Structured Smudge-Resistant Coatings and Methods of Making and Using the Same

• US 20090041984A1
• Filed: 08/11/2008
• Published: 02/12/2009
• Est. Priority Date: 08/10/2007
• Status: Abandoned Application

• Current Assignee: Nano-Terra Incorporated
• Original Assignee: Nano-Terra Incorporated
• Inventors: Agarwal, Sandip, Stewart, Kevin Randall, McLellan, Joseph M., Dickey, Kimberly, Chauhan, Karan, Coffey, David Christopher, Saadi, Wajeeh, Mayers, Brian T.
• Application Number:
  US12/189,485
• Publication Number:
  US 20090041984A1
• Time in Patent Office: Days
• US Class Current: 428/141
• CPC Class Codes: C03C 17/007 containing a dispersed phase, e.g. particles, fibres or flakes, in a continuous phase
• CPC Class Codes: C03C 17/32 with synthetic or natural resins C03C17/30 takes precedence
• CPC Class Codes: C03C 2217/213 SiO2
• CPC Class Codes: C03C 2217/29 Mixtures
• CPC Class Codes: C03C 2217/43 consisting of a dispersed phase in a continuous phase
• CPC Class Codes: C03C 2217/76 Hydrophobic and oleophobic coatings
• CPC Class Codes: C03C 2217/77 Coatings having a rough surface
• CPC Class Codes: C03C 2217/91 Coatings containing at least one layer having a composition gradient through its thickness
• CPC Class Codes: C03C 2218/112 by spraying
• CPC Class Codes: C03C 2218/114 by brushing, pouring or doctorblading
• CPC Class Codes: C03C 2218/328 Partly or completely removing a coating
• CPC Class Codes: C03C 2218/335 Reverse coating
• CPC Class Codes: C09D 125/06 Polystyrene
• CPC Class Codes: C09D 133/12 Homopolymers or copolymers of methyl methacrylate
• CPC Class Codes: C09D 5/1675 Polyorganosiloxane-containing compositions
• CPC Class Codes: G02B 1/18 Coatings for keeping optical surfaces clean, e.g. hydrophobic or photo-catalytic films G02B1/16 takes precedence
• CPC Class Codes: G02B 27/0006 with means to keep optical surfaces clean, e.g. by preventing or removing dirt, stains, contamination, condensation G02B1/18 takes precedence; cleaning in general B08B
• CPC Class Codes: G02B 3/0006 Arrays G02B3/02, G02B5/188 take precedence
• CPC Class Codes: G02B 5/045 Prism arrays
• CPC Class Codes: Y10T 428/24355 Continuous and nonuniform or irregular surface on layer or component [e.g., roofing, etc.]

Abstract

The present invention is directed to smudge-resistant coatings, methods to prepare the coatings, and products prepared by the methods.

Claims

1. A smudge-resistant, composite coating comprising:

a matrix, and

a particulate embedded within, and protruding from, at least a portion of the matrix,

wherein the particulate has a refractive index within about 20% of a refractive index of the matrix, the particulate has a polydispersity index of at least about 1 or greater, and the particulate is present within the matrix in a concentration gradient having a highest concentration at an exterior surface of the matrix, and wherein the composite coating has a root mean square surface roughness of about 100 nm to about 10 μ

m.

2. The composite coating of claim 1, wherein the matrix has a refractive index of about 2 or less.

3. The composite coating of claim 1, wherein the matrix has a glass transition temperature of about 50°

C. to about 250°

C.

4. The composite coating of claim 1, wherein the particulate has a D₅₀ of about 100 nm to about 50 μ

m and a D₉₀ of about 100 μ

m or less

5. The composite coating of claim 1, wherein the matrix has a hardness and the particulate has a hardness at least about 2 times greater than the hardness of the matrix.

6. The composite coating of claim 1, wherein an exterior surface of the composite coating comprises a fluorinated moiety.

7. The composite coating of claim 1, wherein an exterior surface of the composite coating is substantially free of an additional surface coating.

8. A method for preparing a smudge-resistant, composite coating, the method comprising:

depositing a particulate and a matrix to provide an intermediate film; and

curing the intermediate film to provide a smudge-resistant, composite coating,

wherein the curing embeds the particulate at least partially in the matrix to provide a smudge-resistant, composite coating having a concentration gradient of the particulate that is greatest at the exterior surface of the matrix, and wherein the composite coating has a root mean square surface roughness of about 100 nm to about 10 μ

m.

9. The method of claim 8, further comprising hardening the matrix.

10. The method of claim 9, wherein the curing and hardening are performed simultaneously.

11. The method of claim 8, wherein the curing provides a particulate having a D₅₀ of about 200 nm to about 50 μ

m.

12. A distortion-free, smudge-resistant optical coating comprising a substrate having an array of optical elements thereon, the optical elements having an infinite focal length and each optical element having a lateral dimension, measured parallel to the substrate, of about 5 μ

m to about 200 μ

m, wherein the optical coating has a root mean square surface roughness of about 1 μ

m to about 100 μ

m.

13. The distortion-free, smudge-resistant optical coating of claim 12, wherein the array of optical elements is selected from:

an array of compound lenses, an array of prisms, a sawtooth grating, a square-wave grating, a sigmoidal grating, an array of trigonal pyramids, an array of square pyramids, and combinations thereof.

14. The distortion-free, smudge-resistant optical coating of claim 12, wherein an exterior surface of the array of optical elements comprises a fluorinated moiety.

15. The distortion-free, smudge-resistant optical coating of claim 15, wherein the array of optical elements comprises aligned layers of materials that are the same or different, and wherein each layer has a refractive index of about 3 or less.

16. A method for preparing a distortion-free, smudge-resistant optical coating, the method comprising forming on a substrate a layer comprising an array of optical elements, wherein the substrate and the layer are transparent to visible light, wherein the optical elements have an infinite focal length, the optical elements have a lateral dimension, measured parallel to the substrate, of about 5 μ

m to about 200 μ

m, and the layer has an exterior surface having a root mean square surface roughness of about 1 μ

m to about 100 μ

m.

17. The method of claim 16, wherein the forming comprises:

depositing a first layer of a first material on the substrate, wherein the first layer includes a surface having a first three-dimensional pattern thereon;

depositing a second layer of a second material on the first layer, wherein the second material includes a surface having a second three-dimensional pattern thereon;

depositing a third layer of a third material on the second layer, wherein the third layer includes a surface having a third three-dimensional pattern thereon,

wherein the first, second and third three-dimensional patterns are optically aligned to provide an array of optical elements having an infinite focal length, and wherein the first, second and third materials are transparent to visible light.

18. The method of claim 16, wherein the forming comprises molding a material with an elastomeric stamp including a surface having at least one indentation therein to provide the array of optical elements.

19. The method of claim 16, wherein the optical coating has a refractive index less than a refractive index of the substrate.

20. A method for preparing a smudge-resistant film, the method comprising:

depositing a matrix onto a substrate; and

exposing the matrix to an abrasive to produce the smudge-resistant film, wherein the film has a root mean square surface roughness of about 100 nm to about 10 μ

m.

21. The method of claim 20, further comprising at least one of:

chemically, mechanically, or thermally polishing the smudge-resistant film.

22. The method of claim 20, further comprising surface treating the smudge-resistant film to render an exterior surface of the film hydrophobic.

23. A distortion-free, smudge-resistant coating comprising a substrate that is transparent to visible light and having an array of hollow, pointed elements thereon, each element having a height of about 1 μ

m to about 300 μ

m and a thickness of about 100 nm to about 100 μ

m, wherein the thickness of the elements is not more than 30% of the height of the elements, and wherein the elements do not substantially overlap, and wherein the elements comprise a material having a refractive index that is either less than, or not more than 20% greater than, a refractive index of the substrate.