METHOD OF FORMING AN ANTI-GLARE COATING ON A SUBSTRATE

• US 20160041307A1
• Filed: 08/08/2014
• Published: 02/11/2016
• Est. Priority Date: 08/08/2014
• Status: Abandoned Application

• Current Assignee: PPG Industries Ohio Incorporated (Nouryon BV)
• Original Assignee: PPG Industries Ohio Incorporated (Nouryon BV)
• Inventors: Lu, Songwei
• Application Number:
  US14/455,109
• Publication Number:
  US 20160041307A1
• Time in Patent Office: Days
• US Class Current: 1/1
• CPC Class Codes: C09D 183/06 containing silicon bound to oxygen-containing groups C09D183/12 takes precedence
• CPC Class Codes: C09D 183/08 containing silicon bound to organic groups containing atoms other than carbon, hydrogen, and oxygen
• CPC Class Codes: C23C 18/1212 Zeolites, glasses
• CPC Class Codes: C23C 18/122 Inorganic polymers, e.g. silanes, polysilazanes, polysiloxanes
• CPC Class Codes: C23C 18/1254 Sol or sol-gel processing
• CPC Class Codes: C23C 18/1291 by heating of the substrate
• CPC Class Codes: G02B 5/021 the diffusion taking place at the element's surface, e.g. by means of surface roughening or microprismatic structures
• CPC Class Codes: G02B 5/0268 characterized by the fabrication or manufacturing method

Abstract

A method of forming an anti-glare coating on a substrate is provided. The method comprises: (a) heating the substrate to a temperature of at least 100° F. (37.8° C.) to form a hot substrate; (b) applying a curable film-forming sol-gel composition on at least one surface of the hot substrate, to form a coated substrate with a sol-gel network layer having a surface roughness; and (c) subjecting the coated substrate to conditions for a time sufficient to effect cure of the sol-gel layer and form an anti-glare, coated article. The sol-gel network layer is essentially free of inorganic oxide particles and comprises:

(i) a tetraalkoxysilane;

(ii) an epoxy functional trialkoxysilane;

(iii) a metal-containing catalyst; and

(iv) a solvent component. Coated articles prepared by the method above and demonstrating anti-glare properties are also provided.

Claims

1. A method of forming an anti-glare coating on a substrate comprising:

(a) heating the substrate to a temperature of at least 100°

F. (37.8°

C.) to form a hot substrate;

(b) applying a curable film-forming sol-gel composition on at least one surface of the hot substrate, to form a coated substrate with a sol-gel network layer having a surface roughness;

wherein the sol-gel network layer is essentially free of inorganic oxide particles and wherein the curable film-forming sol-gel composition comprises;

(i) a tetraalkoxysilane;

(ii) an epoxy functional trialkoxysilane;

(iii) a metal-containing catalyst; and

(iv) a solvent component; and

(c) subjecting the coated substrate to conditions for a time sufficient to effect cure of the sol-gel layer and form an anti-glare, coated article.

2. The method of claim 1 wherein the substrate comprises a plastic, glass, or metal.

3. The method of claim 1, wherein the substrate comprises glass and is heated in step (a) to a temperature of 230 to 450°

F. (110 to 232.2°

C.).

4. The method of claim 1, wherein, immediately prior to application to the substrate, the curable film-forming composition is kept at ambient temperature.

5. The method of claim 1 wherein the tetraalkoxysilane (i) in the curable film-forming composition comprises tetramethoxysilane and/or tetraethoxysilane.

6. The method of claim 1, wherein the epoxy functional trialkoxysilane (ii) in the curable film-forming composition comprises glycidoxypropyl trimethoxysilane.

7. The method of claim 1 wherein the metal-containing catalyst (iii) in the curable film-forming composition comprises colloidal aluminum hydroxychloride or aluminum acetylacetonate.

8. The method of claim 1 wherein the curable film-forming composition is spray applied to the hot substrate in step (b).

9. The method of claim 1 wherein the coated substrate is heated to a temperature of at least 120°

C. for at least 0.5 hour in step (c).

10. The method of claim 1 wherein the coated article formed in step (c) demonstrates a 60°

gloss value of 15 gloss units to 120 gloss units.

11. A coated article demonstrating anti-glare properties, wherein the coated article is prepared by a process comprising:

(a) heating the substrate to a temperature of at least 100°

F. (37.8°

C.) to form a hot substrate;

(b) applying a curable film-forming sol-gel composition on at least one surface of the hot substrate, to form a coated substrate with a sol-gel network layer having a surface roughness;

wherein the sol-gel network layer is essentially free of inorganic oxide particles and wherein the curable film-forming sol-gel composition comprises;

(i) a tetraalkoxysilane;

(ii) an epoxy functional trialkoxysilane;

(iii) a metal-containing catalyst; and

(iv) a solvent component; and

(c) subjecting the coated substrate to conditions for a time sufficient to effect cure of the sol-gel layer and form an anti-glare, coated article.

12. The coated article of claim 11, wherein said coated article is an optical article.

13. The coated article of claim 12, wherein said optical 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.

14. The coated article of claim 11 wherein the substrate comprises glass and is heated in step (a) to a temperature of 230 to 450°

F. (110 to 232.2°

C.).

15. The coated article of claim 11, wherein, immediately prior to application to the substrate, the curable film-forming composition is kept at ambient temperature.

16. The coated article of claim 11 wherein the tetraalkoxysilane (i) in the curable film-forming composition comprises tetramethoxysilane and/or tetraethoxysilane.

17. The coated article of claim 11 wherein the epoxy functional trialkoxysilane (ii) in the curable film-forming composition comprises glycidoxypropyl trimethoxysilane.

18. The coated article of claim 11 wherein the metal-containing catalyst (iii) in the curable film-forming composition comprises colloidal aluminum hydroxychloride or aluminum acetylacetonate.

19. The coated article of claim 11 wherein the curable film-forming composition is spray applied to the hot substrate in step (b).

20. The coated article of claim 11 wherein the coated article formed in step (c) demonstrates a 60 gloss value of 15 gloss units to 120 gloss units.

21. The coated article of claim 11, wherein at least one additional coating composition is applied to the coated article after step (c).

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

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

(b) a cured film-forming sol-gel composition applied to at least a portion of the flat surface of the substrate, wherein the cured film-forming sol-gel composition is deposited from a composition comprising;

(i) a tetraalkoxysilane;

(ii) an epoxy functional trialkoxysilane;

(iii) a metal-containing catalyst; and

(iv) a solvent component;

and wherein the coated article demonstrates a 60 gloss value of 15 to 120 gloss units and a light transmittance of at least 84%.