Multilayered hydrophobic coating and method of manufacturing the same
First Claim
1. A method of forming a transparent multi-layer coating over a substrate comprising:
- forming an organo-silicon polymer surface-hardening layer over said substrate;
forming a multi-layer abrasion-resistant coating over said organo-silicone polymer surface-hardening layer by sequentially depositing a plurality of alternating layers of silicon dioxide and zirconium dioxide of respectively different thicknesses over said organo-silicone polymer surface-hardening layer using a dry coating technique; and
depositing a transparent perfluorinated hydrophobic coating over said abrasion-resistant coating using a dry coating technique.
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Abstract
A multi-layer coating for a transparent substrate, such as glass, plastic, or other transparent material, which increases the durability and weatherability of the substrate. The coating includes a surface-hardening layer of organo-siloxane formed over the substrate. An abrasion-resistant coating comprising a multi-layer stack of alternating layers of silicon dioxide and zirconium dioxide is formed over the surface-hardening layer. The multi-layer coating further includes a hydrophobic outer layer of perfluoroalkylsilane formed over the abrasion-resistant coating to form an outer moisture-resistant surface. This multi-layer coating configuration increases the abrasion resistance and mechanical strength of the transparent substrate on which it is formed without imparting color to the transparent substrate.
76 Citations
22 Claims
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1. A method of forming a transparent multi-layer coating over a substrate comprising:
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forming an organo-silicon polymer surface-hardening layer over said substrate;
forming a multi-layer abrasion-resistant coating over said organo-silicone polymer surface-hardening layer by sequentially depositing a plurality of alternating layers of silicon dioxide and zirconium dioxide of respectively different thicknesses over said organo-silicone polymer surface-hardening layer using a dry coating technique; and
depositing a transparent perfluorinated hydrophobic coating over said abrasion-resistant coating using a dry coating technique. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10, 11)
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12. A method of forming a transparent multi-layer coating over a transparent plastic substrate to provide abrasion-resistant and hydrophobic properties comprising the steps of;
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providing a transparent plastic substrate;
forming an organo-silicon tie-bond layer on the plastic substrate;
forming a multi-layer abrasion-resistant coating of alternating layers of silicon dioxide and zirconium dioxide over the tie-layer wherein a thickness of a first layer adjacent the tie-layer is larger than each respective subsequent layer; and
depositing a transparent perfluorinated hydrophobic coating over the abrasion-resistant coating with a dry coating technique wherein the thicknesses of each layer and corresponding thermal coefficients of expansion cooperate to match a thermal coefficient of expansion of the plastic substrate over an operative predetermined thermal range. - View Dependent Claims (13, 14, 15, 16, 17)
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18. A method of forming a transparent multi-layer coating over a transparent plastic substrate to provide abrasion-resistant and hydrophobic properties comprising the steps of:
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providing a transparent plastic substrate from one of polycarbonate and acrylic;
forming an organo-silicon tie-bond layer on the plastic substrate;
forming a multi-layer abrasion-resistant coating of alternating layers of silicon dioxide and zirconium dioxide over the tie-bond layer wherein a thickness of a first layer adjacent the tie-bond layer is larger than each respective subsequent layer; and
depositing a perfluoroalkylsilane coating over the multi-layer abrasion-resistant coating of sufficient thickness to make the plastic substrate hydrophobic, wherein the thicknesses of each layer and corresponding thermal coefficients of expansion cooperate to match a thermal coefficient of expansion of the plastic substrate over an operative predetermined thermal range. - View Dependent Claims (19, 20, 21, 22)
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Specification