Bond layer for coatings on plastic substrates

• US 7,056,584 B2
• Filed: 10/11/2002
• Issued: 06/06/2006
• Est. Priority Date: 10/11/2002
• Status: Expired due to Term

• Current Assignee: Sabic Innovative Plastics IP BV (Government of Saudi Arabia)
• Original Assignee: General Electric Company
• Inventors: Iacovangelo, Charles D.
• Primary Examiner(s): Zimmer, Marc S.
• Application Number:
  US10/269,415
• Publication Number:
  US 20040071971A1
• Time in Patent Office: 1,334 Days
• Field of Search: 427/452, 428/412, 428/447
• US Class Current: 428/412
• CPC Class Codes: B05D 1/62 Plasma-deposition of organic layers plasma deposition in general C23C14/00, C23C16/00
• CPC Class Codes: B05D 2201/02 Polymeric substrate
• CPC Class Codes: C08G 77/04 Polysiloxanes
• CPC Class Codes: C08J 2483/00 Characterised by the use of macromolecular compounds obtained by reactions forming in the main chain of the macromolecule a linkage containing silicon with or without sulfur, nitrogen, oxygen, or carbon only; Derivatives of such polymers
• CPC Class Codes: C08J 7/0427 with only one layer of a composition containing a polymer binder with more layers C08J7/042
• 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 7/044 Forming conductive coatings; Forming coatings having anti-static properties
• CPC Class Codes: C08J 7/046 Forming abrasion-resistant coatings; Forming surface-hardening coatings
• CPC Class Codes: C08J 7/123 Treatment by wave energy or particle radiation C08J7/18 takes precedence
• CPC Class Codes: C09D 4/00 Coating compositions, e.g. paints, varnishes or lacquers, based on organic non-macromolecular compounds having at least one polymerisable carbon-to-carbon unsaturated bond ; Coating compositions, based on monomers of macromolecular compounds of groups C09D183/00 - C09D183/16
• CPC Class Codes: Y10T 428/24942 including components having same physical characteristic in differing degree
• CPC Class Codes: Y10T 428/31507 Of polycarbonate
• CPC Class Codes: Y10T 428/3154 Of fluorinated addition polymer from unsaturated monomers
• CPC Class Codes: Y10T 428/31663 As siloxane, silicone or silane
• CPC Class Codes: Y10T 428/31721 Of polyimide
• CPC Class Codes: Y10T 428/31725 Of polyamide
• CPC Class Codes: Y10T 428/31786 Of polyester [e.g., alkyd, etc.]
• CPC Class Codes: Y10T 428/31855 Of addition polymer from unsaturated monomers
• CPC Class Codes: Y10T 428/31935 Ester, halide or nitrile of addition polymer

Abstract

An article of a plastic substrate and a bond layer of a plasma polymerized cyclosiloxane having select unsaturation and a method of forming same.

Claims

1. An article comprising:

a plastic substrate; and

a bond layer on a surface of said plastic substrate, said bond layer comprising a recombined cyclosiloxane, wherein the recombined cyclosiloxane is the product of a plasma deposition process including cyclosiloxane precursor, wherein said cyclosiloxane precursor has at least one C₂ to C₁₀ alkenyl group attached to a silicon atom.

2. The article of claim 1 wherein said cyclosiloxane has the structure:

3. The article of claim 2 wherein at least one R is a C₂ to C₆ alkenyl group;

and n is 3, 4 or 5.

4. The article of claim 3 wherein each R is methyl with the proviso that only one R is a C₂ to C₆ alkenyl group.

5. The article of claim 4 wherein said alkenyl group has a terminal carbon-carbon double bond.

6. The article of claim 5 wherein said ailcenyl group is vinyl;

and n is 4.

7. The article of claim 1 wherein said plastic substrate is comprised of a thermoplastic or thermoset polymer.

8. The article of claim 6 wherein said plastic substrate is selected from the group consisting of polyethylene, polypropylene, polystyrene, polyvinylalcohol, polyvinylacetal, polymethacrylate ester, polyacrylic acids, polyether, polyester, polycarbonate, cellulous resin, polyacrylonitrile, polyamide, polyimide, polyvinyichioride, fluorine-containing resin and polysulfone, acrylic polymer and polyurethane.

9. The article of claim 1 wherein said bond layer is no less than 10 nm thick.

10. The article of claim 1 further comprising one or more additional coatings on top of said bond layer, said additional coatings being one or more UV absorption layers, one or more abrasion resistant layers, one or more transparent conducting layers, or one or more IR reflective layers.

11. An article comprising:

a thermoset or thermoplastic substrate; and

a bond layer on the surface of said substrate, said bond layer comprised of a recombined cyclosiloxane, wherein the recombined cyclosiloxane is the product of a plasma deposition process including cyclosiloxane precursor, wherein said cyclosiloxane precursor has one C₂ to C₆ ailcenyl group attached to a silicon atom, said cyclosiloxane being a cyclotrisiloxane, a cyclotetrasiloxane or a cyclopentasiloxane.

12. The article of claim 11 wherein said substrate is thermoplastic;

and said cyclosiloxane is a cyclotetrasiloxane; and

said aklenyl group is vinyl.

23. The method claim 11 wherein said bond layer is deposited to a thickness of about 200 nm to about 500 nm.

24. The method of claim 12 further comprising depositing a UV absorbing layer on top of said bond layer, said UV absorbing layer comprised of ZnO, TiO₂ or Ce₂O₃.

13. A multilayer article comprising:

a polycarbonate substrate; and

a bond layer on the surface of said polycarbonate substrate, said bond layer comprising plasma reacted heptamethyl(vinyl)cyclotetrasiloxane.

14. A method of forming a multilayer article comprising:

providing a plastic substrate; and

plasma reacting a cyclosiloxane onto a surface of said plastic substrate to form a bond layer, said cyclosiloxane having at least one C₂ to C₁₀ alkenyl group attached to a silicon atom.

15. The method of claim 14 wherein said plasma reacting is performed by expanding thermal plasma, plasma enhanced chemical vapor deposition, inductively coupled plasma or electron cyclotron resonance.

16. The method of claim 14 wherein said cyclosiloxane has the structure:

17. The method of claim 16 wherein at least one R is C₂ to C₆ alkenyl group, and n is 3, 4 or 5.

18. The method of claim 17 wherein each R is methyl with the proviso that only one R is a C₂ to C₆ alkenyl group.

19. The method of claim 18 wherein said alkenyl group has a terminal carbon-carbon double bond.

20. The method of claim 19 wherein said alkenyl group is vinyl;

and n is 4.

21. The method of claim 14 wherein said plastic substrate is comprised of a thermoplastic or thermoset polymer.

22. The method of claim 21 wherein said plastic substrate is selected from the group consisting of an polyethylene, polypropylene, polystyrene, polyvinylalcohol, polyvinylacetal, polymethacrylate ester, polyacrylic acids, polyether, polyester, polycarbonate, cellulous resin, polyacrylointrile, polyamide, polyimide, polyvinylchloride, fluorine-containing resins and polysulfone, acrylic polymers and polyurethane.

25. A method of forming a multilayer article comprising:

providing a thermoset or thermoplastic substrate; and

plasma reacting a cyclosiloxane onto a surface of said substrate to form a bond layer, said cyclosiloxane having one C₂ to C₆ alkenyl group attached to a silicon atom, said cyclosiloxane being a cyclotrisiloxane, a cyclotetrasiloxane, or a cyclopentasiloxane.

26. The method of claim 25 wherein said substrate is thermoplastic and said cyclosiloxane is a cyclotetrasiloxane and said alkenyl group is vinyl.

27. A method of making a multilayer article comprising:

providing a polycarbonate substrate; and

plasma reacting heptamethyl(vinyl)cyclotetrasiloxane onto a surface of said polycarbonate substrate to form a bond layer.

28. The method of claim 27 further comprising depositing one or more abrasion resistant layers atop of said bond layer.