Optical Article Comprising a Double-Layer Abrasion and Scratch Resistant Coating and Method for Production Thereof
Abstract
The invention relates to an optical article comprising a substrate coated with an abrasion- and scratch-resistant coating composed of a lower layer and an upper layer that do adhere to each other, the upper layer and the lower layer being layers of cured upper and lower layer compositions, said upper layer composition comprising at least one organosilane, or a hydrolyzate thereof, of formula R n Y m Si(X) 4-n-m and at least one compound, or a hydrolyzate thereof, of formula M(Z) x , the following ratio being lower than 2.3: Rs = theoretical dry matter weight of compounds I in the upper layer composition theoretical dry matter weight of compounds I I in the upper layer composition said lower layer composition comprising at least one organosilane, or a hydrolyzate thereof, of formula R′ n′ Y′ m′ Si(X′) 4-n′-m′ and, optionally, at least one compound, or a hydrolyzate thereof, of formula M′(Z′) y , the following ratio being higher than 2.3: Ri = theoretical dry matter weight of compounds III in the lower layer composition theoretical dry matter extract of compounds I V in the lower layer composition In the hereabove formulas, M and M′ are metals or metalloids of valences x and y, at least equal to 4, R and R′ groups are monovalent organic groups that are bound to silicon through a carbon atom and that contain at least one epoxy function, X, X′, Z and Z′ groups are hydrolyzable groups, Y and Y′ are monovalent organic groups that are bound to silicon through a carbon atom, n, m, n′ and m′ being integers such that n and n′=1 or 2 with n+m and n′+m′=1 or 2.
Claims
exact text as granted — not AI-modified1 . An optical article comprising a substrate having at least one main surface coated with an abrasion- and scratch-resistant coating, said coating being composed, starting from the substrate, of a lower layer and an upper layer that do adhere with each other, the upper layer being a layer of a cured upper layer composition and the lower layer being a layer of a cured lower layer composition,
wherein said upper layer composition comprises:
at least one organosilane compound, or a hydrolyzate thereof, of formula:
R n Y m Si(X) 4-n-m (I)
in which the R groups, being the same or different, are monovalent organic groups that are bound to silicon through a carbon atom and that contain at least one epoxy function, the X groups, being the same or different, are hydrolyzable groups, Y is a monovalent organic group bound to silicon through a carbon atom, n and m being integers such that n=1 or 2 with n+m=1 or 2, and at least one compound, or a hydrolyzate thereof, of formula:
M(Z) x (II)
in which M represents a metal or a metalloid, the Z groups, being the same or different, are hydrolyzable groups and x, equal to or higher than 4, preferably from 4 to 6, is the metal or metalloid M valence, the ratio:
Rs
=
theoretical
dry
matter
weight
of
compounds
I
in
the
upper
layer
composition
theoretical
dry
matter
weight
of
compounds
I
I
in
the
upper
layer
composition
being lower than or equal to 2.3,
and wherein said lower layer composition comprises:
at least one organosilane compound, or a hydrolyzate thereof, of formula:
R′ n′ Y′ m′ Si(X′) 4-n′-m′ (III)
in which the R′ groups, being the same or different, are monovalent organic groups that are bound to silicon through a carbon atom and that contain at least one epoxy function, the X′ groups, being the same or different, are hydrolyzable groups, Y′ is a monovalent organic group bound to silicon through a carbon atom, n′ and m′ being integers such that n′=1 or 2 with n′+m′=1 or 2, and
optionally, at least one compound, or a hydrolyzate thereof, of formula:
M′(Z′) y (IV)
in which M′ represents a metal or a metalloid, the Z′ groups, being the same or different, are hydrolyzable groups and y, equal to or higher than 4, preferably from 4 to 6, is the metal or metalloid M′ valence, the ratio:
Ri
=
theoretical
dry
matter
weight
of
compounds
III
in
the
lower
layer
composition
theoretical
dry
matter
weight
of
compounds
I
V
in
the
lower
layer
composition
being higher than 2.3.
2 . An article according to claim 1 , wherein compound (II) is of formula Si(Z) 4 , in which the Z groups, being the same or different, are hydrolyzable groups, and/or wherein compound (IV) is of formula Si(Z′) 4 , in which the Z′ groups, being the same or different, are hydrolyzable groups.
3 . An article according to claim 1 or 2 , wherein R 5 is lower than or equal to 2.0, preferably lower than or equal to 1.5, more preferably lower than or equal to 1.25, and even more preferably lower than or equal to 1.1, and higher than or equal to 0.85, more preferably higher than or equal to 0.9, even more preferably higher than or equal to 0.95.
4 . An article according to claim 1 , 2 or 3 , wherein R 1 is higher than or equal to 3.0, preferably higher than or equal to 3.5, more preferably higher than or equal to 4.5, even more preferably higher than or equal to 10.
5 . An article according to any preceding claim, wherein the theoretical dry matter weight of compounds I represents from 30 to 60% of the upper layer composition dry matter weight, more preferably from 40 to 55%.
6 . An article according to any preceding claim, wherein the theoretical dry matter weight of compounds III represents more than 40% of the lower layer composition dry matter weight, more preferably more than 50%, even more preferably more than 60% and most preferably more than 65%.
7 . An article according to any preceding claim, wherein the theoretical dry matter weight of compounds IV represents less than 30% of the lower layer composition dry matter weight, more preferably less than 25%, even more preferably less than 20% and most preferably less than 10%.
8 . An article according to any preceding claim, wherein the thickness of the abrasion- and scratch-resistant coating does vary from 1 to 15 μm, preferably from 1 to 10 μm, more preferably from 2 to 8 μm, and even more preferably from 3 to 6 μm.
9 . An article according to any preceding claim, wherein the thickness ratio of the lower layer to the upper layer is higher than or equal to 1.5, more preferably higher than or equal to 2.0, and even more preferably higher than or equal to 3.0.
10 . An article according to any preceding claim, wherein the X, X′, Z, Z′ hydrolyzable groups are selected, independently from each other, from —O—R 1 alkoxy groups, wherein R 1 is a linear or branched, alkyl group, preferably a C 1 -C 4 alkyl group, or an alkoxyalkyl group, —O—C(O)R 3 acyloxy groups, wherein R 3 is an alkyl group, preferably a C 1 -C 6 alkyl group, preferably a methyl or an ethyl group, halogens such as Cl and Br and amino groups optionally substituted by one or two alkyl or silane group(s).
11 . An article according to any preceding claim, wherein the Y or Y′ groups are selected, independently from each other, from C 1 -C 4 alkyl groups, alkenyl, C 6 -C 10 aryl groups, methacryloxyalkyl, acryloxyalkyl, fluoroalkyl, perfluoroalkyl, (poly)fluoro alkoxy[(poly)alkylenoxy]alkyl and perfluoro alkoxy[(poly)alkylenoxy]alkyl groups.
12 . An article according to any preceding claim, wherein the R or R′ groups are selected, independently from each other, from groups of formulas V and VI:
in which R 2 is an alkyl group, preferably a methyl group, or a hydrogen atom, a and c are integers ranging from 1 to 6, and b is 0, 1 or 2.
13 . An article according to claim 12 , wherein the R or R′ groups are selected, independently from each other, from γ-glycidoxypropyl groups, β-(3,4-epoxycyclohexyl)ethyl and γ-glycidoxyethoxypropyl groups, and preferably represent the γ-glycidoxypropyl group.
14 . An article according to any preceding claim, wherein compounds of formula I and/or III are selected, independently from each other, from compounds of formulas VII and VIII:
in which R 1 is an alkyl moiety having from 1 to 6 carbon atoms, preferably a methyl or an ethyl moiety, a and c are integers ranging from 1 to 6, and b is 0, 1 or 2.
15 . An article according to any preceding claim, wherein compounds of formula II and/or IV are selected, independently from each other, from tetraalkoxysilanes, preferably from tetrathoxysilane, tetramethoxysilane, tetra(n-propoxy)silane, tetra(1-propoxy)silane, tetra(n-butoxy)silane, tetra(sec-butoxy)silane and tetra(t-butoxy)silane.
16 . An article according to any preceding claim, wherein the lower and/or upper layer compositions comprise at least one condensation catalyst and/or at least one curing catalyst.
17 . An article according to claim 0 , wherein the condensation catalyst is selected from acids or anhydrides of polyfunctional saturated or unsaturated acids, preferably from maleic acid, itaconic acid, trimellitic acid and trimellitic anhydride.
18 . An article according to claim 0 or 0 , wherein the curing catalyst is selected from imidazole derivatives and their imidazolium salts, N-cyanoguanidine, acetylacetone metallic salts of formula M(CH 3 COCHCOCH 3 ) n , wherein M is a metallic ion, preferably Zn 2+ , Co 3+ , Fe 3+ or Cr 3+ , and n is an integer ranging from 1 to 3, ammonium tetrathiocyanatodiamine chromate(III), aluminium-based compounds, metal-based carboxylates such as zinc, titanium, zirconium, tin or magnesium, preferably zinc octoate or stannous octoate, iodonium salts and sulfonium salts.
19 . An article according to claim 0 , wherein the aluminium-based compound is selected from aluminium chelates, aluminium(III) acylates and alcoholates, preferably from aluminium acetylacetonate, aluminium ethylmono(acetoacetate) bisacetylacetonate, aluminium monoacetyl acetonate ethyl bis(acetoacetate), di-n-butoxy aluminium ethyl mono(acetoacetate) and di-i-propoxy aluminium ethylmono(acetoacetate).
20 . An article according to any of claims 1 to 0 , wherein the lower and/or upper layer compositions comprise a catalytic system composed of aluminium acetylacetonate or composed of a mixture of itaconic acid and N-cyanoguanidine.
21 . An article according to any preceding claim, wherein the lower and/or upper layer compositions comprise less than 10% by weight of fillers as related to the total weight of the composition, more preferably are free from any filler.
22 . An article according to any preceding claim, wherein it comprises, starting from the substrate, an impact-resistant primer layer coated with said abrasion- and scratch-resistant coating, said primer layer preferably comprising colloidal fillers.
23 . An article according to any preceding claim, wherein it comprises a supplementary layer of an abrasion-resistant and/or scratch-resistant coating contacting said upper layer, said abrasion-resistant and/or scratch-resistant supplementary layer being a layer of cured supplementary abrasion-resistant and/or scratch-resistant layer composition, said supplementary layer composition comprising:
at least one organosilane compound, or a hydrolyzate thereof, of formula:
R″ n″ Y″ m″ Si(X″) 4-n″-m″ (IX)
in which the R″ groups, being the same or different, are monovalent organic groups that are bound to silicon through a carbon atom and that contain at least one epoxy function, the X″ groups, being the same or different, are hydrolyzable groups, Y″ is a monovalent organic group bound to silicon through a carbon atom, n″ and m″ being integers such that n″=1 or 2 with n″+m″=1 or 2, and at least one compound, or a hydrolyzate thereof, of formula:
M″(Z″) z (X)
in which M″ represents a metal or a metalloid, the Z″ groups, being the same or different, are hydrolyzable groups and z, equal to or higher than 4, preferably from 4 to 6, is the metal or metalloid M″ valence, the ratio:
Rss
=
theoretical
dry
matter
weight
of
compounds
IX
in
the
supplementary
layer
composition
theoretical
dry
matter
weight
of
compounds
X
in
the
supplementary
layer
composition
being lower than or equal to 2.3 and strictly lower than ratio Rs, the supplementary theoretical dry matter weight of compounds X representing at least 45% of the dry matter weight of the supplementary abrasion-resistant and/or scratch-resistant layer composition and the thickness of the supplementary abrasion-resistant and/or scratch-resistant layer being lower than that of said upper layer.
24 . An article according to claim 22 , wherein Rss is lower than or equal to 2.0, more preferably lower than or equal to 1.5, even more preferably lower than or equal to 1.25, and most preferably lower than or equal to 1.1.
25 . An article according to claim 23 , wherein Rss is higher than or equal to 0.85, more preferably higher than or equal to 0.9, even more preferably higher than or equal to 0.95.
26 . An article according to any preceding claim, wherein an antireflective coating is deposited onto the abrasion- and scratch-resistant coating.
27 . An article according to any preceding claim, further defined as being an optical lens, preferably an ophthalmic lens.
28 . A method for making an abrasion- and scratch-resistant optical article comprising a substrate, comprising:
a) providing an optical article comprising a substrate having at least one main surface; b) depositing onto a substrate main surface a layer of a lower layer composition such as defined in any of claims 1 to 0 ; c) at least partially curing said lower layer composition using a thermal process; d) depositing onto the layer resulting from the previous step a layer of an upper layer composition such as defined in any of claims 1 to 0 ; e) curing said upper layer composition using a thermal process; f) recovering an optical article comprising a substrate having a main surface coated with an abrasion- and scratch-resistant coating composed of a lower layer adhering to an upper layer.
29 . A method according to claim 27 , wherein the lower layer composition is totally cured using a thermal process during step c) at a temperature ranging from 80 to 150° C., for 30 minutes to 4 hours.
30 . A method according to claim 27 or 28 , wherein the surface of the article resulting from step c) does undergo before step d) a surface preparation treatment intended to increase the adhesion of the upper layer.
31 . A method according to claim 29 , wherein the surface preparation treatment is selected from a bombardment with energetic species, preferably an ion beam or an electron beam, a corona discharge treatment, an ion spallation, an ultraviolet treatment, a plasma treatment under vacuum, an acidic or a basic treatment and/or a treatment with solvents, or any combination of these treatments, preferably a basic solution treatment.
32 . The method of claim 27 , wherein the lower layer composition is partially cured using a thermal process during step c) at a temperature ranging from 70 to 120° C., preferably from 80 to 120° C., for 1 to 30 minutes, more preferably for 3 to 20 minutes and even more preferably for 5 to 10 minutes and wherein the surface of the article resulting from step c) does not undergo before step d) any surface preparation treatment.Join the waitlist — get patent alerts
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