Curable film-forming sol-gel compositions and anti-glare coated articles formed from them

Patent metadata

Field	Value
Publication number	US-2016145441-A1
Application number	US-201514951541-A
Country	US
Kind code	A1
Filing date	Nov 25, 2015
Priority date	Nov 25, 2014
Publication date	May 26, 2016
Grant date	—

Abstract

Curable film-forming sol-gel compositions that are essentially free of inorganic oxide particles are provided. The compositions contain: a tetraalkoxysilane; a solvent component; and non-oxide particles, and further contain either i) a mineral acid or ii) an epoxy functional trialkoxysilane and a metal-containing catalyst. Coated articles demonstrating antiglare properties are also provided, comprising: (a) a substrate having at least one surface; and (b) a cured film-forming composition applied thereon, formed from a curable sol-gel composition comprising a silane and non-oxide particles. A method of forming an antiglare coating on a substrate is also provided. The method comprises: (a) applying a curable film-forming sol-gel composition on at least one surface of the substrate to form a coated substrate; and (b) subjecting the coated substrate to thermal conditions for a time sufficient to effect cure of the sol-gel composition and form a coated substrate with a sol-gel network layer having anti-glare properties.

First claim

What is claimed is:

1 . A curable film-forming sol-gel composition that is essentially free of inorganic oxide particles and comprises:
(i) a tetraalkoxysilane; (ii) a mineral acid; (ill) a solvent component; and (iv) non-oxide particles.

2 . The composition of claim 1 wherein the tetraalkoxysilane (i) comprises tetramethoxysilane and/or tetraethoxysilane.

3 . The composition of claim 1 wherein the mineral acid (ii) comprises nitric acid or hydrochloric acid.

4 . The composition of claim 1 wherein the non-oxide particles (iv) comprise polystyrene, polyurethane, acrylic, alkyd, polyester, polysulfide, polyepoxide, polyurea, polyolefin, and/or silicone-containing rubber polymers, or are in the form of a latex and comprise hollow-sphere acrylic polymeric particles and/or solid polymeric particles.

5 . A curable film-forming sol-gel composition that is essentially free of inorganic oxide particles and comprises:
(i) a tetraalkoxysilane; (ii) an epoxy functional trialkoxysilane; (iii) a metal-containing catalyst; (iv) a solvent component; and (v) non-oxide particles.

6 . The composition of claim 5 wherein the tetraalkoxysilane (i) comprises tetramethoxysilane and/or tetraethoxysilane.

7 . The composition of claim 5 , wherein the epoxy functional trialkoxysilane (ii) comprises glycidoxypropyl trimethoxysilane.

8 . The composition of claim 5 wherein the metal-containing catalyst (iii) comprises colloidal aluminum hydroxychloride or aluminum acetylacetonate.

9 . The composition of claim 5 wherein the non-oxide particles (v) are inorganic and comprise at least one of Si 3 N 4 , BN, SiC, and S.

10 . The composition of claim 5 wherein the non-oxide particles (v) comprise polystyrene, polyurethane, acrylic, alkyd, polyester, polysulfide, polyepoxide, polyurea, polyolefin, and/or silicone-containing rubber polymers, or are in the form of a latex and comprise hollow-sphere acrylic polymeric particles and/or solid polymeric particles.

11 . A coated article demonstrating anti-glare properties, wherein the coated article comprises:
(a) a substrate having at least one flat surface; and (b) a cured film-forming composition applied to at least a portion of the flat surface of the substrate, wherein the cured film-forming composition is formed from a curable sol-gel composition comprising a silane and non-oxide particles, the non-oxide particles have an average particle size, agglomerated or monodispersed, of between 50 nm and 2.0 microns, and the coated article demonstrates a 60° gloss value of 15 to 120 gloss units and a light transmittance of at least 84%.

12 . The coated article of claim 11 , wherein the curable film-forming sol-gel composition comprises either (A):
(i) a tetraalkoxysilane; (ii) an epoxy functional trialkoxysilane; (iii) a metal-containing catalyst; (iv) a solvent component; and (v) non-oxide nanoparticles; or (B): (i) a tetraalkoxysilane; (ii) a mineral acid; (iii) a solvent component; and (iv) non-oxide particles.

13 . The coated article of claim 11 , wherein the article comprises a window, touch screen, cell phone screen, tablet screen, GPS screen, voting machine screen, POS (Point-Of-Sale) screen, computer screen, display sheet in a picture frame, or an active or passive liquid crystal cell element or device.

14 . A method of forming an anti-glare coating on a substrate comprising:
(a) applying a curable film-forming sol-gel composition on at least one surface of the substrate to form a coated substrate, wherein the curable film-forming sol-gel composition is essentially free of inorganic oxide particles and comprises a silane and non-oxide particles, the non-oxide particles have an average particle size, agglomerated or monodispersed, of between 50 nm and 2.0 microns; and (b) subjecting the coated substrate to thermal conditions for a time sufficient to effect cure of the sol-gel composition and form a coated substrate with a sol-gel network layer having anti-glare properties.

15 . The method of claim 14 wherein the substrate comprises a plastic, glass, or metal.

16 . The method of claim 14 , wherein, immediately prior to application to the substrate, the substrate and the curable film-forming composition are kept at ambient temperature.

17 . The method of claim 14 , wherein the curable film-forming sol-gel composition comprises either (A):
(i) a tetraalkoxysilane; (ii) an epoxy functional trialkoxysilane; (iii) a metal-containing catalyst; (iv) a solvent component; and (v) non-oxide particles; or (B); (i) a tetraalkoxysilane; (ii) a mineral acid; (iii) a solvent component; and (iv) non-oxide particles.

18 . The method of claim 14 wherein the curable film-forming sol-gel composition is spray applied or spin or dip coated onto the substrate in step (a).

19 . The method of claim 14 wherein the coated substrate is heated to a temperature of at least 80° C. for at least 10 minutes in step (b).

20 . The method of claim 14 wherein the coated article formed in step (b) demonstrates a 60° gloss value of 15 gloss units to 120 gloss units.

Assignees

• Ppg Ind Ohio Inc

Inventors

• Lu Songwei
• Vanier Noel
• Xu Xiangling
• Swarup Shanti
• Martin David C
• Olson Kurt G
• Schwendeman Irina

Classifications

• G02B1/111

  using layers comprising organic materials · CPC title

• C09D5/006 Primary

  Anti-reflective coatings · CPC title

• C09D183/06 Primary

  containing silicon bound to oxygen-containing groups (C09D183/12 takes precedence) · CPC title

• C03C2218/112

  by spraying · CPC title

• C03C2217/732

  made of a single layer · CPC title