Laminate and method of producing same

Patent metadata

Field	Value
Publication number	US-11338545-B2
Application number	US-201816606574-A
Country	US
Kind code	B2
Filing date	Apr 17, 2018
Priority date	Apr 21, 2017
Publication date	May 24, 2022
Grant date	May 24, 2022

Abstract

A laminate comprising a plastic substrate (A); a hardened organic polymer layer (B) provided on a surface of the plastic substrate (A) and having a storage elastic modulus of from 0.01 to 5 GPa and tan δ of from 0.1 to 2.0 at 25° C. which are measured at a temperature elevating rate of 2° C./min by a dynamic viscoelasticity test stipulated in JIS K 7244; an organic/inorganic composite layer (C) provided on a surface of the hardened organic polymer layer (B) and containing covalently bound organic polymer and metal oxide nanoparticles; and an inorganic layer (D) provided on a surface of the organic/inorganic composite layer (C) and comprising secondary particles of ceramic or metal.

First claim

The invention claimed is:

1. A laminate comprising
a plastic substrate (A);
a hardened organic polymer layer (B) provided on a surface of the plastic substrate (A) and having a storage elastic modulus of from 0.01 to 5 GPa and tan δ of from 0.1 to 2.0 at 25° C. which are measured at a temperature elevating rate of 2° C./min by a dynamic viscoelasticity test stipulated in JIS K7244 and performed at 10 Hz;
an organic/inorganic composite layer (C) provided on a surface of the hardened organic polymer layer (B) and containing covalently bound organic polymer and metal oxide nanoparticles; and
an inorganic layer (D) provided on a surface of the organic/inorganic composite layer (C) and comprising secondary particles of ceramic or metal.

2. The laminate of claim 1 , wherein the hardened organic polymer layer (B) comprises a hardened photocurable resin.

3. A method of producing a laminate, the method comprising:
a step of forming, on a surface of a plastic substrate (A), a hardened organic polymer layer (B) having a storage elastic modulus of from 0.01 to 5 GPa and tan δ of from 0.1 to 2.0 at 25° C. which are measured by a dynamic viscoelasticity test at a temperature elevating rate of 2° C./min stipulated in JIS K7244 and performed at 10 Hz,
a step of forming, on a surface of the hardened organic polymer layer (B), an organic/inorganic composite layer (C) containing covalently bound organic polymer and metal oxide nanoparticles, and
a step of forming, on the organic/inorganic composite layer (C), an inorganic layer (D) comprising secondary particles of ceramic or metal deposited by an aerosol deposition method.

4. The method of producing a laminate of claim 3 , wherein the step of forming the organic/inorganic composite layer (C) comprises at least one of the following steps (I) to (III):
(I) a step of applying and curing a solution comprising a silane-modified polymer (c1),
(II) a step of applying and curing a reactive silsesquioxane compound (c2), and
(III) a step of applying and curing surface-reactive metal oxide nanoparticles (c3) and a photocurable resin (c4).

Assignees

• Aist
• Arakawa Chem Ind

Inventors

• Noda Hiroaki
• Akedo Jun
• Goda Hideki
• Fukuda Takeshi
• Togashi Haruhisa

Classifications

• B32B2383/00

  Polysiloxanes · CPC title

• B32B2264/107

  Ceramic · CPC title

• C08J7/046

  Forming abrasion-resistant coatings; Forming surface-hardening coatings · CPC title

• C09D163/00

  Coating compositions based on epoxy resins; Coating compositions based on derivatives of epoxy resins · CPC title

• B32B27/00

  Layered products comprising {a layer of} synthetic resin {(fibrous or filamentary layer made of a synthetic resin B32B5/02; particulate layer made of a synthetic resin B32B5/16; foamed layer made of a synthetic resin B32B5/18)} · CPC title