ZrO2 Far-Infrared Transmitting Coating for Scratch Resistance
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Solution Overview
Problem
Far-infrared transmitting members require improved scratch resistance while maintaining effective transmission of far-infrared rays.
Innovation Solution
A far-infrared transmitting member comprising a base material that transmits far-infrared rays, with a functional film having an outermost layer containing ZrO2 as the main component, achieving 50% or more average transmittance for wavelengths between 8 μm and 12 μm, and a refractive index of 2.05 or more for visible light, formed through sputtering to enhance scratch resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a functional film is formed on a base material to transmit far-infrared rays, then far-infrared transmission is achieved, but scratch resistance deteriorates
Solution Approach 1:
The patent applies composite materials by forming a multi-layer functional film structure consisting of an outermost layer containing ZrO2 as main component (50-100 mass%), an intermediate layer, and an innermost layer. This composite structure combines the high scratch resistance of ZrO2 with the far-infrared transmission properties of the underlying layers, resolving the contradiction between transmission performance and mechanical durability
Solution Approach 2:
The patent implements local quality by assigning different functional properties to different layers of the functional film. The outermost layer is specifically designed with high ZrO2 content and high refractive index (2.05 or more) to provide scratch resistance, while the intermediate and innermost layers are optimized for far-infrared transmission, allowing each layer to perform its specific function optimally
2Strength
If the outermost layer contains high ZrO2 content with high refractive index to improve scratch resistance, then scratch resistance is improved, but visible light optical performance may deteriorate
Solution Approach 1:
The patent applies parameter changes by precisely controlling the refractive index of the outermost layer to be 2.05 or more (optimal range 2.15-2.30), and controlling the layer thickness to be 100-300 nm (optimal range 150-250 nm). These parameter optimizations ensure that the high ZrO2 content layer provides sufficient scratch resistance while maintaining acceptable visible light transmission by minimizing reflection losses through proper impedance matching
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 effectively transmits far-infrared rays and improves scratch resistance, reducing the load in the film-forming process while maintaining optical performance.
Implementation Method 1
forming an outermost layer of the functional film on the base material by sputtering
Data Source
AI summary
To appropriately transmit far-infrared rays and improve scratch resistance. A far-infrared transmitting member (20) includes a base material (30) that transmits far-infrared rays and a first functional film (32) formed on the base material (30), in which an average transmittance for light having a wavelength of 8 μm to 12 μm is 50% or more, an outermost layer (36) of the first functional film (32) is a layer containing ZrO2 as a main component, a content of ZrO2 is 50 mass % or more and 100 mass % or less with respect to the whole outermost layer (36), and a refractive index of the outermost layer (36) with respect to light having a wavelength of 550 nm is 2.05 or more.