Method of forming an anti-glare coating on a substrate

Patent metadata

Field	Value
Publication number	US-9707592-B2
Application number	US-201514818359-A
Country	US
Kind code	B2
Filing date	Aug 5, 2015
Priority date	Aug 8, 2014
Publication date	Jul 18, 2017
Grant date	Jul 18, 2017

Abstract

A method of forming an anti-glare coating on a substrate is provided. The method comprises: (a) heating the substrate to a temperature of at least 100° F. (37.8° C.) to form a heated substrate; (b) applying a curable film-forming sol-gel composition on at least one surface of the heated substrate, to form a coated substrate with a sol-gel network layer having a surface roughness; and (c) subjecting the coated substrate to conditions for a time sufficient to effect cure of the sol-gel layer and form an anti-glare, coated article. The sol-gel network layer is essentially free of inorganic oxide particles and comprises:
(i) a tetraalkoxysilane; (ii) an epoxy functional trialkoxysilane; (iii) a metal-containing catalyst; and (iv) a solvent component. Coated articles prepared by the method above and demonstrating anti-glare properties are also provided.

First claim

What is claimed is:

1. A method of forming an anti-glare coating on a substrate comprising:
(a) heating the substrate to a temperature of at least 100° F. (37.8° C.) to form a heated substrate;
(b) applying a curable film-forming sol-gel composition on at least one surface of the heated substrate, to form a coated substrate with a sol-gel network layer having a surface roughness; wherein the sol-gel network layer is essentially free of inorganic oxide particles and wherein the curable film-forming sol-gel composition comprises:
(i) a tetraalkoxysilane;
(ii) an epoxy functional trialkoxysilane;
(iii) a metal-containing catalyst; and
(iv) a solvent component; and
(c) subjecting the coated substrate to conditions for a time sufficient to effect cure of the sol-gel layer and form an anti-glare, coated article.

2. The method of claim 1 wherein the substrate comprises a plastic, glass, or metal.

3. The method of claim 2 wherein the substrate is a metal substrate comprising stainless steel, a different steel alloy, titanium, or aluminum.

4. The method of claim 2 , wherein the substrate comprises glass and is heated in step (a) to a temperature of 230 to 450° F. (110 to 232.2° C.).

5. The method of claim 1 wherein the curable film-forming composition is spray applied to the heated substrate in step (b).

6. The method of claim 1 wherein the coated substrate is heated to a temperature of at least 120° C. for at least 0.5 hour in step (c).

7. The method of claim 1 wherein the coated article formed in step (c) demonstrates a 60° gloss value of 15 gloss units to 120 gloss units.

8. The method of claim 1 wherein the curable film-forming sol-gel composition further comprises (v) a dye or a dispersion of non-hiding, color-imparting organic pigment nanoparticles.

9. The method of claim 1 , wherein the curable film-forming sol-gel composition applied to the surface of the substrate so as to yield a coated article with a gradient gloss across its surface.

10. A coated article demonstrating anti-glare properties, wherein the coated article is prepared by a process comprising:
(a) heating the substrate to a temperature of at least 100° F. (37.8° C.) to form a heated substrate;
(b) applying a curable film-forming sol-gel composition on at least one surface of the heated substrate, to form a coated substrate with a sol-gel network layer having a surface roughness; wherein the sol-gel network layer is essentially free of inorganic oxide particles and wherein the curable film-forming sol-gel composition comprises:
(i) a tetraalkoxysilane;
(ii) an epoxy functional trialkoxysilane;
(iii) a metal-containing catalyst; and
(iv) a solvent component; and
(c) subjecting the coated substrate to conditions for a time sufficient to effect cure of the sol-gel layer and form an anti-glare, coated article.

11. The coated article of claim 10 wherein the substrate comprises glass and is heated in step (a) to a temperature of 230 to 450° F. (110 to 232.2° C.).

12. The coated article of claim 10 wherein the curable film-forming composition is spray applied to the heated substrate in step (b).

13. The coated article of claim 10 wherein the coated article formed in step (c) demonstrates a 60° gloss value of 15 gloss units to 120 gloss units.

14. The coated article of claim 10 , wherein at least one additional coating composition is applied to the coated article after step (c).

15. The coated article of claim 10 wherein the curable film-forming sol-gel composition further comprises (v) a dispersion of non-hiding, color-imparting organic pigment nanoparticles.

16. The coated article of claim 10 wherein the substrate is a metal substrate comprising stainless steel, a different steel alloy, titanium, or aluminum.

17. The coated article of claim 10 wherein the coated article demonstrates a gradient gloss across its surface.

18. A coated article demonstrating anti-glare properties, wherein the coated article comprises:
(a) a substrate having at least one flat surface;
(b) a cured film-forming sol-gel composition applied to at least a portion of the flat surface of the substrate, wherein the cured film-forming sol-gel composition is essentially free of inorganic oxide particles and is deposited from a composition comprising:
(i) a tetraalkoxysilane;
(ii) an epoxy functional trialkoxysilane;
(iii) a metal-containing catalyst; and
(iv) a solvent component;
and wherein the coated article demonstrates a 60° gloss value of 15 to 120 gloss units.

19. The coated article of claim 18 wherein the tetraalkoxysilane (i) in the curable film-forming composition comprises tetramethoxysilane and/or tetraethoxysilane.

20. The coated article of claim 18 , wherein the epoxy functional trialkoxysilane (ii) in the curable film-forming composition comprises glycidoxypropyl trimethoxysilane.

21. The coated article of claim 18 wherein the metal-containing catalyst (iii) in the curable film-forming composition comprises colloidal aluminum hydroxychloride or aluminum acetylacetonate.

22. The coated article of claim 18 , wherein said coated article demonstrates a light transmittance of at least 84% and 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.

23. The coated article of claim 18 wherein the curable film-forming sol-gel composition further comprises (v) a dispersion of non-hiding, color-imparting organic pigment nanoparticles.

24. The coated article of claim 18 wherein the substrate is a metal substrate comprising stainless steel, a different steel alloy, titanium, or aluminum.

25. The coated article of claim 18 wherein the coated article demonstrates a gradient gloss across its surface.

Assignees

• Ppg Ind Ohio Inc

Inventors

• Lu Songwei

Classifications

• C09D183/06 Primary

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

• C08L83/00

  Compositions of macromolecular compounds obtained by reactions forming in the main chain of the macromolecule a linkage containing silicon with or without sulfur, nitrogen, oxygen or carbon only; Compositions of derivatives of such polymers · CPC title

• B05D5/06 Primary

  to obtain multicolour or other optical effects (B05D5/02 takes precedence) · CPC title

• C08G77/14

  containing silicon bound to oxygen-containing groups · CPC title

• C09D4/00

  Coating compositions, e.g. paints, varnishes or lacquers, based on organic non-macromolecular compounds having at least one polymerisable carbon-to-carbon unsaturated bond {; Coating compositions, based on monomers of macromolecular compounds of groups C09D183/00 - C09D183/16} · CPC title