Abstract: A hard coat film comprising a polymer film substrate, an organic adhesion layer formed on a surface of the film substrate by depositing a first organic material on a surface of the film substrate in vacuum, and an organic hard coat layer formed on a surface of the adhesion layer by depositing a second organic material on the adhesion layer in vacuum is disclosed. Preferably, the layers are separately cured following the deposition processes. The adhesion layer has a thickness in a range of about 0.025 ?m to about 20 ?m and the hard coat layer has a thickness in a range of about 0.025 ?m to about 20 ?m. Optionally, the hard coat film includes an inorganic layer formed between the adhesion layer and the hard coat layer. Also disclosed is a process for forming a hard coat film by depositing multiple layers of organic and/or inorganic materials on a substrate in vacuum.

Abstract: The present invention provides a system and method for uniform coating of a substrate at high deposition rates by evaporating a coating material in a vacuum chamber. The system includes an evaporator having a heating crucible for containing a coating material to be evaporated and a generally planar heat source disposed so as to heat a surface of a coating material contained in the heating crucible. Preferably, the heat source is manufactured from a ceramic or intermetallic material and includes a first layer defining a first set of openings and a second layer defining a second set of openings wherein the second layer overlies the first layer and is spaced apart therefrom. The first and second sets of openings allow the evaporated coating material to pass therethrough for dispersion of the coating material in a deposition zone defined by a containment shield disposed above the heat source.

Abstract: The present invention provides a system and method for uniform coating of a substrate at high deposition rates by evaporating a coating material in a vacuum chamber. The system includes an evaporator having a heating crucible for containing a coating material to be evaporated and a generally planar heat source disposed so as to heat a surface of a coating material contained in the heating crucible. Preferably, the heat source is manufactured from a ceramic or intermetallic material and includes a first layer defining a first set of openings and a second layer defining a second set of openings wherein the second layer overlies the first layer and is spaced apart therefrom. The first and second sets of openings allow the evaporated coating material to pass therethrough for dispersion of the coating material in a deposition zone defined by a containment shield disposed above the heat source.