Title of Invention

"A METHOD OF MANUFACTURING A COATED SUBSTRATE TO BE USED AS AUTOMOBILE ANTIGLARE FILTER"

Abstract

A method of manufacturing a coated substrate to be used as but not limited to automobile antiglare filter, said method, comprising providing a transparent substrate made of glass or synthetic material, coating a gradient density absorbing film on one side of the substrate kept at an inclined position with an angle of inclination varying between 5° to 30° with respect to a evaporation source, masking the evaporation source during the deposition of the absorbing material and coating the substrate with one or more Anti Reflection (AR) materials on both surfaces thereby obtaining the antiglare optical device

Full Text

The present invention relates to a method of manufacturing a coated substrate to be used as but not limited to automobile antiglare filter. The invention more particularly relates to an improved antiglare optical device and antiglare article made thereof. Technical Field The present invention relates to a method of deposition of an absorbing material upon plastic/glass substrate by vacuum coating at an angle of inclination between 5° to 30° an using a mask on the evaporation source to produce a graded film material. More particularly, the present invention relates to a method for the preparation of graded density absorbing film useful as an antiglare optical device for protecting the eyes by reducing the glare by absorbing the light intensity falling upon it in a non-uniform fashion. Background Art The necessity of Night driving filter was felt as in the night time It becomes very difficult to drive on the high ways due to the radiations falling on the eye of incoming vehicles 01 the driver's eye, The excessive radiations falling on the eye makes the eye pupil to close resulting in the darkness of the view in front of the driver and accidents occur. Also the UV and IR content of the radiations make the eyes prone to cataract and other diseases. This made it essential to have device which removes this excessive radiations. During night driving, the headlights of the vehicles approaching in the opposite direction emit radiations in the wavelength of 320-400 nm and 750-1400nm. These radiations blind the driver, due to which a number of accidents occur in the night. The frequent blinding glare not only makes the driving difficult, but also impairs the vision. The impairment of the vision occurs due to development of cataract in the crystalline lens by the UV radiation and also retinal deterioration caused due to the thermal effects of IR radiation in the long run. To reduce the blinding effect produced by an approaching vehicle many plastic goggle have been manufactured. A reference may be made to the night driving plastic goggle manufactured by M/s Proview Optical Corporation, Taiwan wherein yellow colored plastic To reduce the blinding effect produced by an approaching vehicle many plastic goggles have been manufactured. A reference may be made to the night driving plastic goggles manufactured by M/s Proview Optical Corporation, Taiwan wherein yellow colored plastic is used whose spectral profile is shown in Fig. 1. The transmission table is given as Table 2. The drawbacks with these goggles as inferred from the spectral profile are as follows: 1. It reduces the transmission in the wavelength region 300 - 540 nm over the entire surface area thereby it also suppresses visualisation of the road on the left side. 2. It does not completely block the blinding glare entering the eyes from the right hand side of the windshield as it is transmitting more than 70% of the radiation in the wavelength region 550 - 750 nm. 3. Due to selective transmission in the visible region i.e. having absorption in the blue region, it distorts the color of the objects which might effect the recognition of the person wearing blue color clothes. Another reference may be made to St. Martin sunglasses manufactured and distributed b Mis Thukral Optics, New Delhi wherein spectacle glasses are claimed to be used as anti radiation for filtering out UV and IR radiation from computer monitors and TV screen a well as for night driving to prevent blind spot. However, the literature of the product does not give any spectral curve or technical clarifications justifying the use of spectacle glasses for night driving. Objects of the Invention The main object of the present invention is to provide a method for preparing a grade density absorbing film useful as an antiglare optical device. Another object of the present invention is to provide a method for the deposition of absorbing film material upon plastic/glass substrate by vacuum coating on a incline substrate with angle of inclination between 5° to 30° and using a mask on the evaporation source. Still another object of the present, invention is to provide a method for the preparation of a antiglare optical device for protecting the eyes of the automobile driver during nigh driving. Yet another object of the present invention is to provide a method for the preparation of an antiglare device to protect the automobile drivers eye from radiation in the wavelength range 320-400nmand750-1400nm. One more object of the present invention is to prevent impairment of vision due to development of cataract in the crystalline lens by the UV radiation and also retina deterioration caused due to the thermal effects of IR radiation in the long run. Summary of the Invention The present invention provides a method of deposition of an absorbing material upon a plastic/glass substrate by vacuum coating at an angle of inclination between 5° to 30° and using a mask on the evaporation source to produce a graded film material. More particularly, the present invention relates to a method for the preparation of graded density absorbing film useful as an antiglare optical device for protecting the eyes by reducing the glare by absorbing the light intensity falling upon it in a non-uniform fashion. Detailed Description of the Invention Accordingly, the present invention provides a method of manufacturing a coated substrate to be used as but not limited to automobile anti-glare filter, said method comprising providing a transparent substrate made of glass or synthetic material, coating a gradient density absorbing film on one side of the substrate kept at an inclined position with an angle of inclination varying between 5° to 30° with respect to a evaporation source, masking the evaporation source during the deposition of the absorbing material and coating the substrate with an Anti Reflection (AR) material on both surfaces thereby obtaining the anti glare optical device. In an embodiment of the present invention, the thickness of the first coating is determined in terms of transmission of the gradient density absorbing film. In another embodiment of the present invention, the deposition of the first coating is done so as to obtain the following transmission data on the substrate: (Table Removed) In another embodiment of the present invention, the evaporation source is a tungsten spiral filament. In still another embodiment of the present invention, the evaporation is done in a vacuum coating plant maintained at 2xlO-5 mb to lxlO-6mb. In yet another embodiment of the present invention, the absorbing material is selected from the group comprising of Inconel, Rhodium, Palladium, Nichrome, chromium and mixtures thereof In one more embodiment of the present invention, the AR material is selected from the group comprising of Magnesium flouride, Silicon dioxide and mixtures thereof. In one another embodiment of the present invention, the synthetic material is polycarbonate plastic. In an embodiment of the present invention, after the absorbing material is coated, the chamber is brought to normal atmospheric pressure and the coated substrate is placed horizontal w .r. t. evaporating source, the chamber is evacuated to get the same vacuum and the AR material is evaporated on both sides. The present invention further provides a method of manufacturing an improved anti glare optical device for automobiles, said method comprising: providing a transparent substrate made of glass or synthetic material, coating a gradient density absorbing film on one side of the substrate kept at an inclined position with an angle of inclination varying between 5° 30° with respect to a evaporation source, masking the evaporation source during the deposition of the absorbing material and coating the substrate with an Anti Reflection (AR) material on both surfaces thereby obtaining the anti glare optical device. In an embodiment of the present invention, the thickness of the first coating is determined in terms of transmission of the gradient density absorbing film. In another embodiment of thej>resent invention, the deposition of the first coating is done so as to obtain the following transmission data on the substrate: (Table Removed) In another embodiment of the present invention, the evaporation source is a tungsten spiral filament. In still another embodiment of the present invention, the evaporation is done in a vacuum coating plant maintained at 2x10~5 mb to lxlO"6mb. In yet another embodiment of the present invention, the absorbing material is selected from the group comprising of Inconel, Rhodium, Palladium, Nichrome, chromium and mixtures thereof. In one more embodiment of the present invention, the AR material is selected from the group comprising of Magnesium flouride, Silicon dioxide and mixtures thereof. In one another embodiment of the present invention, the synthetic material is polycarbonate plastic. In an embodiment of the present invention, after the absorbing material is coated, the chamber is brought to normal atmospheric pressure and the coated substrate is placed horizontal w.r.t. evaporating source, the chamber is evacuated to get the same vacuum and the AR material is evaporated on both sides. The present invention further provides a method of manufacturing an improved anti glare optical device for automobiles, said method comprising: providing a transparent substrate made of glass or synthetic material, coating a gradient density absorbing film on one side of the substrate kept at an inclined position with an angle of inclination varying between 5° to 30° with respect to a evaporation source, masking the evaporation source during the deposition of the absorbing material and coating the substrate with Anti Reflection material on both surfaces thereby obtaining the anti glare optical device. In an embodiment of the present invention, the thickness of the first coating is determined in terms of transmission of the gradient density absorbing film. In another embodiment of the present invention, the deposition of the first coating is done so as to obtain the following transmission data on the substrate: (Table Removed) In still another embodiment of the present invention, the evaporation source is a tungsten spiral filament. In yet another embodiment of the present invention, the evaporation is done in a vacuum coating plant maintained at 2xlO"5 mb to IxlO^mb. In one more embodiment of the present invention, the absorbing material is selected from the group comprising of Inconel, Rhodium, Palladium, Nichrome, and chromium or mixtures thereof. In one another embodiment of the present invention, the AR material is selected from the group comprising of Magnesium flouride and Silicon dioxide. In an embodiment of the present invention, the synthetic material is polycarbonate plastic. In another embodiment of the present invention, after the absorbing material is coated, the chamber is brought to normal atmospheric pressure and the coated substrate is placed horizontal w.r.t. the evaporating source, the chamber is evacuated to get the same vacuum and the AR material is evaporated on both sides. The present invention also provides an improved coated article to be used as but not limited to automobile anti-glare filter, said article comprising a substrate made of transparent material coated at one side with a gradient density absorbing film, said gradient density absorbing film is deposited at an angle of inclination of 5° to 30° w.r.t. an evaporating source, and coated on both the sides with an AR material. In an embodiment of the present invention, the thickness of the first coating is determined in terms of transmission of the gradient density absorbing film. In another embodiment of the present invention, the thickness of the first coatir.g is such that it produces the following transmission data on the substrate: (Table Removed)In still another embodiment of the present invention, the evaporation source is a tungsten spiral filament. In yet another embodiment of the present invention, the evaporation is done in a vacuum coating plant maintained at 2xlO"5 mb to lxlO"6mb. In one more embodiment of the present invention, the absorbing material is selected from the group comprising of Inconel, Rhodium, Palladium, Nichrome, and chromium or mixtures thereof. In one another embodiment of the present invention, the AR material is selected from the group comprising of Magnesium flouride and Silicon dioxide. In an embodiment of the present invention, the synthetic material is polycarbonate plastic. In another embodiment of the present invention, the RHS of the device seen in the direction of view of the driver blocks the blinding glare coupled with attenuation in the wavelength regions 320-400 nm in the UV and 750-1400 nm in the ffi., at the same time visualisation of the road from the center as well as LHS of the filter is not reduced. In still another embodiment of the present invention, the said article protects the driver's eye from the radiation in the wavelength range 320-400 nrn and 750-1400 nm produced by the headlights of approaching vehicles in order to prevent impairment of the vision due to development of cataract in the crystalline lens by the UV radiation and also retinal deterioration caused due to the thermal effects of IR radiation in the long run. In yet another embodiment of the present invention, the neutral transmission of the optical filter in the visible range. In still another embodiment of the present invention, the said article does not distort the color of the object. In yet another embodiment of the present invention, the said article is capable of being used during night driving and to be mounted in front of the driver on the automobile's wind shield, which comprises of a gradient density absorbing film deposited upon glass\plastic substrate by vacuum coating and also Anti-Reflection (AR) coating on both surfaces of the substrate, providing adjustments on the wind shield for the compensation in the drivers eye -level and also providing means to latch on to the automobile's ceiling when not in use, clearing the steering wheel and the driver's head . In one more embodiment of the present invention, the article has the following characteristics: a) size: 300xl50x2-3mm. b) transmission at 550nm: Continuously varying along the length of the device. c) transmission n wavelength ragions: 320-400nm: Less than 10% 400-140* nm: Neutral; neutrality within ± 10% of the value at 550nm. d) position of Max. and Min. transmission: (Table Removed) The article is mounted on the automobile's wind shield in front of the driver. The device is used by the driver during night driving to protect his/her eyes from the blinding glare (excessive visible radiation) and the radiation in the wavelength region 320-400 nm in the ultra-violet (UV) as well as in the region 750-1400 nm in the infra-red (IR), produced by the head lights of the approaching vehicles in order to prevent the road accidents. The frequent blinding glare not only makes the driving difficult, but also impairs the vision. The device has the provisions to be flipped on to the windshield at the driver's eye level during night, and to be latched on to the vehicle's ceiling when not in use. Brief Description of the Accompanying Drawings: In the drawings accompanying the specification, Figure 1 represents the spectral profile of the yellow colored plastic manufactured by M/s Preview Optical Corporation, Taiwan. Figure 2 represents the antiglare optical device of the present invention. Figure 3 represents the gradation profile of the present device. Figure 4 represents the spectral transmission profile of the present device. The invention is described in detail in the examples given below which are provided to illustrate the invention and therefore should not be considered to limit the scope of the present invention. EXAMPLES Example 1 Accordingly the present invention provides an improved antiglare optical device for automobiles useful during night driving; to be mounted in front of the driver on the automobile's wind shield which comprises of a gradient density absorbing film deposited upon glass\plastic substrate by vacuum coating and also Anti-Reflection (AR) coating on both surfaces of the substrate, providing adjustments on the wind shield for the compensation in the drivers eye -level and also providing means to latch on to the automobile's ceiling when not in use, clearing the steering wheel and the driver's head . The provisional specifications of the filter are: Substrate Material: Optical glass, Polycarbonate plastic. Size: 300 x 150 x 2-3 mm duly mounted inmechanical frame for fitment in the car. Coating: Glass Substrate : Graded absorbing film over coated with AR film on one surface and only AR film on second surface. Plastic Substrate : Graded absorbing film over coated with AR film on one surface and cemented with Polycarbonate plastic sheet. AR film on second surface. Coating Materials: The commonly used materials with neutral transmission for the graded coating are Inconel, Rhodium, Palladium, Nichrome, chromium and for the AR coating Magnesium flouride and Silicon dioxide. These are the standard materials and their characteristics are available in all the materials catalogue Spectral Characteristics: Transmission at 550nm : Continuously varying along the length of the filter. Position of Max. and Min. transmission : Distance from RHS % Transmission at 55Qnm 50mm 40 100mm 35 300 mm 75 Transmission in wavelength regions : 320-400 nm: Less than 10% 400-1400 nm: Neutral; neutrality within ± 10% of the value at 550 nm Example 2: Computation of Thickness Gradation The film gradation is designed by taking into consideration the luminance distribution of light on the wind shield from the approaching vehicle, distance between the two vehicles and the distance of the filter from the center of rotation of the eye. In this connection, the necessary data has been generated by conducting the requisite experiments. From this data of luminance distribution the thickness gradation of the film in terms of transmission is found for getting gradient density absorbing film . The required gradation profile is given in Fig.3 Example 3: Experimental methods The glass/plastic substrate after proper cleaning is placed inside the chamber of a vacuum coating plant in an inclined position with respect to evaporation source. The angle of inclination varies from 5° to 30°. Tungsten spiral filament is used as the source for the evaporation of absorbing material and a mask is suitably positioned above the filament; the chamber is then evacuated to a high vacuum. After achieving the vacuum better than 2 x 10 ~ 5 mb the material is evaporated by passing the current in the filament to obtain the graded absorbing film on the substrate. Afterwards AR film is deposited on both surfaces by suitably placing the substrate in the chamber. Figure 3, depicts the gradation profile of the experimental coating without having AR coating on both surfaces. The data for the profile was obtained by measuring the transmission at 550 nm on various locations of the filter. It can be seen from the figure that at a distance of 100 mm from RHS, the absorbance is highest because it is at this point the intensity of light (Glare) is maximum therefore it gets absorbed to the maximum extent and is not felt by the driver. The coated substrate is assembled in the adjustable mechanical mount as shown in figure 2, and then fitted in the car. This mount has the mechanism to flip the filter in and out of driver's field of view on the windshield. Figure 2 clearly shows the various means and parts of the anti glare device capable of being fitted into an automobile. The anti glare device (1) can be attached with the front roof or any suitable structure falling in the front field of view of the driver by a suitable connecting means (2). This connecting means could be a nut and bolt arrangement. A rod (3) capable of being rotated in the horizontal plane is attached with the connecting means (2). Both edges of the rod (3) have means for fixing anti reflective panel (4). The fixing means are capable of rotating the panel in the vertical plane, as well as providing up and down movement to the panel. The panel is coated with anti reflective material, which acts as a filter (5). Thickness of the coating is determined in terms of transmission of the gradient density absorbing coating. Reference may be made to Figure 3 where the variation in transmission is shown as 35 to 75%. The transmission of the coating during deposition is controlled in such a way that the following transmission data is obtained on the substrate: (Table Removed) Example 4: Environmental and other Tests done on the filter. 1- Hardness Test : This was done by using the coating Hardness tester of summer laboratories , USA as per standard no. Mil -C-675 A where it is mentioned that no scratch should be visible after subjecting the coated sample to 20 complete strokes of 1" length with a rubber eraser conforming to MIL -E- 12397 under a force of 2.5 pounds. The coated sample has passed the test as no scratches appeared. 2. Adhesion Test: The coated sample has passed the test as no peel-off is seen. The coated component was subjected to adhesion test as per MEL standard no. MIL- F- 48616. In this test 1/2" wide cellophane tape conforming to type I of L-T-90 is used. The adhesive tape is pressed so as to cover the coated surface and thcr. quickly removed at an angle normal to the coated surface. After removal of the tape the coated surface is examined for any peel-off. 3. Climatic & Environmental Tests : a) Heat Test: The coated sample was kept in an environment of 65°C temperature for three hours. b) Heat & Humidity Test: The samples were kept in an environment of 40° C and 95 % RH for 3 cycles of 24 hours duration. c) Salt spray Test: The samples were subjected to a spray of salt mixture for 2 hours and then kept in the same environment for 24 hours. After the above-mentioned environmental tests, the samples were evaluated by visual examination, adhesion, hardness and spectral transmission, No damage was observed in the visual examination and it has passed the Hardness, Adhesion tests. Spectral transmission was measured on the Perkin -Elmer spectrophotometer. It is observed that there was no appreciable variation of T % of the samples. Preliminary user's trials have been conducted by mounting the improvised device on the windshield of the ambassador car and driving on the city roads (single & dual carriageway) and on the highways in the night which have yielded encouraging response. Reference may be made to Table 1 for the online performance trials. Further work to fabricate the complete device, technical and user's trials and also on plastic substrates are being carried out. Table 1: Online Performance Trial Reports (Table Removed) Table 2: Transmission values of the night driving plastic goggles manufactured by M/s Preview Optical Corporation, Taiwan. (Table Removed) The main advantages of the present invention are: 1. The RHS of the device seen in the direction of view of the driver blocks the blinding glare coupled with attenuation in the wavelength regions 320-400 nm in the UV and 750-1400 nm in the IR , at the same time visualisation of the road from the center as well as LHS of the filter is not reduced. 2. It protects the driver's eye from the radiation in the wavelength range 320-400 nm and 750-1400 nm produced by the headlights of approaching vehicles in order to prevent impairment of the vision due to development of cataract in the crystalline lens by the UV radiation and also retinal deterioration caused due to the thermal effects of IR radiation in the long run. 3. The neutral transmission of the optical filter in the visible range (figure 4) does not distort the colour of the object. We Claims: 1. A method of manufacturing a coated substrate to be used as automobile antiglare filter, said method, comprising providing a transparent substrate made of glass or synthetic material, coating a gradient density absorbing film on one side of the substrate kept at an inclined position with an angle of inclination varying between 5° to 30° with respect to a evaporation source, masking the evaporation source during the deposition of the absorbing material and coating the substrate with one or more Anti Reflection (AR) materials on both surfaces thereby obtaining the antiglare optical device. 2. A method as claimed in claim 1, wherein the thickness of the first coating is determined in terms of transmission of the gradient density absorbing film. 3. A method as claimed in claim 1, wherein the evaporation source is a tungsten spiral filament. 4. A method as claimed in claim 1, wherein the evaporation is done in a vacuum coating plant maintained at 2xlO-5 mb to lxlO-6mb. 5. A method as claimed in claim 1, wherein the absorbing material is selected from the group comprising of Inconel, Rhodium, Palladium, Nichrome, and chromium or mixtures thereof. 6. A method as claimed in claim 1, wherein the AR material is selected from the group comprising of Magnesium flouride and Silicon dioxide. 7. A method as claimed in claim 1, wherein the synthetic material is polycarbonate plastic. 8. A method as claimed in claim 1, wherein after the absorbing material is coated, the chamber is brought to normal atmospheric pressure and the coated substrate is placed horizontal w.r.t. evaporating source, the chamber is evacuated to get the same vacuum and the AR material is evaporated on both sides. 9. A method of manufacturing an improved anti glare optical device for automobiles, said method comprising: providing a transparent substrate made of glass or AR material is selected from the synthetic material, coating a gradient density absorbing film on one side of the substrate kept at an inclined position with an angle of inclination varying between 5° to 30° with respect to a evaporation source, masking the evaporation source during the deposition of the absorbing material and coating the substrate with one or more Anti Reflection (AR) materials on both surfaces thereby 10. A method of manufacturing a coated substrate to be used as automobile antiglare filter substantially as herein describe with reference to examples accompanying this specification.

Documents:

01532-delnp-2003-abstract.pdf

01532-delnp-2003-claims.pdf

01532-delnp-2003-correspondence-others.pdf

01532-delnp-2003-description (complete)-08-05-2008.pdf

01532-delnp-2003-description (complete)-12-05-2008.pdf

01532-delnp-2003-description (complete)-26-05-2008.pdf

01532-delnp-2003-description (complete).pdf

01532-delnp-2003-drawings.pdf

01532-delnp-2003-form-1.pdf

01532-delnp-2003-form-18.pdf

01532-delnp-2003-form-2.pdf

01532-delnp-2003-form-3.pdf

01532-delnp-2003-pct-210.pdf

1532-DELNP-2003-Abstract-08-05-2008.pdf

1532-DELNP-2003-Claims-08-05-2008.pdf

1532-delnp-2003-claims-12-05-2008.pdf

1532-delnp-2003-claims-26-05-2008.pdf

1532-DELNP-2003-Correspondence-Others-07-05-2008.pdf

1532-delnp-2003-correspondence-others-12-05-2008.pdf

1532-DELNP-2003-Drawings-08-05-2008.pdf

1532-DELNP-2003-Form-1-07-05-2008.pdf

1532-delnp-2003-form-1-12-05-2008.pdf

1532-delnp-2003-form-1-26-05-2008.pdf

1532-DELNP-2003-Form-2-08-05-2008.pdf

1532-delnp-2003-form-2-12-05-2008.pdf

1532-DELNP-2003-Form-3-08-05-2008.pdf

1532-delnp-2003-form-3-26-05-2008.pdf

1532-delnp-2003-petition-137-12-05-2008.pdf

1532-DELNP-2003-Petition-138-08-05-2008.pdf