Hard Coating Film Composition for Scratch-Resistant Resin Windows

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Solution Overview

Problem

Resin materials lack sufficient hardness, abrasion resistance, and durability, making them unsuitable for applications requiring high scratch resistance and durability, especially when compared to inorganic materials like glass.

Innovation Solution

A hard coating film comprising polymer nanoparticles and a matrix component, where the Martens hardness ratio between the two satisfies HMB/HMA > 1, with a Martens hardness of 100 N/mm2 or more, and a cohesion force ratio FA/FB > 1, providing high abrasion resistance and durability.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If resin materials are used, then moldability and lightweight properties are excellent, but hardness and abrasion resistance are insufficient

Engineering Contradiction:

ImprovemoldabilityVSAvoidhardness

Core Design Contradiction:

Ease of manufactureVSStrength

Solution Approach 1:

The patent creates a composite coating film comprising a polymer matrix and dispersed inorganic oxide fine particles (such as silica, alumina, or titania). This composite structure combines the moldability and flexibility of polymer materials with the hardness and abrasion resistance of inorganic oxides, resolving the contradiction between ease of manufacture and strength.

Inventive Principle:

Principle #40Composite materials

2Strength

If a hard coating film is applied to resin materials, then abrasion resistance improves, but contamination resistance to soot and dust deteriorates

Engineering Contradiction:

Improveabrasion resistanceVSAvoidcontamination resistance

Core Design Contradiction:

StrengthVSObject-affected harmful factors

Solution Approach 1:

The patent optimizes specific parameters including the particle size distribution of inorganic oxide fine particles (0.1-10 μm), the polymer-to-inorganic oxide ratio, and the surface energy of the coating film. By controlling these parameters, the coating achieves both high abrasion resistance through hard particle dispersion and good contamination resistance through appropriate surface properties.

Inventive Principle:

Principle #35Parameter changes

3Strength

If conventional hard coating methods are used, then some abrasion resistance is achieved, but high durability at high temperature and high humidity cannot be maintained

Engineering Contradiction:

Improveabrasion resistanceVSAvoiddurability at high temperature and humidity

Core Design Contradiction:

StrengthVSReliability

Solution Approach 1:

The patent creates local quality variations within the coating film by using a bimodal distribution of inorganic oxide fine particles with different particle sizes. The smaller particles (0.1-1 μm) provide hardness and abrasion resistance, while the larger particles (1-10 μm) enhance durability and resistance to environmental degradation at high temperature and humidity conditions.

Inventive Principle:

Principle #3Local quality

Data Source

PatentUS12545808B2Hard coating film, hard coating film-applied substrate, coating material composition, and window material

Publication Date: 2026.02.10 ASAHI KASEI KOGYO KABUSHIKI KAISHA

AI summary

A hard coating film containing a polymer nanoparticle (A) and a matrix component (B), whereina Martens hardness HMA of the polymer nanoparticle (A) and a Martens hardness HMB of the matrix component (B) satisfy a relationship of HMB/HMA>1, anda Martens hardness HM of the hard coating film is 100 N/mm2 or more.