Workable and curable epoxy-terminated silane films

A method of forming a shaped abrasion resistant coated article which comprises applying heat and pressure to a partially cured film bonded to a moldable thermoplastic resin said partially cured film comprising at least 15% by weight of material derived from epoxy-terminated silanes represented by the formulae:

• ##STR9## wherein, each R is independently a non-hydrolyzable divalent hydrocarbon radial of less than 20 carbon atoms, or a divalent radical of less than 20 carbon atoms the backbone of which is C atoms which may be interrupted by individual atoms from the group of N and O, the O atoms in the form of ether linkages,
• m is 1, 2, or 3,
• n 0, or 1, and
• R' is an aliphatic hydrocarbon radical of less than 10 carbon atoms, an acyl radical of less than 10 carbon atoms, or a radical of the formula (CH.sub.2 CH.sub.2 O).sub.k Z in which k is an integer of at least 1, and Z is hydrogen or an aliphatic hydrocarbon radical of less than 10 carbon atoms,
• said film cured to a degree such that visually observable dichloromethane attack occurs in not less than 15 seconds and no more than seven-and-one-half minutes when
• 1. a 4.25 cm diameter circle of filter paper is placed on the film,
• 2. the paper is wetted thoroughly with dichloromethane,
• 3. a clear plastic cover is placed over the wetted paper, and
• 4. the time for visually observable attack on the coating is measured,
• said partially cured film further characterized by having a latent catalyst within the film in sufficient amount so that when delatentized the film will cure to a degree so that the partially cured film will not be attacked by dichloromethane under the above conditions within 10 minutes and further using means to delatentize said latent catalyst.

A method of forming a shaped abrasion resistant coated article which comprises applying heat and pressure to a partially cured film bonded to a moldable thermoplastic resin said partially cured film comprising at least 15% by weight of material derived from epoxy-terminated silanes represented by the formulae:

• ##STR10## wherein, each R is independently a non-hydrolyzable divalent hydrocarbon radial of less than 20 carbon atoms, or a divalent radical of less than 20 carbon atoms the backbone of which is C atoms which may be interrupted by individual atoms from the group of N and O, the O atoms in the form of ether linkagres,
• m is 1, 2, or 3,
• n is 0, or 1, and
• R' is an aliphatic hydrocarbon radical of less than 10 carbon atoms, an acyl radical of less than 10 carbon atoms, or a radical of the formula (CH.sub.2 CH.sub.2 O).sub.k Z in which k is an integer of at least 1, and Z is hydrogen or an aliphatic hydrocarbon radical of less than 10 carbon atoms, said film cured to a degree such that visually observable dichloromethane attack occurs is not less than 15 seconds and no more than seven-and-one-half minutes when
• 1. a 4.25 cm diameter circle of filter paper is placed on the film,
• 2. the paper is wetted thoroughly with dichloromethane,
• 3. a clear plastic cover is placed over the wetted paper, and
• 4. the time for visually observable attack on the coating is measured,
• said partially cured film further characterized by having a thermoplastic polymer layer directly bonded thereto, said polymer containing sufficient catalyst therein so that upon heating to a temperature sufficient to allow migration of the catalyst to the partially cured film layer, the partially cured layer will be cured to a degree sufficient so that the then cured film will not be attacked by dichloromethane under the above conditions within 10 minutes, said heat and pressure being sufficient to allow the catalyst to migrate to said partially cured layer and cure said epoxy-terminated silane layer to a degree such that it will withstand dichloromethane attack for more than 10 minutes.