaces.
Innovation Solution
A method involving the formation of an optically clear buffer layer with a generally uniform central region thickness, conformably coating the glass substrate, which prevents crack propagation from the outer protective layer to the substrate, using deposition processes like PVD or PECVD, and ensuring the buffer layer remains unaffected by subsequent deposition processes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Illumination intensity
If a protective coating layer is applied to the glass substrate using conventional deposition processes, then the anti-reflective properties are improved, but stress accumulation and crack propagation occur when the glass is bent, reducing the glass strength
Solution Approach 1:
The patent introduces a buffer layer as an intermediary between the glass substrate and the protective coating layer. This buffer layer absorbs stress and prevents crack propagation from the coating to the glass substrate, thereby maintaining glass strength while preserving the anti-reflective properties of the coating.
Solution Approach 2:
The patent segments the coating structure into multiple distinct layers: the glass substrate, the buffer layer, and the protective coating layer. This segmentation allows each layer to perform its specific function independently - the buffer layer handles stress management while the protective layer provides anti-reflective properties.
2Area of stationary object
If the deposition process coats curved surfaces, then the coverage area is improved, but the film thickness becomes non-uniform, reducing the optical performance
Solution Approach 1:
The patent applies local quality by creating a buffer layer with specifically controlled thickness characteristics - generally uniform in the central region while accommodating the curved geometry. This localized thickness control ensures optimal optical performance in the central viewing area while maintaining conformal coverage across the entire curved surface.
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 buffer layer effectively maintains the original strength of the glass substrate by preventing crack propagation and ensuring uniform anti-reflective properties across the entire surface, even on curved geometries, thereby enhancing the durability and optical performance of glass assemblies.
Implementation Method 1
the buffer layer prevents a crack formed in the protective layer from reaching the optically clear substrate
Implementation Method 2
forming a buffer layer using a first deposition process that conformably coats a curved surface of an optically clear substrate
Implementation Method 3
using deposition processes like PVD or PECVD
Implementation Method 4
forming a protective layer using a second deposition process that conformably coats the buffer layer
Data Source
AI summary
Methods and systems for depositing a thin film are disclosed. The methods and systems can be used to deposit a film having a uniform thickness on a substrate surface that has a non-planar three-dimensional geometry, such as a curved surface. The methods involve the use of a deposition source that has a shape in accordance with the non-planar three-dimensional geometry of the substrate surface. In some embodiments, multiple layers of films are deposited onto each other forming multi-layered coatings. In some embodiments, the multi-layered coatings are antireflective (AR) coatings for windows or lenses.