Fluorinated zirconia-based sol-gel hybrid coatings on polycarbonate with high durability and improved scratch resistance

Hard, scratch-resistant and transparent fluoropolymer-based hybrid coatings are successfully prepared through the sol-gel chemistry and investigated, in the attempt to correlate the chemical, physical and surface properties of these materials with the mechanical properties (i.e. hardness and elastic modulus) measured at the nanoscale by atomic force microscopy (AFM). The organic component of these coatings consists in a hydroxyl-functional fluoropolymer resin, which belongs to the class of chlorotrifluoroethylene-vinylether copolymers and exhibits remarkable properties such as easy handling, great weather resistance, good adhesion and flexibility of coatings. A functionalization of this copolymer is also performed using an isocyanate-functionalized silane in order to assure a covalent cross-linking of organic fluorinated resin with inorganic phases. The combination of the silanized chlorotrifluoroethylene-vinylether copolymer with different sols composed of silica and zirconia is used to obtain high scratch resistance and high durability coatings on polycarbonate. A series of three hybrid coatings with different zirconia/silica molar ratios (0.09/0.48) are developed and analyzed by differential scanning calorimetry (DSC), water contact angle measurements, pencil hardness and adhesion tests. AFM scratch hardness, coating wettability and surface composition measured by Fourier transform infrared spectroscopy (FTIR) are regularly monitored over long-term UV–vis light exposure, to assess the durability of the hybrid coatings. Interestingly, the hybrid fluorinated coatings exhibit an improved scratch resistance and a superior long-term stability when exposed to an accelerated weathering, compared to pristine PC substrates. The mixed silica/zirconia hybrid coatings with a low and intermediate zirconia-to-silica ratio also show excellent mechanical strength, high level of hardness and superior integrity after long-term light exposure.