Coated plastic molded articles

• US 5,498,475 A
• Filed: 12/02/1993
• Issued: 03/12/1996
• Est. Priority Date: 05/31/1990
• Status: Expired due to Fees

• Current Assignee: Nippon Sheet Glass Company Limited (Nippon Telegraph and Telephone Corporation)
• Original Assignee: Nippon Sheet Glass Company Limited (Nippon Telegraph and Telephone Corporation)
• Inventors: Hirayama, Naoto, Kitaoka, Masaki, Takigawa, Akio
• Primary Examiner(s): NAKARANI, DHIRAJLAL S
• Application Number:
  US08/160,327
• Time in Patent Office: 831 Days
• Field of Search: 427/508, 428/215, 428/216, 428/334, 428/335, 428/336, 428/446, 428/447, 428/448, 428/451, 428/412, 428/480, 428/483, 428/520, 428/908.8
• US Class Current: 428/334
• 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 7/576 each layer being cured, at least partially, separately
• CPC Class Codes: B32B 2305/72 Cured, e.g. vulcanised, cross-linked
• CPC Class Codes: B32B 2307/554 Wear resistance
• CPC Class Codes: B32B 2307/712 Weather resistant
• CPC Class Codes: B32B 2307/714 Inert, i.e. inert to chemical degradation, corrosion
• CPC Class Codes: B32B 2307/7265 Non-permeable
• CPC Class Codes: B32B 2383/00 Polysiloxanes
• CPC Class Codes: B32B 27/08 of synthetic resin
• CPC Class Codes: B32B 27/16 specially treated, e.g. irradiated
• CPC Class Codes: B32B 27/283 comprising polysiloxanes
• CPC Class Codes: B32B 27/308 comprising acrylic (co)polymers
• CPC Class Codes: B32B 7/12 using interposed adhesives or interposed materials with bonding properties
• CPC Class Codes: Y10T 428/24967 Absolute thicknesses specified
• CPC Class Codes: Y10T 428/24975 No layer or component greater than 5 mils thick
• CPC Class Codes: Y10T 428/263 Coating layer not in excess of 5 mils thick or equivalent
• CPC Class Codes: Y10T 428/264 Up to 3 mils
• CPC Class Codes: Y10T 428/265 1 mil or less
• CPC Class Codes: Y10T 428/31507 Of polycarbonate
• CPC Class Codes: Y10T 428/31663 As siloxane, silicone or silane
• CPC Class Codes: Y10T 428/31667 : Next to addition polymer from unsaturated monomers, or aldehyde or ketone condensation product
• CPC Class Codes: Y10T 428/31797 : Next to addition polymer from unsaturated monomers
• CPC Class Codes: Y10T 428/31928 : Ester, halide or nitrile of addition polymer

Abstract

A coated plastic molded article comprising a plastic molded article on the surface of which are laminated (a) a first layer comprising a cured composition containing a partially hydrolyzed product of at least one silicon compound, (b) a second layer comprising a cured, partially hydrolyzed product of a second silicon compound, and (c) a third layer comprising silicon dioxide from an aqueous hydrosilicofluoric acid solution supersaturated with silicon dioxide, the coating layers being applied to the plastic molded article in the order stated; and alternate embodiments of a process for preparing the coated plastic molded articles.

Claims

1. A coated plastic molded article consisting essentially of a plastic article onto at least one surface of which are laminated:

(a) at least one first layer having a thickness ranging from 1 to 100 μ

m, and comprising a cured composition containing at least one hydrolyzate of at least one silicon compound which is represented by the formula;

space="preserve" listing-type="equation">R.sup.1 Si(R.sup.2).sub.3

wherein R¹ is selected from the group consisting of a C₁ -C₄ hydrocarbon group, an epoxy group-containing organic group and a fluorine atom-containing organic group, and R² is selected from the group consisting of alkoxy, alkoxyalkoxy, and acetoxy groups and chlorine atoms, provided that said R² s are the same or different from each other;

(b) at least one second layer, on a surface of said first layer, having a thickness ranging from about 1 to 100 nm, but less than 100 nm, and comprising at least one cured hydrolyzate of at least one silicon compound represented by the formula;

space="preserve" listing-type="equation">(R.sup.3).sub.n Si(R.sup.4).sub.4-n

wherein R³ is selected from the group consisting of an acryloxy group-containing organic group, a methacryloxy group-containing organic group and a chlorine-containing organic group, and R⁴ is selected from the group consisting of alkoxy, alkoxyalkoxy and acetoxy groups, and n is 0 or 1, said at least one second layer which makes said at least one second layer and said at least one third layer adhere uniformly together; and

(c) at least one third layer, on a surface of said second layer, which is formed by immersing said plastic article, with said at least one first layer and said at least one second layer thereon, into an aqueous hydrosilicofluoric acid solution supersaturated with silicon dioxide, forming, on a surface of said at least one second layer, said at least one third layer which is abrasion resistant, weather resistant, chemical resistant and impervious to water;

said at least one first layer, said at least one second layer and said at least one third layer being arranged on said at least one surface of said plastic article in the order of, initially, said at least one first layer, followed by said at least one second layer, and then followed by said at least one third layer.

2. The invention of claim 1 further comprising an adhesive layer present between said at least one surface of said coated plastic molded article and said at least one first layer.

3. The invention of claim 2 in which said adhesive layer comprises at least one acrylic polymer.

4. The invention of claim 2 in which said adhesive layer comprises at least one methacrylic polymer.

5. The invention of claim 2 in which said adhesive layer comprises at least one acrylic polymer and at least one methacrylic polymer.

6. The invention of claim 1 wherein said plastic molded article is comprised of at least one material selected from the group consisting of polycarbonate, diethylene glycol-bis-allylcarbonate polymer, acrylic resin and polyester resin.

7. A coated plastic molded article comprising a plastic coated article having on at least one surface thereof:

(a) a first polymer layer having a thickness ranging from 1 to 100 μ

m cured with irradiation of actinic rays;

(b) a second layer, on a surface of said first polymer layer, having a thickness ranging from about 1 to 100 nm, but less than 100 nm, and consisting essentially of at least one cured hydrolyzate of at least one of the silicon compounds represented by the formula;

space="preserve" listing-type="equation">(R.sup.3).sub.n Si(R.sup.4).sub.4-n

wherein R³ is selected from the group consisting of an acryloxy group-containing organic group, a methacryloxy group-containing organic group and a chlorine-containing organic group, and R⁴ is selected from the group consisting of alkoxy, alkoxyalkoxy and acetoxy groups, and n is 0 or 1, said second layer which provides enhanced means for forming thereon at least one adhering and uniform third layer; and

(c) a third layer, on a surface of said second layer, comprising silicon dioxide from an aqueous hydrosilicofluoric acid solution supersaturated with silicon dioxide;

said first polymer layer, said second layer and said third layer being laminated together and onto said a least one surface of said plastic molded article in the order of initially said first polymer layer, followed by said second layer, followed by said third layer, said third layer which is abrasion resistant, chemical resistant and impervious to water.

8. The invention of claim 7 wherein said first layer is formed by a method comprising curing a polyfunctional acrylate compound with irradiation of actinic rays.

9. The invention of claim 7 wherein said plastic molded article is comprised of at least one material selected from the group consisting of poly carbonate, diethylene glycol-bis-allylcarbonate polymer, acrylic resin and polyester resin.