Preparation and evaluation of high-transparent scratch-resistant thin films on plasma treated polycarbonate substrate

New simple aqueous sol–gel procedure has been used for producing hard transparent organic–inorganic coatings on polycarbonate (PC). Sol-gel thins films were prepared by mixing Si and Al aqueous alkoxides and applied on the plasma treated PC. Tetraethyl orthosilicate (TEOS), 3-glycidoxypropyltrimethoxysilane (GPTMS) and aluminum tri sec-butoxide were used as main precursors. Before applying coatings PC were treated by Dielectric Barrier Discharge (DBD) system being conducted at atmosphere pressure. The effects of temperature, sols volume ratios and aging time on the coatings properties were scrutinized. Chemical, structural, morphological, optical and mechanical analyses of the samples were done by ATR-FTIR, EDS, XRD, FE-SEM, TEM, UV/vis spectroscopy, ellipsometry, pencil hardness and eraser scratch methods. TEM results showed well-dispersed nano-particles in the liquid sol. All of the films showed higher average transmittance (89 %) than the raw PC (86 %) that was stemmed from the lower refractive index (1.481) than raw PC (1.58). Films indicated good adhesion onto the plasma treated substrates (5B). The pencil hardness of the PC substrate (4B) improved to 3H (8 pencil grade increment) with just a single layer coating (775 nm thickness) due to the preparation of new hard structures of interlocked Si and Al atoms