TRANSPARENT AND HIGHLY STABLE SCREEN PROTECTOR
20170362697 · 2017-12-21
Inventors
Cpc classification
B23K26/53
PERFORMING OPERATIONS; TRANSPORTING
B23K26/08
PERFORMING OPERATIONS; TRANSPORTING
G06F3/041
PHYSICS
B32B33/00
PERFORMING OPERATIONS; TRANSPORTING
B23K2103/172
PERFORMING OPERATIONS; TRANSPORTING
G06F2203/04107
PHYSICS
B32B2457/20
PERFORMING OPERATIONS; TRANSPORTING
B23K26/0624
PERFORMING OPERATIONS; TRANSPORTING
C23C16/01
CHEMISTRY; METALLURGY
B23K26/359
PERFORMING OPERATIONS; TRANSPORTING
B23K2103/00
PERFORMING OPERATIONS; TRANSPORTING
B23K2101/36
PERFORMING OPERATIONS; TRANSPORTING
B32B38/10
PERFORMING OPERATIONS; TRANSPORTING
G06V40/1329
PHYSICS
International classification
C23C16/01
CHEMISTRY; METALLURGY
C23C14/00
CHEMISTRY; METALLURGY
B23K26/00
PERFORMING OPERATIONS; TRANSPORTING
Abstract
The invention relates to a method for producing at least one solid layer and comprises at least the steps of: providing a carrier substrate (4) having a sacrificial layer (8) arranged thereon or arranging a sacrificial layer (8) on the provided carrier substrate (4), producing a useful layer (6) by way of chemical or physical gas phase deposition on the sacrificial layer (8) to form a multi-layer arrangement (2), removing the useful layer (6) as a result of a material weakening produced between the useful layer (6) and the carrier substrate (4), said material weakening being brought about by modifications (12) to the sacrificial layer (8) which were produced means of laser beams (10).
Claims
1. A method for producing at least one solid layer, comprising at least the steps of: Providing a carrier substrate (4) having a sacrificial layer (8) disposed thereon or arranging a sacrificial layer (8) on the provided carrier substrate (4), Generating a wear layer (6) on the sacrificial layer (8) by chemical or physical vapour deposition to form a multilayer arrangement (2), Separating the wear layer (6) as a consequence of a material weakening created between the wear layer (6) and the carrier substrate (4) wherein the material weakening is caused by modifications (12) generated in the sacrificial layer (8) by LASER beams (10).
2. Method for coating at least a transparent body (14), particularly a display glass (20) or a display protector layer, comprising at least the steps of: Arranging or producing the at least partly transparent body (14), particularly made of plastic, glass or a ceramic material, on a wear layer (6) produced according to claim, or Providing a carrier substrate (4) with a sacrificial layer (8) disposed thereon or arranging a sacrificial layer (8) on the carrier substrate (4) provided, Generating a wear layer (6) by chemical or physical vapour deposition on the sacrificial layer (8) to form a multilayer arrangement (2), Arranging or generating the at least partially transparent body (14) on the wear layer (6), Separating the wear layer (6) as a consequence of a material weakening created between the wear layer (6) and the carrier substrate (4) wherein the material weakening is caused by modifications (12) generated in the sacrificial layer (8) by LASER beams (10).
3. Method according to claim 2, characterised in that the at least partly transparent body (14) is made from a polymer material, wherein the transparent body (14) has a lower modulus of elasticity than the wear layer (6), particularly a modulus of elasticity that is lower by a factor of at least 10 or a factor of 100.
4. Method according to claim 2 or 3, characterised in that the wear layer (6) and the transparent body (14) have an external shape with at least one curved portion (22), wherein the modifications (12) for conducting a crack in the sacrificial layer (8) and/or the wear layer (6) are created corresponding to the external shape of the wear layer (6), or wherein the sacrificial layer (8) is produced with a surface that is curved in such a manner, or the surface of the sacrificial layer (8) is processed after production of the sacrificial layer (8) in such manner that it forms a curved surface shape, and the wear layer (6) is created with a corresponding shape due to its creation on the curved surface of the sacrificial layer (8) or the wear layer (6) substantially as a solid layer with a two-dimensional flat plane and the transparent body (14) has an external shape which includes at least one curved portion, wherein the wear layer (6) is applied to the transparent body (14) in such manner, particularly by bonding, that the wear layer (6) conforms to the outer shape of the transparent body (14).
5. Method according to any one of the preceding claims, characterised in that the wear layer (6) consists of a ceramic material, particularly silicon carbide (SiC) or aluminium oxide (Al.sub.2O.sub.3) and is created in an amorphous or polycrystalline state particularly by sputtering, wherein the wear layer (6) the ceramic material is cured by means of thermal treatment at temperatures higher than 500° C. preferably higher than 700° C. and particularly preferably higher than 1000° C. after or during production of the wear layer (6), wherein the ceramic material preferably comprises corundum, which is produced in a gamma phase or alpha phase.
6. Method according to any one of the preceding claims, characterised in that the wear layer (6) is thinner than 100 μm and preferably thinner than 50 μm and particularly preferably 20 μm thick or thinner than 20 μm.
7. Method according to any one of the preceding claims, characterised in that the modifications (12) are local cracks in the crystal lattice and/or are material parts transferred into another phase and/or the modifications (12) are created by means of LASER radiation (10) introduced over an outer surface of the multilayer arrangement (2) from at least one picosecond or femtosecond LASER.
8. Method according to any one of the preceding claims, characterised in that the wear layer (6) is separated by means of a crack guided between the wear layer (6) and the carrier substrate (4) wherein the crack is guided by modifications (12) generated in the sacrificial layer (8) by LASER beams (10) and/or wherein stresses for initiating and/or propagating the crack are generated via a thermal shock to a stress-inducing layer (16) arranged additionally on the multilayer arrangement (2) the stress-inducing layer (16) contains or consists of a polymer, particularly polydimethylsiloxane (PDMS), wherein the thermal shock is applied in such manner that the polymer undergoes a glass transition, wherein the temperature of the stress-inducing layer (16) is adjusted particularly by means of liquid nitrogen to a temperature at which the polymer undergoes at least partial and preferably complete glass transition, in which the temperature of polymer is preferably cooled to a temperature below room temperature or below 0° C. or below −50° C. or below −100° C. or below −110° C., particularly to a temperature below the glass transition temperature of the stress-inducing layer (16), or the temperature is adjusted a temperature above room temperature, particularly to a temperature between 40° C. and 180° C.
9. Method according to any one of the preceding claims, characterised in that the LASER beams (10) are emitted by at least one LASER device (11), wherein the LASER device (11) for providing the LASER beams (10) to be introduced into the wear layer (6) and/or the sacrificial layer (8) is configured in such manner that the LASER beams (10) emitted thereby create the modifications (12) at predetermined locations within the wear layer (6) and/or the sacrificial layer (8), wherein the LASER device (11) is adjusted such that the LASER beams (10) emitted thereby for generating the modifications (12) penetrate the wear layer (6) and/or the sacrificial layer (8) to a defined depth of less than 200 μm, preferably less than 100 μm and more preferably less than 50 μm and particularly preferably less than 20 μm, wherein the LASER device (11) has a pulse duration of less than 10 ps preferably less than 1 ps and particularly preferably less than 500 fs.
10. Method according to any one of the preceding claims, characterised in that the LASER device (11) comprises a femtosecond LASER (fs LASER) and the energy of the LASER beams (10) of the fs-LASER is chosen such that the propagation of the damage of any modification (12) in the wear layer (6) and/or the sacrificial layer (8) is less than 3 times the Rayleigh length, preferably less than the Rayleigh length and particularly preferably less than one-third of the Rayleigh length and/or the wavelength of the LASER beams (10) of the fs-LASER is chosen such the absorption by the wear layer (6) and/or the sacrificial layer (8) is less than 10 cm.sup.−1 and preferably less than 1 cm.sup.−1 and more preferably less than 0.1 cm.sup.−1 and/or the individual modifications (12) are each generated as a consequence of a o multi-photon excitation effected by the fs-LASER.
11. Method according to any one of the preceding claims, characterised in that the carrier substrate (4) is crystalline and the sacrificial layer (8) serves as a transfer layer, wherein the transfer layer (8) is arranged between the carrier substrate (4) and the wear layer (6) and is joined to the carrier substrate (4) and the wear layer (6), wherein the sacrificial layer (8) is designed such that it transfers a crystal lattice information of the carrier substrate (4) to the wear layer (6), wherein the wear layer (6) is produced or treated in such manner that at least part thereof has a crystal lattice, wherein the formation of the crystal lattice is based at least in part on the crystal lattice information provided by the transfer layer (8).
12. Method according to claim 11, characterised in that the wear layer (6) converted from an amorphous state to an at least partially, particularly mostly crystalline state as a consequence of a temperature change, wherein the wear layer (6) receives the crystal lattice information provided by the transfer layer (8) when changing states, wherein the temperature change is preferably effected by exposure to an electron beam.
13. Method according to claim 10 or claim 11, characterised in that the sacrificial layer (8) is produced on the carrier substrate (4) in a crystalline state or arranged on the carrier substrate (4) in an amorphous state, and is converted at least partly and preferably mostly or completely to a crystalline state by a thermal shock, or the carrier substrate (4) and the wear layer (6) consist of the same material, particularly sapphire or silicon carbide, and the sacrificial layer (8) consists of a different material from the material of the carrier substrate (4) and the wear layer (6), particularly silicon.
14. Method according to any one of claims 10 to 12 characterised in that the wear layer (6) is thinner than 100 μm and preferably thinner than 50 μm and particularly preferably 20 μm thick or thinner than 20 μm and the sacrificial layer (8) is thinner than 10 μm and preferably thinner than 5 μm and particularly preferably 1 μm thick or thinner than 1 μm.
15. Multilayer transparent device, particularly a display element or fingerprint sensor element or glasses lens or visor, particularly a helmet visor, comprising at least an at least partially transparent body (14) and an at least partially transparent wear layer (6) connected to the transparent body (14), wherein the transparent body (14) preferably contains a polymer material or a ceramic material or a viscous material such as glass, and said wear layer (6) consists of a ceramic material, wherein the wear layer (6) is harder than the transparent body (14) and wherein the production of the multilayer transparent device comprises at least the following steps: Generating the wear layer (6) by chemical or physical vapour deposition and Arranging the transparent body (14) on the wear layer (6), particularly by generation or bonding.
16. Electronic device (18), at least comprising an image signal processing device and a display device for outputting an image signal processed by the image signal processing device, characterised in that at least the display device and/or an optically conductive further part, such as a camera cover or a fingerprint sensor or a separate area of a touch screen, is at least partially or completely overlaid by a multilayer transparent display protector according to claim 14.
Description
[0033] In the drawing:
[0034]
[0035]
[0036]
[0037]
[0038]
[0039]
[0040]
[0041]
[0042]
[0043]
[0044]
[0045] In
[0046] In
[0047]
[0048] In this way, so many modifications 12 are generated that a crack forms and spreads and a weakening of the material is created such that the multilayer arrangement is separated or split or fragmented into two solid parts.
[0049] Alternatively within the scope of the present invention, the step described with reference to
[0050]
[0051]
[0052] In addition, this representation shows that the screen or display protector 20 has a curved portion 22. This is advantageous because it allows ergonomic or more ergonomic operation of electronic device 18 and an enlargement of the display area. According to a variant which is not shown, however, it is possible that the curved portion comprises the complete display in both a convex concave or a spherical shape.
[0053]
[0054]
[0055]
[0056]
[0057]
[0058]
[0059]
[0060] In the variant shown, the surface of transparent body 14 on which wear layer 6 is arranged, and wear layer 6 have different curvatures. In this context (as shown) it is also conceivable that wear layer 6 is provided or produced with a flat conformation. Wear layer 6 may thus be deformed when it is arranged on the surface of transparent body 14, particularly to conform to the shape of the surface of transparent body 14 on which it is arranged or to which it is transferred. This is possible because wear layer 6 is very thin, lending it great flexibility.
[0061] Alternatively, it is conceivable that the surface of transparent body 14 on which wear layer 6 is arranged and wear layer 6 are conformed negatively and correspondingly to each other. Wear layer 6 is preferably created in such a shape that it may be arranged flush on the surface of transparent body 14 without deformation.
[0062] In this way, a solid body layer or wear layer 6 is prepared according to the inventive method. Wear layer 6 is preferably produced by the steps listed below: Providing a carrier substrate 4 with a sacrificial layer 8 arranged thereon or arranging a sacrificial layer 8 on the carrier substrate 4 provided, producing a wear layer 6 on sacrificial layer 8 by chemical or physical vapour deposition to form a multilayer arrangement 2, separating wear layer 6 as a result of a material weakness generated between wear layer 6 and carrier substrate 4, wherein the material weakening is caused by modifications 12 created in sacrificial layer 8 by means of LASER beams 10. The wear layer 6 produced in this way is then preferably structured on one or both sides as a solid body layer in the form of a two-dimensional flat plane and is arranged on a transparent body 14 which has an external shape that preferably has at least one curved portion, wherein wear layer 6 is applied particularly by bonding as a protective layer to transparent body 14, particularly a component of an electronic terminal such as a smart watch, a smart phone, tablet PC, TV, etc., in such manner that at least parts and preferably most in terms of area or all of wearing surface 6 conforms to the external shape of transparent body 14. In this way, the present invention provides that capability to protect transparent bodies such as display glasses of a smart watch, a smart phone, a tablet PC, TV, etc. effectively against damage by application of the wear layer, particularly made of sapphire.
[0063]
[0064]
[0065] In
[0066]
[0067]
[0068] The present invention thus relates to a method for coating at least one transparent body, particularly a display glass or a screen protection layer or a glasses lens or a helmet visor, particularly a motorcycle helmet visor. The inventive method comprises at least the steps of: forming or providing a multilayer arrangement, consisting of at least a crystalline carrier substrate, a wear layer and a transfer layer, wherein the transfer layer is arranged between the carrier substrate and the wear layer and joined to the carrier substrate and the wear layer, wherein the transfer layer is designed such that it transmits a crystal lattice information of the carrier substrate to the wear layer, wherein the wear layer is generated or treated in such manner that at least a part thereof has a crystal lattice, wherein the formation of the crystal lattice is determined at least in part by the crystal lattice information provided by the transfer layer, joining the wear layer with the at least partially transparent body, particularly a functional layer, exposing at least a portion of the multilayer arrangement to LASER beams to at least partially create modifications in the transfer layer or in the area of the join between the transfer layer and the carrier substrate or in the wear layer to generate a detachment zone, separating the multilayer arrangement along the detachment zone created particularly as a consequence of the action of the LASER beams.
[0069] Wear layer 6 is preferably designed to be mounted on a transparent body 14 such that it has at least one surface corresponding to the shape of the surface at which wear layer 6 is to be mounted on transparent body 14 or at least partially transparent body 14. Wear layer 6 preferably has a surface with a single and preferably multiple curves and particularly preferably two surfaces which are mutually parallel and describe a single curve and more preferably multiple curves. Wear layer 6 is preferably produced such that the singly curved or multiply curved surface is in a state in which wear layer 6 is not subject to constraining forces. This is advantageous because in this case wear layer 6 is not subject to any internal stresses generated from the outside and in this state it can be mounted on transparent body 14. Alternatively, however, and without departing from the scope of the present invention, wear layer 6, may also be reshaped only by the introduction of external forces to assume a shape having a singly curved or multiply curved portion or surface or surface portion. Wear layer 6, which preferably consists of sapphire or preferably contains sapphire is thus preferably produced having at least one surface that is spherical, particularly curved once or multipled time, particularly curved twice or more than twice, curved three times or more than three times, or curved four times or more than four times. Preferably, a cohesion agent, particularly an adhesion promoter or adhesive, particularly a thermosetting polymer is applied to or produced on the preferably at least one spherically shaped surface of wear layer 6, particularly the sapphire layer and/or to a surface of transparent body 14 on which wear layer 6 is arranged, to produce a cohesive connection between transparent body 14, particularly the glass such as the lens or watch glass, and wear layer 6. Preferably in this way, a sapphire layer with a spherically shaped surface is formed and is arranged on an at least partially transparent body, such as a watch glass or a glasses lens or a visor, cohesively by means of a thermosetting polymer.
[0070] Additionally or alternatively, the present invention may relate to a method for coating at least one transparent body 14, particularly a display glass or a display protection layer, comprising at least the steps of: forming or providing a multilayer arrangement 2 consisting of at least a crystalline carrier substrate 4, a wear layer 6 and a transfer layer 8, wherein transfer layer 8 is disposed between carrier substrate 4 and wear layer 6 and joined to carrier substrate 4 and wear layer 6, wherein transfer layer 8 is designed such that it transmits a crystal lattice information of carrier substrate 4 to wear layer 6, wherein the wear layer 6 is generated or treated in such manner that at least a part thereof has a crystal lattice, wherein the formation of the crystal lattice is determined at least in part on the basis of the crystal lattice information imparted by transfer layer (8), joining wear layer 6 with the at least partially transparent body 14, exposing at least a portion of multilayer arrangement 2 to LASER beams 10 for at least partial creation of modifications 12 in transfer layer 8 or in the region of the joint between transfer layer 8 and carrier substrate 4 or wear layer 6 to generate a detachment zone, separating the multilayer arrangement 2 along the detachment zone.
[0071] At least as regards the objects of
[0072] The present invention further relates in preferred manner to a multilayered transparent device, particularly a display element or fingerprint sensor element or glasses lens or a visor, particularly a helmet visor. The multilayered transparent device comprising in this context preferably at least one at least partially transparent body and one at least partially transparent wear layer 6 connected to transparent body 14, wherein transparent body preferably contains a polymer material or a ceramic material or a viscous material such as glass, and wear layer 6 is made of a ceramic material, wherein wear layer 6 is harder than transparent body 14 and wherein production of the multilayer transparent device preferably includes the following step: generating the wear layer 6 by chemical or physical vapour deposition, and arranging transparent body 14 on wear layer 6, particularly by generation or bonding.
[0073] A thermosetting polymer is advantageously used for bonding the wear layer, which is preferably a sapphire layer, and the display to be protected or the glasses lens or visor to be protected. These polymers can be cured at relatively low temperatures, below 200° C., and provide stronger adhesion than thermoplastic materials. Moreover, they are very easily processable in their uncured form, particularly as a thin intermediate film of optically transparent layers 6 and 14. It is particularly advantageous that the refractive index of thermosetting polymers can be adjusted to match the refractive index of the surface which is to be protected (typically n˜1.5). In this context, bonding may be carried out as preferred before separating the wear layer 6, particularly a sapphire layer, but also after the separation of the wear layer 6, particularly the sapphire layer.
[0074] For convex or spherical transparent bodies, the base for creating wear layer 6 may also be adapted so that it already has a spherical or convex profile and wear layer 6 already assumes the profile, or at least approximates the profile of the surface to be protected when it is created. This is particularly advantageous because it makes possible curves and shapes in three dimensions which a flat wear layer 6 would otherwise not be able to assume, or might lead to undesirable stresses or distortions on the surface to be protected if the protective layer were deformed subsequently. In the case of non-flat layers, it is advantageous to bond first and remove afterwards. This avoids breaking or tearing the thin protective film.
[0075] The invention relates to a method for producing at least one solid layer, at least comprising the steps of: Providing a carrier substrate 4 with a sacrificial layer 8 arranged thereon or disposing a sacrificial layer 8 on the provided carrier substrate 4, producing a wear layer 6 by chemical or physical vapour deposition on sacrificial layer 8 to form a multilayer arrangement 2, separating wear layer 6 by means of a material weakening between wear layer 6 and carrier substrate 4 induced as consequence of a controlled crack, wherein the crack brings about the material weakening in controlled manner as a result of modifications created in sacrificial layer 8 by LASER beams 10.
TABLE-US-00001 LIST OF REFERENCE NUMBERS 2 Multilayer arrangement 14 Transparent body 4 Carrier substrate 18 Electronic device 6 Wear layer 20 Display glass 8 Sacrificial layer 22 Curved portion 10 LASER beams 23 Selection element 11 LASER 24 Frame 12 Modifications 102 Solid body 103 Substrate 116 Second flat surface portion 104 Solid layer 118 Radiation source 105 Sacrificial layer 120 Stabilising element 106 Radiation 130 First beam portion 108 Detachment plane 132 Second beam portion 112 Retaining layer 134 Site of fault creation 114 First flat surface portion