Low-Color Scratch-Resistant Articles with a Multilayer Optical Film

• US 20140376094A1
• Filed: 09/09/2014
• Published: 12/25/2014
• Est. Priority Date: 05/07/2013
• Status: Active Grant

• Current Assignee: Corning Incorporated
• Original Assignee: Corning Incorporated
• Inventors: Bellman, Robert Alan, Hart, Shandon Dee, Koch, Karl William III, Paulson, Charles Andrew
• Granted Patent: US 9,366,784 B2
• Time in Patent Office: Days
• US Class Current: 359/580
• CPC Class Codes: C03C 17/3435 comprising a nitride, oxynitride, boronitride or carbonitride
• CPC Class Codes: C03C 2217/734 comprising an alternation of high and low refractive indexes
• CPC Class Codes: C03C 2217/78 Coatings specially designed to be durable, e.g. scratch-resistant
• CPC Class Codes: G02B 1/10 Optical coatings produced by application to, or surface treatment of, optical elements G02B1/08 takes precedence
• CPC Class Codes: G02B 1/113 using inorganic layer materials only
• CPC Class Codes: G02B 1/115 Multilayers
• CPC Class Codes: G02B 1/14 Protective coatings, e.g. hard coatings
• CPC Class Codes: Y10T 428/24942 including components having same physical characteristic in differing degree
• CPC Class Codes: Y10T 428/315 Surface modified glass [e.g., tempered, strengthened, etc.]

Abstract

Embodiments of this disclosure pertain to articles that exhibit scratch-resistance and improved optical properties. In some examples, the article exhibits a color shift of about 2 or less, when viewed at an incident illumination angle in the range from about 0 degrees to about 60 degrees from normal under an illuminant. In one or more embodiments, the articles include a substrate, and an optical film disposed on the substrate. The optical film includes a scratch-resistant layer and an optical interference layer. The optical interference layer may include one or more sub-layers that exhibit different refractive indices. In one example, the optical interference layer includes a first low refractive index sub-layer and a second a second high refractive index sub-layer. In some instances, the optical interference layer may include a third sub-layer.

Claims

1. An article comprising:

a substrate having a surface; and

an optical film disposed on the substrate surface forming a coated surface, the optical film comprising a scratch-resistant layer;

wherein the article comprises a color shift of about 2 or less, when viewed at an incident illumination angle in the range from about 0 degrees to about 60 degrees from normal incidence under an illuminant.

2. The article of claim 1, wherein the optical film further comprises an optical interference layer disposed between the scratch-resistant layer and the substrate.

3. The article of claim 2, wherein the optical interference layer comprises a first low refractive index (RI) sub-layer and a second high RI sub-layer.

4. The article of claim 3, wherein the difference between the refractive index of the first low RI sub-layer and the refractive index of the second high RI sub-layer is about 0.01 or greater.

5. The article of claim 2, wherein the optical interference layer comprises a plurality of sub-layer sets, the plurality of sub-layer sets comprising a first low RI sub-layer and a second high RI sub-layer.

6. The article of claim 5, wherein the optical interference layer further comprises a third sub-layer disposed between at least one of:

the plurality of sub-layer sets and the scratch-resistant layer; and

the substrate and the plurality of sub-layer sets, and

wherein the third sub-layer has a RI between the refractive index of the first low RI sub-layer and the refractive index of the second high RI sub-layer.

7. The article of claim 5, wherein the optical interference film comprises up to about 10 sub-layer sets.

8. The article of claim 5, wherein at least one of the first low RI sub-layer and the second high RI sub-layer comprises an optical thickness (n*d) in the range from about 2 nm to about 200 nm.

9. The article of claim 2, wherein the optical interference layer comprises a thickness of about 800 nm or less.

10. The article of claim 2, wherein the optical interference layer comprises an average light reflection of about 0.5% or less over the optical wavelength regime.

11. The article of claim 1, wherein the article comprises an average transmittance or average reflectance having an average oscillation amplitude of about 5 percentage points or less over the optical wavelength regime.

12. The article of claim 1, wherein the optical film comprises a sensor layer.

13. The article of claim 1, wherein the article comprises a maximum hardness of about 8 GPa or greater, as measured by a Berkovich Indenter Hardness Test along indentation depths of about 100 nm or greater.

14. The article of claim 1, wherein the substrate comprises an amorphous substrate or a crystalline substrate.

15. The article of claim 14, wherein the amorphous substrate comprises a glass selected from the group consisting of soda lime glass, alkali aluminosilicate glass, alkali containing borosilicate glass and alkali aluminoborosilicate glass.

16. The article of claim 15, wherein the glass is chemically strengthened and comprises a compressive stress (CS) layer with a surface CS of at least 250 MPa extending within the chemically strengthened glass from a surface of the chemically strengthened glass to a depth of layer (DOL) of at least about 10 μ

m.

17. An article comprising:

a substrate comprising a substrate surface; and

an optical film disposed on the substrate surface forming a coated surface,

wherein the optical film comprises a scratch-resistant layer and an optical interference layer disposed between the scratch-resistant layer and the substrate, the optical interference layer comprising at least one set of sub-layers, the set of sub-layers comprising a first low RI sub-layer and a second high RI sub-layer,

wherein the article comprises a maximum hardness in the range from about 8 GPa to about 50 GPa, as measured by a Berkovich Indenter Hardness Test along indentation depths of about 100 nm or greater, and

wherein the article comprises a color shift of less than about 2, when viewed at an incident illumination angle in the range from about 0 degrees to about 60 degrees from normal incidence under an illuminant.

18. The article of claim 17, wherein the first low RI sub-layer comprises at least one of SiO₂, Al₂O₃, GeO₂, SiO, AlO_xN_y, SiO_xN_y, Si_uAl_vO_xN_y, MgO, MgF₂, BaF₂, CaF₂, DyF₃, YbF₃, YF₃, and CeF₃, and wherein the second high RI sub-layer comprises at least one of Si_uAl_vO_xN_y, Ta₂O₅, Nb₂O₅, MN, Si₃N₄, AlO_xN_y, SiO_xN_y, HfO₂, TiO₂, ZrO₂, Y₂O₃, Al₂O₃, and MoO₃.

19. The article of claim 17, wherein the scratch-resistant layer comprises at least one of MN, Si₃N₄, AlO_xN_y, SiO_xN_y, Al₂O₃, SixCy, Si_xO_yC_z, ZrO₂, TiO_xN_y, diamond, diamond-like carbon, and Si_uAl_vO_xN_y.

20. The article of claim 17, wherein the article further comprises a crack mitigating layer.

21. An article comprising:

a substrate having a surface; and

an optical film disposed on the substrate surface forming a coated surface, the optical film comprising a scratch-resistant layer;

wherein the article comprises a color shift of about 2 or less, when viewed at an incident illumination angle in the range from about 0 degrees to about 60 degrees from normal incidence under an illuminant,

wherein the article comprises an abrasion resistance comprising about 1% haze or less, as measured using a hazemeter having an aperture, wherein the aperture has a diameter of about 8 mm, and

wherein the abrasion resistance is measured after a 500-cycle abrasion using a Taber Test.

22. The article of claim 21, wherein the optical film further comprises an optical interference layer disposed between the scratch-resistant layer and the substrate.

23. The article of claim 22, wherein the optical interference layer comprises a first low refractive index RI sub-layer and a second high RI sub-layer.

24. The article of claim 23, wherein the difference between the refractive index of the first low RI sub-layer and the refractive index of the second high RI sub-layer is about 0.01 or greater.

25. The article of claim 21, wherein the substrate comprises an amorphous substrate or a crystalline substrate.

26. An article comprising:

a substrate having a surface; and

an optical film disposed on the substrate surface forming a coated surface, the optical film comprising a scratch-resistant layer;

wherein the article comprises a color shift of about 2 or less, when viewed at an incident illumination angle in the range from about 0 degrees to about 60 degrees from normal incidence under an illuminant,

wherein the article comprises an abrasion resistance comprising a scattered light intensity of about 0.1 (in units of 1/steradian) or less, at a polar scattering angle in the range from about 15°

to about 60°

, as measured at normal incidence in transmission using an imaging sphere for scatter measurements, with a 2 mm aperture at 600 nm wavelength, and

wherein the abrasion resistance is measured after a 500-cycle abrasion using a Taber Test.

27. The article of claim 26, wherein the abrasion resistance comprises any one or more of:

a scattered light intensity of about 0.05 (in units of 1/steradian) or less, at a polar scattering angle of about 40 degrees or less, as measured at normal incidence in transmission using an imaging sphere for scatter measurements, with a 2 mm aperture at 600 nm wavelength, and

a scattered light intensity of about 0.1 (in units of 1/steradian) or less, at a polar scattering angle of about 20 degrees or less, as measured at normal incidence in transmission using an imaging sphere for scatter measurements, with a 2 mm aperture at 600 nm wavelength.

28. The article of claim 26, wherein the optical film further comprises an optical interference layer disposed between the scratch-resistant layer and the substrate.

29. The article of claim 28, wherein the optical interference layer comprises a first low refractive index RI sub-layer and a second high RI sub-layer, and wherein the difference between the refractive index of the first low RI sub-layer and the refractive index of the second high RI sub-layer is about 0.01 or greater.

30. The article of claim 26, wherein the substrate comprises an amorphous substrate or a crystalline substrate.