Transparent plastic optical components and abrasion resistant polymer substrates and methods for making the same
First Claim
1. A plastic component, comprising:
- a transparent synthetic resin substrate having an anterior surface and a posterior surface;
a tie-bond layer formed on said anterior surface and said posterior surface of said synthetic resin substrate; and
a multi-layer surface abrasion resistant coating on the tie-bond layer, the multi-layer surface abrasion resistant coating and tie-bond layer are formed by a single wet coating that is cured to provide at least two layers of the surface abrasion resistant coating having respective different concentrations of colloid particles.
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Accused Products
Abstract
A polymer-based component formed from a synthetic thermoplastic or thermoset resin substrate, such as polymethyl methacrylate, which is resistant to warping and distortion from moisture. A composite multi-layer surface-hardening coating is formed on at least the anterior surface of the resin substrate. The component can include a composite multi-layer reflective coating to form a mirror. A protective back-coat layer is deposited on a posterior surface of the mirror. A multi-layer weather-resistant coating may optionally be applied to the anterior surface of the polymer-based mirror in order to increase the weatherability and durability of the mirror. The various layers coating the synthetic resin substrate have their moisture permeabilities selected so that substantially equal amounts of moisture permeate through to both the anterior and posterior side of the synthetic resin substrate. A sol-gel coating can be used to deposit the multi-layers in a single step by providing gradient zones of zirconia/silica while enabling a hydrophobic or a hydrophilic exterior surface.
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Citations
26 Claims
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1. A plastic component, comprising:
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a transparent synthetic resin substrate having an anterior surface and a posterior surface; a tie-bond layer formed on said anterior surface and said posterior surface of said synthetic resin substrate; and a multi-layer surface abrasion resistant coating on the tie-bond layer, the multi-layer surface abrasion resistant coating and tie-bond layer are formed by a single wet coating that is cured to provide at least two layers of the surface abrasion resistant coating having respective different concentrations of colloid particles. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10, 11)
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12. A plastic component comprising:
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a transparent synthetic resin substrate having an anterior surface and a posterior surface; a tie-bond layer formed on one of said anterior surface and said posterior surface of said synthetic resin substrate; and a transparent multi-layer surface abrasion resistant coating on the tie-bond layer, the multi-layer surface abrasion resistant coating and tie-bond layer are formed by a single wet coating that is cured to provide at least two layers of the surface abrasion resistant coating having respective different concentrations of colloid particles including a first layer, on an exterior surface, containing a majority of the colloid particles by weight. - View Dependent Claims (13, 14, 15, 16, 17, 18, 19, 20, 21, 22, 23, 24, 25, 26)
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Specification