Patent Application
20110033678
The present invention relates to coating systems. In particular the present invention relates to coating systems with low reflectivity and low transmission of ultra-violet (UV) radiation.
UV radiation has a deleterious effect on a wide variety of materials. For example, it can cause yellowing of materials and/or fading of colours. This is a particular issue when the item being exposed is of high value, such as with artwork, but is also a problem for more mundane items such as drapes, carpets, wallpapers and the like. In addition, certain materials are degraded by UV radiation.
UV control films are known. See for example U.S. Pat. No. 4,275,118, U.S. Pat. No. 4,455,205, U.S. Pat. No. 4,799,963, and EP0732356. There are also commercially available films based on organic UV absorbers.
The present invention provides a coating system comprising an antireflective functionality and UV absorbing functionality. The present invention further provides methods, uses, and articles comprising such a system.
As used herein, the term “nano-particles” refers to colloidal particles whose primary particle size is less then 1 μm, preferably of less than 500 nm, more preferably of less than 350 nm.
As used herein, the term “binder” refers to a substance that can chemically cross-link the particles and preferably also between the particles and a substrate.
As used herein, the term “pre-hydrolysing” refers to hydrolysing the metal alkoxide binder precursor to the point that oligomeric species are produced via partial condensation but not to the point that gelation occurs.
Unless otherwise stated all references herein are hereby incorporated by reference.
In one embodiment, the present invention comprises a substrate, a coating layer comprising particle cerium, titanium or zinc oxide or a combination thereof, and a coating layer comprising nano-particles of a metal oxide.
Any suitable substrate may be used herein. Preferably the substrate allows transmission of light in the visible and UV spectra. Preferably the substrate is transparent or translucent. The substrate preferably has a high transparency. Preferably the transparency is about 94% or higher at 2 mm thickness and at wavelength between 425 and 675 nm, more preferably about 96% or higher, even more preferably about 97% or higher, even more preferably about 98% or higher.
The substrate herein may be organic. For example, the substrate may be an organic polymeric such as polyethylene naphthalate (PEN), polycarbonate or polymethylmethacrylate (PMMA), polyester, or polymeric material with similar optical properties. In this embodiment, it is preferred to use a coating that can be cured at temperatures sufficiently low that the organic material remains substantially in its shape and does not suffer substantially due to thermal degradation. One preferred method is to use a catalyst as described in EP-A-1591804. Another preferred method of cure is described in WO 2005/049757.
The substrate herein may be inorganic preferably glass or quartz. Preferred is float glass. Generally, a glass plate has a thickness of 0.5 mm or more, preferable 1 mm or more, most preferably, about 1.8 mm or more. Generally, the glass plate has a thickness of about 20 mm or less, preferably about 10 mm or less, more preferably about 6 mm or less, more preferable about 4 mm or less, and most preferred, about 3 mm or less.
The system of the present invention comprises a UV protective layer. This layer is preferably applied directly to the substrate. This layer comprises particles of cerium oxide, titanium oxide, zinc oxide, or combinations thereof. Preferably the layer comprises particles of cerium dioxide, titanium dioxide, zinc oxide, or combinations thereof. Preferably the layer comprises particles of cerium oxide, more preferably cerium dioxide.
Surprisingly, it has been found that the layer is much more stable and easier to work with when the pH of the coating composition is controlled. Preferably the pH is below about 6, more preferably below about 5.5.
Preferably the UV protective layer comprises a binder. Preferably the binder forms covalent bonds with the particles and the substrate. For this purpose, the binder—before curing—preferably comprises inorganic compounds with alkyl or alkoxy groups. Further, the binder preferably polymerises itself to form a substantially continuous polymeric network.
In one embodiment the binder of the UV layer consists substantially of an inorganic binder. The inorganic binder is preferably derived from one or more inorganic oxides. Preferably the binder is a hydrolysable compound such as metal-alkoxides. Preferably the binder is selected from alkoxy silanes, alkoxy zirconates, alkoxy aluminates, alkoxy titanates, alkyl silicates, sodium silicates, and mixtures thereof. Preferred are alkoxy silanes, preferably tri and tetra alkoxy silanes. Preferably, ethyl silicate, aluminate, zirconate, and/or titanate binders are used. Tetra alkoxy silane is most preferred.
Preferably the binder is ‘pre-hydrolyzed’. That is, the binder has undergone some degree of hydrolyzation prior to formulating with the particles.
The reaction of the particles and binder is preferably performed in a solvent, which is preferably a mixture of water and an organic solvent. Depending on the chemistry of the binder, many solvents are useful. Suitable solvents include, but are not limited to, water, non-protic organic solvents, alcohols, and combinations thereof. Examples of suitable solvents include, but are not limited to, isopropanol, ethanol, acetone, ethylcellosolve, methanol, propanol, butanol, ethyleneglycol, propyleneglycol, methyl-ethyl-ether, methyl-butyl-ether, toluene, methyl-ethylketone, and combinations thereof.
The UV-absorption capacity may be increased by increasing the concentration of particles. However, this can also lead to stability problems due to lack of binder. Therefore, there is always a balance to be struck between physical performance and UV-absorption. One way of increasing the UV-absorption is to add a doping agent. For example, titanium doping agent can be added to the particles.
Preferably the weight ratio of particles to binder in the layer is from about 100:1 to about 1:100, More preferably from about 10:1 to about 1:10. Even more preferably from about 5:1 to about 1:5.
Preferably the layer has a dry thickness of from about 50 nm to about 500 nm. More preferably the layer has a thickness of from about 100 nm to about 250 nm.
Preferably the UV solution is prepared by reacting the particles with binder and allowing the reaction to proceed until substantially complete. Then further binder is added. Surprisingly this helps avoid the formation of an undesirable gel and allows for easier coating of the substrate.
The layer may be applied to the substrate in any suitable manner. Preferred methods of application include meniscus (kiss) coating, spray coating, roll coating, spin coating, and dip coating. Preferably the layer is applied by dipping the substrate in the coating composition and then removing. A constant withdraw is preferred in order to improve the evenness of the coat. A second coat may be applied for extra UV protection.
A preferred method of coating herein comprises:
The system of the present invention comprises an anti-reflective (AR) layer. The AR layer preferably comprises nano-particles of a metal oxide. Examples of suitable particles include, but are not limited to, particles comprising lithium fluoride, calcium fluoride, barium fluoride, magnesium fluoride, titanium dioxide, zirconium oxide, antimony doped tin oxide, tin oxide, aluminum oxide, silicon dioxide, and mixtures thereof. Preferably the particles comprise silicon dioxide. More preferably the particles comprise at least 90% by weight of silicon dioxide.
Preferably the nano-particles have a length of less than 1000 nm, more preferably of less than 500 nm, even more preferably of less than 350 nm.
In one embodiment the particles preferably have an average aspect ratio at least 1.5. Preferably the average aspect ratio of the particles is at least 2, more preferably at least 4, even more preferably at least 6, still more preferably at least 8, even more preferably at least 10. Preferably the aspect ratio will be about 100 or lower, preferably about 50 or lower.
The sizes of the particles may be determined by spreading a dilute suspension of the particles over a surface and measuring the sizes of individual particles by using microscopic techniques, preferably scanning electronic microscopy (SEM) or atomic force microscopy (AFM). Preferably the average sizes are determined by measuring the sizes of at least 100 individual particles. The aspect ratio is the ratio between the length and the width of a particle. In case of rods and worm-like particles the length is the largest distance between two points in the particle and the width is the largest diameter as measured perpendicular to the central axis of the particle. Both length and width are measured from the projection of the particles as observed under the microscope.
The coating AR layer herein may comprise a mixture of different types sizes and shapes of particles.
In one embodiment the particles used herein are non-spherical such as, preferably, rod-like or worm-like particles, preferably worm-like particles. Worm-like particles are particles having a central axis that deviates from a straight line. Examples of worm-like particles are known by the tradename Snowtex (IPA-ST-UP), particles have a diameter of 9-15 nm with a length of 40-300 nm), available from Nissan Chemical. Hereinafter, rod-like and worm-like particles are also denoted as elongated particles.
In a preferred embodiment the particles used herein are substantially spherical. Preferably the spherical particles have an average aspect ratio of about 1.2 or lower, preferably of about 1.1 or lower. Preferably the particles have an average size of about 10 nm or larger, preferably 20 nm or larger. Preferably the particles will have an average size of 200 nm or smaller, preferably 150 nm or smaller, even more preferably about 100 nm or smaller. Substantially spherical particles have the advantage that they form coatings where the volume of nano-pores resulting from the space between the particles is small relative to the volume formed by non-spherical particles. Thus the coatings suffer less from filling of the nano-pores via capillary forces which can cause a loss in anti-reflective performance. These particles may have a narrow or broad particle size distribution, preferably a broad particle size distribution.
The particles herein are generally provided in a solvent. For example, the solvent may be water or an alcohol such as methanol, ethanol or isopropanol (IPA).
The nano-particles are preferably reacted with a surface modifying agent so that particles are obtained which are reactive with the binder. The surface modifying agent(s) react with the nano-particle to cause the particle to be activated so that it is more effectively able to react with the binder. The surface modifying agent is preferably one that is able to form oxides. Preferably, the surface modifying agent is a hydrolysable compound such as, for example, metal-alkoxides. Suitable examples include, but are not limited to, alkoxy silanes, alkoxy zirconates, alkoxy aluminates, alkoxy titanates, alkyl silicates, sodium silicates, and mixtures thereof. Preferably alkoxy silanes, more preferably tri and tetra alkoxy silanes, are used. Tetra alkoxy silane is more preferred.
Generally, the reaction is performed in a solvent. Depending on the chemistry of the binder, many solvents are useful. Suitable examples of solvents include water, non-protic organic solvents, and alcohols. Examples of suitable solvents include, but are not limited to, isopropanol, ethanol, acetone, ethylcellosolve, methanol, propanol, butanol, ethyleneglycol, propyleneglycol, methyl-ethyl-ether, methyl-butyl-ether, 1-methoxy propan-2-ol, toluene, methyl-ethylketone, and mixtures thereof. Preferred are isopropanol, ethanol, methanol, propanol, and mixtures thereof.
The AR layer preferably comprises a binder. The binder has the primary function of keeping the surface activated particles attached to each other the substrate. Preferably the binder forms covalent bonds with the particles and the substrate. For this purpose, the binder—before curing—preferably comprises inorganic compounds with alkyl or alkoxy groups. Further, the binder preferably polymerises itself to form a substantially continuous polymeric network.
In one embodiment of the invention the binder of the coating consists substantially of an inorganic binder. The inorganic binder is preferably derived from one or more inorganic oxides. Preferably the binder is a hydrolysable compound such as metal-alkoxides. Preferably the binder is selected from alkoxy silanes, alkoxy zirconates, alkoxy aluminates, alkoxy titanates, alkyl silicates, sodium silicates, and mixtures thereof. Preferred are alkoxy silanes, preferably tri and tetra alkoxy silanes. Preferably, ethyl silicate, aluminate, zirconate, and/or titanate binders are used. Tetra alkoxy silane is most preferred.
Preferably the pH of the solution is about 2 or higher, more preferred about 3 or higher. The pH is preferably about 5.5 or lower, more preferred about 4.5 or lower.
The nano-particles and binder may be mixed in such a ratio that chosen optical and mechanical properties are obtained. In addition to the particles and binder other components may be added, such as further solvent, catalyst, hydrophobic agent, levelling agent, and the like. In one embodiment the present coating compositions comprise:
Preferably the AR layer is applied to the substrate article so that the resultant dry coating thickness is about 50 nm or greater, preferably about 70 nm or greater, more preferably about 90 nm or greater. Preferably the dry coating thickness is about 300 nm or less, more preferably about 200 nm or less.
The AR layer may be applied to the substrate by any suitable means. Preferably the AR layer is applied after the UV protective layer. Preferably the AR layer is applied on top of the UV protective layer. Preferred methods of application include meniscus (kiss) coating, spray coating, roll coating, spin coating, and dip coating. Dip coating is preferred, as it provides a coating on all sides of the substrate that is immersed, and gives a repeatable and constant thickness. Spin coating can easily be used if smaller glass plates are used, such as ones with 20 cm or less in width or length. Meniscus, roll, and spray coating is useful for continuous processes.
It was surprising that the present AR layer could be easily applied on top of the UV protective layer without significantly affecting the function of either even without the need for curing (hardening) of the UV protective prior to application of the AR layer. Therefore a preferred embodiment of the present system comprises:
Preferably the present coating system is such that, when measured for one coated side at a wavelength between 425 and 675 nm (the visible light region), the minimum reflection is about 2% or less, preferably about 1.5% or less, more preferably about 1% or less. The average reflection at one side, over the region of 425 to 675 nm preferably will be about 2.5% or less, more preferably about 2% or less, even more preferably about 1.5% or less, still more preferably about 1% or less. Generally, the minimum in the reflection will be at a wavelength between 425 and 650 nm, preferably at a wavelength of 450 nm or higher, and more preferably at 500 nm or higher.
The mechanical properties can be tested as steel wool resistance. Preferably, the coating system has ‘acceptable’ steel wool resistance which is defined as less than 10 observable scratches after 10 rubs with 0000 steel wool with a loading of 250 g. More preferably, the steel wool resistance is ‘good’ which is defined 3 or less observable scratches after 10 rubs with 0000 steel wool with a loading of 250 g.
Preferably the present system reduces UV transmission through to the substrate by 50% or more, more preferably 60% or more, even more preferably 70% or more.
Preferably at least about 20% or more, preferably about 50% or more, even more preferably about 90% or more, of one of the surfaces of the substrate is coated with the present system.
For all coating processes, cleaning is an important step, as small amounts of contaminant such as dust, grease and other organic compounds cause the anti reflective coating, or other coatings to show defects. Cleaning can be done in a number of ways, such as firing (heating up to 600-700° C.; applicable if an inorganic substrate is used); and/or cleaning with a cleaning fluid such as soap in demineralised water, alcohol, or acidic or basic detergent systems. When using a cleaning fluid, generally, the glass plate is dried at a temperature between 20° C. and 400° C., optionally with applying an air flow.
In one embodiment a substrate comprising the present system is used for framing of pictures, photos, paintings, posters, etches, drawings, fabrics, tapestries and the like.
The present system may also be used for applications such as display cases, architectural glass, solar panels, automotive glass, and the like.
The invention will be further elucidated by the following examples, without being limited thereto.
98 g of tetraethoxysilane (TEOS) were added to 267 g of isopropanol (IPA), 90 g of water and 10 g of acetic acid before being stirred for 72 hours at room temperature (RT). This mixture was then diluted with 270 g of IPA and 2 g of concentrated aqueous hydrochloric acid. This formed prehydrolysed TEOS.
91.22 g of IPA was mixed with 31.36 g of Snowtex (IPA-ST-UP-15.6 wt % in IPA) particles, 11.76 g of TEOS and 15.66 g of water. The solution was stirred for 4 hours at 80° C. Then a further 150 g of IPA was added along with 11.5 g of pre-hydrolysed TEOS. This formed the AR formulation.
60 g of ceria particles were mixed with 2.25 g of TEOS and stirred for three hours. Then a further 4.3 g of TEOS were added with 93.5 g of IPA. This formed the UV formulation.
A glass plate (10 cm×10 cm) was washed and polished before being dipped in the solution of UV formulation for 4 seconds. The plate was removed at a constant speed of 0.33 cm/s. The solvents were allowed to evaporate. The process was repeated three more times. The plate was then dipped in the AR formulation for 4 seconds and withdrawn at a rate of 0.2 cm/s.
The resultant plate was cured for 4 hours at 450° C.
The plate showed a 75% reduction in transmission of UV radiation and a reflection of 0.42% at 470 nm.
The plate was then tested for abrasion resistance. A flat circular steel surface (diameter=2.1 cm) was cover evenly with steel wool (grade: 0000) with a normal weight of 250 g. The steel wool was then moved back and forth over the surface 5 times making for a total of 10 rubs over a distance of 5 to 10 cm. At this point the surface of the coating is visually inspected and rated according to the number of observable scratches. 0-3 scratches gave a rating of A, 4-10 gave a rating of B, 11-15 gave a rating of C, 16-30 gave a rating of D, coating completely removed gave a rating of E. The plate of this example had a rating of A.
| Number | Date | Country | Kind |
|---|---|---|---|
| 06075305.0 | Feb 2006 | EP | regional |
| 06023433.3 | Nov 2006 | EP | regional |
| Filing Document | Filing Date | Country | Kind | 371c Date |
|---|---|---|---|---|
| PCT/EP07/01181 | 2/12/2007 | WO | 00 | 7/23/2009 |
