Method for forming a protective coating and substrates coated with the same

• US 20010024685A1
• Filed: 03/15/2001
• Published: 09/27/2001
• Est. Priority Date: 06/19/1997
• Status: Abandoned Application

• Current Assignee: Catherine A. Getz, Jonathan M. Boulton, Syed Masood Hassan
• Original Assignee: Catherine A. Getz, Jonathan M. Boulton, Syed Masood Hassan
• Inventors: Boulton, Jonathan M., Hassan, Syed Masood, Getz, Catherine A.
• Application Number:
  US09/808,172
• Publication Number:
  US 20010024685A1
• Time in Patent Office: Days
• US Class Current: 427/162
• CPC Class Codes: C03C 17/02 with glass C03C17/34, C03C17/44 take precedence
• CPC Class Codes: C23C 18/1212 Zeolites, glasses
• CPC Class Codes: C23C 18/122 Inorganic polymers, e.g. silanes, polysilazanes, polysiloxanes
• CPC Class Codes: H01J 2229/8924 having particular properties for protecting the vessel, e.g. against abrasion, water or shock
• CPC Class Codes: H01J 29/88 provided with coatings on the walls thereof; Selection of materials for the coatings H01J29/868 and H01J29/89 take precedence

Abstract

This invention is a substrate with a protective multicomponent coating, and a method for forming such a substrate by the steps of applying a coating solution to the substrate, and firing the substrate at a temperature greater than 450° C., where the coating solution includes a coating solvent; a SiO₂ precursor being a silicon compound having at least one hydrolyzable group; a glass oxide precursor being a compound of an element selected from Group III or Group IV of the periodic table; and a network modifier precursor being a compound of an element selected from Group I or Group II of the periodic table. The invention is also related to the coating solution employed in the method of the invention.

Claims

1. A method for forming a protective multicomponent coating on a substrate, said method comprising the steps of:

(a) applying a coating solution to the substrate, said coating solution comprising

(i) a coating solvent;

(ii) a SiO₂ precursor comprising a silicon compound having at least one hydrolyzable group;

(iii) a glass oxide precursor comprising a compound having an element selected from Group III or Group IV of the periodic table in the form of a salt, an alkoxide, a hydroxide or an acid thereof; and

(iv) a network modifier precursor comprising a compound containing an element selected from Group I or Group II of the periodic table; and

(b) subsequently firing the substrate at a temperature effective to form the protective multicomponent coating on the substrate.

2. A method according to

claim 1

, wherein said network modifier precursor is in the form of a hydroxide, an acetate or an alkoxide.

3. A method according to

claim 2

, wherein said temperature is greater than 450°

C.

4. A method according to

claim 1

, wherein said SiO₂ precursor comprises at least one compound of the general formula R′

_nSi(OR)_4-n, where R is an alkyl group, R′

is an alkyl group or an aryl group, and n is a number between 1 and 3, inclusive.

5. A method according to

claim 4

, wherein said SiO₂ precursor comprises at least one compound of the general formula SiX₄, where X is halide, an acetoxy, an alkoxy, or an aryloxy group.

6. A method according to

claim 1

, wherein said SiO₂ precursor comprises at least one compound of the general formula Y_nSi(Z)_4-n, where Y is an alkyl group, an aryl group, or a non-hydrolyzable group, Z is halide, an alkoxy group, an aryloxy group, —

OCOR, —

NR₂, —

OC(═

CH₂)R, and —

ON═

CR₂, R being an alkyl or an aryl group, and n is a number between 1 and 3, inclusive.

7. A method according to

claim 1

, wherein the element selected from Group III or Group IV of the periodic table comprises B or Al.

8. A method according to

claim 1

, wherein the element selected from Group I or Group II of the periodic table comprises Li, Na, or K.

9. A method according to

claim 1

, wherein the SiO₂ precursor comprises CH₃Si(OCH₃)₃ or CH₃Si(OCH₂CH₃)₃.

10. A method according to

claim 1

, wherein the SiO₂ precursor comprises at least two different silicon compounds each having at least one hydrolyzable substituent.

11. A method according to

claim 1

, wherein the glass oxide precursor comprises B(OH)₃ or B(OC₂H₅)₃.

12. A method according to

claim 1

, wherein the glass oxide precursor comprises a chelated aluminum alkoxide.

13. A method according to

claim 10

, wherein the chelated aluminum alkoxide comprises Al(OⁱC₃H₇)₂C₆H₉O₃.

14. A method according to

claim 1

, wherein said protective coating comprises Al₂O₃, B₂O₃, and SiO₂.

15. A method according to

claim 14

, wherein said protective coating further comprises at least one of Li₂O and Na₂O.

16. A method according to

claim 14

, wherein the content of SiO₂ in said protective coating is greater than 50 wt. %.

17. A method according to

claim 15

, wherein the content of Li₂O and Na₂O combined in said protective coating is less than 20 wt. %.

18. A method according to

claim 14

, wherein the content of B₂O₃ in said protective coating is less than 30 wt. %.

19. A method according to

claim 14

, wherein the content of Al₂O₃ in said protective coating is less than 20 wt. %.

20. A method according to

claim 1

, wherein the coating solvent comprises at least one member selected from the group consisting of an alcohol, ester, ketone, and hydrocarbon.

21. A method according to

claim 1

, wherein the coating solvent comprises at least two members selected from the group consisting of an alcohol, ester, ketone, or hydrocarbon, wherein the selected members have different boiling points.

22. A method according to

claim 1

, wherein the coating solvent comprises at least one additive selected from the group consisting of a surfactant, defoamer, air release additive, flow aid, and viscosifier.

23. A method according to

claim 1

, wherein the substrate is a cathode ray tube face-plate.

24. A method according to

claim 1

, wherein the substrate is a flat overlay for a liquid display application.

25. A method according to

claim 1

, wherein the substrate is used as a touch screen.

26. A substrate with a protective multicomponent coating, said coating formed by a process comprising the steps of:

(a) applying a coating solution to the substrate, said coating solution comprising

(i) a coating solvent;

(ii) a SiO₂ precursor comprising a silicon compound having at least one hydrolyzable group;

(iii) a glass oxide precursor comprising a compound having an element selected from Group III or Group IV of the periodic table in the form of a salt, an alkoxide, hydroxide or an acid thereof; and

(iv) a network modifier precursor comprising a compound containing an element selected from Group I or Group II of the periodic table in the form of a hydroxide, an acetate, or an alkoxide thereof; and

(b) subsequently firing the substrate at a temperature greater than 450°

C. to form the protective multicomponent coating on the substrate.

27. A multicomponent coating solution comprising:

(i) a coating solvent;

(ii) a SiO₂ precursor comprising a silicon compound having at least one hydrolyzable group;

(iii) a glass oxide precursor comprising a compound having an element selected from Group III or Group IV of the periodic table in the form of a salt, an alkoxide, a hydroxide or an acid thereof; and

(iv) a network modifier precursor comprising a compound containing an element selected from Group I or Group II of the periodic table.

28. A coating solution according to

claim 27

, wherein said SiO₂ precursor comprises at least one compound of the general formula R′

_nSi(OR)_4-n, where R is an alkyl group, R′

is an alkyl group or an aryl group, and n is a number between 1 and 3, inclusive.

29. A coating solution according to

claim 28

, wherein said SiO₂ precursor comprises at least one compound of the general formula SiX₄, where X is halide, an acetoxy, an alkoxy, or an aryloxy group.

30. A coating solution according to

claim 27

, wherein said SiO₂ precursor comprises at least one compound of the general formula Y_nSi(Z)_4-n, where Y is an alkyl group, an aryl group, or non hydrolyzable group, Z is halide, an alkoxy group, an aryloxy group, —

OCOR, —

NR₂, —

OC(═

CH₂)R, and —

ON═

CR₂, R being an alkyl or an aryl group, and n is a number between 1 and 3, inclusive.

31. A coating solution according to

claim 27

, wherein the element selected from Group III or Group IV of the periodic table comprises B or Al.

32. A coating solution according to

claim 27

, wherein the element selected from Group I or Group II of the periodic table comprises Li, Na, or K.

33. A coating solution according to

claim 27

, wherein the SiO₂ precursor comprises CH₃Si(OCH₃)₃ or CH₃Si (OCH₂CH₃)₃.

34. A coating solution according to

claim 27

, wherein the SiO₂ precursor comprises at least two different silicon compounds each having at least one hydrolyzable substituent.

35. A coating solution according to

claim 27

, wherein the glass oxide precursor comprises B(OH)₃ or B(OC₂H₅)₃.

36. A coating solution according to

claim 27

, wherein the glass oxide precursor comprises a chelated aluminum alkoxide.

37. A coating solution according to

claim 36

, wherein the chelated aluminum alkoxide comprises Al(Oⁱ C₃H₇)₂C₆H₉O₃.

38. A coating solution according to

claim 27

, wherein said network modifier precursor is in the form of a hydroxide, an acetate or an alkoxide.

39. A coating solution according to

claim 27

, wherein the coating solvent comprises at least one member selected from the group consisting of an alcohol, ester, ketone, and hydrocarbon.

40. A coating solution according to

claim 27

, wherein the coating solvent comprises at least two members selected from the group consisting of an alcohol, ester, ketone, or hydrocarbon, wherein the selected members have different boiling points.

41. A coating solution according to

claim 27

, wherein the coating solvent comprises at least one additive selected from the group consisting of a surfactant, defoamer, air release additive, flow aid, and viscosifier.

42. A coating solution according to

claim 27

, further comprising non-soluble particles in an amount effective to modify at least one optical or electrical property of a coating prepared from said coating solution.