Anti-fog coating composition, process, and article

Abstract

An anti-fog coating composition comprises a silicone polymer or oligomer, a water dispersible polyurethane polymer or oligomer, and water. A process for forming an anti-fog film comprises applying the anti-fog coating composition to a substrate and coalescing the silicone and polyurethane compounds to form the film. In another embodiment, the process for forming the anti-fog film comprises applying the components of the anti-fog coating composition to a substrate and crosslinking the components to form the anti-fog film. The components generally include a polyol, an isocyanate, a catalyst, and a silicone polymer or oligomer.

What is claimed is:  
     
         1 . A process for forming an anti-fog film on a substrate comprising 
 applying an aqueous coating composition to the substrate, wherein the aqueous coating composition comprises a silicone compound free from a sulfonic acid group, a water dispersible polyurethane compound, and water; and    coalescing the silicone compound and polyurethane compound to form a film on the substrate wherein the silicone compound is organosiloxane of the formula:   M a  M′ b D c D′ d T e T′ f Q g ,   wherein the subscripts a, c, d, e, f, and g are zero or a positive integer, subject to the limitation that the sum of the subscripts b, d, and f is one or greater; M has the formula: R 1   3  SiO 1/2 , wherein each R 1  is independently a monovalent hydrocarbon radical having from one to forty carbon atoms; M′ has the formula: R 2   3-h  R 3   h  SiO 1/2 , wherein each R 2  and R 3  are independently monovalent hydrocarbon radicals having from one to forty carbon atoms, and the subscript h is 1, 2, or 3; D has the formula: R 4   2  SiO 2/2 , wherein each R 4  is independently a monovalent hydrocarbon radical having from one to forty carbon atoms; D′ has the formula: R 5   2-i R 6   i SiO 2/2 , wherein each of R 5  and R 6  is independently a monovalent hydrocarbon radical having from one to forty carbon atoms, and the subscript i is 1 or 2; T has the formula: R 7 SiO3/2, wherein each R 7  is a monovalent hydrocarbon radical having from one to forty carbon atoms; T′ has the formula: R 8 SiO 3/2 , wherein R 8  is a monovalent hydrocarbon radical having from one to forty carbon atoms; and Q has the formula: SiO 4/2 ;    or an ionic or nonionic siloxane alkoxylate of the formula:                          wherein each of R 9-17  are independently a monovalent hydrocarbon radical, R 18  is of the general formula: R 19 -Z-(C m H (2m-1) R 20 O) j (C n H 2n O) k R 21 , m and n are integers greater than or equal to 0; j and k are integers greater than or equal to 0, subject to the proviso that the sum of j+k is greater than or equal to 1; Z is —O—, —S—, —CO—, —NH—, or —NH 2 —; R 19  is a divalent hyrdocarbylene radical, R 20  and R 21  are independently hydrogen, alkyl, hydroxyalkyl, amino, amido, amineoxide, cyano, isocyano, aryl, arylene, carboxy, alkoxy, halogen, haloalkyl, haloalkoxy, sulfo, sulfamo, phosphono, salts thereof, combinations comprising at least one of the foregoing, and the like; and wherein x and y are integers greater than or equal to 0, subject to the proviso that x+y is greater than or equal to 1.    
     
     
         2 . The process according to  claim 1 , further comprising heating the substrate to a temperature of about 20° C. to about 150° C.  
     
     
         3 . The process according to  claim 1 , wherein the substrate comprises a polyester, a cellulose ester, a polycarbonate, a polystyrene, a polyvinyl acetate, a polyolefin, and combinations comprising at least one of the foregoing.  
     
     
         4 . The process according to  claim 1 , wherein the aqueous coating composition further comprises a co-solvent selected from the group consisting of N-methyl pyrrolidone, glycol ether, isopropanol, and combinations comprising at least one of the foregoing co-solvents.  
     
     
         5 . The process according to  claim 1 , wherein the silicone compound is chemically bound to the polyurethane compound.  
     
     
         6 . The process according to  claim 1 , wherein the co-solvent is about 5 to about 10 weight percent of the coating composition.  
     
     
         7 . The process according to  claim 1 , wherein the silicone is a polydimethylsiloxane selected from poly[dimethylsiloxane-co-methyl(3-hydroxypropyl)siloxane]graft-poly(ethylene glycol) methyl ether, poly[dimethylsiloxane-co-[3-[2-(2-hydroxyethoxy)ethoxy]propyl]methylsiloxane, poly[dimethylsiloxane-co-(3-aminopropyl)methylsiloxane], poly[dimethylsiloxane-co-methyl(3-hydroxypropyl)siloxane]-graft poly(ethylene/propylene glycol) methyl ether, poly[dimethylsiloxane-co-methyl(3-hydroxypropyl)siloxane]-graft-tetrakis(1,2-butylene glycol), poly(dimethylsiloxane-co-alkylmethylsiloxane), poly[dimethylsiloxane-co-methyl(stearoyloxyalkyl)siloxane], poly[dimethylsiloxane-co-methyl(3-hydroxypropyl)siloxane]-graft-poly(ethylene/propylene glycol), poly[dimethylsiloxane-co-methyl(3-hydroxypropyl)siloxane]-graft-poly(ethylene glycol) [3-(trimethylammonio)propyl chloride, poly[dimethylsiloxane-co-methyl(3-hydroxypropyl)siloxane]graft-poly(ethylene glycol) 3-aminopropyl ether, poly[dimethylsiloxane-co-methyl(3,3,3-trifluoropropyl)siloxane], poly(dimethylsiloxane bis[[3-[(2-aminoethyl)amino]propyl]dimethoxysilyl] ether, and poly(dimethylsiloxane) ethoxylate/propoxylated.  
     
     
         8 . A process for forming an anti-fog film, the process comprising: 
 applying a coating composition to a substrate, wherein the coating composition comprises a silicone compound free from a sulfonic acid functional group, an isocyanate, a polyol and a catalyst; and    crosslinking the coating composition to form the anti-fog film, wherein the crosslinking comprises heating the substrate to a temperature and for a time effective to form the film.    
     
     
         9 . The process according to  claim 8 , wherein the silicone compound is of the formula: 
       M a  M′ b D c D′ d T e T′ f Q g , 
       wherein the subscripts a, c, d, e, f, and g are zero or a positive integer, subject to the limitation that the sum of the subscripts b, d, and f is one or greater; M has the formula: R 1   3  SiO 1/2 , wherein each R 1  is independently a monovalent hydrocarbon radical having from one to forty carbon atoms; M′ has the formula: R 2   3-h  R 3   h  SiO 1/2 , wherein each R 2  and R 3  are independently monovalent hydrocarbon radicals having from one to forty carbon atoms, and the subscript h is 1, 2, or 3; D has the formula: R 4   2  SiO 2/2 , wherein each R 4  is independently a monovalent hydrocarbon radical having from one to forty carbon atoms; D′ has the formula: R 5   2-i R 6   i SiO 2/2 , wherein each of R 5  and R 6  is independently a monovalent hydrocarbon radical having from one to forty carbon atoms, and the subscript i is 1 or 2; T has the formula: R 7 SiO 3/2 , wherein each R 7  is a monovalent hydrocarbon radical having from one to forty carbon atoms; T′ has the formula: R 8 SiO 3/2 , wherein R 8  is a monovalent hydrocarbon radical having from one to forty carbon atoms; and Q has the formula: SiO 4/2 .  
     
     
         10 . The process according to  claim 8 , wherein the silicone compound is an ionic or nonionic siloxane alkoxylate of the formula:  
       
         
           
           
               
               
           
         
       
       wherein each of R 9-17  are independently a monovalent hydrocarbon radical, R 18  is of the general formula: R 19 -Z-(C m H (2m-1) R 20 O) j  (C n H 2n O) k  R 21 , m and n are integers greater than or equal to 0; j and k are integers greater than or equal to 0, subject to the proviso that the sum of j+k is greater than or equal to 1; Z is H, —O—, —S—, —SH—, —CO—, —NH—, or —NH 2 —; R 19  is a divalent hyrdocarbylene radical, R 20  and R 21  are independently hydrogen, alkyl, hydroxyalkyl, amino, amido, amineoxide, cyano, isocyano, aryl, arylene, carboxy, alkoxy, halogen, haloalkyl, haloalkoxy, sulfo, sulfamo, phosphono, salts thereof, combinations comprising at least one of the foregoing, and the like; and wherein x and y are integers greater than or equal to 0, subject to the proviso that x+y is greater than or equal to 1.  
     
     
         11 . The process according to  claim 8 , wherein crosslinking the coating composition to form the anti-fog film comprises heating the substrate to a temperature of about 20° C. to about 150° C.  
     
     
         12 . The process according to  claim 8 , wherein the substrate comprises a polyester, a cellulose ester, a polycarbonate, a polystyrene, a polyvinyl acetate, a polyolefin, and combinations comprising at least one of the foregoing.  
     
     
         13 . The process according to  claim 8 , wherein the polyol comprises a polycarbonate polyol.  
     
     
         14 . The process according to  claim 8 , wherein the catalyst comprises a metal acetyl acetonate.  
     
     
         15 . The process according to  claim 8 , wherein the catalyst is selected from bis(2,4-pentanedionate) nickel (II), diacetonitrilediacetylacetonato nickel, diphenylnitrilediacetylacetonato nickel, and bis(triphenylphosphine)diacetyl acetylacetonato nickel.  
     
     
         16 . The process according to  claim 8 , wherein the coating composition further comprises a co-solvent.  
     
     
         17 . A glass or plastic article having an anti-fogging surface comprising: 
 a glass or plastic substrate; and    an anti-fog coating disposed on at least one surface of the substrate, the anti-fog coating comprising a crosslinked film formed from a silicone, an isocyanate, a polyol and a catalyst.    
     
     
         18 . The glass or plastic article of  claim 17 , wherein the silicone compound is of the formula: 
       M a  M′ b D c D′ d T e T′ f Q g , 
       wherein the subscripts a, c, d, e, f, and g are zero or a positive integer, subject to the limitation that the sum of the subscripts b, d, and f is one or greater; M has the formula: R 1   3  SiO 1/2 , wherein each R 1  is independently a monovalent hydrocarbon radical having from one to forty carbon atoms; M′ has the formula: R 2   3-h  R 3   h  SiO 1/2 , wherein each R 2  and R 3  are independently monovalent hydrocarbon radicals having from one to forty carbon atoms, and the subscript h is 1, 2, or 3; D has the formula: R 4   2  SiO 2/2 , wherein each R 4  is independently a monovalent hydrocarbon radical having from one to forty carbon atoms; D′ has the formula: R 5   2-i R 6   i SiO 2/2 , wherein each of R 5  and R 6  is independently a monovalent hydrocarbon radical having from one to forty carbon atoms, and the subscript i is 1 or 2; T has the formula: R 7 SiO3/2, wherein each R 7  is a monovalent hydrocarbon radical having from one to forty carbon atoms; T′ has the formula: R 8 SiO 3/2 , wherein R 8  is a monovalent hydrocarbon radical having from one to forty carbon atoms; and Q has the formula: SiO 4/2 .  
     
     
         19 . The glass or plastic article of  claim 17 , wherein the silicone compound is an ionic or nonionic siloxane alkoxylate of the formula:  
       
         
           
           
               
               
           
         
       
       wherein each of R 9-17  are independently a monovalent hydrocarbon radical, R 18  is of the general formula: R 19 -Z-(C m H (2m-1) R 20 O) j  (C n H 2n O) k  R 21 , m and n are integers greater than or equal to 0; j and k are integers greater than or equal to 0, subject to the proviso that the sum of j+k is greater than or equal to 1; Z is —O—, —S—, —CO—, —NH—, or —NH 2 —; R 19  is a divalent hyrdocarbylene radical, R 20  and R 21  are independently hydrogen, alkyl, hydroxyalkyl, amino, amido, amineoxide, cyano, isocyano, aryl, arylene, carboxy, alkoxy, halogen, haloalkyl, haloalkoxy, sulfo, sulfamo, phosphono, salts thereof, combinations comprising at least one of the foregoing, and the like; and wherein x and y are integers greater than or equal to 0, subject to the proviso that x+y is greater than or equal to 1.  
     
     
         20 . The glass or plastic article of  claim 17 , wherein the polyol comprises a polycarbonate polyol.  
     
     
         21 . The glass or plastic article of  claim 17 , wherein the catalyst comprises a metal acetyl acetonate.  
     
     
         22 . The glass or plastic article of  claim 17 , wherein the catalyst is selected from bis(2,4-pentanedionate) nickel (II), diacetonitrilediacetylacetonato nickel, diphenylnitrilediacetylacetonato nickel, and bis(triphenylphosphine)diacetyl acetylacetonato nickel.