Abstract:
The present invention relates to 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 and 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.

Description:
FIELD OF THE INVENTION  
         [0001]    The present invention relates to 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 failing upon it in a non-uniform fashion.  
         BACKGROUND AND PRIOR ART TO THE INVENTION  
         [0002]    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 on the driver&#39;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.  
           [0003]    During night driving, the headlights of the vehicles approaching in the opposite direction emit radiations in the wavelength of 320-400 nm and 750-1400 nm. 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.  
           [0004]    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 b) 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:  
           [0005]    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.  
           [0006]    2. it does not completely block the blinding glare entering the eyes from the right hand side of the windshield as it is transmitting mole than 70% of the radiation in the wavelength region 550-750 nm.  
           [0007]    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.  
           [0008]    Another reference may be made to St. Martin sunglasses manufactured and distributed by M/s 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 as well as for night driving to prevent blind spot. However, the literature of the product does not give any spectra curve or technical clarifications justifying the use of spectacle glasses for night driving.  
         OBJECTS OF THE INVENTION  
         [0009]    The main object of the present invention is to provide a method for preparing a graded density absorbing film useful as an antiglare optical device  
           [0010]    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 inclined substrate with angle of inclination between 5° to 30° and using a mask on the evaporation source.  
           [0011]    Still another object of the present invention is to provide a method for the preparation of an antiglare optical device for protecting the eyes of the automobile driver during night driving.  
           [0012]    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 320-400 nm and 750-1400 nm.  
           [0013]    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 retinal deterioration caused due to the thermal effects of IR radiation in the long run.  
         SUMMARY OF THE INVENTION  
         [0014]    The present invention relates to 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  
         [0015]    Accordingly, the present invention provides a method of manufacturing 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.  
           [0016]    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.  
           [0017]    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:  
                                                   Distance from RHS   % Transmission at 550 nm                            50 nm   45 to 50           100 nm   30 to 35           200 nm   50 to 60           300 nm   75 to 80                      
 
           [0018]    In another embodiment of the present invention, the evaporation source is a tungsten spiral filament.  
           [0019]    In still another embodiment of the present invention, the evaporation is done in a vacuum coating plant maintained at 2×10 −5  mb to 1×10 −6  mb.  
           [0020]    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 mixtures thereof.  
           [0021]    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.  
           [0022]    In one another embodiment of the present invention, the synthetic material is polycarbonate plastic.  
           [0023]    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.  
           [0024]    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 lass 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.  
           [0025]    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.  
           [0026]    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:  
                                                   Distance from RHS   % Transmission at 550 nm                            50 nm   45 to 50           100 nm   30 to 35           200 nm   50 to 60           300 nm   75 to 80                      
 
           [0027]    In still another embodiment of the present invention, the evaporation source is a tungsten spiral filament.  
           [0028]    In yet another embodiment of the present invention, the evaporation is done in a vacuum coating plant maintained at 2×10 −5  mb to 1×10 −6  mb.  
           [0029]    In one more embodiment of the present invention, the absorbing material is selected from the group comprising of Inconel, Rhodium, Palladium, Nichrome, and chronmium or mixtures thereof.  
           [0030]    In one another embodiment of the present invention, the AR material is selected from the group comprising of Magnesium flouride and Silicon dioxide.  
           [0031]    In an embodiment of the present invention, the synthetic material is polycarbonate plastic.  
           [0032]    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.  
           [0033]    The present invention also provides an improved coated article to be used as but not limited to automobile anti-glare filter, said articlc 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.  
           [0034]    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.  
           [0035]    In another embodiment of the present invention, the thickness of the first coating is such that it produces the following transmission data on the substrate:  
                                                   Distance from RHS   % Transmission at 550 nm                            50 nm   45 to 50           100 nm   30 to 35           200 nm   50 to 60           300 nm   75 to 80                      
 
           [0036]    In still another embodiment of the present invention, the evaporation source is a tungsten spiral filament.  
           [0037]    In yet another embodiment of the present invention, the evaporation is done in a vacuum coating plant maintained at 2×10 −5  mb to 1×10 −6  mb.  
           [0038]    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.  
           [0039]    In one another embodiment of the present invention, the AR material is selected from the group comprising of Magnesium flouride and Silicon dioxide.  
           [0040]    In an embodiment of the present invention, the synthetic material is polycarbonate plastic.  
           [0041]    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 IR, at the same time visualisation of the road from the center as well as LHS of the filter is not reduced.  
           [0042]    In still another embodiment of the present invention, the said article protects the driver&#39;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.  
           [0043]    In yet another embodiment of the present invention, the neutral transmission of the optical filter in the visible range.  
           [0044]    In still another embodiment of the present invention, the said article does not distort the color of the object.  
           [0045]    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&#39;s wind shield, which comprises of a gradient density absorbing film deposited upon glassplastic 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&#39;s ceiling when nor in use, clearing the steering wheel and the driver&#39;s head.  
           [0046]    In one more embodiment of the present invention, the article has the following characteristics:  
           [0047]    a) size: 300×150×2-3 mm.  
           [0048]    b) transmission at 550 nm: Continuously varying along the length of the device.  
           [0049]    c) transmission in wavelength regions:  
           [0050]    320-400 nm: Less than 10%  
           [0051]    400-1400 nm: Neutral; neutrality within ±10% of the value at 550 nm.  
           [0052]    d) position of Max. and Min. transmission:  
                                                   Distance from RHS   % Transmission at 550 nm                            50 nm   45 to 50           100 nm   30 to 35           200 nm   50 to 60           300 nm   75 to 80                      
 
           [0053]    The article is mounted on the automobile&#39;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&#39;s eye level during night, and to be latched on to the vehicle&#39;s ceiling when not in use. 
       
    
    
     BRIEF DESCRIPTION OF THE ACCOMPANYING DRAWINGS  
       [0054]    In the drawings accompanying the specification;  
         [0055]    [0055]FIG. 1 represents the spectral profile of the yellow colored plastic manufactured by M/s Proview Optical Corporation, Taiwan.  
         [0056]    [0056]FIG. 2 represents the antiglare optical device of the present invention.  
         [0057]    [0057]FIG. 3 represents the gradation profile of the present device.  
         [0058]    [0058]FIG. 4 represents the spectral transmission profile of the present device. 
     
    
       [0059]    The invention is described in detail in the examples given below which arc provided to illustrate the invention and therefore should not be considered to limit the scope of the present invention.  
       EXAMPLES  
     Example 1  
       [0060]    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&#39;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&#39;sceiling when not in use, clearing the steering wheel and the driver&#39;s head. The provisional specifications of the filter are:  
                                       Substrate   Optical glass, Polycarbonate plastic.       Material:       Size:   300 × 150 × 2-3 mm duly mounted immechanical 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   The commonly used materials with neutral transmission for       Materials:   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                  
 
         [0061]    Spectral Characteristics:  
         [0062]    Transmission at 550 nm: Continuously varying along the length of the filter.  
         [0063]    Position of Max. and Min. transmission:  
                                                   Distance from RHS   % Transmission at 550 nm                            50 mm   40           100 mm   35           300 mm   75                      
 
         [0064]    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  
       [0065]    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  
       [0066]    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 2×10 −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. FIG. 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.  
         [0067]    The coated substrate is assembled in the adjustable mechanical mount as shown in FIG. 2, and then fitted in the car. This amount has the mechanism to flip the filter in and out of driver&#39;s field of view on the windshield.  
         [0068]    Thickness of the coating is determined in terms of transmission of the gradient density absorbing coating. Reference may be made to FIG. 3 where the variation in transmission is shown as 35 to 75%.  
         [0069]    The transmission of the coating during deposition is controlled in such a way that the following transmission data is obtained on the substrate:  
                                                   Distance from RHS   % Transmission at 550 nm                            50 nm   45 to 50           100 nm   30 to 35           200 nm   50 to 60           300 nm   75 to 80                      
 
       Example 4  
     Environmental and other Tests done on the filter.  
       [0070]    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.  
         [0071]    2. Adhesion Test: The coated sample has passed the test as no peel-off is seen. The coated component was subjected to an adhesion test as per MIL standard no. MIL-F-48616. In this test ½″ 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 then quickly removed at an angle normal to the coated surface. After removal of the tape the coated surface is examined for any peel-off.  
         [0072]    3. Climatic &amp; Environmental Tests:  
         [0073]    a) Heat Test: The coated sample was kept in an environment of 65° C. temperature for three hours.  
         [0074]    b) Heat &amp; Humidity Test: The samples were kept in an environment of 40° C. and 95% RH for 3 cycles of 24 hours duration.  
         [0075]    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.  
         [0076]    After the above mentioned environmental tests, the samples were evaluated by visual examination, adhesion, hardness and spectral transmission.  
         [0077]    No damage was observed in the visual examination and it has passed the Hardness, Adhesion tests.  
         [0078]    Spectral transmission was measured on the Perkin-Elmer spectrophotometer. It is observed that there was no appreciable variation of T % of the samples.  
         [0079]    Preliminary user&#39;s trials have been conducted by mounting the improvised device on the windshield of the ambassador car and driving on the city roads (single &amp; dual carriage-way) 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&#39;s trials and also on plastic substrates are being carried out.  
                                                                           TABLE 1                           Online Performance Trial Reports                    One/                           Distance   Two way   Unlighted                   Date/   Covered   Traffic   Road   Speed               Distance   (Km)   (Km)   (Km)   (Km/hr)   Driver/Age   Observations                    22/9/2000   25   6/19   2   30-50   Amar   Glare reduced       7.00 to                   Chand   significantly,       7.30 pm                   58   overall view                               little bit dark       26/9/2000   40   10/30   10   30-50   Dilbagh   Glare reduced       6.30 to                   Singh   significantly,       7.30 pm                   38   overall view                               little bit dark       27/9/2000   40   25/15   25   30-70   Amrik   No glare,                           Singh   overall view                           37   good.                  
 
         [0080]    [0080]                                                           TABLE 2                           Transmission values of the night driving plastic goggles manufactured       by M/s Proview Optical Corporation, Taiwan.                    Transmission       Transmission           Wavelength   Values   Wavelength   Values                            300   0.0   310   0.0           320   0.0   330   0.0           340   0.0   350   0.0           360   0.0   370   0.0           380   0.0   390   0.0           400   0.0   410   2.2           420   6.8   430   6.8           440   5.4   450   5.1           460   5.5   470   5.7           480   7.1   490   11.1           500   16.2   510   21.2           520   29.5   530   44.0           540   59.8   550   70.0           560   75.0   570   77.3           580   78.4   590   79.2           600   79.8   610   80.5           620   81.1   630   81.4           640   81.6   650   81.9           660   82.2   670   82.7           680   83.2   690   83.6           700   83.9   710   84.5           720   85.1   730   85.4           740   86.2   750   87.2           760   87.6   770   88.4           780   88.7                        
         [0081]    The Main Advantages of the Present Invention are  
         [0082]    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 lime visualisation of the road from the center as well as LHS of the filter is not reduced  
         [0083]    2. It protects the driver&#39;s eye from the radiation in the wavelength range 320-400 nm 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 of IR radiation in the long run.  
         [0084]    3. The neutral transmission of the optical filter in the visible range (FIG. 4) does not distort the colour of the object.