Articles with patterned coatings

Patent metadata

Field	Value
Publication number	US-2019144331-A1
Application number	US-201916249199-A
Country	US
Kind code	A1
Filing date	Jan 16, 2019
Priority date	Mar 21, 2014
Publication date	May 16, 2019
Grant date	—

Abstract

Embodiments of a article including include 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

1 - 43 . (canceled)

44 . An article, comprising: a patterned coating with a bimodal distribution of coating thickness, the bimodal distribution comprising a lower-mode thickness in a range from 10 nm to 90 nm, and a higher-mode thickness in a range from about 50 nm to about 5000 nm.

45 . The article of claim 44 , 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.

46 . The article of claim 44 , further comprising a substrate, whereby the patterned coating is disposed on a surface of the substrate.

47 . The article of claim 46 , 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.

48 . The article of claim 46 , 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.

49 . The article of claim 44 , wherein the lower-mode thickness comprises a full-width- at half-maximum (FWHM) of about 1 nm or less and the higher-mode thickness comprises a FWHM greater than the FWHM of the lower-mode thickness.

50 . The article of claim 49 , wherein the FWHM of the higher-mode thickness is less than differences in surface topographical heights of the lower-mode thickness and the higher-mode thickness.

51 . The article of claim 50 , wherein the patterned coating comprises a plurality of peaks and a plurality of valleys between the peaks.

52 . The article of claim 51 , wherein the patterned coating at the plurality of valleys comprises a coating thickness of at least about 5 nm.

53 . The article of claim 46 , 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%.

54 . The article of claim 44 , 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.

55 . A consumer electronic device, comprising: a patterned coating with a bimodal distribution of coating thickness, the bimodal distribution having 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.

56 . The consumer electronic device of claim 55 , 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.

57 . The consumer electronic device of claim 55 , wherein the FWHM of the higher-mode thickness is at most two times the difference in surface topographical heights of the lower-mode thickness and the higher-mode thickness.

58 . The consumer electronic device of claim 55 , wherein the patterned coating comprises a plurality of peaks and a plurality of valleys between the peaks.

59 . The consumer electronic device of claim 55 , wherein the lower-mode thickness is in a range from about 0 nm to about 100 nm, and the higher-mode thickness is in a range from about 200 nm to about 5000 nm.

Assignees

• Corning Inc

Inventors

• Hart Shandon Dee
• Hu Guangli
• Smith Nicholas James

Classifications

• C09D1/02

  alkali metal silicates · CPC title

• C03C2217/42

  consisting of particles only · CPC title

• C03C2204/00

  Glasses, glazes or enamels with special properties · CPC title

• C03C2217/478

  Silica · CPC title

• C03C2217/78

  Coatings specially designed to be durable, e.g. scratch-resistant · CPC title