Coated article with low-E coating including IR reflecting layer(s) and corresponding method

• US 20040229073A1
• Filed: 03/11/2004
• Published: 11/18/2004
• Est. Priority Date: 07/11/2000
• Status: Active Grant

• Current Assignee: Guardian Glass LLC (KOCH Industries Incorporated)
• Original Assignee: Centre Luxembourgeois de Recherches pour le Verre et la Ceramique SA, Guardian Industries Corporation (KOCH Industries Incorporated)
• Inventors: Lingle, Philip J., Lemmer, Jean-Marc, Dietrich, Anton, Muller, Jens-Peter
• Granted Patent: US 7,879,448 B2
• Time in Patent Office: Days
• US Class Current: 428/627
• 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 17/10229 Metallic layers sandwiched by dielectric layers
• 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 17/3626 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 17/3652 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 17/3694 one layer having a composition gradient through its thickness
• CPC Class Codes: C03C 2217/78 Coatings specially designed to be durable, e.g. scratch-resistant
• CPC Class Codes: C03C 2218/154 by sputtering
• CPC Class Codes: C23C 14/0015 characterized by the colour of the layer
• CPC Class Codes: C23C 14/0084 Producing gradient compositions
• CPC Class Codes: C23C 14/0652 Silicon nitride
• CPC Class Codes: Y10T 428/12576 Boride, carbide or nitride component
• CPC Class Codes: Y10T 428/12611 Oxide-containing component
• CPC Class Codes: Y10T 428/12632 Four or more distinct components with alternate recurrence of each type component
• CPC Class Codes: Y10T 428/12854 Next to Co-, Fe-, or Ni-base component
• CPC Class Codes: Y10T 428/31678 : Of metal

Abstract

A coated article is provided that may be heat treated in certain example embodiments. A coating of the coated article includes a zinc oxide inclusive layer located over and contacting a contact layer that is in contact with an infrared (IR) reflecting layer of a material such as silver. It has been found that the use of such a zinc oxide inclusive layer results in improved thermal stability upon heat treatment, increased visible transmission, and/or lower sheet resistance (R_s).

Claims

1. A coated article comprising a coating supported by a glass substrate, the coating comprising:

a first dielectric layer;

a first infrared (IR) reflecting layer comprising silver located over at least the first dielectric layer;

a first layer comprising zinc oxide located over at least the first IR reflecting layer and the first dielectric layer;

a second IR reflecting layer comprising silver located over and contacting the first layer comprising zinc oxide;

a layer comprising an oxide of NiCr located over and contacting the second IR reflecting layer;

a second layer comprising zinc oxide located over and contacting the layer comprising the oxide of NiCr; and

another dielectric layer located over at least the second layer comprising zinc oxide.

2. The coated article of claim 1, wherein at least one of the first and second layers comprising zinc oxide further comprising aluminum.

3. The coated article of claim 1, wherein the coated article is heat treated.

4. The coated article of claim 1, further comprising another layer comprising zinc oxide located between the first dielectric layer and the first IR reflecting layer, and wherein the first dielectric layer comprises silicon nitride.

5. The coated article of claim 1, wherein the first dielectric layer comprises silicon nitride, and said another dielectric layer also comprises silicon nitride.

6. The coated article of claim 1, further comprising a layer comprising tin oxide located between the first IR reflecting layer and the first layer comprising zinc oxide.

7. The coated article of claim 1, further comprising a layer comprising tin oxide located between the second layer comprising zinc oxide and said another dielectric layer, and wherein the layer comprising tin oxide contacts the second layer comprising zinc oxide.

8. The coated article of claim 1, wherein the first dielectric layer comprises silicon nitride which is Si-rich so as to be represented by Si_xN_y, where x/y is from 0.8 to 1.4.

9. The coated article of claim 1, wherein the coated article comprises a heat treated substrate which supports the coating, and when measured monolithically following heat treatment has a visible transmission of at least 79% and a sheet resistance (R_s) of less than or equal to 3.0 ohms/square.

10. The coated article of claim 1, wherein the coated article comprises a heat treated substrate which supports the coating, and when measured monolithically following heat treatment has a visible transmission of at least 80% and a sheet resistance (R_s) of less than or equal to 2.5 ohms/square.

11. The coated article of claim 1, wherein the coated article comprises a heat treated substrate which supports the coating, and when measured monolithically following heat treatment has a visible transmission of at least 81% and a sheet resistance (R_s) of less than or equal to 2.1 ohms/square.

12. The coated article of claim 1, wherein the coated article comprises a laminate including said substrate which supports the coating and is heat treated and that is laminated to another heat treated glass substrate, the laminate having a visible transmission of at least 76% and a sheet resistance (R_s) of less than or equal to 3.0 ohms/square.

13. The coated article of claim 1, wherein the coated article comprises a laminate including said substrate which supports the coating and is heat treated and that is laminated to another heat treated glass substrate, the laminate having a visible transmission of at least 77% and a sheet resistance (R_s) of less than or equal to 2.5 ohms/square.

14. The coated article of claim 1, wherein the coated article comprises a laminate including said substrate which supports the coating and is heat treated and that is laminated to another heat treated glass substrate, the laminate having a visible transmission of at least 78% and a sheet resistance (R_s) of less than or equal to 2.5 ohms/square.

15. A coated article comprising a coating supported by a glass substrate, the coating comprising:

a first dielectric layer;

a first infrared (IR) reflecting layer comprising silver located over at least the first dielectric layer;

a second dielectric layer located over at least the first IR reflecting layer;

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

a layer comprising an oxide of Ni and/or Cr located over and contacting the second IR reflecting layer;

a layer comprising zinc oxide located over and contacting the layer comprising the oxide of Ni and/or Cr; and

another dielectric layer located over at least the layer comprising zinc oxide.

16. The coated article of claim 15, wherein the layer comprising zinc oxide further comprises aluminum.

17. The coated article of claim 15, wherein the coated article is heat treated, and when measured monolithically has a visible transmission of at least 80% and a sheet resistance of less than or equal to 3.0 ohms/square.

18. The coated article of claim 15, further comprising another layer comprising zinc oxide located directly under and contacting the second IR reflecting layer.

19. The coated article of claim 15, wherein the first dielectric layer comprises silicon nitride.

20. The coated article of claim 15, wherein the first dielectric layer comprises silicon nitride, said second dielectric layer comprises silicon nitride, and said another dielectric layer comprises silicon nitride.

21. The coated article of claim 15, further comprising a layer comprising tin oxide located between the first IR reflecting layer and the second IR reflecting layer.

22. The coated article of claim 15, further comprising a layer comprising tin oxide located between the layer comprising zinc oxide and said another dielectric layer, and wherein the layer comprising tin oxide contacts the layer comprising zinc oxide.

23. The coated article of claim 15, wherein the first dielectric layer comprises silicon nitride which is Si-rich so as to be represented by Si_xN_ywhere x/y is from 0.8 to 1.4.

24. The coated article of claim 15, wherein the coated article comprises a heat treated substrate which supports the coating, and when measured monolithically following heat treatment the coated article has a visible transmission of at least 79% and a sheet resistance (R_s) of less than or equal to 3.0 ohms/square.

25. The coated article of claim 15, wherein the coated article comprises a heat treated substrate which supports the coating, and when measured monolithically following heat treatment the coated article has a visible transmission of at least 80% and a sheet resistance (R_s) of less than or equal to 2.5 ohms/square.

26. The coated article of claim 15, wherein the coated article comprises a heat treated substrate which supports the coating, and when measured monolithically following heat treatment the coated article has a visible transmission of at least 81% and a sheet resistance (R_s) of less than or equal to 2.1 ohms/square.

27. The coated article of claim 15, wherein the coated article comprises a laminate including said substrate which supports the coating and is heat treated and that is laminated to another heat treated glass substrate, the laminate having a visible transmission of at least 76% and a sheet resistance (R_s) of less than or equal to 3.0 ohms/square.

28. The coated article of claim 15, wherein the coated article comprises a laminate including said substrate which supports the coating and is heat treated and that is laminated to another heat treated glass substrate, the laminate having a visible transmission of at least 77% and a sheet resistance (R_s) of less than or equal to 2.5 ohms/square.

29. The coated article of claim 15, wherein the coated article comprises a laminate including said substrate which supports the coating and is heat treated and that is laminated to another heat treated glass substrate, the laminate having a visible transmission of at least 78% and a sheet resistance (R_s) of less than or equal to 2.5 ohms/square.

30. A coated article including a glass substrate which supports a coating, the coating comprising from the glass substrate outwardly at least the following layers:

a dielectric layer comprising silicon nitride;

a first layer comprising zinc oxide;

a first IR reflecting layer contacting the first layer comprising zinc oxide;

at least one dielectric layer comprising at least one of tin oxide and silicon nitride;

a second layer comprising zinc oxide;

a second IR reflecting layer contacting the second layer comprising zinc oxide;

a layer comprising an oxide of Ni and/or Cr;

a third layer comprising zinc oxide contacting the layer comprising the oxide of Ni and/or Cr; and

another dielectric layer located over at least the third layer comprising zinc oxide.

31. The coated article of claim 30, wherein the coated article comprises a laminate including said glass substrate which supports the coating and is heat treated, said glass substrate being laminated to another heat treated glass substrate to form the laminate, said laminate having a visible transmission of at least 78% and a sheet resistance (R_s) of less than or equal to 2.5 ohms/square.

32. A coated article including a glass substrate which supports a coating, the coating comprising from the glass substrate outwardly at least the following layers:

a dielectric layer comprising silicon nitride;

a first contact layer;

a first IR reflecting layer comprising silver contacting the first contact layer;

at least one dielectric layer comprising at least one of tin oxide and silicon nitride;

a second contact layer;

a second IR reflecting layer comprising silver contacting the second contact layer;

a layer comprising an oxide of NiCr;

a layer comprising zinc oxide contacting the layer comprising the oxide of NiCr; and

another dielectric layer comprising silicon nitride located over at least the layer comprising zinc oxide.

33. The coated article of claim 32, wherein the coated article comprises a laminate including said glass substrate which supports the coating and is heat treated, said glass substrate being laminated to another heat treated glass substrate to form the laminate, said laminate having a visible transmission of at least 78% and a sheet resistance (R_s) of less than or equal to 2.5 ohms/square.

34. A coated article comprising a coating supported by a glass substrate, the coating comprising the following layers in the recited order from the glass substrate outwardly:

a first layer comprising zinc oxide;

a layer comprising silver located over and contacting the first layer comprising zinc oxide;

a layer comprising an oxide of Ni and/or Cr located over and contacting the layer comprising silver;

a second layer comprising zinc oxide located over and contacting the layer comprising the oxide of Ni and/or Cr.