Anti-Glare Coatings with Sacrificial Surface Roughening Agents and Methods for Forming the Same
AssigneeIntermolecular, Inc.
InventorsNikhil Kalyankar, Scott Jewhurst
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Abstract
Embodiments provided herein describe optical coatings, panels having optical coatings thereon, and methods for forming optical coatings and panels. A sol-gel matrix is formed above a surface of a substrate. Organic micro-particles are embedded in a surface of the sol-gel matrix. A heat treatment is applied to the sol-gel matrix and the embedded plurality of organic micro-particles. Substantially all of the organic micro-particles are removed during the heat treatment, and after the heat treatment, the sol-gel matrix has a surface roughness suitable to provide anti-glare properties.
Claims20
A method of forming an anti-glare coating, the method comprising:
- forming a sol-gel matrix above a surface of a substrate;
- embedding a plurality of organic micro-particles in a surface of the sol-gel matrix, wherein the plurality of organic micro-particles have a size distribution between about 0.1 micrometers (μm) and 10 μm;
- applying a heat treatment to the sol-gel matrix and the embedded plurality of organic micro-particles, wherein substantially all of the embedded plurality of organic micro-particles are removed during the heat treatment, and after the heat treatment, the sol-gel matrix has an effective surface roughness between 0.2 μm and 0.8 μm.
A method of forming an anti-glare coating, the method comprising:
- forming a sol-gel matrix, wherein the sol-gel matrix comprises a plurality of organic micro-particles having a size distribution between about 0.1 μm and 10 μm;
- applying the sol-gel matrix to a surface of a substrate, wherein the plurality of organic micro-particles segregate to a top surface of the sol-gel matrix after the applying of the sol-gel matrix;
- applying a heat treatment to the sol-gel matrix, wherein substantially all of the plurality organic micro-particles are removed from the sol-gel matrix during the heat treatment, and after the heat treatment, the sol-gel has an effective surface roughness between 0.2 μm and 0.8 μm.
A method of forming an anti-glare coating, the method comprising:
- forming a sol-gel matrix;
- forming a particle dispersion formulation, wherein the particle dispersion formulation comprises a plurality of organic micro-particles having a size distribution between about 0.1 μm and 10 μm;
- applying the sol-gel matrix to a surface of a substrate;
- applying the particle dispersion formulation to a top surface of the sol-gel matrix, the sol-gel matrix and the particle dispersion formulation jointly forming a coating;
- applying a heat treatment to the coating, wherein substantially all of the plurality of organic micro-particles are removed from the coating during the heat treatment, and after the heat treatment, the coating maintains a surface roughness between 0.2 μm and 0.8 μm.
Dependencies are inferred from the claim text.