Coating Compositions, Articles, And Methods Of Coating Articles

Abstract

To provide transparent plastic coatings with a combination of abrasion resistance and formability, a composition comprises an aqueous-organic solvent mixture containing hydrolysis products and partial condensates of an epoxy functional silane and/or a diol functional organopolysiloxane mixed with a multifunctional crosslinker selected from multifunctional carboxylic acids, an hydrides or silylated anhydrides, wherein the molar ratio of the epoxy functional silane and/or the diol functional organopolysiloxane to the multifunctional crosslinker is from about 10:1 to 1:10, and water in an amount sufficient to hydrolyze the components.

1 . A composition which, when applied to a substrate and cured, provides an abrasion resistant formable coating on said substrate, comprising:
 an aqueous-organic solvent mixture having hydrolysis products and partial condensates of at least one of an epoxy functional silane and a diol functional organopolysiloxane and at least one multifunctional crosslinker, wherein said multifunctional crosslinker comprises a silylated multifunctional anhydride, and wherein said at least one of said epoxy functional silane and said diol functional organopolysiloxane is present in a molar ratio to said multifunctional crosslinker from about 10:1 to 1:10; and   an amount of water sufficient to hydrolyze said epoxy functional silane, said diol functional organopolysiloxane, and said silylated multifunctional crosslinker.   
     
     
         2 . The composition as claimed in  claim 1  wherein said at least one of said epoxy functional silane and said diol functional organopolysiloxane is present in a molar ratio to said multifunctional crosslinker of about 2:1 to 1:2. 
     
     
         3 . The composition as claimed in  claim 1  wherein said coating can be formed to a radius from about 1 inch to less than about 10 inches on a polycarbonate substrate. 
     
     
         4 . The composition as claimed in  claim 1  wherein said coating can be formed to a radius from about 3 inches to about 5 inches on a polycarbonate substrate. 
     
     
         5 . The composition as claimed in  claim 1  wherein said coating has a Taber number of between less than about 10 percent to less than about 2 percent after 50 revolutions of a Taber wheel. 
     
     
         6 . The composition as claimed in  claim 1  wherein said coating has a Taber number of between less than about 45 percent to less than about 15 percent after 200 revolutions of a Taber wheel. 
     
     
         7 . The composition as claimed in  claim 1  wherein said at least one of said epoxy functional silane and said diol functional organopolysiloxane comprises about 5 to about 90 percent by weight of the solids of said composition, and wherein said multifunctional crosslinker comprises about 10 to about 95 percent by weight of the solids of said composition. 
     
     
         8 . The composition as claimed in  claim 1  wherein the solvent constituent of said aqueous-organic solvent mixture comprises from about 40 to about 98 percent by weight of the composition. 
     
     
         9 . The composition as claimed in  claim 1  wherein the solvent constituent of said aqueous-organic solvent mixture is selected from an ether, a glycol or a glycol ether, a ketone, an ester, a glycolether acetate, alcohols having the formula ROH where R is an alkyl group containing from 1 to about 10 carbon atoms, and mixtures thereof. 
     
     
         10 . The composition as claimed in  claim 1  wherein the solvent constituent of said aqueous-organic solvent mixture is selected from glycols, ethers, glycol ethers having the formula R 1 —(OR 2 ) x —OR 1  where x is 0, 1, 2, 3 or 4, R 1  is hydrogen or an alkyl group containing from 1 to about 10 carbon atoms and R 2  is an allylene group containing from 1 to about 10 carbon atoms and combinations thereof. 
     
     
         11 . The composition as claimed in  claim 1  wherein said epoxy functional silane is represented by the formula R 3   x Si(OR 4 ) 4-x , wherein:
 x is an integer of 1, 2 or 3;   R 3  is H, an allyl group, a functionalized allyl group, an alkylene group, an aryl group, an allyl ether, and combinations thereof containing from 1 to about 10 carbon atoms and having at least 1 epoxy functional group;   R 4  is H, an alkyl group containing from 1 to about 5 carbon atoms, an acetyl group, a —Si(OR 5 ) 3-y R 6   y  group where y is an integer of 0, 1, 2, or 3, and combinations thereof;   R 5  is H, an allyl group containing from 1 to about 5 carbon atoms, an acetyl group, or another —Si(OR 5 ) 3-y R 6   y  group and combinations thereof; and   R 6  is H, an alkyl group, a functionalized alkyl group, an alkylene group, an aryl group, an alkyl ether, and combinations thereof containing from 1 to about 10 carbon atoms.   
     
     
         12 . A composition which, when applied to a substrate and cured, provides an abrasion resistant formable coating on said substrate, comprising:
 an aqueous-organic solvent mixture having hydrolysis products and partial condensates of a diol functional organopolysiloxane and at least one multifunctional crosslinker, wherein said multifunctional crosslinker is selected from multifunctional carboxylic acids, multifunctional anhydrides, and silylated multifunctional anhydrides, and wherein said diol functional organopolysiloxane is present in a molar ratio to said multifunctional crosslinker of from about 10:1 to 1:10; and   an amount of water sufficient to hydrolyze said diol functional organopolysiloxane and said silylated multifunctional crosslinker.   
     
     
         13 . The composition as claimed in  claim 12  wherein said aqueous-organic solvent mixture further comprises hydrolysis products and partial condensates of an epoxy functional silane and said at least one multifunctional crosslinker. 
     
     
         14 . A composition which, when applied to a substrate and cured, provides an abrasion resistant formable coating on said substrate, comprising:
 an aqueous-organic solvent mixture having hydrolysis products and partial condensates of an epoxy functional silane and at least one multifunctional crosslinker, wherein said multifunctional crosslinker is selected from multifunctional carboxylic acids, multifunctional anhydrides, and silylated multifunctional anhydrides, and wherein said at least one of said epoxy functional silane is present in a molar ratio to said multifunctional crosslinker of from about 10:1 to 1:10; and   an amount of water sufficient to hydrolyze the epoxy functional silane and the multifunctional crosslinker, wherein said composition contains an amount of at least one of tetrafunctional silanes, disilanes, and alkyl silanes insufficient to render said coating rigid on said substrate.   
     
     
         15 . The composition as claimed in  claim 14  wherein said composition includes at least one of a tetrafunctional silane and a disilane, and wherein said epoxy functional silane is present in a molar ratio to said at least one of said tetrafunctional silane and said disilane of at least about 5.5:1. 
     
     
         16 . The composition as claimed in  claim 14  wherein said aqueous-organic solvent mixture further comprises hydrolysis products and partial condensates of a diol functional organopolysiloxane and said multifunctional crosslinker. 
     
     
         17 . The composition as claimed in  claim 14  wherein:
 said tetrafunctional silane has a formula of Si(OR 9 ) 4 , where R 9  is H, an alkyl group containing from 1 to about 5 carbon atoms and ethers thereof, an (OR 9 ) carboxylate, a —Si(OR 10 ) 3  group where R 10  is a H, an alkyl group containing from 1 to about 5 carbon atoms and ethers thereof, an (OR 10 ) carboxylate, or another —Si(OR 10 ) 3  group and combinations thereof, wherein:   said disilane has a formula of (R 11 O) x R 12   3-x Si—R 13   y SiR 14   3-x (OR 15 ) x ; wherein x is 0, 1, 2, or 3 and y is 0 or 1; wherein R 12  and R 14  comprises H, an allyl group containing from about 1 to about 10 carbon atoms, a fictionalized alkyl group, an alkylene group, an aryl group, an alkypolyether group, and combinations thereof; wherein R 12  and R 15  comprises H, an allyl group containing from about 1 to, about 10 carbon atoms, an acetyl group, and combinations thereof; wherein if y is 1 then R 13  comprises an alkylene group containing from about 1 to about 12 carbon atoms, an alkylenepolyether containing from about 1 to about 12 carbon atoms, an aryl group, an alkylene substituted aryl group, an alkylene group which may contain one or more olefins, S, or O; wherein it x is 0 then R 12  and R 14  comprises Cl or Br; and wherein if y is 0 then there is a direct silicon-silicon bond, and wherein:   said allyl silane has a formula of R 16   x Si(OR 17 ) 4-x  where x is a number of 1, 2 or 3; R 16  is H, or an alkyl group containing from 1 to about 10 carbon atoms, a functionalized alkyl group, an allylene group, an aryl group an alkoxypolyether group and combinations thereof; R 17  is H, an alkyl group containing from 1 to about 10 carbon atoms, an acetyl group; and combinations thereof.   
     
     
         18 . The composition as claimed in  claim 14  wherein said composition includes at least one alkyl silane, and wherein said epoxy functional silane is present in a molar ratio to said at least one allyl silane of at least about 2.5:1. 
     
     
         19 . An article, comprising:
 a substrate and an abrasion resistant formable coating formed on at least one surface of said substrate by curing a coating composition, comprising:
 an aqueous-organic solvent mixture having hydrolysis products and partial condensates of at least one of an epoxy functional silane and a diol functional organopolysiloxane and at least one multifunctional crosslinker, wherein said multifunctional crosslinker comprises a silylated multifunctional anhydride, and wherein said at least one of said epoxy functional silane and said diol functional organopolysiloxane is present in a molar ratio to said multifunctional crosslinker from about 10:1 to 1:10; and 
 an amount of water sufficient to hydrolyze said epoxy functional silane, said diol functional organopolysiloxane, and said silylated multifunctional crosslinker. 
   
     
     
         20 . The article as claimed in  claim 19  wherein said article comprises a formed article comprising a formed substrate and said abrasion resistant formable coating formed on at least one surface of said substrate by applying said coating composition to a substrate, curing said coating composition, and subsequently forming said substrate such that said formed substrate is formed. 
     
     
         21 . The article as claimed in claimed  19  further comprising at least one primer disposed on said at least one surface of said substrate between said substrate and said coating. 
     
     
         22 . An article, comprising:
 a substrate and an abrasion resistant formable coating formed on at least one surface of said substrate by curing a coating composition, comprising:
 an aqueous-organic solvent mixture having hydrolysis products and partial condensates of a diol functional organopolysiloxane and at least one multifunctional crosslinker, wherein said multifunctional crosslinker is selected from multifunctional carboxylic acids, multifunctional anhydrides, and silylated multifunctional anhydrides, and wherein said diol functional organopolysiloxane is present in a molar ratio to said multifunctional crosslinker of from about 10:1 to 1:10; and 
 an amount of water sufficient to hydrolyze said diol functional organopolysiloxane and said silylated multifunctional crosslinker. 
   
     
     
         23 . An article, comprising:
 a substrate and an abrasion resistant formable coating formed on at least one surface of said substrate by curing a coating composition, comprising:
 an aqueous-organic solvent mixture having hydrolysis products and partial condensates of an epoxy functional silane and at least one multifunctional crosslinker, wherein said multifunctional crosslinker is selected from multifunctional carboxylic acids, multifunctional anhydrides, and silylated multifunctional anhydrides, and wherein said epoxy functional silane is present in a molar ratio to said multifunctional crosslinker of from about 10:1 to 1:10; and 
 an amount of water sufficient to hydrolyze said epoxy functional silane and said silylated multifunctional crosslinker, wherein said composition contains an amount of at least one of tetrafunctional silanes, disilanes, and alkyl silanes insufficient to render said coating rigid on said substrate. 
   
     
     
         24 . The article as claimed in  claim 23  wherein said coating composition includes at least one of a tetrafunctional silane and a disilane, and wherein said epoxy functional silane is present in a molar ratio to said at least one of said tetrafunctional silane and said disilane of at least about 5.5:1. 
     
     
         25 . The article as claimed in  claim 23  wherein said coating composition includes at least one alkyl silane, wherein said epoxy functional silane is present in a molar ratio to said at least one alkyl silane of at least about 2.5:1. 
     
     
         26 . A process for providing a substantially transparent abrasion resistant formable coating, comprising:
 applying a coating composition to a substrate; and   curing said coating composition, wherein said coating composition comprises:
 an aqueous-organic solvent mixture having hydrolysis products and partial condensates of at least one of an epoxy functional silane and a diol functional organopolysiloxane and at least one multifunctional crosslinker, wherein said multifunctional crosslinker comprises a silylated multifunctional anhydride, and wherein said at least one of said epoxy functional silane and said diol functional organopolysiloxane is present in a molar ratio to said multifunctional crosslinker from about 10:1 to 1:10; and 
 an amount of water sufficient to hydrolyze said epoxy functional silane, said diol functional organopolysiloxane, and said silylated multifunctional crosslinker. 
   
     
     
         27 . The process as claimed in  claim 26  further comprising the step of forming said coated substrate. 
     
     
         28 . The process as claimed in  claim 26  further comprising applying a primer to said substrate prior to applying said coating composition to said substrate on said primer. 
     
     
         29 . A process for providing an abrasion resistant formable coating, comprising:
 applying a coating composition to a substrate; and   curing said coating composition, wherein said coating composition comprises:
 an aqueous-organic solvent mixture having hydrolysis products and partial condensates of a diol functional organopolysiloxane and at least one multifunctional crosslinker, wherein said multifunctional crosslinker is selected from multifunctional carboxylic acids, multifunctional anhydrides, and silylated multifunctional anhydrides, and wherein said diol functional organopolysiloxane is present in a molar ratio to said multifunctional crosslinker of from about 10:1 to 1:10; and 
 an amount of water sufficient to hydrolyze said diol functional organopolysiloxane and said silylated multifunctional crosslinker. 
   
     
     
         30 . A process for providing an abrasion resistant formable coating, comprising:
 applying a coating composition to a substrate; and   curing said coating composition, wherein said coating composition comprises:
 an aqueous-organic solvent mixture having hydrolysis products and partial condensates of an epoxy functional silane and at least one multifunctional crosslinker, wherein said multifunctional crosslinker is selected from multifunctional carboxylic acids, multifunctional anhydrides, and silylated multifunctional anhydrides, and wherein said epoxy functional silane is present in a molar ratio to said multifunctional crosslinker of from about 10:1 to 1:10; and 
 an amount of water sufficient to hydrolyze said epoxy functional silane and said silylated multifunctional crosslinker, wherein said composition contains an amount of at least one of tetrafunctional silanes, disilanes, and alkyl silanes insufficient to render said coating rigid on said substrate. 
   
     
     
         31 . The method as claimed in  claim 30  wherein said composition includes at least one of a tetrafunctional silane and a disilane, and wherein said epoxy functional silane is present vin a molar ratio to said at least one of said tetrafunctional silane and said disilane of at least about 5.5:1. 
     
     
         32 . The method as claimed in  claim 30  wherein said composition includes at least one alkyl silane, and wherein said epoxy functional silane is present in a molar ratio to said at least one alkyl silane of at least about 2.5:1.