Anti-Glare Coatings with Sacrificial Surface Roughening Agents and Methods for Forming the Same

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.

What is claimed: 
     
         1 . 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.   
     
     
         2 . The method of  claim 1  wherein the sol-gel matrix has a thickness between 1 μm and 100 μm. 
     
     
         3 . The method of  claim 1  wherein the plurality of organic micro-particles comprise polystyrene beads, polymethylmethacrylate (PMMA) beads, or a combination thereof. 
     
     
         4 . The method of  claim 1  wherein each of the plurality organic micro-particles have one of a solid, hollow, or core-shell construction. 
     
     
         5 . The method of  claim 1  wherein the embedding of the plurality of organic micro-particles into the surface of the sol-gel matrix is performed using high velocity spray, application of a mechanical force, or a combination thereof. 
     
     
         6 . The method of  claim 1  wherein the heat treatment comprises heating the sol-gel matrix and the embedded plurality of organic micro-particles to a temperature in the range of 450° C. to 700° C. 
     
     
         7 . 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.   
     
     
         8 . The method of  claim 7  wherein the sol-gel matrix has a thickness between 1 μm and 100 μm. 
     
     
         9 . The method of  claim 7  wherein the plurality of organic micro-particles comprise polystyrene beads, polymethylmethacrylate (PMMA) beads, or a combination thereof. 
     
     
         10 . The method of  claim 7  wherein each of the plurality organic micro-particles have one of a solid, hollow, or core-shell construction. 
     
     
         11 . The method of  claim 7  wherein the heat treatment comprises heating the sol-gel matrix to a temperature in the range of 450° C. to 700° C. 
     
     
         12 . The method of  claim 7  wherein the segregation of the plurality of organic micro-particles to the top surface of the sol-gel matrix is facilitated by at least one of the use of micro-particles that are buoyant in the sol-gel matrix, a surface segregating surfactant within the sol-gel matrix, or by the application of an external electric field. 
     
     
         13 . 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.   
     
     
         14 . The method of  claim 13  wherein the coating has a thickness between 1 μm and 100 μm. 
     
     
         15 . The method of  claim 13  wherein the plurality of organic micro-particles comprise polystyrene beads, polymethylmethacrylate (PMMA) beads, or a combination thereof. 
     
     
         16 . The method of  claim 13  wherein each of the plurality organic micro-particles have one of a solid, hollow, or core-shell construction. 
     
     
         17 . The method of  claim 13  wherein the heat treatment comprises heating the coating to a temperature in the range of 450° C. to 700° C. 
     
     
         18 . The method of  claim 13  wherein the applying of the sol-gel matrix and the applying of the particle dispersion formulation occur simultaneously. 
     
     
         19 . The method of  claim 13  wherein the applying of the sol-gel matrix and the applying of the particle dispersion formulation are performed with a coating mechanism having a first slot and a second slot, wherein the sol-gel matrix is dispensed from the first slot and the particle dispersion formulation is dispensed from the second slot. 
     
     
         20 . The method of  claim 13 , wherein the plurality of organic micro-particles are completely embedded within the coating.