Member including laminate and method of producing member including laminate

Patent metadata

Field	Value
Publication number	US-12173131-B2
Application number	US-202218051574-A
Country	US
Kind code	B2
Filing date	Nov 1, 2022
Priority date	Nov 10, 2021
Publication date	Dec 24, 2024
Grant date	Dec 24, 2024

Abstract

Provided is a member in which the strength of a second layer located on the outermost surface of the exterior is improved in order to sufficiently exhibit and maintain the functions, to thereby improve impact resistance and scratch resistance. The member is a member including a base material, a first layer, a second layer, and a third layer in the stated order, wherein the first layer is an inorganic porous layer in which a plurality of inorganic particles are joined to each other, and the first layer and the second layer have a total thickness of 0.3 μm or more and 2 μm or less, wherein the third layer contains a resin and has a thickness of 0.4 μm or more and 2,000 μm or less, and wherein the second layer contains the inorganic particles and the resin.

First claim

What is claimed is:

1. A member comprising a base material, a first layer, a second layer, and a third layer in the stated order,
wherein the first layer is an inorganic porous layer in which a plurality of inorganic particles are joined to each other,
wherein the third layer is a layer containing a resin,
wherein the second layer is a layer containing the plurality of inorganic particles and the resin,
wherein the first layer and the second layer have a total thickness of 0.3 μm to 2 μm,
wherein the third layer has a thickness of 0.4 μm to 2,000 μm, and
wherein the first layer has a pore volume of 0.1 cm 3 /g to 0.51 cm 3 /g.

2. The member according to claim 1 , wherein the first layer contains the plurality of inorganic particles in an amount of 50 vol % or more.

3. The member according to claim 1 , wherein the plurality of inorganic particles each contain a metal oxide.

4. The member according to claim 3 , wherein the plurality of inorganic particles each contain any one selected from the group consisting of: SiO 2 ; Al 2 O 3 ; TiO 2 ; ZnO 2 ; and ZrO 2 .

5. The member according to claim 1 , wherein at least one of the plurality of inorganic particles is one of a solid particle, a chain-shaped particle, or a hollow particle.

6. The member according to claim 1 , wherein the plurality of inorganic particles are joined to each other via an inorganic binder.

7. The member according to claim 6 , wherein the inorganic binder is a silicon oxide binder.

8. A member comprising a base material, a first layer, a second layer, and a third layer in the stated order,
wherein the first layer is an inorganic porous layer in which a plurality of inorganic particles are joined to each other,
wherein the third layer is a layer containing a resin,
wherein the second layer is a layer containing the plurality of inorganic particles and the resin,
wherein the first layer and the second layer have a total thickness of 0.3 μm to 2 μm,
wherein the third layer has a thickness of 0.4 μm to 2,000 μm, and
wherein the second layer has a thickness of 0.1 μm to 1 μm.

9. The member according to claim 8 , wherein the first layer has a pore volume of 0.1 cm 3 /g to 0.51 cm 3 /g.

10. A member comprising a base material, a first layer, a second layer, and a third layer in the stated order,
wherein the first layer is an inorganic porous layer in which a plurality of inorganic particles are joined to each other,
wherein the third layer is a layer containing a resin,
wherein the second layer is a layer containing the plurality of inorganic particles and the resin,
wherein the first layer and the second layer have a total thickness of 0.3 μm to 2 μm,
wherein the third layer has a thickness of 0.4 μm to 2,000 μm, and
wherein the member further comprises a fifth layer between the base material and the first layer.

11. The member according to claim 10 , wherein the fifth layer contains at least one selected from the group consisting of: zirconium oxide; titanium oxide; tantalum oxide; niobium oxide; hafnium oxide; silicon oxide; aluminum oxide; and a resin.

12. The member according to claim 1 , wherein the third layer has any one function selected from the group consisting of: an antifouling property; hydrophilicity; an antibacterial property; an antiviral property; and decoration.

13. A method of producing the member according to claim 1 , the method comprising:
applying a coating liquid containing the plurality of inorganic particles and a solvent onto the base material to form a coating film;
drying and/or calcining the base material having the coating film formed thereon to form a porous layer in which the plurality of inorganic particles are joined to each other; and
applying a coating liquid containing the resin onto the porous layer to cause part of the resin to intrude into part of the porous layer, followed by curing.

14. A method of producing the member according to claim 9 , the method comprising:
applying a coating liquid containing the plurality of inorganic particles and a solvent onto the base material to form a coating film;
drying and/or calcining the base material having the coating film formed thereon to form a porous layer in which the plurality of inorganic particles are joined to each other; and
applying a coating liquid containing the resin onto the porous layer to cause part of the resin to intrude into part of the porous layer, followed by curing,
wherein the porous layer has a pore volume of 0.1 cm 3 /g to 0.51 cm 3 /g.

15. The method according to claim 13 , wherein the plurality of inorganic particles each contain a metal oxide.

16. The method according to claim 13 , wherein the plurality of inorganic particles each contain any one selected from the group consisting of: SiO 2 ; Al 2 O 3 ; TiO 2 ; ZnO 2 ; and ZrO 2 .

17. The method according to claim 13 , wherein the coating liquid containing the plurality of inorganic particles and the solvent contains a component serving as a binder for joining the plurality of inorganic particles to each other.

18. The method according to claim 17 , wherein the component serving as the binder is a silicon oxide compound.

Assignees

• Canon Kk

Inventors

• Teramoto Yoji

Classifications

• B32B19/045

  of synthetic resin · CPC title

• C09D7/61

  inorganic · CPC title

• B05D7/536

  each layer being cured, at least partially, separately · CPC title

• C09D201/00

  Coating compositions based on unspecified macromolecular compounds · CPC title

• C09D1/00 Primary

  Coating compositions, e.g. paints, varnishes or lacquers, based on inorganic substances · CPC title