COATING STACK COMPRISING A LAYER OF BARRIER COATING

• US 20070224357A1
• Filed: 05/23/2007
• Published: 09/27/2007
• Est. Priority Date: 10/22/2001
• Status: Active Grant

• Current Assignee: Vitro Flat Glass LLC (Compagnie De Saint-Gobain)
• Original Assignee: PPG Industries Ohio Incorporated (Nouryon BV)
• Inventors: Buhay, Harry, Thiel, James, Finley, James
• Granted Patent: US 9,556,068 B2
• Time in Patent Office: Days
• US Class Current: 427/404
• 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 17/3628 one layer at least containing a sulfide
• 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 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: C03C 2217/94 Transparent conductive oxide layers [TCO] being part of a multilayer 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 1/10 : Optical coatings produced by application to, or surface treatment of, optical elements G02B1/08 takes precedence
• CPC Class Codes: G02B 1/14 : Protective coatings, e.g. hard coatings
• CPC Class Codes: Y02T 50/60 : Efficient propulsion technologies, e.g. for aircraft
• CPC Class Codes: Y10T 428/12493 : Composite; i.e., plural, adjacent, spatially distinct metal components [e.g., layers, joint, etc.]
• CPC Class Codes: Y10T 428/12535 : with additional, spatially distinct nonmetal component
• CPC Class Codes: Y10T 428/12576 : Boride, carbide or nitride component
• CPC Class Codes: Y10T 428/12611 : Oxide-containing component
• CPC Class Codes: Y10T 428/24942 : including components having same physical characteristic in differing degree

Abstract

A coating composition that contains at least one degradable coating layer and at least one layer of barrier coating is disclosed. The coating composition can be used to make a coated substrate having improved performance over conventional coated substrates after exposure to heat and certain chemicals like halides such as chlorides, sulfur, salt, chlorine, alkali, and enamels.

Claims

1. A method of forming a multilayered coated substrate, comprising:

providing a coating comprising at least one degradable layer on a substrate; and

providing at least one barrier layer over the degradable layer, wherein the barrier layer has a permeability to oxygen of no greater than 10 grams per m² per day at a temperature of 900°

F.

2. The method according to claim 1, further comprising providing additional coating layers on the degradable layer prior to applying the barrier layer.

3. The method according to claim 1, further comprising providing an additional barrier layer between the substrate and the degradable layer.

4. The method according to claim 1, wherein the barrier layer is the last coating layer applied on the substrate.

5. The method according to claim 1, further comprising providing additional coating layers over the barrier layer.

6. The method according to claim 1, wherein the at least one barrier layer is a single layer comprising one or more metal oxide materials selected from aluminum oxide, silicon oxide, and mixtures thereof.

7. The method according to claim 6, wherein the barrier layer has a thickness of up to 2 microns.

8. The method according to claim 1 wherein the barrier layer is a multi-layer coating comprising a first layer selected from silica, alumina, and mixtures thereof and a second layer selected from silica, alumina, and mixtures thereof.

9. The method according to claim 1, wherein the at least one degradable layer comprises an electromagnetic radiation reflective material selected from gold, copper, silver, conductive nitride, and mixtures thereof.

10. The method according to claim 9, wherein the at least one degradable layer comprises silver.

11. The method according to claim 10, wherein the coating further comprises first and second layers of dielectric material and at least one layer of primer, and further wherein the degradable layer is on at least a portion of the first layer of dielectric material;

the at least one layer of primer is on at least a portion of the degradable layer;

the second layer of dielectric material is on at least a portion of the at least one layer of primer; and

the at least one barrier layer is on at least a portion of the second layer of dielectric material.

12. The method according to claim 11 wherein the first and second layers of dielectric material are each selected from indium tin oxide, titanium oxide, zinc oxide, tin oxide and mixtures and alloys thereof.

13. The method according to claim 11, wherein the at least one layer of primer is selected from titanium, copper, aluminum, niobium, yttrium, zirconium, hafnium, chromium, and mixtures and alloys thereof;

nickel-chromium alloy;

cobalt-chromium alloy;

indium tin sub-oxide;

titanium sub-oxide;

zinc aluminum sub oxide;

silicon nitride and mixtures thereof

14. The method according to claim 1, wherein the coating further comprises a layer of transparent conductive oxide.

15. The method according to claim 14, wherein the at least one degradable layer is on at least a portion of the layer of transparent conductive oxide and the at least one barrier layer is on at least a portion of the at least one degradable layer.

16. The method according to claim 14, wherein the layer of transparent, conductive oxide is on at least a portion of the at least one degradable layer and the barrier layer is on at least a portion of the layer of transparent, conductive oxide.

17. The method according to claim 14, wherein the at least one degradable layer is on at least a portion of the layer of transparent conductive oxide, a primer layer is on at least a portion of the degradable layer, and the at least one barrier layer is on at least a portion of the primer layer.

18. A method of forming a multilayered coated substrate, comprising:

providing a functional coating comprising an inner layer and an outer layer;

providing at least one degradable layer between the inner layer and the outer layer; and

providing at least one barrier layer over the degradable layer, wherein the barrier layer has a permeability to oxygen of no greater than 10 grams per m² per day at a temperature of 900°

F.

19. The method of claim 18, wherein the barrier layer is located between the inner layer and the outer layer.