Articles with patterned coatings

Patent metadata

Field	Value
Publication number	US-10214445-B2
Application number	US-201515128004-A
Country	US
Kind code	B2
Filing date	Mar 17, 2015
Priority date	Mar 21, 2014
Publication date	Feb 26, 2019
Grant date	Feb 26, 2019

Abstract

Embodiments of an article including a substrate and a patterned coating are provided. In one or more embodiments, when a strain is applied to the article, the article exhibits a failure strain of 0.5% or greater. Patterned coating may include a particulate coating or may include a discontinuous coating. The patterned coating of some embodiments may cover about 20% to about 75% of the surface area of the substrate. Methods for forming such articles are also provided.

First claim

What is claimed is:

1. An article comprising:
a substrate including a surface;
a patterned coating disposed on the surface forming a coated surface,
wherein, when a strain is applied to the article, the article exhibits a failure strain of 0.5% or greater,
wherein the patterned coating comprises a bimodal distribution of coating thickness, the bimodal distribution comprising a lower-mode thickness in the range from 10 nm to 90 nm, and a higher-mode thickness in the range from about 50 to about 5000 nm, and
wherein the substrate surface has a surface area and the patterned coating covers at least about 20% of the surface area.

2. The article of claim 1 , wherein, when a strain is applied to the article, the patterned coating has a first region and a second region, and wherein the first region comprises a first tensile stress and the second region comprises a second tensile stress greater than the first tensile stress.

3. The article of claim 1 , wherein, when a strain is applied to the article, the substrate comprises a maximum substrate tensile stress and the patterned coating has at least one local region comprising a local tensile stress that is less than the maximum substrate tensile stress.

4. The article of claim 1 , wherein, when a strain is applied to the article, the substrate comprises a maximum substrate tensile strain and the patterned coating has at least one local region comprising a local tensile strain that is less than the maximum substrate tensile strain.

5. The article of claim 1 , wherein the patterned coating comprises a bimodal distribution of coating thickness, the bimodal distribution comprising a lower-mode thickness comprising a full-width-at half-maximum (FWHM) of about 1 nm or less and a higher-mode thickness comprising a FWHM greater than the FWHM of the lower-mode thickness.

6. The article of claim 5 , wherein the FWHM of the higher-mode thickness is less than the difference in the surface topographical heights of the lower-mode thickness and the higher-mode thickness.

7. The article of claim 6 , wherein the patterned coating comprises a plurality of peaks and a plurality of valleys between the peaks.

8. The article of claim 7 , wherein the patterned coating at the plurality of valleys comprises a coating thickness of at least about 5 nm.

9. The article of claim 1 , wherein the substrate exhibits an average strain-to-failure that is greater than an amount selected from 0.7%, 1.0%, 1.5%, 2%, 2.5% and 3%.

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

11. A consumer electronic device comprising:
a substrate including a surface;
a patterned coating disposed on the surface,
wherein, when a strain is applied to the article, the crack onset strain of the patterned coating is greater than 0.5%,
wherein the patterned coating comprises a bimodal distribution of coating thickness, the bimodal distribution comprising a lower-mode thickness comprising a full-width-at half-maximum (FWHM) of about 1 nm or greater, and a higher-mode thickness comprising a FWHM greater than the FWHM of the lower-mode thickness, and
wherein the substrate surface has a surface area and the patterned coating covers at least about 20% of the surface area.

12. The consumer electronic device of claim 11 , wherein the patterned coating comprises a hardness of 8 GPa or greater, as measured by a Berkovich Indenter Hardness Test along indentation depths of about 100 nm or greater.

13. The consumer electronic device of claim 11 , wherein the FWHM of the higher-mode thickness is at most two times the difference in the surface topographical heights of the lower-mode thickness and the higher-mode thickness.

14. The consumer electronic device of claim 11 , wherein the patterned coating comprises a plurality of peaks and a plurality of valleys between the peaks.

15. The consumer electronic device of claim 11 , wherein the patterned coating comprises a bimodal distribution of coating thickness, the bimodal distribution comprising a lower-mode thickness in the range from about 0 to about 100 nm, and a higher-mode thickness in the range from about 200 to about 5000 nm.

Assignees

• Corning Inc

Inventors

• Hart Shandon Dee
• Hu Guangli
• Smith Nicholas James

Classifications

• Y10T428/24926

  including ceramic, glass, porcelain or quartz layer · CPC title

• Y10T428/24917

  including metal layer · CPC title

• C03C2217/948

  Layers comprising indium tin oxide [ITO] · CPC title

• C03C2217/732

  made of a single layer · CPC title

• C03C2217/478

  Silica · CPC title