Curable film-forming sol-gel compositions and anti-glare coated articles formed from them

• US 10,723,890 B2
• Filed: 11/25/2015
• Issued: 07/28/2020
• Est. Priority Date: 11/25/2014
• Status: Active Grant

• Current Assignee: PPG Industries Ohio Incorporated (Nouryon BV)
• Original Assignee: PPG Industries Ohio Incorporated (Nouryon BV)
• Inventors: Lu, Songwei, Vanier, Noel, Xu, Xiangling, Swarup, Shanti, Martin, David C., Olson, Kurt G., Schwendeman, Irina
• Primary Examiner(s): Langman, Jonathan C
• Application Number:
  US14/951,541
• Publication Number:
  US 20160145441A1
• Time in Patent Office: 1,707 Days
• CPC Class Codes: B05D 3/0236 with ovens B05D3/0227 takes precedence
• CPC Class Codes: B05D 3/0272 with ovens
• CPC Class Codes: B05D 5/061 Special surface effect
• CPC Class Codes: C03C 17/30 with silicon-containing compounds
• CPC Class Codes: C03C 2217/29 Mixtures
• CPC Class Codes: C03C 2217/732 made of a single layer
• CPC Class Codes: C03C 2218/112 by spraying
• CPC Class Codes: C03C 2218/32 After-treatment
• CPC Class Codes: C08F 212/08 Styrene
• CPC Class Codes: C08F 220/286 and containing polyethylene oxide in the alcohol moiety, e.g. methoxy polyethylene glycol (meth)acrylate
• CPC Class Codes: C08F 220/34 Esters containing nitrogen , e.g. N,N-dimethylaminoethyl (meth)acrylate
• CPC Class Codes: C08F 257/02 on to polymers of styrene or alkyl-substituted styrenes
• CPC Class Codes: C08G 77/02 Polysilicates
• CPC Class Codes: C08G 77/14 containing silicon bound to oxygen-containing groups C08G77/045 takes precedence
• CPC Class Codes: C08K 3/01 characterized by their specific function
• CPC Class Codes: C08K 3/28 Nitrogen-containing compounds
• CPC Class Codes: C08L 25/00 Compositions of, homopolymers or copolymers of compounds having one or more unsaturated aliphatic radicals, each having only one carbon-to-carbon double bond, and at least one being terminated by an aromatic carbocyclic ring; Compositions of derivatives of such polymers
• CPC Class Codes: C09D 125/06 Polystyrene
• CPC Class Codes: C09D 183/02 Polysilicates
• CPC Class Codes: C09D 183/04 Polysiloxanes
• CPC Class Codes: C09D 183/06 : containing silicon bound to oxygen-containing groups C09D183/12 takes precedence
• CPC Class Codes: C09D 5/006 : Anti-reflective coatings
• CPC Class Codes: G02B 1/111 : using layers comprising organic materials
• CPC Class Codes: G06F 2203/04103 : Manufacturing, i.e. details related to manufacturing processes specially suited for touch sensitive devices
• CPC Class Codes: G06F 3/0412 : Digitisers structurally integrated in a display

Abstract

Curable film-forming sol-gel compositions that are essentially free of inorganic oxide particles are provided. The compositions contain: a tetraalkoxysilane; a solvent component; and non-oxide particles, and further contain either i) a mineral acid or ii) an epoxy functional trialkoxysilane and a metal-containing catalyst. Coated articles demonstrating antiglare properties are also provided, comprising: (a) a substrate having at least one surface; and (b) a cured film-forming composition applied thereon, formed from a curable sol-gel composition comprising a silane and non-oxide particles. A method of forming an antiglare coating on a substrate is also provided. The method comprises: (a) applying a curable film-forming sol-gel composition on at least one surface of the substrate to form a coated substrate; and (b) subjecting the coated substrate to thermal conditions for a time sufficient to effect cure of the sol-gel composition and form a coated substrate with a sol-gel network layer having anti-glare properties.

Claims

1. A coated article demonstrating anti-glare properties, wherein the coated article comprises:

(a) a substrate having at least one flat surface; and

(b) a cured film-forming composition containing non-oxide particles and applied to at least a portion of the flat surface of the substrate, wherein the cured film-forming composition is formed from a curable sol-gel composition comprising a silane and the non-oxide particles, wherein the non-oxide particles are selected from the group consisting of Si₃N₄;

BN;

SiC;

Zn;

polystyrene;

polyurethane;

acrylic;

alkyd;

polyester;

polysulfide;

polyepoxide;

polyurea;

polyolefin;

silicone-containing rubber polymers;

sodium salts of 3-allyloxy-2-hydroxy-1-propanesulfonic acid, 2-Acrylamido-2-methylpropane sulfonic acid, styrene sulfonic acid, or (meth) acrylic acid;

ammonium salts of 3-allyloxy-2-hydroxy-1-propanesulfonic acid, 2-Acrylamido-2-methylpropane sulfonic acid, styrene sulfonic acid, or (meth) acrylic acid;

Vinylbenzyltrimethyl ammonium chloride;

diallyldimethylammonium chloride;

dimethylaminoethyl (meth)acrylate;

tert-butylaminoethyl methacrylate;

trimethyl(2-methacryloxylethyl) ammonium chloride;

dimethylaminopropyl (meth)acrylamide;

trimethyl(2-methacrylamidopropyl) ammonium chloride; and

mixtures thereof;

wherein when the non-oxide particles are acrylic or polystyrene polymers, they are added to the curable sol-gel composition in the form of cationic or anionic aqueous dispersions of acrylic or polystyrene polymer particles, the non-oxide particles have an average particle size, agglomerated or monodispersed, of between 50 nm and 2.0 microns, and the coated article demonstrates a 60°

gloss value of 15 to 120 gloss units and a light transmittance of at least 84%.

2. The coated article of claim 1, wherein the curable film-forming sol-gel composition comprises either (A):

(i) a tetraalkoxysilane;

(ii) an epoxy functional trialkoxysilane;

(iii) a metal-containing catalyst;

(iv) a solvent component; and

(v) the non-oxide particles;

or (B);

(i) a tetraalkoxysilane;

(ii) a mineral acid;

(iii) a solvent component; and

(iv) the non-oxide particles.

3. The coated article of claim 1, wherein the article comprises a window, touch screen, cell phone screen, tablet screen, GPS screen, voting machine screen, POS (Point-Of-Sale) screen, computer screen, display sheet in a picture frame, or an active or passive liquid crystal cell element or device.

4. A method of forming the coated article demonstrating anti-glare properties of claim 1 comprising:

(a) applying a curable film-forming sol-gel composition on at least one surface of the substrate to form a coated substrate, wherein the curable film-forming sol-gel composition is essentially free of inorganic oxide particles and comprises a silane and non-oxide particles;

wherein the non-oxide particles are selected from the group consisting of Si₃N₄;

BN;

SiC;

Zn;

polystyrene;

polyurethane;

acrylic;

alkyd;

polyester;

polysulfide;

polyepoxide;

polyurea;

polyolefin;

silicone-containing rubber polymers;

sodium salts of 3-allyloxy-2-hydroxy-1-propanesulfonic acid, 2-Acrylamido-2-methylpropane sulfonic acid, styrene sulfonic acid, or (meth) acrylic acid;

ammonium salts of 3-allyloxy-2-hydroxy-1-propanesulfonic acid, 2-Acrylamido-2-methylpropane sulfonic acid, styrene sulfonic acid, or (meth) acrylic acid;

Vinylbenzyltrimethyl ammonium chloride;

diallyldimethylammonium chloride;

dimethylaminoethyl (meth)acrylate;

tert-butylaminoethyl methacrylate;

trimethyl(2-methacryloxylethyl) ammonium chloride;

dimethylaminopropyl (meth)acrylamide;

trimethyl(2-methacrylamidopropyl) ammonium chloride; and

mixtures thereof;

wherein when the non-oxide particles are acrylic or polystyrene polymers, they are added to the film-forming sol-gel composition in the form of cationic or anionic aqueous dispersions of acrylic or polystyrene polymer particles, the non-oxide particles have an average particle size, agglomerated or monodispersed, of between 50 nm and 2.0 microns; and

(b) subjecting the coated substrate to thermal conditions for a time sufficient to effect cure of the sol-gel composition and form a coated substrate with a sol-gel network layer having anti-glare properties.

5. The method of claim 4 wherein the substrate comprises a plastic, glass, or metal.

6. The method of claim 4, wherein, immediately prior to application to the substrate, the substrate and the curable film-forming composition are kept at ambient temperature.

7. The method of claim 4, wherein the curable film-forming sol-gel composition comprises either (A):

(i) a tetraalkoxysilane;

(ii) an epoxy functional trialkoxysilane;

(iii) a metal-containing catalyst;

(iv) a solvent component; and

(v) the non-oxide particles;

or (B);

(i) a tetraalkoxysilane;

(ii) a mineral acid;

(iii) a solvent component; and

(iv) the non-oxide particles.

8. The method of claim 4 wherein the curable film-forming sol-gel composition is spray applied or spin or dip coated onto the substrate in step (a).

9. The method of claim 4 wherein the coated substrate is heated to a temperature of at least 80°

C. for at least 10 minutes in step (b).