Molded articles having hard coat layer and method for producing same

• US 5,725,960 A
• Filed: 06/07/1995
• Issued: 03/10/1998
• Est. Priority Date: 12/28/1992
• Status: Expired due to Fees

• Current Assignee: Nippon Zeon Co., Ltd. (BASF SE)
• Original Assignee: Nippon Zeon Co., Ltd. (BASF SE)
• Inventors: Takahashi, Nobukazu, Tada, Mitsushi, Hosaka, Tohru, Konishi, Yuichiro, Kohara, Teiji, Natsuume, Tadao
• Primary Examiner(s): Thisodeau, Paul J.
• Assistant Examiner(s): TARAZANO, DONALD LAWRENCE
• Application Number:
  US08/448,557
• Time in Patent Office: 1,007 Days
• Field of Search: 428/451, 428/517, 428/519, 428/522, 428/521, 428/426, 428/441, 351/166
• US Class Current: 428/451
• CPC Class Codes: C08J 2365/00 Characterised by the use of macromolecular compounds obtained by reactions forming a carbon-to-carbon link in the main chain C08J2307/00 - C08J2357/00, C08J2361/00 take precedence; Derivatives of such polymers
• 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: Y10T 428/31667 Next to addition polymer from unsaturated monomers, or aldehyde or ketone condensation product
• CPC Class Codes: Y10T 428/31924 Including polyene monomers
• CPC Class Codes: Y10T 428/31935 Ester, halide or nitrile of addition polymer

Abstract

A molded article having an adhesion of at least 50 squares per 100 squares in crosscut adhesion test and at least 40 squares per 100 squares even after kept in a warm water of 70° C. for 1 hour, a haze value of 1.0% or less in Taber abrasion test and a pencil hardness of 2H or higher, said molded article being obtained by modifying the surface of a substrate formed of a thermoplastic norbornene resin to have a surface tension of 50 dynes/cm or greater by a treatment such as corona discharge treatment or the like or forming a preliminary primer layer of a modified product obtained by introducing a polar group into a copolymer of a vinyl aromatic compound and a conjugated diene, or the like; forming a primer layer for silicone hard coating agent on the modified surface or the preliminary primer layer, and then forming thereon a silicone hard coat layer, and a method for producing the molded article.

Claims

1. A molded article comprising a substrate formed of a thermoplastic norbornene resin having no polar groups, in which the surface of said substrate has been modified to produce a modified surface layer having a surface tension of at least 50 dynes/cm;

a primer layer formed on the modified surface layer; and

a silicone hard coat layer formed on said primer layer as a top coat layer.

2. A molded article according to claim 1, wherein the thermoplastic norbornene resin is at least one member selected from the group consisting of ring-opened polymers of norbornene monomers and hydrogenation products thereof, addition polymers of norbornene monomers, addition copolymers of norbornene monomers and olefins, and hydrogenation products of the addition polymers and copolymers.

3. A molded article according to claim 1, wherein the thermoplastic norbornene resin has a number-average molecular weight of 10,000-200,00.

4. A molded article according to claim 1, wherein the silicon hard coat layer is a hydrolyzate of a silicone compound of the formula R¹_m Si(OR²)_4-m or R¹_m Si(OCOR²)_4-m, wherein R¹ is a hydrocarbon group of 1-8 carbon atoms, a halogenated hydrocarbon group of 1-8 carbon atoms or an organic group having thereon an amino group, mercapto group, epoxy group or (meth)acrylic group;

R² is a hydrocarbon group of 1-6 carbon atoms, and m is 0, 1 or 2;

or a partial condensate of said hydrolyzate.

5. A molded article according to claim 4, wherein the silicone compound is at least one member selected from the group consisting of methyltrimethoxysilane, methyltriethoxysilane, methyltributoxysilane, methyltris(2-methoxyethoxy)silane, ethyltrimethoxisilane, ethyltriethoxysilane, phenyltrimethoxysilane, phenyltriethoxisilane, dimethyldimethoxysilane, dimethyldiethoxysilane, diphenyldimethoxysilane, diphenyldiethoxysilane, tetramethoxysilane, tetraethoxysilane, tetrabutoxysilane and glycidoxymethyltrimethoxysilane.

6. A molded article according to claim 1, wherein the silicone hard coat layer contains fine particles of silica.

7. A molded article according to claim 1, wherein the silicone hard coat layer is dyed.

8. A molded article according to claim 1, wherein the silicone hard coat layer has haze value of 1.0% or less after having been subjected to Taber abrasion testing.

9. A molded article according to claim 1, wherein the silicone hard coat layer has a pencil hardness of 2H or higher.

10. A molded article according to claim 1, wherein the silicone hard coat layer has a thickness of 1-30 μ

m.

11. A molded article according to claim 1 which is a lens.

12. A molded article according to claim 11, wherein the modified surface layer of the substrate has been produced by energy beam irradiation treatment.

13. A molded article according to claim 12, wherein the energy beam irradiation treatment is a corona discharge, plasma, electron beam irradiation or ultraviolet ray irradiation treatment.