Method for forming abrasion-resistant polycarbonate articles, and articles of manufacture produced thereby

• US 4,842,941 A
• Filed: 04/06/1987
• Issued: 06/27/1989
• Est. Priority Date: 04/06/1987
• Status: Expired due to Term

• Current Assignee: General Electric Company
• Original Assignee: General Electric Company
• Inventors: Reed, Clive W., Rzad, Stefan J., Devins, John C.
• Primary Examiner(s): NOT, DEFINED
• Assistant Examiner(s): Bueker, Margaret
• Application Number:
  US07/034,890
• Time in Patent Office: 813 Days
• Field of Search: 429/39, 429/40, 429/41, 429/162, 429/163, 429/164, 428/412, 427/419.2
• US Class Current: 428/412
• CPC Class Codes: B05D 1/62 Plasma-deposition of organic layers plasma deposition in general C23C14/00, C23C16/00
• CPC Class Codes: B05D 7/02 to macromolecular substances, e.g. rubber treatment or coating of shaped articles made of macromolecular substances C08J7/00
• CPC Class Codes: B05D 7/54 No clear coat specified
• CPC Class Codes: C08J 2369/00 Characterised by the use of polycarbonates; Derivatives of polycarbonates
• CPC Class Codes: C08J 2433/08 Homopolymers or copolymers of acrylic acid esters
• CPC Class Codes: C08J 7/0427 with only one layer of a composition containing a polymer binder with more layers C08J7/042
• CPC Class Codes: C08J 7/043 Improving the adhesiveness of the coatings per se, e.g. forming primers adhesives in the form of films or foils characterised by the primer layers between the polymer carriers and the adhesives C09J7/50
• CPC Class Codes: C08J 7/046 Forming abrasion-resistant coatings; Forming surface-hardening coatings
• CPC Class Codes: C08J 7/123 Treatment by wave energy or particle radiation C08J7/18 takes precedence
• CPC Class Codes: Y10T 428/31507 Of polycarbonate

Abstract

An abrasion-resistant article and method for making is disclosed. The article includes a polycarbonate substrate, an interfacial layer of an adherent resinous composition on the substrate, and an abrasion-resistant top layer applied on the interfacial layer by plasma-enhanced chemical vapor deposition.

Claims

1. A method for forming an abrasion-resitant article, comprising the steps of:

(a) Applying an interfacial layer on the surface of a polycarbonate substrate wherein the interfacial layer comprises a curable organopolysiloxane composition containing a dispersion of colloidal silica in a solution of the partial condensate of a silanol having the formula RSi(OH)3 or R2Si(OH)2, wherein R is selected from the group consisting of alkyl groups having about 1 to 3 carbon atoms and aryl groups having about 6 to 20 carbon atoms, wherein at least 70 weight percent of the silanol is CH3Si(OH)3 or (CH3)2Si(OH)2 in a mixture of an aliphatic alcohol and water; and

(b) Applying an abrasion-resistant top layer containing a material selected from the group consisting of silicon carbide, silicon dioxide, silicon nitride, silicon oxynitride, boron oxide, boron nitride, aluminum oxide, aluminum nitride, and titanium dioxide, on the interfacial layer by;

(i) situating the polycarbonate substrate having the interfacial layer disposed thereover in a reactor chamber which is pressurized at between about 50 millitorrs and about 10 torrs; and

(ii) passing into the reactor chamber with a carrier gas at least one gaseous reactant capable of reacting to form the composition of said top layer in a laminar flow having a Reynolds value of about 2.5 relative to the surface of the interfacial layer at a flow rate of between 500 sccm and 10,000 sccm while generating an electric field in the chamber to form a sustained plasma of the gaseous reactant, wherein the plasma is formed by an electrical generator operating at dc or at ac frequencies of betwen about 50 Hz and about 10 GHz and at a power value of between 10 watts and 5000 watts, said substrate being heated to a temperature between about room temperature and 130°

C., said gaseous reactant reacting in the plasma and on the interfacial layer to form said top layer.

2. The article produced by the method of claim 1.