Articles including nanosilica-based primers for polymer coatings and methods

Abstract

The present disclosure provides articles that include polymer coatings on substrates primed with a primer coating containing silica nanoparticles, and methods of coating. The polymer coating is preferably a silicone-based polymeric material.

1 . A coated article comprising a substrate surface, a nanoparticle-containing primer disposed on the substrate surface, and a silicone-based material bonded to the nanoparticle-containing primer, wherein the nanoparticle-containing primer comprises agglomerates of silica nanoparticles, said agglomerates providing a continuous three-dimensional porous network of acid-sintered silica nanoparticles, and the silica nanoparticles being bonded to adjacent silica nanoparticles. 
     
     
         2 . The coated article of  claim 1 , wherein the silica nanoparticles are spherical and have an average particle diameter of less than 40 nanometers. 
     
     
         3 . The coated article of  claim 1 , wherein the nanoparticle-containing primer is 100 Å to 10,000 Å thick. 
     
     
         4 . The coated article of  claim 1 , wherein the silicone-based material is substantially free of catalysts and initiators. 
     
     
         5 . A method of coating a substrate surface, the method comprising:
 applying a primer coating composition to the substrate surface to form a primed surface;   
       wherein applying a primer coating composition to the substrate surface comprises:
 contacting the substrate surface with a nanoparticle-containing coating composition, wherein the nanoparticle-containing coating composition comprises:
 an aqueous dispersion having a pH of less than 5 comprising silica nanoparticles and an acid having a pKa of ≤3.5; and 
 drying the nanoparticle-containing coating composition to provide a silica nanoparticle primer coating on the substrate surface; 
 
 contacting the primed surface with a silicone-containing coating composition; and 
 curing the silicone-containing coating composition to form a crosslinked silicone-containing coating. 
 
     
     
         6 . A coated article comprising a substrate surface, a nanoparticle-containing primer disposed on the substrate surface, a silicone tie layer disposed on the nanoparticle-containing primer, and a silicone-based material bonded to the silicone tie layer, wherein the tie layer is at least one of UV or thermally cured, and wherein the nanoparticle-containing primer comprises agglomerates of silica nanoparticles, said agglomerates providing a continuous three-dimensional porous network of acid-sintered silica nanoparticles, and the silica nanoparticles being bonded to adjacent silica nanoparticles. 
     
     
         7 . The coated article of  claim 6 , wherein the silica nanoparticles are spherical and have an average particle diameter of less than 40 nanometers and wherein the nanoparticle-containing primer is 100 Å to 10,000 Å thick. 
     
     
         8 . The coated article of  claim 6 , wherein the silicone-based material is substantially free of catalysts and initiators. 
     
     
         9 . The coated article of  claim 1 , wherein the silicone-based material is non-tackified. 
     
     
         10 . The coated article of  claim 1 , wherein the silicone-based material is a surface-structured silicone-based material.