Durable light-polarizing articles and method of making the same

Abstract

Described herein are polarizing articles and methods of making the same. The methods are useful in preparing polarizing articles having high durability and increased polarizing efficiency. The polarizing articles are useful in any article where it is desirable to reduce or remove glare.

1 . A polarizing article comprising:
 a. a support comprising a surface, wherein one or more polarizing dyes are adjacent to the surface of the support;   b. a first polymer layer adjacent to the support and the polarizing dye, wherein the first polymer comprises a urethane group, a urea group, an isocyanate group, or any combination thereof, wherein the first polymer layer is formed in situ on the surface of the support; and   c. a protective layer adjacent to the first polymer layer,   
     wherein the article (i) passes the dry adhesion test and hot water adhesion test, and (ii) the article has a polarization efficiency greater than 95%. 
   
   
       2 . The polarizing article of  claim 1 , wherein the polarizing article has a polarizing efficiency greater than or equal to 98%. 
   
   
       3 . The polarizing article of  claim 1 , wherein the polarizing article further passes the acidic sweat test and contains no microbubbles. 
   
   
       4 . The polarizing article of  claim 1 , wherein the support comprises an inorganic glass with a plurality of parallel grooves. 
   
   
       5 . The polarizing article of  claim 1 , wherein when the support comprises an organic material having a first surface and an inorganic adhesion layer applied on the first surface of the support. 
   
   
       6 . The polarizing article of  claim 1 , wherein the first polymer layer comprises at least one free isocyanate group. 
   
   
       7 . The polarizing article of  claim 1 , wherein the first polymer layer has a thickness from 0.05 microns to 20 microns. 
   
   
       8 . The polarizing article of  claim 1 , wherein the protective layer comprises a polymer comprising a functional group that reacts with an isocyanate group. 
   
   
       9 . The polarizing article of  claim 1 , wherein the article comprises an ophthalmic lens, a window, or a display screen. 
   
   
       10 . A method for producing a polarizing article, the method comprising:
 a. depositing on a surface of a support one or more polarizing dyes to produce a polarizing support;   b. applying a polymer precursor to the polarizing support, wherein the polymer precursor comprises an ethylenically unsaturated compound, the ethylenically unsaturated compound comprising a urethane group, a urea group, an acrylate, a methacrylate, an allyl, a vinyl compound, an isocyanate group, or any combination thereof,   c. polymerizing the polymer precursor in situ on the polarizing support to produce a first polymer layer on the polarizing support, wherein the first polymer comprises a urethane group, a urea group, an isocyanate group, or any combination thereof, and wherein the first polymer layer comprises at least one free isocyanate group; and   d. applying a protective layer to the first polymer layer.   
   
   
       11 . The method of  claim 10 , wherein the depositing step (a) comprises contacting the surface of the support with an aqueous solution comprising one or more polarizing dyes. 
   
   
       12 . The method of  claim 10 , wherein the aqueous solution further comprises a non-ionic surfactant. 
   
   
       13 . The method of  claim 10 , wherein after step (a) and prior to step (b), contacting the polarizing support with an aqueous solution of inorganic salts to stabilize the polarizing support. 
   
   
       14 . The method of  claim 10 , wherein after step (a) and prior to step (b), contacting the polarizing support with a first coupling agent, wherein the first coupling agent comprises a straight or branched-chain aminosilane, aminoalkoxysilane, aminoalkylsilane, aminoarylsilane, aminoaryloxysilane, or a derivative or salt thereof. 
   
   
       15 . The method of  claim 14 , further comprising after contacting the polarizing support with the first coupling agent, contacting the polarizing support with a second coupling agent comprising an epoxyalkyltrialkoxysilane prior to step (b). 
   
   
       16 . The method of  claim 15 , wherein after contacting the polarizing support with the second coupling agent, contacting the polarizing support in the following order: (1) a third coupling agent, wherein the third coupling agent comprises a straight or branched-chain aminosilane, aminoalkoxysilane, aminoalkylsilane, aminoarylsilane, aminoaryloxysilane, or a derivative or salt thereof, and (2) a fourth coupling agent, wherein the fourth coupling agent comprises an epoxyalkyltrialkoxysilane. 
   
   
       17 . The method of  claim 10 , wherein after polymerization step (c), the first polymer comprises one or more blocked or unblocked isocyanate groups. 
   
   
       18 . The method of  claim 10 , wherein the protective layer is produced by (1) applying a UV-curable monomer comprising at least one isocyanate-reactive group on the surface of the first layer and (2) exposing the UV-curable monomer to light to polymerize the UV-curable monomer. 
   
   
       19 . The method of  claim 18 , wherein the UV-curable monomer comprises a hydroxyalkyl acrylate, a hydroxyalkyl methacrylate, an aminoalkyl acrylate, an aminoalkyl methacrylate, an allyl alcohol, a vinyl alcohol, or any combination thereof. 
   
   
       20 . The method of  claim 10 , wherein step of applying the protective layer comprises applying a polymer comprising at least one isocyanate-reactive group on the surface of the first layer. 
   
   
       21 . The method of  claim 10 , wherein when the support comprises an organic material having a first surface and, prior to step (a), applying an inorganic adhesion layer on the first surface of the support. 
   
   
       22 . A polarizing article produced by the process comprising:
 a. depositing on a surface of a support one or more polarizing dyes to produce a polarizing support;   b. applying a polymer precursor to the polarizing support, wherein the polymer precursor comprises a urethane group, a urea group, an isocyanate group, or any combination thereof;   c. polymerizing the polymer precursor in situ on the polarizing support to produce a first polymer layer on the polarizing support, wherein the first polymer layer comprises a urethane group, a urea group, an isocyanate group, or any combination thereof, wherein the first polymer layer comprises at least one free isocyanate group; and   d. applying a protective layer to the first polymer layer.