Methods of changing the visible light transmittance of coated articles and coated articles made thereby

• US 20030228476A1
• Filed: 04/24/2003
• Published: 12/11/2003
• Est. Priority Date: 10/22/2001
• 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:
  US10/422,096
• Publication Number:
  US 20030228476A1
• Time in Patent Office: Days
• US Class Current: 428/469
• 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: C03C 2217/78 Coatings specially designed to be durable, e.g. scratch-resistant
• 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 1/111 using layers comprising organic materials
• CPC Class Codes: G02B 5/0808 having a single reflecting layer G02B5/0883, G02B5/0891 take precedence
• CPC Class Codes: G02B 5/0875 the reflecting layers comprising two or more metallic layers
• CPC Class Codes: G02B 5/208 : for use with infrared or ultraviolet radiation, e.g. for separating visible light from infrared and/or ultraviolet radiation
• CPC Class Codes: Y10T 428/265 : 1 mil or less
• CPC Class Codes: Y10T 428/266 : of base or substrate

Abstract

A method is provided for changing the visible light transmittance of a coated article having a functional coating having at least one anti-reflective material and at least one infrared reflective material. The anti-reflective material includes an alloying material capable of combining or alloying with the infrared reflective material. A protective coating is deposited over the functional coating to prevent or retard the diffusion of atmospheric gas and/or vapor into the functional coating. The coated article is heated to a temperature sufficient to cause at least some of the alloying material to combine with at least some of the infrared reflective material to form a substance having a different visible light transmittance than the infrared reflective material.

Claims

1. A method of changing the visible light transmittance of a coated article, comprising:

providing a substrate having a functional coating, the functional coating comprising at least one anti-reflective material and at least one infrared reflective material, wherein the anti-reflective material includes an alloying material capable of combining with the infrared reflective material;

depositing a protective coating over the functional coating, the protective coating preventing or retarding the diffusion of atmospheric gas and/or vapor into the functional coating; and

heating the coated article to a temperature sufficient to cause at least some of the alloying material to combine with at least some of the infrared reflective material to form a combination having a different visible light transmittance than the infrared reflective material.

2. The method of claim 1, wherein the anti-reflective material includes at least one of tin, antimony, bismuth, indium, or combinations thereof.

3. The method of claim 1, wherein the alloying material is selected from tin, antimony, bismuth, indium, or combinations thereof.

4. The method of claim 1, wherein the infrared reflective material includes at least one of gold, copper, silver, or mixtures or combinations thereof.

5. The method of claim 1, wherein the protective coating includes at least one metal oxide selected from aluminum oxide, silicon oxide, and mixtures thereof.

6. The method of claim 1, including forming the protective coating to a thickness in the range of greater than 100 Å

to less than 10 microns.

7. The method of claim 1, wherein the protective coating has a refractive index in the range of 1.4 to 1.8.

8. The method of claim 1, including forming the protective coating to a thickness of greater than or equal to 1 micron.

9. The method of claim 1, including forming the protective coating to a thickness of less than or equal to 5 microns.

10. The method of claim 1, wherein the protective coating comprises 0 wt. % to 100 wt. % alumina and 100 wt. % to 0 wt. % silica.

11. The method of claim 1, wherein the protective coating comprises at least 35 wt. % alumina.

13. The method of claim 1, wherein the protective coating comprises 15 wt. % to 70 wt. % alumina and 85 wt. % to 30 wt. % silica.

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

15. The method of claim 1, wherein the protective coating comprises a first layer formed over the functional coating and a second layer formed over the first layer, wherein the first layer comprises 50 wt. % to 100 wt. % alumina and 50 wt. % to 0 wt. % silica, and the second layer comprises 50 wt. % to 100 wt. % silica and 50 wt. % to 0 wt. % alumina.

16. The method of claim 15, wherein the first layer comprises 70 wt. % to 100 wt. % alumina and 30 wt. % to 0 wt. % silica.

17. The method of claim 16, wherein the first layer has a thickness in the range of 50 Å

to 1 micron.

18. The method of claim 16, wherein the first layer has a thickness in the range of 100 Å

to 250 Å

.

19. The method of claim 15, wherein the second layer comprises 70 wt. % to 100 wt. % silica and 30 wt. % to 0 wt. % alumina.

20. The method of claim 19, wherein the second layer has a thickness in the range of 50 Å

to 2,000 Å

.

21. The method of claim 19, wherein the second layer has a thickness in the range of 300 Å

to 500 Å

.

22. The method of claim 1, wherein the protective coating provides an oxygen permeability of less than or equal to 1.5 cubic cm of oxygen gas at a thickness of one mil for 100 square inches over a period of twenty-four hours under an oxygen partial pressure differential of one atmosphere at 23°

C. and a relative humidity of zero.

23. The method of claim 1, further including depositing an alloy prevention layer adjacent the infrared reflective layer, the alloy prevention layer configured to prevent or reduce combination of the infrared reflective material with the alloying material.

24. The method of claim 23, wherein the alloy prevention layer is at least partially crystalline.

25. The method of claim 24, wherein the alloy prevention layer includes at least one of zinc oxide, titania, and zirconia.

12. The method of claim, wherein the protective coating comprises 50 wt. % to 75 wt. % alumina and 25 wt. % to 50 wt. % silica.

26. A method of making a coated article, comprising:

providing a substrate having a functional coating, the functional coating comprising at least one anti-reflective layer and at least one infrared reflective layer, wherein the anti-reflective layer includes an alloying material capable of combining with the material of the infrared reflective layer;

depositing an alloy prevention layer adjacent the infrared reflective layer, the alloy prevention layer configured to prevent or reduce combination of the infrared reflective material with the alloying material;

depositing a protective coating over the functional coating; and

heating the article.

27. The method of claim 26, wherein the anti-reflective material includes at least one of tin, antimony, bismuth, indium, or combinations thereof.

28. The method of claim 26, wherein the alloying material is selected from tin, antimony, bismuth, indium, or combinations thereof.

29. The method of claim 26, wherein the infrared reflective material includes at least one of gold, copper, silver, or mixtures or combinations thereof.

30. The method of claim 26, wherein the protective coating includes at least one metal oxide selected from aluminum oxide, silicon oxide, and mixtures thereof.

31. The method of claim 26, including forming the protective coating to a thickness in the range of greater than 100 Å

to less than 10 microns.

32. The method of claim 26, wherein the protective coating comprises 0 wt. % to 100 wt. % alumina and 100 wt. % to 0 wt. % silica.

33. The method of claim 26, wherein the protective coating comprises a first layer formed over the functional coating and a second layer formed over the first layer, wherein the first layer comprises 50 wt. % to 100 wt. % alumina and 50 wt. % to 0 wt. % silica, and the second layer comprises 50 wt. % to 100 wt. % silica and 50 wt. % to 0 wt. % alumina.

34. The method of claim 26, wherein the alloy prevention layer is at least partially crystalline.

35. The method of claim 34, wherein the alloy prevention layer includes at least one of zinc oxide, titania, and zirconia

36. A coated article, comprising:

a substrate;

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

at least on anti-reflective layer;

at least one alloy prevention layer deposited over at least a portion of the anti-reflective layer; and

at least one infrared reflective layer deposited over at least a portion of the alloy prevention layer, wherein the anti-reflective layer includes an alloying material capable of combining with the infrared reflective layer; and

a protective coating deposited over at least a portion of the infrared reflective layer.

37. The article of claim 36, wherein the anti-reflective layer includes at least one of tin, antimony, bismuth, indium, or combinations thereof.

38. The article of claim 36, wherein the alloying material is selected from tin, antimony, bismuth, indium, or combinations thereof.

39. The article of claim 36, wherein the infrared reflective layer includes at least one of gold, copper, silver, or mixtures or combinations thereof.

40. The article of claim 36, wherein the protective coating includes a metal oxide selected from aluminum oxide, silicon oxide, and mixtures thereof.

41. The article of claim 36, wherein the protective coating has a thickness in the range of greater than 100 Å

to less than 10 microns.

42. The article of claim 36, wherein the protective coating has a refractive index in the range of 1.4 to 1.8.

43. The article of claim 36, wherein the article is an automotive transparency.

44. The article of claim 36, wherein the protective coating comprises 0 wt. % to 100 wt. % alumina and 100 wt. % to 0 wt. % silica.

45. The article of claim 36, wherein the protective coating comprises 50 wt. % to 75 wt. % alumina and 25 wt. % to 50 wt. % silica.

46. The article of claim 36, wherein the protective coating comprises a first layer formed over the functional coating and a second layer formed over the first layer, wherein the first layer comprises 50 wt. % to 100 wt. % alumina and 50 wt. % to 0 wt. % silica, and the second layer comprises 50 wt. % to 100 wt. % silica and 50 wt. % to 0 wt. % alumina.

47. The article of claim 36, wherein the alloy prevention layer is adjacent the infrared reflective layer and is at least partially crystalline.

48. The article of claim 36, wherein the alloy prevention layer includes at least one of zinc oxide, titania, and zirconia.

49. A coated article, comprising:

a substrate;

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

an anti-reflective layer;

an infrared reflective layer deposited over at least a portion of the antireflective layer, wherein the anti-reflective layer contains a material capable of alloying with the material of the infrared reflective layer; and

a protective coating deposited over at least a portion of the infrared reflective layer.

50. The article of claim 49, wherein the anti-reflective layer includes at least one of tin, antimony, bismuth, indium, or combinations thereof.

51. The article of claim 49, wherein the alloying material is selected from tin, antimony, bismuth, indium, or combinations thereof.

52. The article of claim 49, wherein the infrared reflective layer includes at least one of gold, copper, silver, or mixtures or combinations thereof.

53. The article of claim 49, wherein the protective coating includes a metal oxide selected from aluminum oxide, silicon oxide, and mixtures thereof.

54. The article of claim 49, wherein the protective coating has a thickness in the range of greater than 100 Å

to less than 10 microns.

55. The article of claim 49, wherein the article is an automotive transparency.

56. The article of claim 49, wherein the protective coating comprises 0 wt. % to 100 wt. % alumina and 100 wt. % to 0 wt. % silica.

57. The article of claim 49, wherein the protective coating comprises 50 wt. % to 75 wt. % alumina and 25 wt. % to 50 wt. % silica.

58. The article of claim 49, wherein the protective coating comprises a first layer formed over the functional coating and a second layer formed over the first layer, wherein the first layer comprises 50 wt. % to 100 wt. % alumina and 50 wt. % to 0 wt. % silica, and the second layer comprises 50 wt. % to 100 wt. % silica and 50 wt. % to 0 wt. % alumina.

59. The article of claim 49, further including at least one alloy prevention layer deposited over at least a portion of the anti-reflective layer.

60. The article of claim 59, wherein the alloy prevention layer is at least partially crystalline.

61. The article of claim 60, wherein the alloy prevention layer includes at least one of zinc oxide, titania, and zirconia.