Coated plastic substrate
First Claim
1. A laminate which comprises:
- a) a plastic substrate having a surface;
b) an adhesion promoter layer which is a first plasma polymerized organosilicon compound deposited on the surface of the substrate at a power level in the range of about 5×
107 J/kg to about 5×
109 J/kg, and in the substantial absence of oxygen; and
c) a protective coating layer which is a second plasma polymerized organosilicon compound deposited on the surface of the adhesion layer at a power density from about 106 J/kg to about 108 J/kg, and in the presence of a higher level of oxygen than used in step (b).
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Accused Products
Abstract
The present invention is a laminate which comprises:
a) a plastic substrate having a surface;
b) an adhesion promoter layer which is a first plasma polymerized organosilicon compound deposited on the surface of the substrate in the substantial absence of oxygen; and
c) a protective coating layer which is a second plasma polymerized organosilicon compound deposited on the surface of the adhesion layer at a power density from about 106 J/kg to about 108 J/kg, and in the presence of a sufficient stoichiometric excess of oxygen to form a silicon polymer of SiO1.8-2.4 C0.3-1.0 and H0.7-4.0.
The coating layer provides abrasion and solvent resistance for the substrate, and the adhesion promoter prevents the coating layer from peeling off the substrate. The coated plastic substrate can be used in liquid crystal display devices as an alternative to glass.
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Citations
12 Claims
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1. A laminate which comprises:
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a) a plastic substrate having a surface; b) an adhesion promoter layer which is a first plasma polymerized organosilicon compound deposited on the surface of the substrate at a power level in the range of about 5×
107 J/kg to about 5×
109 J/kg, and in the substantial absence of oxygen; andc) a protective coating layer which is a second plasma polymerized organosilicon compound deposited on the surface of the adhesion layer at a power density from about 106 J/kg to about 108 J/kg, and in the presence of a higher level of oxygen than used in step (b). - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10)
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11. A laminate which comprises:
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a) a plastic substrate having a surface and a thickness of not less than about 0.1 mm and not more than about 10 mm; b) an adhesion promoter layer which is a plasma polymerized tetramethyldisiloxane deposited on the surface of the substrate at a power level in the range of about 5×
107 J/kg to about 5×
109 J/kg and in the substantial absence of oxygen, which adhesion promoter has a thickness of not less than about 1000 Å and
not more than 2000 Å
;c) a protective coating layer which is a plasma polymerized tetramethyldisiloxane deposited on the surface of the adhesion promoter layer at a power density from about 106 J/kg to about 108 J/kg in the presence of a sufficient stoichiometric excess of oxygen with respect to tetramethyldisiloxane to form an organosilicon compound having the formula SiO1.8-2.4 C0.3-1.0 and H0.7-4.0 that contains trapped water and at least one of the following functional groups;
--Si--O--Si--, --Si--CH2 --, --Si--H, or --Si--OH;wherein the thickness of the protective coating layer is not less than about 0.1 micron and not greater than about 2 microns; and d) an SiOx layer which is a layer of a plasma polymerized tetramethyldisiloxane deposited on the surface of the protective coating layer, in the presence of a stoichiometric excess of oxygen, and at a power density of at least four times the power density used to form the protective coating layer, wherein the SiOx layer has a thickness of not less than about 0.05 micron and not more than about 1 micron.
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12. A laminate which comprises:
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a) a plastic substrate having a surface; and b) an adhesion promoter layer which is a plasma polymerized organosilicon compound deposited on the surface of the substrate at a power level in the range of about 5×
107 J/kg to about 5×
109 J/kg, and in the substantial absence of oxygen.
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Specification