Coated substrates that include an undercoating

• US 20060029813A1
• Filed: 08/09/2004
• Published: 02/09/2006
• Est. Priority Date: 08/09/2004
• Status: Active Grant

• Current Assignee: Vitro Flat Glass LLC (Compagnie De Saint-Gobain)
• Original Assignee: PPG Industries Ohio Incorporated (Nouryon BV)
• Inventors: Harris, Caroline S., Lu, Songwei, Kutilek, Luke A., Athey, Patricia R.
• Granted Patent: US 7,431,992 B2
• Time in Patent Office: Days
• US Class Current: 428/426
• CPC Class Codes: C03C 17/3417 all coatings being oxide coatings
• CPC Class Codes: C03C 17/3435 comprising a nitride, oxynitride, boronitride or carbonitride

Abstract

A coated substrate is disclosed. The coated substrate includes a substrate; an undercoating having one or more materials selected from tin oxide, silica, titania, alumina, zirconia, zinc oxide and alloys and mixtures thereof nitrides of titanium, zirconium, hafnium, silicon, aluminum and mixtures thereof, and oxy-nitrides of titanium, zirconium, hafnium, silicon, aluminum and mixtures thereof overlaying at least a portion of the substrate; and a functional coating overlaying at least a portion of the undercoating. As a result of the undercoating, the coated substrate can exhibit improved properties such as improved aesthetic properties, increased durability, photocatalytic activity, mechanical durability, etc.

Claims

1. A coated substrate comprising:

a. a substrate;

b. an undercoating comprised of one or more materials selected from tin oxide, silica, titania, alumina, zirconia, zinc oxide and alloys and mixtures thereof nitrides of titanium, zirconium, hafnium, silicon, aluminum and mixtures thereof, and oxy-nitrides of titanium, zirconium, hafnium, silicon, aluminum and mixtures thereof overlaying at least a portion of the substrate; and

c. a functional coating overlaying at least a portion of the undercoating.

2. The coated substrate according to claim 1, wherein the undercoating is a single layer.

3. The coated substrate according to claim 2, wherein the undercoating comprises a mixture selected from titania and silica;

silica and tin oxide;

alumina and tin oxide;

alumina and zirconia;

alumina and zinc oxide;

silica and zirconia;

silica and zinc oxide;

alumina and silica;

titania and alumina; and

silica, titania and alumina.

4. The coated substrate according to claim 1, wherein the undercoating is a multi-layer configuration.

5. The coated substrate according to claim 4, wherein the undercoating comprises a layer of silica and a layer of tin oxide.

6. The coated substrate according to claim 1, wherein the substrate has an index of refraction, the functional coating has an index of refraction, and the undercoating has an index of refraction which is greater than or equal to the index of refraction of the substrate and less than or equal to the index of refraction of the functional coating.

7. The coated substrate according to claim 6, wherein the visible reflectance of the coated substrate is no greater than 25% as measured from the coated side of the substrate.

8. A coated substrate comprising:

a. a substrate having an index of refraction;

b. an undercoating comprised of one or more materials more materials selected from tin oxide, silica, titania, alumina, zirconia, zinc oxide and alloys and mixtures thereof deposited on at least a portion of the substrate; and

c. a functional coating having an index of refraction deposited on at least a portion of the undercoating,

wherein the undercoating has an index of refraction that is greater than or equal to the index of refraction of the substrate and less than or equal to the index of refraction of the functional coating and the coated substrate has a visible reflectance of no greater than 25% as measured from the coated side of the substrate.

9. The coated substrate according to claim 8, wherein the undercoating comprises a single layer of coating.

10. The coated substrate according to claim 9, wherein the undercoating comprises a mixture of a first material having an index of refraction that is equal to or lower than the index of refraction of the substrate and a second material having an index of refraction that is equal to or higher than the index of refraction of the substrate.

11. The coated substrate according to claim 8, wherein the undercoating comprises one or more materials that are doped with a dopant.

12. A coated substrate according to claim 11, wherein the dopant is fluorine.

13. A coated substrate according to claim 8, wherein the undercoating comprises multiple layers of coating.

14. A coated substrate according to claim 13, wherein the undercoating comprises a layer of silica and a layer of tin oxide.

15. A coated substrate according to claim 8, wherein the functional coating is a photocatalytic coating.

16. A coated substrate according to claim 15, wherein the photocatalytic coating comprises at least one metal oxide.

17. A coated substrate according to claim 16, wherein the photocatalytic coating is selected from titania, iron oxide, silver oxide, copper oxide, tungsten oxide, tin oxide and alloys and mixtures thereof.

18. A coated substrate according to claim 17, wherein the photocatalytic coating comprises titania.

19. A coated substrate according to claim 8, wherein the undercoating is applied using a CVD method.

20. A coated substrate according to claim 8, wherein the functional coating is applied using a CVD method.

21. A coated substrate according to claim 8, wherein the substrate is glass.

22. A coated substrate according to claim 21, wherein the substrate is a glass ribbon.

23. A coated substrate comprising:

a. a glass substrate;

b. an undercoating comprising fluorine doped tin oxide on at least a portion of the glass substrate; and

c. a functional coating comprising titania on at least a portion of the undercoating.

24. A coated substrate comprising:

a. a glass substrate;

b. an undercoating comprising a layer of tin oxide and a layer of silica on at least a portion of the glass substrate; and

C. a functional coating comprising titania on at least a portion of the undercoating.

25. A method for enhancing the aesthetic properties of a substrate coated with a functional coating comprising:

a. applying an undercoating having an index of refraction on at least a portion of a substrate having an index of refraction; and

b. applying a functional coating having an index of refraction on at least a portion of the undercoating,

wherein the index of refraction of the undercoating is greater than or equal to the index of refraction of the substrate and less than or equal to the index of refraction of the functional coating and the coated substrate has a visible reflectance no greater than 25% as measured from the coated side of the substrate.

26. A method according to claim 25 further comprising annealing the coated substrate.

27. A method for providing a barrier layer between a substrate and a functional coating over the substrate comprising:

a. applying an undercoating comprised of one or more materials selected from tin oxide, silica, titania, alumina, zirconia, zinc oxide and alloys and mixtures thereof on at least a portion of a substrate; and

b. applying a functional coating on at least a portion of the undercoating.