Transparent substrate coated with a polymer layer
The invention relates to a transparent substrate coated on at least one of its faces with a polymer layer deposited under vacuum. This polymer layer is provided with an adhesion prelayer of organic or organoinorganic nature. The invention also relates to the process for manufacturing such a coated substrate and to its applications.
1. A substrate comprising a surface that is coated with an adhesion prelayer and an overlying polymer layer; the adhesion prelayer being comprised of molecules/compounds, at least one of which has at least one B group which is reactive with the precursors of the polymer layer and at least one A group which is reactive with the material on which it is deposited, said reactive group A being in the form of: Me(OR) 3−m Cl m , wherein m≧1, Me is Si, Ti, Sn or Ge or MeCl 4 and said reactive group B being compounds containing an olefinically unsaturated bond, alkyne, alcohol, aldehyde, amide, amine, acid anhydride, ketone, ester, ether, acid halide, nitrile, carbylamine, isocyanate, thiocyanate, peracid, acid, thiol, amino acid, ketone acid, sulfonic acid, epoxide or azo, with the adhesion prelayer being in direct contact with the polymer layer.
2. The substrate of claim 1 , wherein the adhesion prelayer is in direct contact with the surface.
3. The substrate of claim 1 , further comprising one or more intermediate coating layers between the adhesion prelayer and the surface.
4. The substrate of claim 1 , wherein the substrate comprises glass, silica, silicon, a vitroceramic polymer, an organic polymer, and mixtures thereof.
5. The substrate of claim 3 , wherein the one or more intermediate coating layers is selected from the group consisting of a metal oxide, metal nitride, metal, silicon oxide, silicon oxynitride, silicon oxycarbide, silicon nitride, and mixtures thereof.
6. The substrate of claim 1 , wherein the thickness of the polymer layer is at least 5 times greater than the thickness of the adhesion layer.
7. The substrate of claim 1 , wherein the polymer layer has a thickness ranging from about 5 nm to 5 mm.
8. The substrate of claim 1 , wherein the adhesion prelayer has a thickness ranging from about 0.2 nm to 10 mm.
9. The substrate of claim 1 , wherein the adhesion prelayer is discontinuous.
10. The substrate of claim 1 , wherein the polymer layer is prepared by polymerizing one or more polymer precursors selected from the group consisting of unsaturated polyester resins, thiol-polyene resins, polyester acrylates, epoxy acrylates, urethane acrylates, polysiloxanes, difunctional epoxide polymers, telechelic epoxide polymers, vinyl ethers, and mixtures thereof.
11. The substrate of claim 2 , wherein the polymer layer is prepared by polymerizing one or more polymer precursors selected from the group consisting of unsaturated polyester resins, thiol-polyene resins, polyester acrylates, epoxy acrylates, urethane acrylates, polysiloxanes, difunctional epoxide polymers, telechelic epoxide polymers, vinyl ethers, and mixtures thereof.
12. The substrate of claim 1 , wherein the polymer layer is prepared by polymerizing one or more polymer precursors having an acrylic functional group.
13. The substrate of claim 10 , wherein the polymer precursors are selected from the group consisting of lauryl acrylate, isodecyl acrylate, polyethylene glycol acrylate, 1,6-hexanediol diacrylate, bisphenol A epoxy acrylate, polysiloxanes with vinyl terminal groups, siliconetrifluoropropylmethylsiloxane copolymers, triacrylates, dipentaerythritol pentaacrylate, propoxylated glyceryl triacrylate, vinylmethoxysiloxane and mixtures thereof.
14. The substrate of claim 1 , wherein the polymer layer is fluorinated.
15. The substrate of claim 1 , wherein the polymer layer is prepared by polymerizing one or more polymer precursors having a condensation functional group selected from the group consisting of alcohols, amides, amines, acid anhydrides, esters, ethers, acid halides, nitriles, carbylamines, isocyanates, thiocyanates, peracids, acids, thiols, amino acids, ketone acids, sulphonic acids, epoxides, and mixtures thereof.
16. The substrate of claim 15 , wherein the polymer precursors are selected from the group consisting of pyromellitic dianhydride, decamethylenediamine, diaminodiphenyl ether, 1,6-diisocyanatohexane, trans-1,4-cyclohexynene diisocyanate, 1,6-hexanediamine, 1,2-diaminocyclohexane, polydimethylsiloxanes, polymethylsiloxanes, and mixtures thereof.
17. The substrate of claim 14 , wherein the polymer layer has a refractive index ranging from about 1.75 to 1.29.
18. The substrate of claim 14 , wherein the polymer layer has a contact angle with water of greater than 90°.
19. The substrate of claim 3 , wherein the adhesion prelayer comprises a first functional group that can react with the one or more polymer precursors and a second functional group that can react with the intermediate coating.
20. The substrate of claim 14 , wherein the adhesion prelayer forms covalent bonds with the substrate.
21. The substrate of claim 3 , wherein the adhesion prelayer forms covalent bonds with the intermediate coating.
22. The substrate of claim 1 , wherein the adhesion prelayer forms covalent bonds with the polymer layer.
23. The substrate of claim 3 , wherein the adhesion prelayer forms covalent bonds with the polymer layer.
24. The substrate of claim 1 , further comprising an inorganic layer in contact with the polymer layer.
25. The substrate of claim 1 , wherein the adhesion prelayer and the polymer layer are substantially transparent.
26. The substrate of claim 1 , wherein the polymer layer is selected from the group consisting of polyimides, polyureas, polyamides, polyurethanes, polyesters, and mixtures thereof.
27. The substrate of claim 3 , wherein the one or more intermediate coatings comprises an inorganic layer.
28. A process for manufacturing the substrate of claim 1 comprising:
providing the substrate;
coating the substrate with one or more precursors to the adhesion prelayer, wherein the one or more precursors to the adhesion prelayer react with the substrate;
coating the one or more precursors to the adhesion prelayer with one or more polymer precursors;
polymerizing or crosslinking the one or more polymer precursors; and
reacting the one or more polymer precursors with the one or more precursors to the adhesion prelayer.
29. The process of claim 1 , wherein the one or more polymer precursors have an acrylic functional group that is crosslinked by, ultraviolet radiation, electron bombardment, or a heat treatment.