Multi-layer wet-dry hardcoats including dual-sided wet hardcoats for flexible cover lens structures, and related methods and coating systems

A method of forming a cover lens structure, comprising:

• depositing a first hardcoat layer on a first side of a substrate layer using a first wet deposition process;
• depositing a second hardcoat layer on a second side of the substrate layer using a second wet deposition process;
• depositing one or more adhesion promotion layers above the second side;
• depositing a third hardcoat layer above the second side using a dry deposition process;
• depositing an anti-smudge layer above the second side;
• and
• disposing the cover lens structure to position the first hardcoat layer above a touch panel and a display structure of a display device.

A coating system, comprising:

• a first rotatable stem configured to receive a first storage reel;
• a second rotatable stem configured to receive a second storage reel;
• a plurality of transfer rollers disposed along a transfer path between the first storage reel and the second storage reel;
• a coating module interfacing with a first section of the transfer path, the coating module comprising one or more of:
• a bar, a slot die, one or more comma rollers, a micro-gravure, a gravure, one or more cast nozzles, one or more cast rollers, or one or more spray nozzles;
• and
• a curing module interfacing with a second section of the transfer path.