UV Curable Hard Transparent Hybrid Coating Materials on Polycarbonate Prepared by the Sol-Gel Method

Abstract

UV curable, hard, transparent inorganic/organic composites with covalent links between the inorganic and the organic networks were prepared by the sol-gel method. These hybrid coating materials were synthesized using a commercially available, acrylate end-capped polyester or polyurethane oligomeric resin (EBC80, EBC284), hexanedioldiacrylate (HDDA) as a reactive solvent, 3-(trimethoxysilyl)propoxymethacrylate (TMSPM) as a coupling agent between the organic and inorganic phase, and a metal alkoxide, tetraethylorthosilicate (TEOS). The materials were applied on primer or oxygen plasma pretreated polycarbonate sheets and UV cured, followed by a thermal treatment to give a transparent coating with a good adhesion and abrasion resistance. The high transmission and the thermogravimetric behavior indicate the presence of a nanoscale hybrid composite, as is confirmed by SAXS and TEM measurements. In a Taber Abrasion Test, uncoated polycarbonate sheets exhibit a 48% decrease in light transmittance at 600 nm after 300 wear cycles, whereas the EBC80 hybrid coating system containing 9 wt% SiO2 (EBC80/25Si) shows only 28% decrease in light transmittance. A maximal improvement of the abrasion resistance is achieved when 23 wt% SiO2 is incorporated (EBC80/60Si, EBC284/60Si) with only 20% decrease in light transmittance. The abrasion resistance of glass is not yet encountered. For optimal results, it is essential that the rate of condensation of the silanol groups is sufficiently high to form a dense three-dimensional network.