Patent Application
20220299678
The present disclosure generally relates to an article including a coating including a plurality of particles dispersed in a host material; and a plurality of optical elements embedded on a surface of the coating. A method of making the coating, and the article is disclosed.
Optical devices can include a coating to provide optical feature to the device and/or physically protect the optical device from the environment. However, a single coating is not likely to provide both optical and physical features to the optical device because the materials used in an optical coating may not provide the requisite properties needed in a physical coating. For example, a scratch resistance coating is frequently hard, yet brittle, and would not provide impact resistance. An impact resistance coating is frequently pliable, yet is also likely to scratch. In particular, glass or inorganic solids sensor devices are not impact resistance and shatter easily because of the high hardness and low energy absorbing properties when impacted. Conversely, polymer sensor devices are impact resistant but do not exhibit abrasion resistance.
What is needed is a coating, such as a single coating, that can be engineered to provide specific functions with components representing different ends of a scale. The coating can be engineered to create unique optical, mechanical, chemical, and biological performance. The combination of components, such as discreet elements and host materials, can include the opposite ends of a scale relating to dimension, hardness, aspect ratio, and/or structural shape.
Features of the present disclosure are illustrated by way of example and not limited in the following figure(s), in which like numerals indicate like elements, in which:
In an aspect, there is disclosed an article, including a coating including a plurality of particles dispersed in a host material; and a plurality of optical elements embedded on a surface of the coating.
In another aspect, there is disclosed a method of making an article including depositing, on a substrate, a coating including a plurality of particles dispersed in a host material; and embedding a plurality of optical elements on a surface of the coating.
Additional features and advantages of various embodiments will be set forth, in part, in the description that follows, and will, in part, be apparent from the description, or can be learned by the practice of various embodiments. The objectives and other advantages of various embodiments will be realized and attained by means of the elements and combinations particularly pointed out in the description herein.
For simplicity and illustrative purposes, the present disclosure is described by referring to examples thereof. In the following description, numerous specific details are set forth in order to provide a thorough understanding of the present disclosure. It will be readily apparent however, that the present disclosure may be practiced without limitation to these specific details. In other instances, some methods and structures have not been described in detail so as not to unnecessarily obscure the present disclosure.
Additionally, the elements depicted in the accompanying figures may include additional components and some of the components described in those figures may be removed and/or modified without departing from scopes of the present disclosure. Further, the elements depicted in the figures may not be drawn to scale and thus, the elements may have sizes and/or configurations that differ from those shown in the figures. Any references to “top” or “bottom” are for ease of understanding positions relative to another element and should not be considered limiting. Additionally, if more than one element is present, then the element is identified as a first, second, third, etc. for ease of understanding.
In its broad and varied embodiments, disclosed herein is a coating, and an article, such as an optical device including the coating; and methods of making and using the coatings, and the articles. The article can be an optical device, for example, a glass sensor device, an inorganic solids sensor device, a polymer sensor device, a sensor window, a sensor viewport, a display (e.g., for use in personal devices like a cell phone or tablet), touch panels (e.g., ATM, airport self-check-in, hospital equipment), camera lenses on cell phones.
The present disclosure describes an article 10, including a coating 12 including a plurality of particles 14 dispersed in a host material 16; and a plurality of optical elements 18 embedded on a surface of the coating 12. The coating 12 with the embedded optical elements 18 can be an outer interface between an article 10 they are either a part of or are meant to enhance a performance of, with built-in engineerable (adjustable) features designed to protect optical and mechanical functions of the article 10 and provide various elements of safety to their users. In particular, the engineered features include mechanisms for providing enhanced scratch resistance, impact resistance, anti-smudging, water, oil and soil repellency to protect the intended pristine optical functions of the articles 10.
The article 10 can exhibit a synergy between optical and mechanical properties because of the different scales of the physical dimensions of the components in the article 10, their different mechanical properties and aspect ratios. For example, the article 10 can include hard elements, such as the plurality of optical elements 18, and pliable elements, such as a coating 12 including a host material 16. As another example, the article 10 can include physically large components, such as the plurality of optical elements 18, and physically small elements, such as a coating 12 including a plurality of particles 14, which can be nanoparticles. As a further example, the article 10 can include elements on opposite ends of a mechanical hardness spectrum, e.g., elements that are closer to the Shore A scale and other elements in the upper level of the Mohs scale.
By combining elements from opposite ends of several different parameters, an article 10 can be engineered with specific optical and functional properties. As an example, an article 10 can include scratch resistance and impact resistance. This is a significant achievement because generally scratch resistance coatings need to be mechanically hard, but the materials can be brittle thereby breaking upon impact. Conversely, a coating that provides improved impact resistance can be mechanically softer, but the materials can easily scratch.
In an aspect, the plurality of particles 14 in the coating 12 can be selected based upon a particular shape and/or size; such as a particular aspect ratio of the particles 14 or an average particle size of the particles 14, in order to realize desired optical and non-optical functions, such as electrical conductivity, dissipation of static charge, and/or biological protection of a surface of the coating 12.
The coating 12 can have a physical thickness that depends upon the intended use of the coating 12 within the article 10. In an aspect, the coating 12 can have a physical thickness ranging from about 100 nm to about 1,000,000 nm, for example, from about 1,000 nm to about 500,000 nm, and as a further example; from about 10,000 nm to about 100,000 nm.
The coating 12 can include a host material 16. The host material 16 can be any suitable medium for enabling a distribution of the plurality of particles 14. The host material 16 can be chosen from an organic polymer, an inorganic polymer, and a composite material. Non-limiting examples of the organic polymer include thermoplastics, such as polyesters, polyolefins, polycarbonates, polyamides, polyimides, polyurethanes, acrylics, acrylates, polyvinylesters, polyethers, polythiols, silicones, fluorocarbons, and various co-polymers thereof; thermosets, such as epoxies, polyurethanes, acrylates, melamine formaldehyde, urea formaldehyde, and phenol formaldehyde; and energy curable materials, such as acrylates, epoxies, vinyls, vinyl esters, styrenes, and silanes. Non-limiting examples of inorganic polymers includes silanes, siloxanes, titanates, zirconates, aluminates, silicates, phosphazanes, polyborazylenes, and polythiazyls.
The polymer chains in the host material 16 can be crosslinked and cured, Non-limiting examples include photoinduced polymerization, such as free radical polymerization, spectrally sensitized photoinduced free radical polymerization, photoinduced cationic polymerization, spectrally sensitized photoinduced cationic polymerization, and photoinduced cycloaddition; electron beam induced polymerization, such as electron beam induced free radical polymerization, electron beam induced cationic polymerization, and electron beam induced cycloaddition; and thermally induced polymerization, such as thermally induced cationic polymerization. Non-limiting examples of a curing process include a non-radical cure system, ultraviolet light, visible light, infrared, and electron beam. In an aspect, the host material 16 can be mechanical energy dissipating.
The host material 16 can include additives, for example, in addition to the plurality of particles 14. The additives can be dispersed in the host material 16. The additives can include, but are not limited to, colorants, such as dyes and pigments; quantum dots; micelles; chalcogenides; leveling agents, such as a polyacrylate; photoinitiators, such as a phosphineoxide; an oxygen inhibition mitigation composition; a defoamer; wetting aids; dispersants; curing agent; hardener; antioxidants; and combinations thereof. The coating 12 can also include a solvent.
The plurality of particles 14 can be randomly present in the host material 16, as shown in
In an aspect, the ordered spatial distribution can be a continuous gradient throughout the host material 16 of the coating 12. For example, a physical concentration of the plurality of particles 14 can taper between surfaces of the coating 12 thereby forming a continuous gradient throughout the coating 12, as shown in
The plurality of particles 14 can include any particles having an average particle size ranging in the nanometers, e.g., from about 1 nm to submicron size (less than a micron). In an effort to avoid light scattering, an average particle size of the plurality of particles 14 can be adapted to a select wavelength. The plurality of particles 14 has a specific shape and/or aspect ratio specific for an optical and/or non-optical function. As an example of a non-optical function, the plurality of particles 14 can provide low surface energy, which can result in superhydrophobicity. In an aspect, the particles 14 can be spherical in shape. In another aspect, the particles 14 can each be lamellar in shape, for example, with an aspect ratio from about 2:1 to 10:1 length to width.
The particles 14 can include a material chosen from metals, metal oxides, metal carbonates, metal sulfides, metal fluorides, metal nitrides, organic compounds or polymers, and mixtures thereof. Non-limiting examples of metal oxides includes aluminum oxide, calcium oxide, cerium oxide, chromium oxide, cobalt oxide, copper oxide, iron oxide, lead oxide, magnesium oxide, nickel oxide, niobium oxide, silicon dioxide, silver oxide, tin oxide, and zinc oxide. Non-limiting examples of metal sulfides include barium sulfide, cobalt sulfide, copper sulfide, iron sulfide, manganese sulfide, nickel sulfide, silver sulfide, tin sulfide, titanium sulfide, and zinc sulfide, Non-limiting examples of metal fluorides include aluminum fluoride, barium fluoride, calcium fluoride, cerium fluoride, chromium fluoride, cobalt fluoride, copper fluoride, gold fluoride, iron fluoride, magnesium fluoride, nickel fluoride, niobium fluoride, silver fluoride, tin fluoride, and titanium fluoride. Non-limiting examples of organic compounds or polymers include polyimidothiethers; polyphosphonates, sulfur-containing polyimide, polyferrocenes, polyferrocenylsilanes, and organic-inorganic nanocomposites. The particles 14 can include a magnetic and/or a ferromagnetic material.
The particles 14 can have a refractive index, such as a high refractive index or a low refractive index. A particle 14 with a high refractive index is defined herein as greater than about 1.65. A particle 14 with a low refractive index is defined herein as about 1.65 or less. Non-limiting examples of a high refractive index particle 14 include aluminum oxide (Al2O3), zinc sulfide (ZnS), zinc oxide (ZnO); zirconium oxide (ZrO2), titanium dioxide (TiO2); diamond-like carbon, indium oxide (In2O3), indium-tin-oxide (ITO), tantalum pentoxide (Ta2O5), cerium oxide (CeO2), yttrium oxide (Y2O3), europium oxide (Eu2O3), iron oxides such as (II)diiron(III) oxide (Fe3O4) and ferric oxide (Fe2O3), hafnium nitride (HfN), hafnium carbide (HfC), hafnium oxide (HfO2); lanthanum oxide (La2O3), magnesium oxide (MgO), neodymium oxide (Nd2O3), praseodymium oxide (Pr6O11), samarium oxide (Sm2O3), antimony trioxide (Sb2O3), silicon, silicon monoxide (SiO), selenium trioxide (Se2O3), tin oxide (SnO2), tungsten trioxide (WO3), combinations thereof, and the like. Non-limiting examples of a low refractive index particle 14 include silicon dioxide (SiO2), magnesium fluoride (MgF2), aluminum fluoride (AlF3), cerium fluoride (CeF3), lanthanum fluoride (LaF3), sodium aluminum fluorides (e.g., Na3AlF6 or Na5Al3F14), neodymium fluoride (NdF3), samarium fluoride (SmF3), barium fluoride (BaF2), calcium fluoride (CaF2), lithium fluoride (LiF), ytterbium fluoride (YbF3), yttrium fluoride (YF3), hollow core particles and micro- and nanosized capsules (containing air and/or functional material), and combinations thereof.
The plurality of particles 14 can include particles, as disclosed above, that are the same or different. For example, the plurality of particles 14 can be the same material, the same refractive index, the same density, etc. The plurality of particles 14 can be different so that the plurality of particles 14 is a mixture of different parts. For example, the plurality of particles 14 can include a first part of magnetic particles 14, and a second part of non-magnetic particles 14.
The coating 12 can also include a plurality of microcapsules in a surface of the coating 12. In the event of a scratch in the coating 12, the plurality of microcapsules can rupture to fill a void in the coating 12 due to the scratch. The coating 12 can be polymerized so that the coating 12 cures. In this manner, the coating 12 can be considered self-healing. The host material 16 can include an active material, such as the microcapsules, or an elastic material phase, to provide self-healing.
In an aspect, the host material 16 can have a mechanical hardness that s than (Shore A scale) a mechanical hardness of the plurality of optical elements 18 (upper levels of Mohs scale). The host material 16 can include a refractive index that can match a plurality of optical elements 18, the substrate 20, or both.
The article 10 can also include a substrate 20. The coating 12 can be applied on a surface of the substrate 20, as shown in
The plurality of optical elements 18 can each independently have a size ranging from 0.5 micron to 5 mm, for example, from about 1 micron to about 3 mm, and as a further example, from about 5 microns to about 1 mm.
A plurality of optical elements 18 can be embedded on a surface of the coating 12. In an aspect, a portion of each optical element 18 can be embedded a depth into the coating 12, so that another portion of each optical element 18 extends beyond the surface of the coating 12. The plurality of optical elements 18 can be oriented to form a quasi-continuous optical surface, for example, as shown in
Each optical element of the plurality of optical elements 18 can be a three-dimensional element chosen from a lens, a platelet, a cube, a cuboid, a prism, a sphere, a pyramid, a cylinder, and a cone. In an aspect, the plurality of optical elements 18 can be a same three-dimensional element. In another aspect, the plurality of optical elements 18 can be different three-dimensional elements.
Each optical element of the plurality of optical elements 18 can have at least one surface chosen from flat, curved, and textured.
Each optical element of the plurality of optical elements 18 can be made of a transparent material, such as glass, synthetic minerals, minerals, optical polymers, micro-capsules, or other optical materials. A micro-capsule can contain functional liquids impacting self-healing properties, light absorption, and/or refraction characteristics. In this manner, a micro-capsule can have mechanical and optical functions.
Each optical element of the plurality of optical elements 18 can have a coating 22 on at least a portion of a surface of each optical element 18, as shown in
As shown in
A method of making an article 10 can include depositing, on a substrate 20, a coating 12 including a plurality of particles 14 dispersed in a host material 16; and embedding a plurality of optical elements 18 on a surface of the coating 12. The coating 12 can be deposited using a liquid coating process.
A 1 micron coating including a plurality of silicon carbide nanoparticles dispersed in a host material of epoxy was applied to a Gorilla glass substrate (Sample A), The same coating, as Sample A, was applied at a thickness of 2 microns to a Gorilla glass substrate (Sample B). Additionally, the same coating, as Sample A, was coated on a layer of silicon dioxide, which was on top of Gorilla glass (Sample C) The optical transmission of incident light was measured and the results shown in
From the foregoing description, those skilled in the art can appreciate that the present teachings can be implemented in a variety of forms. Therefore, while these teachings have been described in connection with particular embodiments and examples thereof, the true scope of the present teachings should not be so limited, Various changes and modifications can be made without departing from the scope of the teachings herein.
This scope disclosure is to be broadly construed. It is intended that this disclosure disclose equivalents, means, systems and methods to achieve the devices, activities and mechanical actions disclosed herein. For each device, article, method, mean, mechanical element or mechanism disclosed, it is intended that this disclosure also encompass in its disclosure and teaches equivalents, means, systems and methods for practicing the many aspects, mechanisms and devices disclosed herein. Additionally, this disclosure regards a coating and its many aspects, features and elements. Such a device can be dynamic in it use and operation, this disclosure is intended to encompass the equivalents, means, systems and methods of the use of the device and/or optical device of manufacture and its many aspects consistent with the description and spirit of the operations and functions disclosed herein. The claims of this application are likewise to be broadly construed. The description of the inventions herein in their many embodiments is merely exemplary in nature and, thus, variations that do not depart from the gist of the invention are intended to be within the scope of the invention. Such variations are not to be regarded as a departure from the spirit and scope of the invention.
This application claims priority to U.S. Provisional Application No. 63/163,436, filed Mar. 19, 2021, the entire disclosure of which is hereby incorporated by reference.
| Number | Date | Country | |
|---|---|---|---|
| 63163436 | Mar 2021 | US |
