Method of making coated articles and coated articles made thereby

• US 20020172775A1
• Filed: 04/25/2002
• Published: 11/21/2002
• Est. Priority Date: 10/24/2000
• Status: Abandoned Application

• Current Assignee: Vitro Flat Glass LLC (Compagnie De Saint-Gobain)
• Original Assignee: Vitro Flat Glass LLC (Compagnie De Saint-Gobain)
• Inventors: Thiel, James P., Finley, James J., Buhay, Harry, Lehan, John P.
• Application Number:
  US10/133,805
• Publication Number:
  US 20020172775A1
• Time in Patent Office: Days
• US Class Current: 427/376.2
• CPC Class Codes: B32B 17/10036 comprising two outer glass sheets
• CPC Class Codes: B32B 17/10174 Coatings of a metallic or dielectric material on a constituent layer of glass or polymer
• CPC Class Codes: B32B 17/10761 containing vinyl acetal
• CPC Class Codes: C03C 17/3417 all coatings being oxide coatings
• CPC Class Codes: C03C 17/36 at least one coating being a metal
• CPC Class Codes: C03C 17/3618 Coatings of type glass/inorganic compound/other inorganic layers, at least one layer being metallic
• 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 17/3652 the coating stack containing at least one sacrificial layer to protect the metal from oxidation
• 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 17/38 at least one coating being a coating of an organic material
• CPC Class Codes: C03C 17/42 at least one coating of an organic material and at least one non-metal coating
• CPC Class Codes: C23C 14/08 Oxides C23C14/10 takes precedence
• CPC Class Codes: C23C 14/3414 Metallurgical or chemical aspects of target preparation, e.g. casting, powder metallurgy
• CPC Class Codes: C23C 14/5806 Thermal treatment
• CPC Class Codes: G02B 5/0808 having a single reflecting layer G02B5/0883, G02B5/0891 take precedence
• CPC Class Codes: G02B 5/0858 the reflecting layers comprising a single metallic layer with one or more dielectric layers
• CPC Class Codes: G02B 5/0866 incorporating one or more organic, e.g. polymeric layers
• CPC Class Codes: G02B 5/0875 the reflecting layers comprising two or more metallic layers

Abstract

A method of making a coated substrate includes providing a substrate having at least one functional coating with a first emissivity value; depositing at least one coating material having a second emissivity value over at least a portion of the at least one functional coating wherein the deposited coating has a thickness ranging from greater than 100 Å to less than 10 microns and a refractive index ranging from 1.4 to 2. The resulting coating stack has an emissivity value greater than the emissivity value of the functional coating. Optionally the coated substrate is heated whereby the coated substrate can be bent to a desired shape and/or tempered.

Claims

1. A method of making a coated substrate, comprising:

providing a substrate having at least one functional coating with a first emissivity value; and

depositing at least one coating material having a second emissivity value over at least a portion of the functional coating to provide a coating stack having an emissivity value greater than the emissivity value of the functional coating, wherein the thickness of the deposited coating material has a thickness of greater than 100 Angstroms and less than 10 microns and has a refractive index in the range of 1.4 to about 2.

2. The method of claim 1, including heating the coated substrate.

3. The method of claim 1, including heating the coated substrate to a temperature selected from that sufficient for bending the coated substrate to a desired shape and/or that sufficient for tempering the coated substrate.

4. The method of claim 1, wherein the coating material comprises 35 wt. % to 100 wt. % alumina and 0 wt. % to 65 wt. % silica.

5. The method of claim 1, wherein the coating material comprises 60 wt. % to 75 wt. % alumina and 25 wt. % to 40 wt. % silica.

6. The method of claim 1, wherein the coating material comprises 75 wt. % to 85 wt. % alumina and 15 wt. % to 25 wt. % silica.

7. The method of claim 1, wherein the coating material comprises 86 wt. % to 90 wt. % alumina and 10 wt. % to 14 wt. % silica.

8. The method of claim 1, including depositing the coating material to a thickness in the range of greater than 100 Å

to 1.5 microns.

9. The method of claim 1, wherein the coating material has an index of refraction substantially the same as the index of refraction of the substrate.

10. The method of claim 1, wherein the substrate is glass, wherein the coating material comprises 35 wt. % to 100 wt. % alumina and 0 wt. % to 65 wt. % silica.

11. A method of making a laminated article, comprising the steps of:

providing a first substrate having a major surface;

applying a functional coating having an emissivity value over at least a portion of the first substrate major surface;

applying a protective coating over at least a portion of the functional coating to form a coating stack having an emissivity value greater than the emissivity value of the functional coating;

providing a second substrate;

heating the first and second substrates to desired shapes; and

laminating the first and second substrates together with an interlayer, with the protective coating facing the interlayer.

12. The method of claim 11, wherein the coating material comprises 35 wt. % to 100 wt. % alumina and 0 wt. % to 65 wt. % silica.

13. The method of claim 11, wherein the coating material comprises 60 wt. % to 75 wt. % alumina and 25 wt. % to 40 wt. % silica.

14. The method of claim 11, wherein the coating material comprises 75 wt. % to 85 wt. % alumina and 15 wt. % to 25 wt. % silica.

15. The method of claim 11, wherein the coating material comprises 86 wt. % to 90 wt. % alumina and 10 wt. % to 14 wt. % silica.

16. The method of claim 11, including depositing the coating material to a thickness in the range of greater than 100 Å

to 1.5 microns.

17. The method of claim 11, wherein the protective coating has a refractive index of less than 2.

18. The method of claim 11, wherein the protective coating has a refractive index about the same as the refractive index of the interlayer.

19. A method of making a coated article, comprising the steps of:

providing a coating having a predetermined solar infrared reflectance and a predetermined thermal emissivity; and

altering the coating such that the thermal emissivity increases but the solar infrared reflectance remains substantially the same.

20. A laminated article, comprising:

a first ply having a first major surface;

a functional coating deposited over at least a portion of the first major surface and having an emissivity value;

a protective coating deposited over at least a portion of the functional coating to form a coating stack having an emissivity, the protective coating configured to increase the emissivity of the coating stack over the emissivity of the functional coating alone;

a second ply; and

an interlayer located between the first and second plies, with the protective coating facing the interlayer.

21. The article of claim 20, wherein the first and second plies are selected from glass, plastic, and ceramic material.

22. The article of claim 20, wherein the protective coating has a refractive index in the range of about 1.4 to about 1.8

23. The article of claim 20, wherein the protective coating increases the emissivity of the coating stack to be in the range of 0.3 to 0.9.

25. The article as claimed in claim 24, wherein the substrate is selected from glass, plastic, and ceramic.

26. The article as claimed in claim 24, wherein the article is an motor vehicle automotive transparency.

27. The article as claimed in claim 24 wherein the article is selected from the group of window, single pane of glass, window with multiple panes of glass, air craft transparency, and motor vehicle transparency.

28. The article as claimed in claim 24, wherein the substrate has a thickness of 0.2 mm to 20 mm.

29. The article of in claim 24, wherein the functional coating has an emissivity of 0.1 or less.

30. The article of claim 24, wherein the protective coating increases the emissivity of the coating stack by at least a factor of two with respect to the emissivity of the functional coating.

31. The article of claim 24, wherein the protective coating increases the emissivity of the coating stack by a factor in the range of 2 to 20 compared to the emissivity of the functional coating.

32. The article as claimed in claim 24, wherein the functional coating has an emissivity of 0.1 or less and the coating stack has an emissivity of 0.5 or more.

33. The article as claimed in claim 24, wherein the emissivity of the coating stack is 0.5 to 0.8.

34. The article as claimed in claim 24, wherein the protective coating has a thickness of greater than 1 micron.

35. The article as claimed in claim 24, wherein the protective coating has a thickness of less than 5 microns.

36. The article as claimed in claim 24, wherein the protective coating comprises at least 35 weight percent alumina.

37. The articles claimed in claim 24, wherein the coating material comprises 60 wt. % to 75 wt. % alumina and 25 wt. % to 40 wt. % silica.

38. The article as claimed in claim 24, wherein the protective coating comprises 75 wt. % to 85 wt. % alumina and 15 wt. % to 25 wt. % silica.

39. The article as claimed in claim 24, wherein the protective coating comprises 86 wt. % to 90 wt. % alumina and 10 wt. % to 14 wt. % silica.

40. The article as claimed in claim 24, wherein the protective coating is solar absorbing in at least one of the UV, IR, or visible regions of the electromagnetic spectrum.

24. An article, comprising:

a substrate;

a functional coating deposited over at least a portion of the substrate; and

a protective coating deposited over the functional coating, wherein the functional coating and the protective coating define a coating stack and the protective coating provides the coating stack with an emissivity higher than the emissivity of the functional coating alone wherein the thickness of the protective coating has a thickness of greater than 100 Angstroms and less than 10 microns and has a refractive index in the range of about 1.4 to about 1.8.

41. A monolithic transparency, comprising:

a glass substrate;

a functional coating deposited over at least a portion of the glass substrate; and

a protective coating deposited over the functional coating to form a coating stack, the protective coating comprising aluminum oxide having a thickness in the range of 1 micron to 10 microns and providing the coating stack.

42. The transparency as claimed in claim 41, wherein having an emissivity of at least 0.5

43. The transparency of claim 41, wherein the protective coating increases the emissivity of the coating stack to be in the range of 0.1 0.3 to 0.9.

44. The transparency of claim 41, wherein the protective coating increases the emissivity of the coating stack to be in the range of 0.3 to 0.9.

45. The transparency of claim 41, wherein the protective coating increases the emissivity of the coating stack to greater than or equal to 0.5.

46. The transparency of claim 41, including adding a sufficient protective coating such that the emissivity of the coating stack is within 0.2 of the emissivity of the first substrate.

47. The transparency as claimed in claim 41, wherein the protective coating comprises 70 wt. % to 90 wt. % alumina and 10 wt. % to 30 wt. % silica.

48. The transparency of claim 41, wherein the coating material comprises 35 wt. % to 100 wt. % alumina and 0 wt. % to 65 wt. % silica.

50. The transparency of claim 41, wherein the coating material comprises 60 wt. % to 75 wt. % alumina and 25 wt. % to 40 wt. % silica.

51. The transparency of claim 41, wherein the coating material comprises 75 wt. % to 85 wt. % alumina and 15 wt. % to 25 wt. % silica.

52. The transparency of claim 41, wherein the coating material comprises 86 wt. % to 90 wt. % alumina and 10 wt. % to 14 wt. % silica.

53. The transparency of claim 41, including depositing the coating material to a thickness in the range of greater than 100 Å

to 1.5 microns.

54. A method of making a coated substrate, comprising:

providing a substrate having at least one solar infrared reflective dielectric coating ; and

depositing a coating material so that the deposited coating material has a thickness of greater than 100 Angstroms and less than 10 microns and has a refractive index in the range of about 1.4 to about 1.8.

55. The method of claim 54, including heating the coated substrate.

56. The method of claim 54, including heating the coated substrate to a temperature selected from the group comprising that which is sufficient for bending the coated substrate to a desired shape and/or that which is sufficient to temper the coated substate.

57. The method of claim 54, wherein the coating material comprises 35 wt. % to 100 wt. % alumina and 0 wt. % to 65 wt. % silica.

58. The method of claim 54, wherein the coating material comprises 60 wt. % to 75 wt. % alumina and 25 wt. % to 40 wt. % silica.

59. The method of claim 54, wherein the coating material comprises 75 wt. % to 85 wt. % alumina and 15 wt. % to 25 wt. % silica.

60. The method of claim 54, wherein the coating material comprises 86 wt. % to 90 wt. % alumina and 10 wt. % to 14 wt. % silica.

61. The method of claim 54, wherein the substrate is glass.

62. An article, comprising:

a substrate;

at least one solar infrared reflective dielectric functional coating deposited over at least a portion of the substrate; and

a protective coating deposited over the functional coating, wherein the protective coating has a thickness of greater than 100 Angstroms and less than 10 microns and has a refractive index in the range of 1.4 to about 2.

63. The article of claim 62, wherein the coating material comprises 35 wt. % to 100 wt. % alumina and 0 wt. % to 65 wt. % silica.

64. The article of claim 62, wherein the coating material comprises 60 wt. % to 75 wt. % alumina and 25 wt. % to 40 wt. % silica.

65. The article of claim 62, wherein the coating material comprises 75 wt. % to 85 wt. % alumina and 15 wt. % to 25 wt. % silica.

66. The article of claim 62, wherein the coating material comprises 86 wt. % to 90 wt. % alumina and 10 wt. % to 14 wt. % silica.

67. The article of claim 62, wherein the substrate is glass.