Low-E matchable coated articles having doped seed layer under silver, and corresponding methods

• US 10,301,215 B1
• Filed: 07/16/2018
• Issued: 05/28/2019
• Est. Priority Date: 07/16/2018
• Status: Active Grant

• Current Assignee: Guardian Glass LLC (KOCH Industries Incorporated)
• Original Assignee: Guardian Glass LLC (KOCH Industries Incorporated)
• Inventors: Xu, Yongli, Boyce, Brent, Boussaad, Salah, Lingle, Philip J., Lao, Jingyu, Vernhes, Richard
• Primary Examiner(s): Colgan, Lauren R
• Application Number:
  US16/035,810
• Time in Patent Office: 316 Days
• Field of Search: 428426, 428428, 428432, 428434, 428701, 428702
• CPC Class Codes: C03C 17/36 at least one coating being a metal
• CPC Class Codes: C03C 17/3626 one layer at least containing a nitride, oxynitride, boronitride or carbonitride
• CPC Class Codes: C03C 17/3639 Multilayers containing at least two functional metal layers
• CPC Class Codes: C03C 17/3644 the metal being silver
• CPC Class Codes: C03C 17/3649 made of metals other than silver
• CPC Class Codes: C03C 17/366 Low-emissivity or solar control coatings
• CPC Class Codes: C03C 17/3681 the multilayer coating being used in glazing, e.g. windows or windscreens
• CPC Class Codes: C03C 2217/216 ZnO
• CPC Class Codes: C03C 2217/228 Other specific oxides
• CPC Class Codes: C03C 2217/24 Doped oxides
• CPC Class Codes: C03C 2217/256 Ag
• CPC Class Codes: C03C 2217/281 Nitrides
• CPC Class Codes: C03C 2218/156 by magnetron sputtering

Abstract

A low-E coating has good color stability (a low ΔE* value) upon heat treatment (HT). The provision of an as-deposited crystalline or substantially crystalline layer of or including zinc oxide, doped with at least one dopant (e.g., Sn), immediately under an infrared (IR) reflecting layer of or including silver in a low-E coating has effect of significantly improving the coating'"'"'s thermal stability (i.e., lowering the ΔE* value). One or more such crystalline, or substantially crystalline, layers may be provided under one or more corresponding IR reflecting layers comprising silver.

Claims

1. A coated article including a coating on a glass substrate, wherein the coating comprises:

a first crystalline or substantially crystalline layer comprising zinc oxide doped with from about 1-30% Sn (wt. %), provided on the glass substrate;

a first infrared (IR) reflecting layer comprising silver located on the glass substrate and directly over and contacting the first crystalline or substantially crystalline layer comprising zinc oxide doped with from about 1-30% Sn;

a layer comprising an oxide of silicon and zirconium located under and directly contacting the first crystalline or substantially crystalline layer comprising zinc oxide doped with from about 1-30% Sn, so that no silicon nitride based layer is located directly under and contacting the first crystalline or substantially crystalline layer comprising zinc oxide doped with from about 1-30% Sn; and

wherein the coated article is configured to have, measured monolithically, at least one of;

(i) a transmissive Δ

E* value of no greater than 3.0 due to a reference heat treatment for 8 minutes at a temperature of about 650 degrees C., (ii) a glass side reflective Δ

E* value of no greater than 3.0 due to the reference heat treatment for 8 minutes at a temperature of about 650 degrees C., and (iii) a film side reflective Δ

E* value of no greater than 3.5 due to the reference heat treatment for 8 minutes at a temperature of about 650 degrees C.

2. The coated article of claim 1, wherein the first crystalline or substantially crystalline layer comprising zinc oxide is doped with from about 1-20% Sn (wt. %).

3. The coated article of claim 1, wherein the first crystalline or substantially crystalline layer comprising zinc oxide is doped with from about 5-15% Sn (wt. %).

4. The coated article of claim 1, wherein the first crystalline or substantially crystalline layer comprising zinc oxide is doped with about 10% Sn (wt. %).

5. The coated article of claim 1, wherein the first crystalline or substantially crystalline layer comprising zinc oxide doped with Sn is crystalline or substantially crystalline as sputter-deposited.

6. The coated article of claim 1, wherein the coated article is configured to have, measured monolithically, at least two of:

(i) a transmissive Δ

E* value of no greater than 3.0 due to the reference heat treatment for 8 minutes at a temperature of about 650 degrees C., (ii) a glass side reflective Δ

E* value of no greater than 3.0 due to the reference heat treatment for 8 minutes at a temperature of about 650 degrees C., and (iii) a film side reflective Δ

E* value of no greater than 3.5 due to the reference heat treatment for 8 minutes at a temperature of about 650 degrees C.

7. The coated article of claim 1, wherein the coated article is configured to have, measured monolithically, all of:

(i) a transmissive Δ

E* value of no greater than 3.0 due to the reference heat treatment for 8 minutes at a temperature of about 650 degrees C., (ii) a glass side reflective Δ

E* value of no greater than 3.0 due to the reference heat treatment for 8 minutes at a temperature of about 650 degrees C., and (iii) a film side reflective Δ

E* value of no greater than 3.5 due to the reference heat treatment for 8 minutes at a temperature of about 650 degrees C.

8. The coated article of claim 1, wherein the coated article is configured to have, measured monolithically, at least two of:

(i) a transmissive Δ

E* value of no greater than 2.5 due to a reference heat treatment for 12 minutes at a temperature of about 650 degrees C., (ii) a glass side reflective Δ

E* value of no greater than 2.0 due to the reference heat treatment for 12 minutes at a temperature of about 650 degrees C., and (iii) a film side reflective Δ

E* value of no greater than 3.0 due to the reference heat treatment for 12 minutes at a temperature of about 650 degrees C.

9. The coated article of claim 1, wherein the coated article is configured to have, measured monolithically, all of:

(i) a transmissive Δ

E* value of no greater than 2.5 due to a reference heat treatment for 12 minutes at a temperature of about 650 degrees C., (ii) a glass side reflective Δ

E* value of no greater than 2.0 due to the reference heat treatment for 12 minutes at a temperature of about 650 degrees C., and (iii) a film side reflective Δ

E* value of no greater than 3.0 due to the reference heat treatment for 12 minutes at a temperature of about 650 degrees C.

10. The coated article of claim 1, wherein the coated article is configured to have, measured monolithically, at least one of:

(i) a transmissive Δ

E* value of no greater than 2.3 due to a reference heat treatment for 16 minutes at a temperature of about 650 degrees C., (ii) a glass side reflective Δ

E* value of no greater than 1.0 due to the reference heat treatment for 16 minutes at a temperature of about 650 degrees C., and (iii) a film side reflective Δ

E* value of no greater than 2.0 due to the reference heat treatment for 16 minutes at a temperature of about 650 degrees C.

11. The coated article of claim 1, wherein said coating has a sheet resistance (R_s) of no greater than 20 ohms/square.

12. The coated article of claim 1, wherein said coating has a sheet resistance (R_s) of no greater than 10 ohms/square.

13. The coated article of claim 1, wherein said coating has a sheet resistance (R_s) of no greater than 2.2 ohms/square.

14. The coated article of claim 1, wherein said coated article, measured monolithically, has a visible transmission of at least 50%.

15. The coated article of claim 1, wherein said coated article, measured monolithically, has a visible transmission of at least 68%.

16. The coated article of claim 1, wherein the layer comprising an oxide of silicon and zirconium is located between and directly contacting the first crystalline or substantially crystalline layer comprising zinc oxide doped with Sn and the glass substrate.

17. The coated article of claim 1, wherein the coating as deposited further comprises a first amorphous or substantially amorphous layer comprising zinc stannate located on the glass substrate over at least the first IR reflecting layer comprising silver.

18. The coated article of claim 17, wherein the first amorphous or substantially amorphous layer comprising zinc stannate has a metal content of from about 40-60% Zn and from about 40-60% Sn (wt. %).

19. The coated article of claim 1, wherein the coating further comprises a contact layer located over and directly contacting the first IR reflecting layer comprising silver.

20. The coated article of claim 19, wherein the contact layer comprises Ni and Cr.

21. The coated article of claim 1, wherein the coating further comprises:

a second IR reflecting layer comprising silver located on the glass substrate over at least the first IR reflecting layer comprising silver,

a second crystalline or substantially crystalline layer comprising zinc oxide doped with from about 1-30% Sn (wt. %), located under and directly contacting the second IR reflecting layer comprising silver; and

wherein no silicon nitride based layer is located between the glass substrate and the second IR reflecting layer comprising silver.

22. The coated article of claim 21, wherein the coating further comprises an amorphous or substantially amorphous layer, as deposited, comprising zinc stannate located on the glass substrate over at least the second IR reflecting layer comprising silver.

23. The coated article of claim 22, wherein the amorphous or substantially amorphous layer comprising zinc stannate, which is amorphous or substantially amorphous as deposited, has a metal content of from about 40-60% Zn and from about 40-60% Sn (wt. %).

24. The coated article of claim 22, wherein the coating further comprises a layer comprising silicon nitride located over at least the amorphous or substantially amorphous layer comprising zinc stannate.

25. The coated article of claim 22, wherein the coating further comprises a contact layer comprising Ni and/or Cr located over and directly contacting the second IR reflecting layer comprising silver.

26. The coated article of claim 1, wherein the glass substrate is thermally tempered.

27. The coated article of claim 1, wherein the coated article is configured to have, measured monolithically, each of:

(i) a transmissive Δ

E* value of no greater than 3.5 due to a reference heat treatment for 16 minutes at a temperature of about 650 degrees C., and (ii) a glass side reflective Δ

E* value of no greater than 1.8 due to the reference heat treatment for 16 minutes at a temperature of about 650 degrees C.

28. The coated article of claim 1, wherein the layer comprising an oxide of silicon and zirconium further comprises nitrogen.

29. The coated article of claim 1, wherein the coated article further comprises a metallic or substantially metallic absorber layer located between the glass substrate and the layer comprising an oxide of silicon and zirconium.

30. The coated article of claim 29, wherein the absorber layer is sandwiched between and contacting first and second layers comprising silicon nitride.

31. The coated article of claim 30, wherein the absorber layer comprises Ni and Cr.

32. The coated article of claim 1, wherein the coating further comprises:

a second IR reflecting layer comprising silver located on the glass substrate over at least the first IR reflecting layer comprising silver;

a second layer comprising zinc oxide doped with from about 1-30% Sn (wt. %), located under and directly contacting the second IR reflecting layer comprising silver; and

a layer comprising zinc stannate located between the first IR reflecting layer and the second layer comprising zinc oxide doped with from about 1-30% Sn.

33. The coated article of claim 32, wherein the coated article further comprises a layer comprising zirconium oxide, and/or another layer comprising an oxide of silicon and zirconium, located between the layer comprising zinc stannate and the second layer comprising zinc oxide doped with from about 1-30% Sn.

34. The coated article of claim 1, wherein the coated article is configured to have, measured monolithically, at least one of:

(i) a transmissive Δ

E* value of no greater than 3.0 due to a reference heat treatment for 8 minutes at a temperature of about 650 degrees C. on a reference glass substrate about 3 mm thick, (ii) a glass side reflective Δ

E* value of no greater than 3.0 due to the reference heat treatment for 8 minutes at a temperature of about 650 degrees C. on a reference glass substrate about 3 mm thick, and (iii) a film side reflective Δ

E* value of no greater than 3.5 due to the reference heat treatment for 8 minutes at a temperature of about 650 degrees C. on a reference glass substrate about 3 mm thick.

35. A coated article including a coating on a glass substrate, wherein the coating comprises:

a crystalline or substantially crystalline layer comprising zinc oxide doped with from about 1-30% Sn (wt. %), provided on the glass substrate;

an infrared (IR) reflecting layer comprising silver located on the glass substrate and directly over and contacting the layer comprising zinc oxide doped with from about 1-30% Sn;

at least one dielectric layer on the glass substrate over at least the IR reflecting layer comprising silver and the crystalline or substantially crystalline layer comprising zinc oxide doped with from about 1-30% Sn; and

a layer comprising an oxide of silicon and zirconium located under and directly contacting the crystalline or substantially crystalline layer comprising zinc oxide doped with from about 1-30% Sn, so that no silicon nitride based layer is located directly under and contacting the layer comprising zinc oxide doped with from about 1-30% Sn; and

wherein the coated article is configured to have, measured monolithically, at least one of;

(i) a transmissive Δ

E* value of no greater than 3.0 due to a reference heat treatment for 8 minutes at a temperature of about 650 degrees C., (ii) a glass side reflective Δ

E* value of no greater than 3.0 due to the reference heat treatment for 8 minutes at a temperature of about 650 degrees C., and (iii) a film side reflective Δ

E* value of no greater than 3.5 due to the reference heat treatment for 8 minutes at a temperature of about 650 degrees C.

36. The coated article of claim 35, wherein the layer comprising zinc oxide is doped with from about 5-15% Sn (wt. %).

37. The coated article of claim 35, wherein the layer comprising zinc oxide is doped with about 10% Sn (wt. %).

38. The coated article of claim 35, wherein the layer comprising an oxide of silicon and zirconium is in direct contact with the glass substrate.

39. The coated article of claim 35, wherein the layer comprising an oxide of silicon and zirconium has a physical thickness of from about 40-400 Å

.

40. The coated article of claim 35, wherein the layer comprising an oxide of silicon and zirconium has a physical thickness of from about 50-300 Å

.

41. The coated article of claim 35, wherein the layer comprising an oxide of silicon and zirconium comprises from 0-10% nitrogen (atomic %).

42. The coated article of claim 35 wherein the layer comprising an oxide of silicon and zirconium comprises from 0-5% nitrogen (atomic %).

43. A coated article including a coating on a glass substrate, wherein the coating comprises:

a crystalline or substantially crystalline layer comprising zinc oxide doped with at least from 1-30% Sn (wt. %) provided on the glass substrate;

a first infrared (IR) reflecting layer comprising silver located on the glass substrate and directly over and contacting the layer comprising zinc oxide doped with at least from 1-30% Sn (wt. %);

at least one dielectric layer on the glass substrate over at least the first IR reflecting layer comprising silver and the layer comprising zinc oxide doped with at least from 1-30% Sn (wt. %);

wherein no silicon nitride based layer is located directly under and contacting the layer comprising zinc oxide doped with at least from 1-30% Sn (wt. %);

a second IR reflecting layer comprising silver located on the glass substrate over at least the first IR reflecting layer and the at least one dielectric layer;

a dielectric layer comprising an oxide of silicon and zirconium located on the glass substrate between at least the glass substrate and the layer comprising zinc oxide doped with at least from 1-30% Sn (wt. %), wherein the dielectric layer comprising an oxide of silicon and zirconium directly contacts the layer comprising zinc oxide doped with at least from 1-30% Sn; and

wherein the coated article is configured to have, measured monolithically, at least one of;

(i) a transmissive Δ

E* value of no greater than 3.0 due to a reference heat treatment for 8 minutes at a temperature of about 650 degrees C., (ii) a glass side reflective Δ

E* value of no greater than 3.0 due to the reference heat treatment for 8 minutes at a temperature of about 650 degrees C., and (iii) a film side reflective Δ

E* value of no greater than 3.5 due to the reference heat treatment for 8 minutes at a temperature of about 650 degrees C.

44. The coated article of claim 43, wherein the layer comprising zinc oxide is doped with about 1-20% Sn (wt. %).

45. The coated article of claim 43, wherein the dielectric layer comprising an oxide of silicon and zirconium is in direct contact with the glass substrate.

46. The coated article of claim 45, wherein the dielectric layer comprising an oxide of silicon and zirconium has a physical thickness of from about 40-400 Å

.

47. The coated article of claim 43, wherein the dielectric layer comprising an oxide of silicon and zirconium comprises from 0-10% nitrogen (atomic %).

48. The coated article of claim 43, wherein the coating further comprises:

another layer comprising zinc oxide doped with at least one metal, located under and directly contacting the second IR reflecting layer comprising silver; and

a layer comprising zinc stannate located between the first IR reflecting layer and the another layer comprising zinc oxide doped with at least one metal.