Scratch resistant transparent articles and methods of making the same

Abstract

Transparent articles and methods of producing transparent articles are provided. The transparent article includes hydrophobic nanoparticles dispersed within poly(methyl methacrylate). The method of producing transparent articles includes pouring a transparent article precursor into a mold, the transparent article precursor comprising nanoparticles, a solvent, and a polymer, and the mold comprising a flat surface. The method also includes placing the mold into a container having an adjustable opening and allowing the solvent to evaporate from the transparent article precursor, thereby forming the transparent article over the flat surface of the mold. The method further includes flattening the transparent article, in which flattening the transparent article includes positioning a flat article on a first side of the transparent article, and compressing the transparent article between the flat surface and the flat article.

1 - 20 . (canceled) 
     
     
         21 . A method of manufacturing a photovoltaic panel comprising a scratch resistant transparent article, the method comprising:
 producing the transparent article by:
 pouring a transparent article precursor into a mold comprising a flat surface, the transparent article precursor comprising nanoparticles, a solvent, and a polymer, wherein the transparent article precursor comprises a weight ratio of nanoparticles to polymer of from 1:200 to 1:20; 
 placing the mold into a container having an adjustable opening; and 
 allowing the solvent to evaporate from the transparent article precursor, thereby forming the transparent article over the flat surface of the mold; and 
 flattening the transparent article by:
 positioning a flat article on a first side of the transparent article; and 
 compressing the transparent article between the flat surface and the flat article; and 
 
   incorporating the transparent article as a component of the photovoltaic panel.   
     
     
         22 . The method of  claim 21 , wherein the nanoparticles are selected from the group consisting of silica nanoparticles, titanium oxide nanoparticles, zinc oxide nanoparticles, zirconium oxide nanoparticles, and combinations thereof. 
     
     
         23 . The method of  claim 21 , wherein the nanoparticles comprise hydrophobic nanoparticles, the hydrophobic nanoparticles being a product of reacting silica nanoparticles, titanium oxide nanoparticles, zinc oxide nanoparticles, zirconium oxide nanoparticles, or combinations thereof, with a modifying agent selected from the group consisting of alkylsilanes, alkoxysilanes, alkylalkoxysilanes, alkylhalosilanes, alkoxyhalosilanes, alkylalkoxyhalosilanes, (haloalkyl)silanes, (haloalkoxy)silanes, (haloalkyl)alkoxysilanes, alkyl(haloalkoxy)silanes, (haloalkyl)(haloalkoxy)silanes, (haloalkyl)halosilanes, (haloalkoxy)halosilane s, (haloalkyl)alkoxyhalosilanes, alkyl(haloalkoxy)halosilanes, (haloalkyl)(haloalkoxy)halosilanes, and combinations thereof. 
     
     
         24 . The method of  claim 23 , wherein the modifying agent is selected from the group consisting of dimethyldichlorosilane, methyltriethoxysilane, ethyltriethoxysilane, pentyltriethoxysilane, dodecyltriethoxysilane, and combinations thereof. 
     
     
         25 . The method of  claim 21 , further comprising mixing the nanoparticles, the solvent, and the polymer to form the transparent article precursor. 
     
     
         26 . The method of  claim 25 , wherein mixing the nanoparticles, the solvent, and the polymer comprises:
 adding the nanoparticles to the solvent to form a nanoparticle mixture;   sonicating the nanoparticle mixture to disperse the nanoparticles within the nanoparticle mixture; and   adding the polymer to the nanoparticle mixture to form the transparent article precursor.   
     
     
         27 . The method of  claim 21 , wherein 99% of the nanoparticles have a particle size of from 7 nanometers to 50 nanometers. 
     
     
         28 . The method of  claim 21 , wherein compressing the transparent article comprises applying greater than 5 Newtons of pressure perpendicular to the flat surface. 
     
     
         29 . A method of manufacturing a photovoltaic panel comprising a scratch resistant transparent article, the method comprising:
 producing the transparent article by:
 pouring a transparent article precursor into a mold comprising a flat surface, the transparent article precursor comprising nanoparticles, a solvent selected from C 1 -C 5  haloalkanes, and a polymer; 
 placing the mold into a container having an adjustable opening; and 
 allowing the solvent to evaporate from the transparent article precursor, thereby forming the transparent article over the flat surface of the mold; and 
 flattening the transparent article by:
 positioning a flat article on a first side of the transparent article; and 
 compressing the transparent article between the flat surface and the flat article; and 
 
   incorporating the transparent article as a component of the photovoltaic panel.   
     
     
         30 . The method of  claim 29 , wherein the solvent is selected from the group consisting of C 2 -C 5  chloroalkanes, C 2 -C 5  fluoroalkanes, monohalomethanes, dihalomethanes, trihalomethanes, and combinations thereof. 
     
     
         31 . The method of  claim 30 , further comprising, while allowing the solvent to evaporate, increasing an open area of the adjustable opening of the container to increase an evaporation rate of the solvent. 
     
     
         32 . The method of  claim 29 , wherein allowing the solvent to evaporate from the transparent article precursor comprises:
 closing the adjustable opening of the container after placing the mold into the container;   opening the adjustable opening of the container after closing the adjustable opening of the container; and   allowing the solvent to evaporate for at least 2 days.   
     
     
         33 . A photovoltaic panel comprising a scratch resistant transparent article, the transparent article comprising:
 a polymer selected from the group consisting of poly(methyl methacrylate), polycarbonate, polystyrene, polyetherimide, and acrylonitrile butadiene styrene;   0.5 wt. % to 5 wt. % hydrophobic nanoparticles, based on the total weight of the transparent article, wherein 99% of the nanoparticles have a particle size of from 7 nanometers to 50 nanometers;   an optical transmittance greater than 80% at wavelengths from 400 nm to 750 nm; and   a scratch resistance higher than a scratch resistance of the polymer without nanoparticles.   
     
     
         34 . The photovoltaic panel of  claim 33 , wherein the hydrophobic nanoparticles are a product of reacting silica nanoparticles, titanium oxide nanoparticles, zinc oxide nanoparticles, zirconium oxide nanoparticles, or combinations thereof, with a modifying agent selected from the group consisting of alkylsilanes, alkoxysilanes, alkylalkoxysilanes, alkylhalosilanes, alkoxyhalosilanes, alkylalkoxyhalosilanes, (haloalkyl)silanes, (haloalkoxy)silanes, (haloalkyl)alkoxysilanes, alkyl(haloalkoxy)silanes, (haloalkyl)(haloalkoxy)silanes, (haloalkyl)halosilanes, (haloalkoxy)halosilanes, (haloalkyl)alkoxyhalosilanes, alkyl(haloalkoxy)halosilanes, (haloalkyl)(haloalkoxy)halosilanes, and combinations thereof. 
     
     
         35 . The photovoltaic panel of  claim 34 , wherein the modifying agent is selected from the group consisting of dimethyldichlorosilane, methyltriethoxysilane, ethyltriethoxysilane, pentyltriethoxysilane, dodecyltriethoxysilane, and combinations thereof. 
     
     
         36 . The photovoltaic panel of  claim 33 , wherein the polymer comprises poly(methyl methacrylate) and the hydrophobic nanoparticles comprise silica nanoparticles. 
     
     
         37 . The photovoltaic panel of  claim 36 , wherein the silica nanoparticles are fumed silica.