Hybrid adhesives, articles, and methods

Abstract

Described are curable adhesives containing a polyacrylate component and an epoxy component, and that are preferably optically clear, as well as methods of using such adhesives and optical components and optical elements prepared from the adhesives.

1 . A multi-layer assembly comprising a cured adhesive comprising an interpenetrating polymer network comprising polyacrylate component and epoxy component, wherein the adhesive composition is optically clear, and wherein the adhesive bonds a low moisture vapor transfer layer to an outgassing layer.  
   
   
       2 . The assembly of  claim 1  wherein the outgassing layer comprises a material selected from the group consisting of a polycarbonate and a poly(methyl methacrylate).  
   
   
       3 . The assembly of  claim 2  wherein after aging at 90° C. for 500 hours, or 80° C. and 90% relative humidity for 500 hours, the bond between the outgassing layer and the low moisture vapor transfer layer does not delaminate or bubble, and the optical product remains optically clear such that 
 the luminous transmission of the optical product is greater than 90%,    the haze of the optical product is less than 2%, and    the opacity of the optical product is less than 1%.    
   
   
       4 . The assembly of  claim 2  wherein the low moisture vapor transfer layer comprises a metallized polymeric film.  
   
   
       5 . The assembly of  claim 2  wherein the low moisture vapor transfer layer has a moisture vapor transmission rate below about 30 grams per (square meter×24 hours).  
   
   
       6 . The assembly of  claim 2  wherein the assembly comprises an antireflective optical element comprising a rigid polycarbonate layer adhered with the adhesive to a surface of a polyethylene terephthalate layer, an opposite surface of the polyethylene terephthalate layer being coated with multiple alternating layers of indium-tin-oxide and silicon oxide.  
   
   
       7 . The assembly of  claim 2  wherein the adhesive comprises an inter-reacted interpenetrating polymer network.  
   
   
       8 . The assembly of  claim 2  wherein the low moisture vapor transfer layer comprises an infrared reflecting film.  
   
   
       9 . The assembly of  claim 1  wherein the assembly comprises a conductive optical element comprising a rigid polycarbonate layer adhered with the adhesive to a surface of a polymeric film layer, an opposite surface of the polymeric film layer being coated with a conductive layer.  
   
   
       10 . A multi-layer assembly comprising a cured adhesive comprising an interpenetrating polymer network comprising polyacrylate component and epoxy component, wherein the adhesive composition is optically clear, and wherein the assembly comprises a fragile layer adhered to the adhesive.  
   
   
       11 . The assembly of  claim 10  wherein the cured adhesive provides structural support for the fragile layer.  
   
   
       12 . The assembly of  claim 10  wherein the fragile layer is a polarizing layer comprising oriented polyvinyl alcohol.  
   
   
       13 . The assembly of  claim 12  further comprising a second adhesive adhered to a second surface of the polarizer.  
   
   
       14 . The assembly of  claim 13  wherein the second adhesive is an optically clear cured adhesive comprising an interpenetrating polymer network comprising polyacrylate component and epoxy component.  
   
   
       15 . The assembly of  claim 12  consisting of a fragile polarizer bonded on both surfaces to an optically clear cured adhesive comprising an interpenetrating polymer network comprising polyacrylate component and epoxy component.  
   
   
       16 . The assembly of  claim 10  comprising: 
 a fragile polarizer bonded on a surface to a polycarbonate material, and    a polyethylene terephthalate film bonded with an adhesive to a second surface of the fragile polarizer,    wherein at least one of the adhesives is an optically clear cured adhesive comprising an interpenetrating polymer network comprising polyacrylate component and epoxy component.    
   
   
       17 . The assembly of  claim 16  wherein the polycarbonate is bonded to glass using a pressure sensitive adhesive.  
   
   
       18 . A method of preparing a multi-layer article, the method comprising 
 coating onto a release liner a curable adhesive composition comprising 
 polyacrylate component,  
 epoxy component,  
 cationic initiator, and  
 solvent  
   drying the curable adhesive composition to remove the solvent,    laminating the curable adhesive composition on a substrate, and    activating the initiator to cure the adhesive.    
   
   
       19 . A method of providing structural support to a fragile optical element, the method comprising applying a curable adhesive composition comprising polyacrylate component, epoxy component, and cationic initiator, to a surface of the fragile optical element, and curing the adhesive.