# US 2013/0157066 A1 · Method for manufacturing a hard, water-resistant anti-fog coating

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- Number: US 2013/0157066 A1
- Document ID: US20130157066A1
- Status: Published application
- Kind: A1
- Application number: 13/325,318
- Filed: 2011-12-14
- Published: 2013-06-20
- Earliest claimed: 2011-12-14
- Assignees: Tamkang University
- Inventors: Liao-Ping CHENG; Ching-Chung Chen; Feng-Hsi Huang; Hsu-Hsien Chang
- Web page: https://patentgrep.com/patent/US20130157066A1

## CPC

- G02B 1/14: Protective coatings, e.g. hard coatings
- C08J 7/0423: {with at least one layer of inorganic material and at least one layer of a composition containing a polymer binder}
- C08J 7/043: Improving the adhesiveness of the coatings per se, e.g. forming primers (adhesives in the form of films or foils characterised by the primer layers between the polymer carriers and the adhesives C09J7/50)
- C08J 7/046: Forming abrasion-resistant coatings; Forming surface-hardening coatings
- C08J 7/054: Forming anti-misting or drip-proofing coatings
- C08J 7/056: Forming hydrophilic coatings
- G02B 1/18: Coatings for keeping optical surfaces clean, e.g. hydrophobic or photo-catalytic films (G02B1/16 takes precedence)
- G02B 27/0006: {with means to keep optical surfaces clean, e.g. by preventing or removing dirt, stains, contamination, condensation (G02B1/18 takes precedence; cleaning in general B08B)}
- G02B: OPTICAL ELEMENTS, SYSTEMS OR APPARATUS
- C08J: WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H (working, e.g. shaping, of plastics B29)

## Abstract

The present invention relates to a method for manufacturing a hard, water-resistant anti-fog coating, and particularly relates to a method for manufacturing a hard, water-resistant anti-fog coating on plastic material. In this method, an organic-inorganic hard adhesion layer and a hydrophilic anti-fog coating film are prepared for manufacturing a hard, water-resistant anti-fog coating. Both of the organic-inorganic hard adhesion layer and the hydrophilic anti-fog coating have C=C double bonds. Therefore, the organic-inorganic hard adhesion layer and the hydrophilic anti-fog coating are adhered to each other tightly. It brings high hardness, high water resistance and good anti-fog effect.

## Claims

### Claim 1

A method for manufacturing a hard, water-resistant anti-fog coating, comprising:
forming an organic-inorganic hybrid hard adhesion layer on a base material; and
forming a hydrophilic anti-fog coating film on said organic-inorganic hybrid hard adhesion layer.

### Claim 2 (depends on 1)

The method of claim 1, wherein said base material is a plastic material.

### Claim 3 (depends on 1)

The method of claim 1, wherein said step of forming an organic-inorganic hybrid hard adhesion layer on a base material comprises:
preparing an inorganic gel by hydrolysis condensation of an inorganic monomer;
adding a coupling agent into said inorganic gel to continue hydrolysis condensation for modifying surface of said inorganic gel to form an inorganic hybrid gel;
adding a photoinitiator and a photosensitive monomer into said inorganic hybrid gel to form an adhesion coating;
coating said base material with said adhesion coating; and
performing a soft bake, a UV curing, and a hard bake to said adhesion coating coated on said base material to form said organic-inorganic hybrid hard adhesion layer.

### Claim 4 (depends on 3)

The method of claim 3, wherein said inorganic monomer is tetraethoxylsilane (TEOS).

### Claim 5 (depends on 4)

The method of claim 4, wherein said step of preparing an inorganic gel by hydrolysis condensation of an inorganic monomer is performed by uniformly mixing said tetraethoxylsilane (TEOS) and 2-propanol and by adding a hydrochloric acid solution to perform hydrolysis condensation reaction after.

### Claim 6 (depends on 5)

The method of claim 5, wherein mixing percentage of said tetraethoxylsilane (TEOS) is 10%-90% weight percentage (w/w), and mixing percentage of said 2-propanol is 10%-90% weight percentage (w/w).

### Claim 7 (depends on 6)

The method of claim 6, wherein mixing percentage of said tetraethoxylsilane (TEOS) is 20%-80% weight percentage (w/w), and mixing percentage of said 2-propanol is 20%-80% weight percentage (w/w).

### Claim 8 (depends on 7)

The method of claim 7, wherein mixing percentage of said tetraethoxylsilane (TEOS) is 35%-65% weight percentage (w/w), and mixing percentage of said 2-propanol is 35%-65% weight percentage (w/w).

### Claim 9 (depends on 5)

The method of claim 5, wherein pH value of said hydrochloric acid solution is 1-3.

### Claim 10 (depends on 3)

The method of claim 3, wherein said coupling agent is 3-(trimethoxy silyl) propyl methacrylate (MSMA).

### Claim 11 (depends on 3)

The method of claim 3, wherein said step of adding a coupling agent into said inorganic gel further comprises a step of resupplying a hydrochloric acid solution to continue said hydrolysis condensation.

### Claim 12 (depends on 11)

The method of claim 11, wherein pH value of said hydrochloric acid solution is 1-3.

### Claim 13 (depends on 3)

The method of claim 3, wherein said photoinitiator is Darocure 1173, Irgacure 907, or Isopropyl thioxanthone (ITX).

### Claim 14 (depends on 3)

The method of claim 3, wherein said photosensitive monomer is Dipentaerythritol hexaacrylate (DPHA), Trimethylol propane triacrylate (TMPTA), Pentaerythritol tetraacrylate (PETA), Di(trimethylolpropane) tetraacrylate (DiTMPTA), or 1,6-Hexanediol diacrylate (HDODA).

### Claim 15 (depends on 3)

The method of claim 3, wherein said step of adding a photoinitiator and a photosensitive monomer into said inorganic hybrid gel comprises adding 1%-99% weight percentage of said photosensitive monomer, and adding 0.1%-10% weight percentage (wt %) of said photoinitiator.

### Claim 16 (depends on 15)

The method of claim 15, wherein said step of adding a photoinitiator and a photosensitive monomer into said inorganic hybrid gel comprises adding 5%-80% weight percentage of said photosensitive monomer, and adding 0.5%-8% weight percentage (wt %) of said photoinitiator.

### Claim 17 (depends on 16)

The method of claim 16, wherein said step of adding a photoinitiator and a photosensitive monomer into said inorganic hybrid gel comprises adding 10%-50% weight percentage of said photosensitive monomer, and adding 1%-5% weight percentage (wt %) of said c photoinitiator.

### Claim 18 (depends on 3)

The method of claim 3, wherein said step of performing UV curing to said adhesion coating is performed by illuminating said adhesion coating coated on said base material with proper UV energy and UV exposure, and at the time of curing said adhesion coating coated on said base material, portion of carbon-carbon double bonds (C=C) in said adhesion coating does not react with UV light wherein said organic-inorganic hybrid hard adhesion layer has good chemical attachment with said hydrophilic anti-fog coating film by reaction between said carbon-carbon double bonds (C=C) and said hydrophilic anti-fog coating film.

### Claim 19 (depends on 18)

The method of claim 18, wherein said proper UV energy is 0.01-100 mJ/cm2.

### Claim 20 (depends on 19)

The method of claim 19, wherein said proper UV energy is 0.1-50 mJ/cm2.

### Claim 21 (depends on 20)

The method of claim 20, wherein said proper UV energy is 0.5-20 mJ/cm2.

### Claim 22 (depends on 1)

The method of claim 1, wherein said step of forming a hydrophilic anti-fog coating film on said organic-inorganic hybrid hard adhesion layer comprises:
preparing a modified surfactant;
preparing a modified silicon dioxide;
mixing said modified surfactant and said modified silicon dioxide to form a mixed solution of said modified surfactant and said modified silicon dioxide;
adding a photoinitiator and a photosensitive monomer into said mixed solution to prepare a hydrophilic anti-fog coating;
coating said organic-inorganic hybrid hard adhesion layer with said hydrophilic anti-fog coating; and
performing a soft bake, a UV curing, and a hard bake to said hydrophilic anti-fog coating coated on said organic-inorganic hybrid hard adhesion layer to form said hydrophilic anti-fog coating film.

### Claim 23 (depends on 22)

The method of claim 22, wherein said step of preparing a modified surfactant comprises:
mixing 2-Hydroxy-ethyl methacrylate (2-HEMA) and isophorondiisocyanate (IPDI) to prepare a 2-HEMA-IPDI; and
adding a surfactant into said 2-HEMA-IPDI to prepare said modified surfactant wherein after reaction of hydroxyl groups of said surfactant and said 2-HEMA-IPDI, said modified surfactant still contains portion of carbon-carbon double bonds of said 2-HEMA-IPDI which can be utilized to perform following UV curing process.

### Claim 24 (depends on 23)

The method of claim 23, wherein said step of mixing 2-Hydroxy-ethyl methacrylate (2-HEMA) and isophorondiisocyanate (IPDI) is performed by mixing 10%-90% mole percentage (mol/mol) of said 2-Hydroxy-ethyl methacrylate (2-HEMA) and 10%-90% mole percentage (mol/mol) of said isophorondiisocyanate (IPDI).

### Claim 25 (depends on 24)

The method of claim 24, wherein said step of mixing 2-Hydroxy-ethyl methacrylate (2-HEMA) and isophorondiisocyanate (IPDI) is performed by mixing 20%-80% mole percentage (mol/mol) of said 2-Hydroxy-ethyl methacrylate (2-HEMA) and 20%-80% mole percentage (mol/mol) of said isophorondiisocyanate (IPDI).

### Claim 26 (depends on 25)

The method of claim 25, wherein said step of mixing 2-Hydroxy-ethyl methacrylate (2-HEMA) and isophorondiisocyanate (IPDI) is performed by mixing 35%-65% mole percentage (mol/mol) of said 2-Hydroxy-ethyl methacrylate (2-HEMA) and 35%-65% mole percentage (mol/mol) of said isophorondiisocyanate (IPDI).

### Claim 27 (depends on 23)

The method of claim 23, wherein said surfactant is a hydrophilic surfactant.

### Claim 28 (depends on 27)

The method of claim 27, wherein said hydrophilic surfactant is Tween 80, Tween 20, Glycerol, or PEG 600.

### Claim 29 (depends on 23)

The method of claim 23, wherein said step of adding a surfactant into said 2-HEMA-IPDI is performed by mixing 10%-90% mole percentage (mol/mol) of said 2-HEMA-IPDI and 10%-90% mole percentage (mol/mol) of said surfactant.

### Claim 30 (depends on 29)

The method of claim 29, wherein said step of adding a surfactant into said 2-HEMA-IPDI is performed by mixing 20%-80% mole percentage (mol/mol) of said 2-HEMA-IPDI and 20%-80% mole percentage (mol/mol) of said surfactant.

### Claim 31 (depends on 30)

The method of claim 30, wherein said step of adding a surfactant into said 2-HEMA-IPDI is performed by mixing 35%-65% mole percentage (mol/mol) of said 2-HEMA-IPDI and 35%-65% mole percentage (mol/mol) of said surfactant.

### Claim 32 (depends on 22)

The method of claim 22, wherein said step of preparing a modified silicon dioxide comprises:
preparing a silica sol by hydrolysis condensation of a silicon oxide compound; and
adding a coupling agent into said silica sol to continue said hydrolysis condensation for modifying surface of said silica sol to form a silicon dioxide hybrid gel.

### Claim 33 (depends on 22)

The method of claim 22, wherein said step of mixing said modified surfactant and said modified silicon dioxide is performed by mixing 0.01%-99.99% weight percentage (w/w) of said modified silicon dioxide and 0.01%-99.99% weight percentage (w/w) of said modified surfactant.

### Claim 34 (depends on 33)

The method of claim 33, wherein said step of mixing said modified surfactant and said modified silicon dioxide is performed by mixing 0.1%-99.9% weight percentage (w/w) of said modified silicon dioxide and 0.1%-99.9% weight percentage (w/w) of said modified surfactant.

### Claim 35 (depends on 34)

The method of claim 34, wherein said step of mixing said modified surfactant and said modified silicon dioxide is performed by mixing 1%-99% weight percentage (w/w) of said modified silicon dioxide and 1%-99% weight percentage (w/w) of said modified surfactant.

### Claim 36

A hard, water-resistant anti-fog coating, comprising:
an organic-inorganic hybrid hard adhesion layer formed on a plastic material for increasing hardness and adhesion of said hard, water-resistant anti-fog coating to make said hard, water-resistant anti-fog coating to be adhered on said plastic material well;
a hydrophilic anti-fog coating film formed on said organic-inorganic hybrid hard adhesion layer for bringing anti-fog property to said plastic material; and
a cross-linked layer between said organic-inorganic hybrid hard adhesion layer and said hydrophilic anti-fog coating film wherein said cross-linked layer is formed by cross-linking of said organic-inorganic hybrid hard adhesion layer and said hydrophilic anti-fog coating film, and said hydrophilic anti-fog coating film is adhered to said organic-inorganic hybrid hard adhesion layer tightly by said cross-linked layer.

### Claim 37 (depends on 36)

The hard, water-resistant anti-fog coating of claim 36, wherein said organic-inorganic hybrid hard adhesion layer is silicon dioxide hybrid layer.