Coatings of non-planar substrates and methods for the production thereof

Abstract

A coated article is described herein that may comprise a substrate and an optical coating. The substrate may have a major surface comprising a first portion and a second portion. A first direction that is normal to the first portion of the major surface may not be equal to a second direction that is normal to the second portion of the major surface. The optical coating may be disposed on at least the first portion and the second portion of the major surface. The coated article may exhibit at the first portion of the substrate and at the second portion of the substrate hardness of about 8 GPa or greater at an indentation depth of about 50 nm or greater as measured on the anti-reflective surface by a Berkovich Indenter Hardness Test.

What is claimed is: 
     
         1 . A coated article, comprising:
 a chemically strengthed non-planar glass-ceramic substrate; and   an optical coating on the chemically strengthened glass-ceramic substrate, the optical coating comprising a scratch-resistant layer and a compositional gradient layer,   wherein the compositional gradient layer extends from the scratch-resistant layer to the chemically strengthened glass-ceramic substrate.   
     
     
         2 . The coated article of  claim 1 , wherein:
 the chemically strengthened non-planar glass-ceramic substrate having a major surface, the major surface comprising a first portion and a second portion, wherein a first direction that is normal to the first portion of the major surface is not equal to a second direction that is normal to the second portion of the major surface, and the angle between the first direction and the second direction is in a range of from about 10 degrees to about 180 degrees.   
     
     
         3 . The coated article of  claim 1 , wherein:
 the coated article exhibits a photopic reflectance as measured at the optical coating at the first portion of the major surface of about 10% or less, wherein the photopic reflectance of the first portion is measured at a first incident illumination angle relative to the first direction, wherein the first incident illumination angle comprises an angle in a range from about 0 degrees to about 10 degrees from the first direction;   the coated article exhibits a photopic reflectance as measured at the optical coating at the second portion of the major surface of about 10% or less, wherein the photopic reflectance of the second portion is measured at a second incident illumination angle relative to the second direction, wherein the second incident illumination angle comprises an angle in a range from about 0 degrees to about 10 degrees from the second direction;   the photopic reflectance at the first portion and at the second portion is measured over an optical wavelength regime in a range of from about 400 nm to about 800 nm.   
     
     
         4 . The coated article of  claim 1 , wherein the coated article further comprising:
 a difference in reflected color of the coated article between the first portion of the major surface and the second portion of the major surface is less than or equal to about 5 as measured by the reflectance color coordinates in the (L*, a*, b*) colorimetry system under an International Commission on Illumination illuminant, wherein the difference in reflected color is defined as √((a* first portion −a* second portion ) 2 +(b* first portion −b* second portion ) 2 ), and wherein the reflected color at the first portion is measured at a first incident illumination angle relative to the first direction, wherein the first incident illumination angle comprises an angle in a range from about 0 degrees to about 60 degrees from the first direction, and the reflected color at the second portion is measured at a second incident illumination angle relative to the second direction, wherein the second incident illumination angle comprises an angle in a range from about 0 degrees to about 60 degrees from the second direction.   
     
     
         5 . The coated article of  claim 1 , wherein the coated article exhibits at the first portion of the major surface and at the second portion of the major surface a hardness of about 8 GPa or greater at an indentation depth of about 50 nm or greater as measured on the major surface by an Berkovich Indenter Hardness Test. 
     
     
         6 . The coated article of  claim 1 , wherein the chemically strengthened non-planar glass-ceramic substrate comprises a depth of compression (DOC) of 50 μm or greater, and a central tension (CT) of 50 MPa or greater. 
     
     
         7 . The coated article of  claim 1 , further comprising:
 an easy-to-clean coating;   an additional compositional gradient layer, and   wherein the additional compositional gradient layer is between the fingerprint resistant layer and the scratch-resistant layer.   
     
     
         8 . The coated article of  claim 1 , further comprising:
 an easy-to-clean coating;   an anti-reflective coating, and   wherein the anti-reflective coating is between the fingerprint resistant layer and the scratch-resistant layer.   
     
     
         9 . The coated article of  claim 1 , wherein the scratch-resistant layer comprises SiN x , SiAlON, or SiO x N y . 
     
     
         10 . The coated article of  claim 1 , wherein the compositional gradient comprises SiO x N y . 
     
     
         11 . The coated article of  claim 1 , wherein the compositional gradient layer has a thickness from about 10 nm to 1000 nm. 
     
     
         12 . The coated article of  claim 1 , wherein the compositional gradient layer has a refractive index which varies from within 0.2 of a refractive index of the chemically strengthened non-planar glass-ceramic substrate in portions that contact the chemically strengthened non-planar glass-ceramic substrate to within 0.2 of a refractive index of the scratch-resistant layer in portions that contact the scratch-resistant layer. 
     
     
         13 . A consumer electronic product, comprising:
 a housing having a front surface, a back surface and side surfaces;   electrical components at least partially within the housing, the electrical components including at least a controller, a memory, and a display, the display at or adjacent the front surface of the housing; and   a cover substrate disposed over the display,   wherein at least one of a portion of the housing or the cover substrate comprises the coated article of  claim 1 .   
     
     
         14 . A coated article, comprising:
 a chemically strengthed non-planar glass-ceramic substrate; and   an optical coating on the chemically strengthened glass-ceramic substrate, the optical coating comprising a scratch-resistant layer and an anti-reflective coating,   wherein the anti-reflective coating extends from the scratch-resistant layer to the chemically strengthened glass-ceramic substrate.   
     
     
         15 . The coated article of  claim 14 , wherein:
 the chemically strengthened non-planar glass-ceramic substrate having a major surface, the major surface comprising a first portion and a second portion, wherein a first direction that is normal to the first portion of the major surface is not equal to a second direction that is normal to the second portion of the major surface, and the angle between the first direction and the second direction is in a range of from about 10 degrees to about 180 degrees.   
     
     
         16 . The coated article of  claim 14  wherein:
 the coated article exhibits a photopic reflectance as measured at the optical coating at the first portion of the major surface of about 10% or less, wherein the photopic reflectance of the first portion is measured at a first incident illumination angle relative to the first direction, wherein the first incident illumination angle comprises an angle in a range from about 0 degrees to about 10 degrees from the first direction; 
 the coated article exhibits a photopic reflectance as measured at the optical coating at the second portion of the major surface of about 10% or less, wherein the photopic reflectance of the second portion is measured at a second incident illumination angle relative to the second direction, wherein the second incident illumination angle comprises an angle in a range from about 0 degrees to about 10 degrees from the second direction; 
 the photopic reflectance at the first portion and at the second portion is measured over an optical wavelength regime in a range of from about 400 nm to about 800 nm. 
 
     
     
         17 . The coated article of  claim 14 , wherein the coated article further comprising:
 a difference in reflected color of the coated article between the first portion of the major surface and the second portion of the major surface is less than or equal to about 5 as measured by the reflectance color coordinates in the (L*, a*, b*) colorimetry system under an International Commission on Illumination illuminant, wherein the difference in reflected color is defined as √((a* first portion −a* second portion ) 2 +(b* first portion −b* second portion ) 2 ), and wherein the reflected color at the first portion is measured at a first incident illumination angle relative to the first direction, wherein the first incident illumination angle comprises an angle in a range from about 0 degrees to about 60 degrees from the first direction, and the reflected color at the second portion is measured at a second incident illumination angle relative to the second direction, wherein the second incident illumination angle comprises an angle in a range from about 0 degrees to about 60 degrees from the second direction.   
     
     
         18 . The coated article of  claim 14 , wherein the coated article exhibits at the first portion of the major surface and at the second portion of the major surface a hardness of about 8 GPa or greater at an indentation depth of about 50 nm or greater as measured on the major surface by an Berkovich Indenter Hardness Test. 
     
     
         19 . The coated article of  claim 14 , further comprising:
 an easy-to-clean coating;   an additional anti-reflective coating, and   wherein the additional anti-reflective coating is between the fingerprint resistant layer and the scratch-resistant layer.   
     
     
         20 . The coated article of  claim 14 , wherein the chemically strengthened non-planar glass-ceramic substrate comprises a depth of compression (DOC) of 50 μm or greater, and a central tension (CT) of 50 MPa or greater. 
     
     
         21 . A consumer electronic product, comprising:
 a housing having a front surface, a back surface and side surfaces;   electrical components at least partially within the housing, the electrical components including at least a controller, a memory, and a display, the display at or adjacent the front surface of the housing; and   a cover substrate disposed over the display,   wherein at least one of a portion of the housing or the cover substrate comprises the coated article of  claim 14 .   
     
     
         22 . A coated article comprising:
 a substrate having a major surface, the major surface comprising a first portion and a second portion, wherein a first direction that is normal to the first portion of the major surface is not equal to a second direction that is normal to the second portion of the major surface, and the angle between the first direction and the second direction is in a range of from about 10 degrees to about 180 degrees; and   an optical coating disposed on at least the first portion and the second portion of the major surface, wherein:   the coated article exhibits at the first portion of the major surface and at the second portion of the major surface a hardness of about 8 GPa or greater;   the coated article exhibits a photopic reflectance as measured at the optical coating at the first portion of the major surface of about 10% or less, wherein the photopic reflectance of the first portion is measured at a first incident illumination angle relative to the first direction, wherein the first incident illumination angle comprises an angle in a range from about 0 degrees to about 10 degrees from the first direction;   the coated article exhibits a photopic reflectance as measured at the optical coating at the second portion of the major surface of about 10% or less, wherein the photopic reflectance of the second portion is measured at a second incident illumination angle relative to the second direction, wherein the second incident illumination angle comprises an angle in a range from about 0 degrees to about 10 degrees from the second direction;   the photopic reflectance at the first portion and at the second portion is measured over an optical wavelength regime in a range of from about 400 nm to about 800 nm.   
     
     
         23 . The coated article of  22 , wherein the substrate is a glass-ceramic substrate. 
     
     
         24 . A consumer electronic product, comprising:
 a housing having a front surface, a back surface and side surfaces;   electrical components at least partially within the housing, the electrical components including at least a controller, a memory, and a display, the display at or adjacent the front surface of the housing; and   a cover substrate disposed over the display,   wherein at least one of a portion of the housing or the cover substrate comprises the coated article of  claim 22 .   
     
     
         25 . A coated article comprising:
 a substrate having a major surface, the major surface comprising a first portion and a second portion, wherein a first direction that is normal to the first portion of the major surface is not equal to a second direction that is normal to the second portion of the major surface, and the angle between the first direction and the second direction is in a range of from about 10 degrees to about 180 degrees; and   an optical coating disposed on at least the first portion and the second portion of the major surface, wherein:   the coated article exhibits at the first portion of the major surface and at the second portion of the major surface a hardness of about 8 GPa or greater;   the coated article exhibits a photopic reflectance as measured at the optical coating at the first portion of the major surface of about 10% or less, wherein the photopic reflectance of the first portion is measured at a first incident illumination angle relative to the first direction, wherein the first incident illumination angle comprises an angle in a range from about 0 degrees to about 60 degrees from the first direction;   the coated article exhibits a photopic reflectance as measured at the optical coating at the second portion of the major surface of about 10% or less, wherein the photopic reflectance of the second portion is measured at a second incident illumination angle relative to the second direction, wherein the second incident illumination angle comprises an angle in a range from about 0 degrees to about 60 degrees from the second direction;   the photopic reflectance at the first portion and at the second portion is measured over an optical wavelength regime in a range of from about 400 nm to about 800 nm; and   the coated article further comprising:   a difference in reflected color of the coated article between the first portion of the major surface and the second portion of the major surface is less than or equal to about 5 as measured by the reflectance color coordinates in the (L*, a*, b*) colorimetry system under an International Commission on Illumination illuminant, wherein the difference in reflected color is defined as √((a* first portion −a* second portion ) 2 +(b* first portion −b* second portion ) 2 ), and wherein the reflected color at the first portion is measured at a first incident illumination angle relative to the first direction, wherein the first incident illumination angle comprises an angle in a range from about 0 degrees to about 60 degrees from the first direction, and the reflected color at the second portion is measured at a second incident illumination angle relative to the second direction, wherein the second incident illumination angle comprises an angle in a range from about 0 degrees to about 60 degrees from the second direction.   
     
     
         26 . The coated article of  25 , wherein the substrate is a glass-ceramic substrate. 
     
     
         27 . A consumer electronic product, comprising:
 a housing having a front surface, a back surface and side surfaces;   electrical components at least partially within the housing, the electrical components including at least a controller, a memory, and a display, the display at or adjacent the front surface of the housing; and   a cover substrate disposed over the display,   wherein at least one of a portion of the housing or the cover substrate comprises the coated article of  claim 25 .   
     
     
         28 . A coated article comprising:
 a substrate having a major surface, the major surface comprising a first portion and a second portion, wherein a first direction that is normal to the first portion of the major surface is not equal to a second direction that is normal to the second portion of the major surface, and the angle between the first direction and the second direction is in a range of from about 10 degrees to about 180 degrees; and   an optical coating disposed on at least the first portion and the second portion of the major surface, the optical coating forming a surface, wherein:   the coated article exhibits at the first portion of the major surface and at the second portion of the major surface a hardness of about 8 GPa or greater;   the coated article exhibits a photopic reflectance as measured at the optical coating at the first portion of the major surface of about 10% or less, wherein the photopic reflectance of the first portion is measured at a first incident illumination angle relative to the first direction, wherein the first incident illumination angle comprises an angle in a range from about 0 degrees to about 60 degrees from the first direction;   the coated article exhibits a photopic reflectance as measured at the optical at the second portion of the major surface of about 10% or less, wherein the photopic reflectance of the second portion is measured at a second incident illumination angle relative to the second direction, wherein the second incident illumination angle comprises an angle in a range from about 0 degrees to about 60 degrees from the second direction;   the photopic reflectance at the first portion and at the second portion is measured over an optical wavelength regime in a range of from about 400 nm to about 800 nm; and   the optical coating comprises a first gradient layer in contact with the substrate, a scratch-resistant layer over the first gradient layer, and a second gradient layer over the scratch-resistant layer, wherein:   the refractive index of the first gradient layer at the substrate is within 0.2 of the refractive index of the substrate;   the refractive index of the first gradient layer at the scratch-resistant layer is within 0.2 of the refractive index of the scratch-resistant layer;   the refractive index of the second gradient layer at the scratch-resistant layer is within 0.2 of the refractive index of the scratch-resistant layer; and   the refractive index of the second gradient layer at the surface is from about 1.35 to about 1.7.   
     
     
         29 . The coated article of  28 , wherein the substrate is a glass-ceramic substrate. 
     
     
         30 . A consumer electronic product, comprising:
 a housing having a front surface, a back surface and side surfaces;   electrical components at least partially within the housing, the electrical components including at least a controller, a memory, and a display, the display at or adjacent the front surface of the housing; and   a cover substrate disposed over the display,   wherein at least one of a portion of the housing or the cover substrate comprises the coated article of  claim 28 .