Optical element

Patent metadata

Field	Value
Publication number	US-10473822-B2
Application number	US-201515121395-A
Country	US
Kind code	B2
Filing date	Apr 7, 2015
Priority date	Apr 9, 2014
Publication date	Nov 12, 2019
Grant date	Nov 12, 2019

Abstract

An optical element comprises an antireflective layer that is disposed on and in contact with a substrate. The antireflective layer has a refractive index of greater than 1 to less than 1.41 and has a pore size ranging from greater than 0 to less than 300 nm. The antireflective layer includes an outermost surface having a water contact angle ranging from greater than or equal to 70° to less than or equal to 120° as determined using ASTM 5946-04.

First claim

The invention claimed is:

1. An optical element comprising:
a substrate; and
an antireflective layer comprising:
a first layer comprising an oxidatively-cured product of a silicon-based resin selected from a silsesquioxane resin having a number average molecular weight from 600 to 150,000 grams per mole (g/mol) and having the formula:
(R 3 SiO 1/2) ) a (R 2 SiO 2/2 ) b (RSiO 3/2 ) c (SiO 4/2 ) d

wherein each R is independently chosen from hydrogen, alkyl and alkenyl groups, and alkyl and alkenyl groups substituted with halogen, nitrogen, oxygen, and sulfur atoms, provided that on average at least two R groups are hydrogen, wherein a, b, c and d are mole fractions, wherein a+b+c+d is one and wherein c+d is greater than zero, disposed on and in direct contact with the substrate and having a refractive index ranging from greater than 1 to less than 1.41 and having a pore size ranging from greater than 0 to less than 300 nanometers (nm), wherein an outermost surface of the antireflective layer has a water contact angle ranging from greater than or equal to 70 degrees)(°) to less than or equal to 120° as determined using ASTM 5946-04; and
an outermost layer disposed on and in direct contact with the first layer such that the first layer is between the substrate and the outermost layer.

2. The optical element according to claim 1 , wherein light transmittance in the visible spectrum through the antireflective layer is from greater than 85 percent (%) to 100%; or wherein the haze value through the antireflective layer is from 0% to less than 15%; or wherein light transmittance in the visible spectrum through the antireflective layer is from greater than 85% to 100% and wherein the haze value through the antireflective layer is from 0% to less than 15%.

3. The optical element according to claim 1 , wherein the thickness of the first layer ranges from 50 nm to 1000 nm.

4. The optical element according to claim 1 wherein the outermost surface of the antireflective layer has a water contact angle ranging from greater than or equal to 70° to less than or equal to 120° as determined using ASTM 5946-04; or wherein the outermost surface of the antireflective layer has water contact angle ranging from greater than or equal to 70° to less than or equal to 120° as determined using ASTM 5946-04 after 100 cycles of cloth abrasion; or wherein the outermost surface of the antireflective layer has a water contact angle ranging from greater than or equal to 70° to less than or equal to 120° as determined using ASTM 5946-04 and wherein the outermost surface of the antireflective layer has water contact angle ranging from greater than or equal to 70° to less than or equal to 120° as determined using ASTM 5946-04 after 100 cycles of cloth abrasion.

5. The optical element according to claim 1 , wherein the outermost surface of the antireflective layer has surface energy of less than 40 milliNewtons per meter (mN/m) measured at 20 degrees Celsius (° C.); or wherein the outermost surface of the antireflective layer has surface energy of less than 30 mN/m measured at 20° C.; or wherein the outermost surface of the antireflective layer has surface energy of less than 25 mN/m measured at 20° C.

6. The optical element according to claim 1 , wherein the outermost layer comprises a polyfluoropolyether silane according to the general formula (A):
Y—Z a —[(OC 3 F 6 ) b —(OCF(CF 3 )CF 2 ) c —(OCF 2 CF(CF 3 )) d —(OC 2 F 4 ) e —(CF(CF 3 )) f —(OCF 2 ) g ]—(CH 2 ) h —X′—(C n H 2n )—((SiR 1 2 —O) m —SiR 1 2 ) i —(C j H 2j )—Si—(X″) 3-z (R 2 ) z ;

wherein Z is independently selected from —(CF 2 )—, —(CF(CF 3 )CF 2 O)——(CF 2 CF(CF 3 )O)—, —(CF(CF 3 )O)—, —(CF(CF 3 )CF 2 )—, —(CF 2 CF(CF 3 ))—, and —(CF(CF 3 ))—; a is an integer from 1 to 200; b, c, d, e, f, and g are integers each independently selected from 0 to 200; h, n and j are integers each independently selected from 0 to 20; i and m are integers each independently selected from 0 to 5; X′ is a bivalent organic group or O; R 1 is an independently selected C 1 -C 22 hydrocarbyl group; z is an integer independently selected from 0 to 2; X″ is an independently selected hydrolysable group; R 2 is an independently selected C 1 -C 22 hydrocarbyl group which is free of aliphatic unsaturation; and Y is selected from H, F, and (R 2 ) z (X″) 3-z Si—(C j H 2j )—((SiR 1 2 —O) m —SiR 1 2 ) i —(C n H 2n )—X′—(CH 2 ) h —; wherein X″, X′, z, R 1 , R 2 , j, m, i, n and h are as defined above;
provided that when subscript i is 0, subscript j is also 0; when subscript i is an integer selected from 1 to 5, subscript j is an integer selected from 1 to 20 and m is an integer selected from 1 to 5.

7. The optical element according to claim 1 wherein the outermost layer comprises a silicon-containing material.

8. The optical element according to claim 1 wherein the outermost layer is covalently bonded to the first layer.

9. A photovoltaic device, window, or touch screen panel having an optical element according to claim 1 .

10. A method for forming an optical element comprising a substrate and an antireflective layer disposed on and in direct contact with the substrate and having a refractive index ranging from greater than 1 to less than 1.41 and having a pore size ranging from greater than 0 to less than 300 nanometers (nm), wherein an outermost surface of the antireflective layer has a water contact angle ranging from greater than or equal to 70 degrees)(°) to less than or equal to 120° as determined using ASTM 5946-04, the method for forming the optical element comprising:
(I) applying a silicon-based resin on the substrate;
(II) oxidatively curing the silicon-based resin on the substrate to form a first layer disposed on and in direct contact with the substrate, the first layer having a pore size ranging from greater than 0 to less than 300 nm; and
(III) disposing an outermost layer on and in direct contact with the first layer such that the first layer is between the substrate and the outermost layer;
wherein the silicon-based resin is selected from a silsesquioxane resin having a number average molecular weight from 600 to 150,000 grams per mole (q/mol) and having the formula:
(R 3 SiO 1/2 ) a (R 2 SiO 2/2 ) b (RSiO 3/2 ) c (SiO 4/2 ) d

wherein each R is independently chosen from hydrogen, alkyl and alkenyl groups, and alkyl and alkenyl groups substituted with halogen, nitrogen oxygen, an sulfur atoms, provided that on average at least two R groups are hydrogen, wherein a, b, c and d are mole fractions, wherein a+b+c+d is one and wherein c+d is greater than zero.

11. The method according to claim 10 , wherein step (ll) comprises oxidatively curing and heat treating the silicon-based resin on the substrate to form a first layer disposed on and in direct contact with the substrate, the first layer having a pore size ranging from greater than 0 to less than 300 nm.

12. The method according to claim 10 , wherein the silicon-based resin further comprises porogen and wherein the porogen is removed from the silicon-based resin prior to Step ( 111 ).

Assignees

• Dow Corning
• Dow Silicones Corp

Inventors

• Fan Fengqiu
• Harkness Jr Brian R
• Liu Junying
• Rong Wei
• Tsuda Takeaki
• Bradford Michael L

Classifications

• G02F1/133502

  Antiglare, refractive index matching layers · CPC title

• G02B2207/107

  Porous materials, e.g. for reducing the refractive index · CPC title

• G02B1/111 Primary

  using layers comprising organic materials · CPC title

• C08J9/28

  by elimination of a liquid phase from a macromolecular composition or article, e.g. drying of coagulum · CPC title

• C03C2217/732

  made of a single layer · CPC title