UV Curable Hard Transparent Hybrid Coating Materials on Polycarbonate Prepared by the Sol-Gel Method

UV curable, hard, transparent inorganic/organic composites with covalent links between the inorganic and the organic networks were prepared by the sol-gel method. These hybrid coating materials were synthesized using a commercially available, acrylate end-capped polyester or polyurethane oligomeric resin (EBC80, EBC284), hexanedioldiacrylate (HDDA) as a reactive solvent, 3-(trimethoxysilyl)propoxymethacrylate (TMSPM) as a coupling agent between the organic and inorganic phase, and a metal alkoxide, tetraethylorthosilicate (TEOS). The materials were applied on primer or oxygen plasma pretreated polycarbonate sheets and UV cured, followed by a thermal treatment to give a transparent coating with a good adhesion and abrasion resistance. The high transmission and the thermogravimetric behavior indicate the presence of a nanoscale hybrid composite, as is confirmed by SAXS and TEM measurements. In a Taber Abrasion Test, uncoated polycarbonate sheets exhibit a 48% decrease in light transmittance at 600 nm after 300 wear cycles, whereas the EBC80 hybrid coating system containing 9 wt% SiO₂ (EBC80/25Si) shows only 28% decrease in light transmittance. A maximal improvement of the abrasion resistance is achieved when 23 wt% SiO₂ is incorporated (EBC80/60Si, EBC284/60Si) with only 20% decrease in light transmittance. The abrasion resistance of glass is not yet encountered. For optimal results, it is essential that the rate of condensation of the silanol groups is sufficiently high to form a dense three-dimensional network.     

UV curing of organic–inorganic hybrid coating materials

The effect of UV-curing time on the mechanism of interaction between the various precursor phases in a novel sol–gel-derived organic–inorganic hybrid coating material and the resulting mechanical and thermal properties of this material when coated onto substrates in thin film form have been examined using a variety of chemical and physical characterisation methods. Microstructurally, the hybrid coating materials examined were all a single amorphous phase and were all optically transparent. The degree of interaction between the organic and inorganic phases, the scratch behaviour of the coating materials and the thermal stability of the coating materials were all found to depend strongly on the UV curing time. For the particular proportions of inorganic and organic components used to make up this hybrid coating material, an optimum UV curing time of 10 min under a UV intensity of 46.3 mW cm⁻² was found to produce transparent coatings which adhered well to the substrates and which were robust in scratch tests on aluminium and polycarbonate substrates and abrasion tests on polycarbonate substrates.     

Using Taguchi experimental design to reveal the impact of parameters affecting the abrasion resistance of sol–gel based UV curable nanocomposite films on polycarbonate

This work aims at studying the abrasion resistance of differently formulated organic–inorganic hybrid coatings prepared by sol–gel method. The organic phase contained UV curable urethane acrylate oligomers and monomers having different functionalities. The inorganic phase was composed of tetraethyl orthosilicate (TEOS) and 3-methacryloxy propyltrimethoxy silane (MEMO). Through a Taguchi experimental design, the impact of influencing parameters such as molar ratio of precursors, hydrolysis ratio (R), post-curing temperature, post-curing time and weight percentage of inorganic to organic part were investigated. Very high transparency of hybrid coatings indicated that nano sized inorganic phase had formed. MEMO could facilitate the connection of two phases, preventing macro phase separation. However, high levels of MEMO lead to ‘defect structure’ in silica network as well as to decreased transparency and mechanical properties. The optimum condition in which highly transparent films with great abrasion resistance occurred was observed at equimolar ratio of water to alkoxide and TEOS: MEMO ratio being unity. Statistical analysis revealed that thermal post-curing was not significantly important.     

Adhesion of Sol-Gel-Derived Organic-Inorganic Hybrid Coatings on Polyester

Inorganic coatings, including metal-oxide coatings, provide polymer surfaces with excellent abrasion and wear resistance, and protection against environmental degradation. However, one drawback associated with the incorporation of such ceramic coatings to polymeric materials is the adhesion characteristic at the ceramic-polymer interface. In this paper, two strategies for adhesion enhancement of ceramic coatings on polymer substrates were proposed: (1) formation of chemical bonds through surface condensation reactions, and (2) development of interlocked ceramic and polymeric networks through diffusion of alkoxide precursors. The current research has focused on the adhesion of sol-gel-derived organic-inorganic hybrid coatings on polyester by forming chemical bonds between the polymer substrate and the hybrid coatings, as well as developing interlocked polymeric and inorganic networks at the interface. Contact angle, wettability tests, and chemicalanalysis were done to verify the effectiveness of the adhesion of organic-inorganic hybrid coatings on polyester substrates. In addition, dry and wet thermal cycling tests were done to analyze the adhesion behavior of the hybrid coatings on polyester, followed by microscopy examination. It was found that although both approaches resulted in excellent adhesion of hybrid coatings on polyester, adhesion with interlocked ceramic and polymeric networks was far better than that with chemical bonds in the presence of water at elevated temperatures.     

Synthesis, characterization and flame retardant of UV-curable hybrid coatings containing SiO2–P2O5–B2O3 via sol–gel method

A ternary sol containing silicon, phosphorus and boron modified by ??-methacryloxypropyltrimethoxysilane was synthesized by sol?Cgel method. The ternary sol was incorporated into the organic matrix and UV-curable organic/inorganic hybrid coating materials were obtained. Hardness, transmittance, haze, cross-cut adhesion and abrasion resistance results showed that the mechanical properties of the hybrid coatings improved effectively with no comprising on optical properties by increasing sol content. Scanning electron microscopy and Energy Dispersive X-ray spectrometer studies indicated that inorganic particles were homogenously dispersed in the organic matrix. The flame retardancy of the UV-curable coatings was investigated by thermogravimetric analysis and microscale combustion calorimeter. The results showed that the incorporation of sol into the organic network led to an improvement in the thermal stability and flame retardancy of the hybrid coating materials. It is a desirable achievement to improve simultaneously both flame retardancy and mechanical properties of the coatings.     

The maleimide modified epoxy resins for the preparation of UV‐curable hybrid coatings

In the present study, maleimide‐modified epoxide resin containing UV‐curable hybrid coating materials were prepared and coated on polycarbonate substrates in order to improve their surface properties. UV‐curable, bismaleimide‐modified aliphatic epoxy resin was prepared from N‐(p‐carboxyphenyl) maleimide (p‐CPMI) and cycloaliphatic epoxy (Cyracure‐6107) resin. The structure of the bismaleimide modified aliphatic epoxy resin was analyzed by FTIR and the characteristic absorption band for maleimide ring was clearly observed at 3100 cm^?1. Silica sol was prepared from tetraethylorthosilicate (TEOS) and methacryloxy propyl trimethoxysilane (MAPTMS) by sol–gel method. The coating formulations with different compositions were prepared from UV‐curable bismaleimide‐based epoxy oligomer and sol–gel mixture. The molecular structure of the hybrid coating material was analyzed by ²⁹Si‐CP/MAS NMR spectroscopy techniques. In the ²⁹Si CP/MAS NMR spectrum of the hybrid coating, mainly two kinds of signals were observed at ?68 and ?110 ppm that correspond to T³ and Q⁴ peaks, respectively. This result shows that a fully condensed structure was obtained. The thermal and morphological properties of these coatings materials were investigated by using TGA and SEM techniques. Hardness and abrasion resistance properties of coating materials were examined and both were found to increase with sol–gel precursor content of the coating. The photopolymerization kinetics was investigated by using RT‐IR. 70% conversion was attained with the addition of 15 wt% of BMI resin into the acrylate‐based coating formulation. It was found that the UV‐curable organic–inorganic hybrid coatings improved the surface properties of polycarbonate. Copyright © 2009 John Wiley & Sons, Ltd.     

Numerical Modeling of Thin Film Deposition in Expanding Thermal Plasma

Expanding thermal plasma (ETP) is a widely used technique for deposition of a thin layer of ceramic materials and metal oxide on a substrate for a wide range of applications including abrasion resistance, UV absorption, as well as conductive and optical coatings. The coating quality is found to be dependent on operating parameters as well as reactor designs. In this article, we have presented a CFD based model of the ETP process to simulate the deposition of silica-like coatings on a polycarbonate substrate. Along with the flow-thermal model of plasma jet expansion process, the study also reports the development of a simplified gas phase and surface reaction model to simulate the coating phenomena. The model has been used further to study the effect of various operating conditions on the coating thickness, viz. reactor pressure, reagent flow rate, distance of the substrate from the arc and substrate alignment.     

Synthesis and characterization of UV‐curable phosphorus containing hybrid materials prepared by sol–gel technique

In this study, a series of ultraviolet (UV)‐curable organic–inorganic hybrid coating materials containing phosphorus were prepared by sol–gel approach from acrylate end‐capped urethane resin, acrylated phenyl phosphine oxide oligomer (APPO), and inorganic precursors. TEOS and MAPTMS were used to obtain the silica network and Ti:acac complex was employed for the formation of the titania network in the hybrid coating systems. Coating performance of the hybrid coating materials applied on aluminum substrates was determined by the analysis techniques, such as hardness, gloss, impact strength, cross‐cut adhesion, taber abrasion resistance, which were accepted by international organization. Also, stress–strain test of the hybrids was carried out on the free films. These measurements showed that all the properties of the hybrids were enhanced effectively by gradual increase in sol–gel precursors and APPO oligomer content. The thermal behavior of the hybrid coatings was investigated by thermogravimetric analysis (TGA) analysis. The flame retardancy of the hybrid materials was examined by the limiting oxygen index (LOI); the LOI values of pure organic coating (BF) increased from 31 to 44 for the hybrid materials containing phosphorus (BF‐P:40/Si:10). The data from thermal analysis and LOI showed that the hybrid coating materials containing phosphorus have higher thermal stability and flame resistance properties than the organic polymer. Besides that, it was found that the double bond conversion values for the hybrid mixtures were adequate in order to form an organic matrix. The polycondensation reactions of TEOS and MAPTMS compounds were also investigated by ²⁹Si‐NMR spectroscopy. SEM studies of the hybrid coatings showed that silica/titania particles were homogenously dispersed through the organic matrix. In addition, it was determined that the hybrid material containing phosphorus and silica showed fibrillar structure. Copyright © 2009 John Wiley & Sons, Ltd.     

Transition metal based hybrid organic-inorganic copolymers

The synthesis of transition metal based hybrid copolymers is achieved by using transition metal alkoxides modified by chelating ligands functionalized with polymerizable organic groups. The heterofunctional precursor is an acetoacetoxyethylmethacrylate modified zirconium propoxyde. The hybrid copolymers obtained by double polymerization of heterofunctional precursors are characterized in the liquid and in the solid state by using light scattering, SAXS measurements, UV-visible, FTIR, ¹³C MAS NMR spectroscopies and several chemical and gravimetric analyses. Both inorganic polycondensation and organic polymerization occured and the chemical bond between organic and inorganic moities is conserved. These hybrids consist of polyzirconates chemically bonded to polymeric methacrylate chains via the -diketo complexing function. The determination of the conversion degree of both polymerization reactions reveals the competition between the two types of reactions. This competition controls the scale of homogeneity. The modification ratio (R = AAEM/Zr) of zirconium alkoxide appears to be the key parameter for the tuning of the homogeneity. A careful adjustment of this parameter leads to zirconium oxo species with more or less open structures and to the tailoring of the ratio between organic and inorganic components.     

Wet-Chemical Processing of Transparent and Antiglare Conducting ITO Coating on Plastic Substrates

The paper reviews a low temperature sol-gel processing of transparent and antiglare conducting Sn doped indium oxide (ITO) coatings. The approach uses already crystalline nanoparticles which can be fully redispersed in an ethanolic sol containing a polymerisable organic binder. Thick single layers up to 600 nm can be deposited by spin and dip coating techniques followed either by a low temperature (<130°C) heat treatment or by a UV light irradiation. Stable resistivity down to 9.5 × 10^–2 cm (sheet resistance of 1.7 k for a 560 nm thick layer) have been obtained, together with high visible transparency (T 87%), good adhesion (DIN 58196-K2, and 53151) and abrasion resistance (DIN 58-196 G10 and H25) and 1 H hardness. Irradiation through a mask allows to easily pattern the coatings. Antiglare-conducting coatings with adjustable gloss (60 to 80 GU) and maintaining a good optical resolution (>8 lines/nm) were obtained by a conventional spraying technique. These techniques have been successfully applied to several plastic substrates such as polycarbonate (PC), polymethylmetacrylate (PMMA), polyimide, polyethylene (PE) as well as glasses.     

Effect of Sintering Temperature on the Corrosion and Wear Behavior of Protective SiO2-Based Sol-Gel Coatings

Sol-gel hybrid organic-inorganic and inorganic SiO₂-based protective coatings with and without added 3 m glass particles were developed and tested for their corrosion and wear behavior of an stainless steel substrate (AISI316L). The corrosion resistance greatly increases by incorporating glass particles in the sols. The incorporation of particles in the coatings allows the synthesis of thicker crack-free coatings. On the other hand, the corrosion resistance increases for coatings with a higher organic content obtained at lower sintering temperature. These coatings are also highly stable in saline aqueous solutions. However, the wear resistance is badly affected by the hybrid character of the SiO₂ matrix. The optimum coating process in terms of corrosion and wear resistance, appears to be a hybrid system with a dense SiO₂ network achieved at intermediate sintering temperatures.     

EB/UV treatment of protective coatings for porous materials

A method for improving surface properties of porous inorganic materials is presented. The method is particularly tailored to cement-based materials in order to obtain properties suitable for mechanical applications such as dies manufacturing, where hardness, abrasion resistance and low friction are requested. The coating system is based upon using two coatings of different characteristics. The underlying base coating layer is infiltrated in air on three different formulations of hardened cement composite. Two different bi-component resins, one relatively soft and the other relatively hard, were tested as underlying surface coating. The outer surface coating, based upon a bi-component resin characterized by high hardness, is added after hardening and curing of the first layer. Both coatings were chemically hardened and then cured with EB. UV curing is also suitable for the outer surface coating. An experimental campaign was carried out in order to evaluate the influence of radiation processing as curing treatment with reference to particular investigated materials. Hardness and resistance to peeling of coating systems have been measured and are presented.     

Sol–gel derived hybrid coatings as an environment friendly surface treatment for corrosion protection of metals and their alloys

Sol?Cgel derived organic inorganic hybrid coatings are effective corrosion protective systems for metals. They offer an excellent adhesion to metal as well as to the subsequent coat via strong covalent bond and a three dimensional network of ?CSi?CO?CSi?C linkages which helps to retard the penetration of corrosive medium through the coating. Unlike conventional surface protection methodology, silane based pre-treatment is an environment friendly technology with number of advantages like room temperature synthesis, chemical inertness, high oxidation and abrasion resistance, excellent thermal stability, very low health hazard etc. Further, the hybrid silane provides required flexibility and an increased compatibility with the subsequent coating in multicoat systems. The performance properties of hybrid systems depend on number of parameters like type of silane (mono or bis), degree of hydrolysis, type and dosage of inhibitive/barrier pigments (in case of pigmented system), application techniques, curing temperature and curing schedule, need to be optimized. A guideline formulation for maximum corrosion resistance with low environmental impact consist of a superprimer (a bis-silane with conventional resins, chrome free inhibitive pigments and additives) followed by epoxy or polyurethane top coat as per the exposure conditions.     

Vacuum ultraviolet irradiation on siliceous coatings on polycarbonate substrates

We studied the effect of vacuum ultraviolet (vuv) irradiation on siliceous coatings of polycarbonate (PC) substrates derived by the sol–gel method, with the aim of improving the abrasion resistance of the substrate surface. Methyltriethoxysilane with colloidal silica was used to prepare the sol solution. The sol solution was spin-coated on PC and this was followed by vuv irradiation with a Xe excimer lamp at 172 nm under N₂ atmosphere. The PC substrate with vuv irradiated coating retained its high transmittance in the visible region for about 3 or more times of scraping turns by a steel wool tester on the surface, compared with the non-irradiated or mercury lamp-irradiated coatings, which demonstrated the remarkable improvement of the abrasion resistance by the vuv irradiation. The chemical changes under the vuv irradiation were also investigated by FTIR–ATR spectroscopy, composition analysis conducted with X-ray photoelectron spectroscopy and hardness measurements. It was concluded that the vuv light irradiation resulted in degrading the Si–CH₃ bond in sol–gel derived siliceous coatings to yield hardening of the coatings. The transmittance of the coating in vuv region also increased with the Xe lamp irradiation.     

Sol–gel derived hybrid coatings for the improvement of scratch resistance of polyethylene

Organic–inorganic hybrid materials were prepared through the sol–gel approach starting from tetraethoxysilane (TEOS), as silica precursor, and triethoxysilane terminated polymers; before gelling the solutions were applied to polyethylene (PE) films and slabs by spin-coating, without any previous surface pre-treatment of the substrate, and finally the coatings were thermally cured at 60 °C for 24 h. Among the various polymers used to prepare the coatings, only polyethylene-b-poly(ethylene glycol) copolymers gave good results in terms of adhesion to the PE substrates, and hybrid coatings with different organic–inorganic ratios were prepared. As suggested by visual inspection and SEM investigation, and confirmed by the critical loads derived from scratch tests, a good adhesion of the coating to the PE substrates was obtained, probably due to the presence of PE segments in the organic phase of the coating. Transparency as well as SEM and DSC data were in agreement with the formation of a nanostructured hybrid coating, with a high level of interpenetration between organic and inorganic domains. It was also observed that these hybrid coatings are able to improve significantly the scratch resistance and slightly increase the wettability with respect to uncoated PE. This approach to the surface-properties modification of PE appears as a simple and convenient method for the functionalization of PE substrates.     

New protein-resistant coatings for water filtration membranes based on quaternary ammonium and phosphonium polymers

Several simple, lightly cross-linked quaternary phosphonium- and ammonium-based polymer coatings were found to effectively resist the non-specific adsorption of proteins (i.e., bovine serum albumin (BSA) and fibrinogen (Fg)) from aqueous solution under both static exposure and dynamic membrane fouling conditions. In some cases, their protein-resistance performance is comparable to, or even better than, cross-linked poly(ethylene glycol) (i.e., PEG)-based polymers, which are considered benchmark protein-resistant coating materials. Similarly, these quaternary phosphonium and ammonium polymers exhibit comparable or better resistance to protein adsorption compared to polymeric analogues of some of the best organic functional groups identified in prior self-assembled monolayer-based protein-resistance studies. In particular, initial results of dynamic membrane fouling experiments showed that lightly cross-linked poly[trimethyl-(4-vinyl-benzyl)-phosphonium bromide] has exceptional protein-fouling resistance and better water transport properties than a representative PEG-based polymer coating. In addition to surface functional group chemistry, it was also found that the sub-surface chemistry; the nature of the substrate that the coating is on (i.e., substrate type and morphology); and the protein exposure conditions (i.e., static adsorption vs. dynamic filtration testing) can greatly affect the overall protein adsorption-resistance behavior of the coating. Finally, preliminary studies show that the presence of a regular nanostructure on the polymeric coating surface can lead to enhancement of protein resistance under static exposure conditions even with the same functional groups present, similar to what has been observed with inorganic surfaces.     

Enhancing corrosion resistance of zinc-filled protective coatings using conductive polymers

Organic coatings containing zinc are amply used for the protection of metals, particularly steel structures. Ways to reduce the zinc content in the coating materials are sought for environmental and financial reasons. Our previous work (Kohl, Prog Org Coat 77:512–517, 2014; Kohl and Kalendová, Mater Sci Forum 818: 171–174, 2015a) suggested that one of the options consists in the use of conductive polymers in the formulation of the zinc coatings. The benefits of conductive polymers include nontoxicity, high stability, electric conductivity and redox potential. Previously we focussed on the effect of conductive polymers added to the organic coatings so as to complete the zinc volume concentration to 67%. The anticorrosion efficiency of the organic coatings was found to improve with increasing polyaniline phosphate or polypyrrole concentrations. Zinc content reduction in the system, however, did not attain more than 5%. The present work focusses on systems where the organic coatings are prepared with zinc having a pigment volume concentration PVC = 50%. Zinc content reduction in the system attains up to 20%. This work examines the mechanical and anticorrosion properties of the organic coatings with reduced zinc contents. The present work was devoted to the feasibility of using of conductive polymers in the formulation of coatings with reduced zinc contents. The conductive polymers included polyaniline, polypyrrole and poly(phenylenediamine); these were synthesised and characterised using physico-chemical methods. Polyphenylenediamine as a potential corrosion inhibitor has not been paid adequate attention so far. Subsequently, organic coatings with reduced zinc contents and containing the pigments at 0.5, 1 and 3% volume concentrations were formulated. The coatings were subjected to mechanical tests and accelerated corrosion tests to assess their mechanical and corrosion resistance. The corrosion resistance of the organic coatings was also studied by linear polarisation. The results of the mechanical tests, accelerated corrosion tests and linear polarisation measurements indicate that the organic coating properties get affected by the conductive polymer type as well as by the pigment volume concentration. The important finding is that the use of conductive polymers in coatings with reduced zinc contents was beneficial in all cases.     

Development of hard materials by radiation curing technology

For studying nanoglobular modification effects in radiation cured polymeric composites, we prepared polymerization active silico-organic nanoparticles. With their polymerization active ligands, these nanoparticles form crosslinks by modifying the viscoelastic properties in radiation cured polymeric nanocomposites. In this process, there was a polymerization activity imparted to the particle surfaces of nanopowders, thus applying the physico-chemical modification scheme of a heterogeneous copolymerization to novel scratch and abrasion resistant coatings. By varying the nanoparticle-monomer formulation and the curing method, additional property can be achieved. In this works, we also investigated the influence of various factors such as addition of photoinitiators and other additives into the formulations. The coating materials were applied to the substrate by using different type of coaters. These materials were cured by ultraviolet light and electron beam irradiation. Properties of coatings were characterized using Universal scratch tester and Taber abrasion tester.     

Preparation of photocurable silica–titania hybrid coatings by an anhydrous sol–gel process

Photocurable silica-titania hybrid coatings were prepared through an anhydrous sol–gel process. Moreover, test samples were prepared by the addition of definite ratios of fluoro acrylate oligomers into the formulations to manage the optical properties of transmitted light. Formulations were applied to corona-treated polycarbonate substrates. Upon adding the inorganic component to the coating material, thermal, mechanical, and other properties, such as hardness, gloss, contact angle, and flame resistance were improved. The photocured hybrid films showed an increase in the refractive index with increasing the titanium tetraisopropoxide content. As expected, a decrease was observed in the refractive index of the coatings with the incorporation of fluoro acrylate resin. The surface morphology of the hybrid films was characterized by ESEM analysis. In addition the chemical composition of the surface of the coatings was identified by ESEM–EDS technique. ESEM studies indicated that inorganic particles were dispersed homogenously throughout the organic matrix.