Anti-Glare Coatings with Aqueous Particle Dispersions and Methods for Forming the Same

Abstract

Embodiments provided herein describe optical coatings, panels having optical coatings thereon, and methods for forming optical coatings and panels. A substrate is provided. A coating formulation is applied to the substrate. The coating formulation includes an aqueous-based suspension of particles. The particles have a sheet-like morphology and a thickness of less than about 100 nanometers (nm). The coating formulation is cured to form an anti-glare coating above the substrate. The anti-glare coating has a thickness of between 1 micrometer (μm) and 100 μm.

What is claimed: 
     
         1 . A method for coating an article, the method comprising:
 providing a substrate;   applying a coating formulation to the substrate, the coating formulation comprising an aqueous-based suspension of particles, wherein the particles have a sheet-like morphology and a thickness of less than about 100 nanometers (nm); and   curing the coating formulation to form an anti-glare coating above the substrate, the anti-glare coating having a thickness of between 1 micrometer (μm) and 100 μm.   
     
     
         2 . The method of  claim 1 , wherein the coating formulation further comprises a hydrophilic silicone or silane emulsion, a hydrophilic silicone or silane solution, or a combination thereof. 
     
     
         3 . The method of  claim 1 , wherein the particles comprise silicon oxide. 
     
     
         4 . The method of  claim 1 , wherein the coating formulation further comprises a plurality of nano-particles. 
     
     
         5 . The method of  claim 4 , wherein each of the nano-particles has a width of between about 3 and 50 nm. 
     
     
         6 . The method of  claim 5 , wherein each of the nano-particles are made of a metal oxide. 
     
     
         7 . The method of  claim 1 , wherein the coating formulation comprises a silane emulsion, and wherein the silane emulsion comprises an aminoalkoxysilane, a glycidoxyalkoxysilane, a carboxylalkoxysilane, a water soluble silicate, a hydrophilic alkoxysilane, or a combination thereof. 
     
     
         8 . The method of  claim 5 , wherein the curing the coating formulation comprises an ultraviolet (UV) cure, a thermal cure, or a combination thereof. 
     
     
         9 . The method of  claim 1 , wherein the coating formulation is a sol-gel formulation. 
     
     
         10 . The method of  claim 1 , wherein the substrate comprises glass. 
     
     
         11 . A method for coating an article, the method comprising:
 providing a transparent substrate;   applying a coating formulation to the transparent substrate, the coating formulation comprising an aqueous-based suspension of particles and a hydrophilic silicone or silane emulsion, a hydrophilic silicone or silane solution, or a combination thereof, wherein the particles have a sheet-like morphology and a thickness that is less than about 100 nanometers (nm); and   curing the coating formulation to form an coating above the transparent substrate, the coating having a thickness of between 1 micrometer (μm) and 100 μm.   
     
     
         12 . The method of  claim 11 , wherein the particles comprise silicon oxide. 
     
     
         13 . The method of  claim 12 , wherein the coating formulation further comprises a plurality of nano-particles, wherein each of the nano-particles has a width of between about 3 and 50 nm. 
     
     
         14 . The method of  claim 13 , wherein the curing the coating formulation comprises an ultraviolet (UV) cure, a thermal cure, or a combination thereof. 
     
     
         15 . The method of  claim 14 , wherein the coating formulation is a sol-gel formulation. 
     
     
         16 . A coated article comprising:
 a substrate; and   a coating formed above the substrate, the coating comprising an aqueous-based suspension of particles and having a thickness of between 1 micrometer (μm) and 100 μm, wherein the particles have a sheet-like morphology and a thickness of less than about 100 nanometers (nm).   
     
     
         17 . The coated article of  claim 16 , wherein the coating further comprises at least one of a hydrophilic silicone, water soluble silicate or silane emulsion a hydrophilic silicone or silane emulsion, a hydrophilic silicone or silane solution, or a combination thereof. 
     
     
         18 . The coated article of  claim 17 , wherein the coating comprises a silane emulsion, and wherein the silane emulsion comprises an aminoalkoxysilane, a glycidoxyalkoxysilane, a carboxylalkoxysilane, a water soluble silicate, a hydrophilic alkoxysilane, or a combination thereof. 
     
     
         19 . The coated article of  claim 18 , wherein the coating further comprises a plurality of nano-particles, wherein each of nano-particles has a width of between about 3 and 50 nm. 
     
     
         20 . The coated article of  claim 16 , wherein each of the particles comprises silicon oxide.