Poly(vinyl alcohol)-containing and silica nanoparticle multilayer coatings and methods

• US 9,926,458 B2
• Filed: 04/25/2014
• Issued: 03/27/2018
• Est. Priority Date: 05/30/2013
• Status: Active Grant

• Current Assignee: 3M Innovative Properties Company (3M Company)
• Original Assignee: 3M Innovative Properties Company (3M Company)
• Inventors: Jindal, Karan, Riddle, Justin A., Armstrong, Paul B., Carpenter, Samuel J., Dudley, William R., Lachmansingh, Garry W., Petrin, Jason T., Jing, Naiyong
• Primary Examiner(s): Vo, Hai
• Application Number:
  US14/893,262
• Publication Number:
  US 20160096969A1
• Time in Patent Office: 1,432 Days
• CPC Class Codes: B05D 3/0272 with ovens
• CPC Class Codes: B05D 7/542 the two layers being cured or baked together
• CPC Class Codes: B05D 7/582 all layers being cured or baked together
• CPC Class Codes: B05D 7/5823 all layers being applied simultaneously
• CPC Class Codes: C03C 17/34 with at least two coatings having different compositions C03C17/44 takes precedence
• CPC Class Codes: C03C 2217/425 consisting of a porous layer
• CPC Class Codes: C03C 2217/734 comprising an alternation of high and low refractive indexes
• CPC Class Codes: C08J 7/0423 with at least one layer of inorganic material and at least one layer of a composition containing a polymer binder
• 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: C08J 7/048 Forming gas barrier coatings
• CPC Class Codes: C08J 7/054 Forming anti-misting or drip-proofing coatings
• CPC Class Codes: C08J 7/056 Forming hydrophilic coatings
• CPC Class Codes: C08K 3/36 Silica
• CPC Class Codes: C08K 5/5415 containing at least one Si—O bond
• CPC Class Codes: C09D 129/04 Polyvinyl alcohol; Partially hydrolysed homopolymers or copolymers of esters of unsaturated alcohols with saturated carboxylic acids
• CPC Class Codes: C09D 5/00 Coating compositions, e.g. paints, varnishes or lacquers, characterised by their physical nature or the effects produced electrically insulating plastics, resins or waxes H01B3/30; Filling pastes
• CPC Class Codes: C09D 5/1618 inorganic
• CPC Class Codes: C09D 5/1693 as part of a multilayer system
• CPC Class Codes: C09D 7/40 Additives

Abstract

Articles having poly(vinyl alcohol)-containing (PVA-containing) and silica nanoparticle multilayer coatings are provided. More specifically, articles include a substrate and a multilayer coating attached to the substrate. The multilayer coating includes a first silica layer and a first PVA-containing layer. The first silica layer is a primer layer of the multilayer coating, and the silica layer comprises a plurality of acid-sintered interconnected silica nanoparticles arranged to form a continuous three-dimensional porous network. The PVA-containing and silica nanoparticle multilayer coatings can be used on a large variety of substrates and tend to be resistant to wet and dry abrasions, scratches, and impacts.

Claims

1. An article comprising:

a. a substrate; and

b. a multilayer coating attached to the substrate, the multilayer coating comprising

i. a first silica layer that is a primer layer of the multilayer coating directly attached to the substrate, the first silica layer comprising a plurality of acid-sintered interconnected silica nanoparticles arranged to form a continuous three-dimensional porous network; and

ii. a first PVA-containing layer disposed directly adjacent to the first silica layer, the first PVA-containing layer comprising between 10 weight percent and 100 weight percent poly(vinyl alcohol) (PVA).

2. The article of claim 1, wherein the first PVA-containing layer comprises between 0.5 weight percent and 90 weight percent silica nanoparticles.

3. The article of claim 1 further comprising a second PVA-containing layer disposed adjacent to the first PVA-containing layer, the second PVA-containing comprising between 10 weight percent and 100 weight percent PVA.

4. The article of claim 3, wherein at least one of the first PVA-containing layer and the second PVA-containing layer comprises crosslinked PVA.

5. The article of claim 3, wherein the second PVA-containing layer further comprises a plurality of silica nanoparticles.

6. The article of claim 3, further comprising a second silica layer that is an outermost layer of the multilayer coating, wherein the second silica layer is attached directly to the second PVA-containing layer.

7. The article of claim 1, wherein the first silica layer further comprises PVA.

8. The article of claim 1, wherein the plurality of acid-sintered interconnected silica nanoparticles are formed from a dispersion comprising the silica nanoparticles acidified with an acid having a pKa less than 3.5 to a pH in a range of 2 to 5.

9. The article of claim 1, wherein the first PVA-containing layer comprises a silane-modified PVA.

10. The article of claim 1, further comprising a second silica layer that is an outermost layer of the multilayer coating.

11. The article of claim 10, wherein the second silica layer comprises a plurality of acid-sintered interconnected silica nanoparticles arranged to form a continuous three-dimensional porous network.

12. The article of claim 10, wherein the second silica layer further comprises PVA.

13. A method of making an article, the method comprising:

a. providing a substrate;

b. attaching a multilayer coating to a surface of the substrate, the attaching comprising

i. forming a first silica layer that is a primer layer of the multilayer coating directly attached to the substrate, the first silica layer comprising a plurality of acid-sintered interconnected silica nanoparticles arranged to form a continuous three-dimensional porous network; and

ii. forming a first PVA-containing layer directly adjacent to the first silica layer, the first PVA-containing layer comprising between 10 weight percent and 100 weight percent PVA;

wherein the forming of the first silica layer and the forming of the first PVA-containing layer comprises;

A. flowing a first fluid down a first slide surface of a slide coater, the first fluid comprising a plurality of acidified silica nanoparticles and corresponding to the first silica layer;

B. flowing a second fluid down a second slide surface of the slide coater to form a second fluid layer over the first slide surface, the second fluid comprising PVA and corresponding to the first PVA-containing layer; and

C. coating the substrate with the first fluid and the second fluid, to form a multilayer fluid coating, the first fluid being the lowermost fluid of the multilayer fluid coating and coated directly onto the substrate by the slide coater.

14. The method of claim 13, further comprising forming a second silica layer that is an outermost layer of the multilayer coating.

15. The method of claim 13, wherein the first PVA-containing layer further comprises a plurality of silica nanoparticles.

16. The method of claim 13, wherein forming the first silica layer comprises preparing a dispersion containing the silica nanoparticles acidified with an acid having a pKa less than 3.5 to a pH in a range of 2 to 5, coating the dispersion on the substrate, and drying the coating to form the plurality of acid-sintered silica nanoparticles.

17. The method of claim 16, wherein the first silica layer further comprises PVA.

18. The method of claim 17, wherein the first PVA-containing layer comprises a silane-modified PVA.

19. The method of claim 13, further comprising flowing a third fluid down a third slide surface of a slide coater, the third fluid comprising a plurality of acidified sintered silica nanoparticles and the third fluid being the uppermost fluid of the multilayer fluid coating coated onto the substrate by the slide coater.

20. The method of claim 13, further comprising crosslinking the PVA of the second fluid.