Transparent Optical Element With Controlled Plasma Polymerization
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Solution Overview
Problem
Existing deposition processes for optical coatings in motor vehicles face challenges in controlling polymerization and crosslinking degrees, difficulty in mixing precursor compounds, and achieving thin, multi-functional layers with properties like antifogging, anti-condensation, and anti-reflective properties.
Innovation Solution
A transparent optical element with a second layer formed by polymerization of precursor compounds assisted by a volume dielectric barrier atmospheric discharge plasma, allowing precise control over polymerization and crosslinking, and enabling the deposition of thin layers with desired properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If arc plasma is used for antifogging or anti-condensation coatings, then the coatings achieve desired antifogging properties, but the organic part of the precursor compounds is destroyed and only oxide, nitride or oxynitride coatings are obtained
Solution Approach 1:
The patent changes the energy parameter of the plasma from high-energy arc plasma to low-energy plasma-assisted CVD, which preserves the organic part of precursor compounds while still achieving antifogging properties through controlled polymerization
Solution Approach 2:
The patent utilizes phase transition of precursor compounds from monomeric to polymeric state through controlled polymerization in low-energy plasma, transforming the chemical form while maintaining organic structure and achieving desired coating properties
2Ease of manufacture
If plasma-assisted chemical vapor deposition is used for polymer-based coatings, then organic polymer-based coating layers can be produced, but the degree of polymerization and crosslinking is difficult to control
Solution Approach 1:
The patent introduces feedback control through monitoring and adjusting plasma parameters (power, gas flow, pressure) during deposition to precisely control the degree of polymerization and crosslinking, achieving reproducible coating properties
Solution Approach 2:
The patent employs dynamic control of deposition parameters during the coating process, adjusting plasma power and precursor flow rates in real-time to optimize polymerization degree and crosslinking for specific application requirements
3Productivity
If existing deposition processes are used, then coatings can be deposited, but the layer thickness is in the micrometer range which needs to be reduced
Solution Approach 1:
The patent applies partial action by using low-energy plasma to deposit thin polymer layers incrementally, achieving the desired sub-micrometer thickness through controlled, gradual deposition rather than excessive material application
4Adaptability or versatility
If existing deposition processes are used, then coatings can be formed, but it is difficult or impossible to mix precursor compounds, preventing deposition of layers with multiple properties
Solution Approach 1:
The patent merges multiple precursor compounds in the gas phase before plasma exposure, allowing simultaneous or sequential deposition of layers with different properties (antifogging, anti-reflective, anti-corrosion) in a single manufacturing process
Solution Approach 2:
The patent creates a universal deposition process using low-energy plasma that can handle multiple types of precursor compounds (monomers, oligomers, additives) and produce coatings with multiple functions simultaneously, making the process adaptable to various coating requirements
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 thin, multi-functional coatings with improved properties such as antifogging, anti-corrosion, and anti-reflective capabilities, enhancing the performance of vehicle lighting and remote sensing systems.
Implementation Method 1
polymerization being assisted by means of a volume dielectric barrier atmospheric discharge plasma
Implementation Method 2
volume dielectric barrier atmospheric discharge plasma
Implementation Method 3
transmits at least one electromagnetic radiation, for example visible light or a radar wave, by refraction
Data Source
AI summary
A transparent optical element for a vehicle, in particular a motor vehicle, includes at least one first transparent layer made of a polymer material. The transparent optical element includes at least one transparent second layer formed by the polymerization of at least one precursor compound, the polymerization being assisted by atmospheric plasma with volume dielectric barrier discharge.