Method of making coated article including ion beam treatment of metal oxide protective film

• US 20080199702A1
• Filed: 11/19/2007
• Published: 08/21/2008
• Est. Priority Date: 01/29/2007
• Status: Active Grant

• Current Assignee: Guardian Glass LLC (KOCH Industries Incorporated)
• Original Assignee: Guardian Industries Corporation (KOCH Industries Incorporated)
• Inventors: Wang, Jiangping, Petrmichl, Rudolph Hugo, Murphy, Nestor P., Frati, Maximo
• Granted Patent: US 7,964,238 B2
• Time in Patent Office: Days
• US Class Current: 428/408
• CPC Class Codes: C03C 17/22 with other inorganic material C03C17/34, C03C17/44 take precedence
• CPC Class Codes: C03C 17/3441 comprising carbon, a carbide or oxycarbide
• CPC Class Codes: C03C 2217/78 Coatings specially designed to be durable, e.g. scratch-resistant
• CPC Class Codes: C03C 2217/91 Coatings containing at least one layer having a composition gradient through its thickness
• CPC Class Codes: C03C 2218/154 by sputtering
• CPC Class Codes: C03C 2218/328 Partly or completely removing a coating
• CPC Class Codes: C03C 2218/355 Temporary coating
• CPC Class Codes: Y10T 428/30 Self-sustaining carbon mass or layer with impregnant or other layer

Abstract

There is provided a method of making a heat treated (HT) coated article to be used in shower door applications, window applications, or any other suitable applications where transparent coated articles are desired. For example, certain embodiments of this invention relate to a method of making a coated article including a step of heat treating a glass substrate coated with at least a layer of or including diamond-like carbon (DLC) and an overlying protective film (e.g., of or including zinc oxide) thereon. In certain example embodiments, the protective film may be ion beam treated with at least carbon ions. It has been found that the ion beam treatment improves the shelf-life of the product prior to HT. Following and/or during heat treatment (e.g., thermal tempering, or the like), the protective film may be removed.

Claims

1. A method of making a heat treated coated article, the method comprising:

providing a glass substrate;

forming at least one layer comprising diamond-like carbon (DLC) on the glass substrate;

forming a protective film comprising zinc oxide on the glass substrate over at least the layer comprising DLC,

ion beam treating the protective film comprising zinc oxide with at least carbon ions;

heat treating the glass substrate with the layer comprising DLC and the protective film thereon so that during the heat treating the protective film prevents significant burnoff of the layer comprising DLC, wherein the heat treating comprises heating the glass substrate to temperature(s) sufficient for thermal tempering, heat strengthening, and/or heat bending; and

exposing the protective film to a release liquid and removing at least part of the protective film during and/or after said heat treating.

2. The method of claim 1, wherein the ion beam treating forms a layer comprising zinc oxycarbide at least at a surface portion of the protective film.

3. The method of claim 1, wherein the protective film include a release layer and an oxygen barrier layer, the release layer and the oxygen barrier layer being of different material and/or different stoichiometry relative to each other;

and wherein one or both of the release layer and oxygen barrier layer is subjected to the ion beam treating; and

wherein the release layer comprises an oxide of one or more of boron, titanium boride, magnesium and/or zinc.

4. The method of claim 1, wherein the protective film comprises a release layer and an oxygen barrier layer, wherein the release layer and the oxygen barrier layer of the protective film both comprise zinc but are of different stoichiometries.

5. The method of claim 4, wherein, in the protective film, the release layer comprising zinc is more metallic than is the oxygen barrier layer comprising zinc oxide prior to the heat treating.

6. The method of claim 1, wherein the protective film comprising zinc oxide is oxidation graded in a continuous or non-continuous manner prior to the heat treating so that prior to the heat treating the layer is more oxided at a location further from the layer comprising DLC than at a location closer to the layer comprising DLC.

7. The method of claim 1, wherein the layer comprising DLC is formed via an ion beam(s).

8. The method of claim 1, wherein the protective film is at least partially formed via sputtering.

9. The method of claim 1, further comprising forming a barrier layer comprising silicon oxide and/or silicon nitride on the glass substrate so as to be located between at least the glass substrate and the layer comprising DLC.

10. The method of claim 1, wherein the heat treating comprises heating the glass substrate with the layer comprising DLC and the protective film thereon using at least temperature(s) of at least 550 degrees C.

11. The method of claim 1, wherein the layer comprising DLC comprises amorphous DLC and has more sp³ carbon-carbon bonds than sp² carbon-carbon bonds.

12. The method of claim 1, wherein the layer comprising DLC has an average hardness of at least 10 GPa.

13. The method of claim 1, wherein the layer comprising DLC has an average hardness of at least 20 GPa.

14. The method of claim 1, wherein the layer comprising DLC has a density of at least about 2.7 gm/cm³, and wherein the layer comprising DLC is hydrogenated.

15. The method of claim 1, wherein the coated article is substantially transparent and is used as a shower door.

16. The method of claim 1, wherein after said removing at least part of the layer comprising DLC is exposed so as to be an outermost layer of the coated article.

17. A method of making a heat treated coated article, the method comprising:

providing a glass substrate;

forming at least one layer comprising carbon on the glass substrate;

forming a protective film comprising at least one metal oxide on the glass substrate over at least the layer comprising carbon;

ion beam treating the protective film with at least carbon ions;

heat treating the glass substrate with the layer comprising carbon and the protective film thereon so that during the heat treating the protective film prevents significant burnoff of the layer comprising carbon, wherein the heat treating comprises heating the glass substrate to temperature(s) sufficient for thermal tempering, heat strengthening, and/or heat bending.

18. The method of claim 17, further comprising exposing the protective film to a release liquid and removing at least part of the protective film during and/or after said heat treating.

19. The method of claim 17, wherein the protective film comprises zinc oxide.

20. The method of claim 17, wherein the ion beam treating forms a layer comprising metal(s) oxycarbide at least at a surface portion of the protective film.

21. A coated article comprising:

a glass substrate;

a layer comprising diamond-like carbon (DLC) on the glass substrate;

a protective film comprising zinc oxide on the glass substrate over at least the layer comprising DLC;

a layer or layer portion comprising zinc oxycarbide provided at a surface portion of the protective film comprising zinc oxide, so that the protective film comprising zinc oxide is graded, continuously or discontinuously, with respect to carbon content so as to have more carbon at a location in the protective film further from the glass substrate than at a location in the protective film closer to the glass substrate.

22. The coated article of claim 21, wherein the coated article is not heat treated.

23. The coated article of claim 21, further comprising a barrier layer provided between the glass substrate and the layer comprising DLC.

24. A method of making a heat treated coated article, the method comprising:

providing a glass substrate;

forming at least one layer comprising diamond-like carbon (DLC) on the glass substrate;

forming a protective film comprising zinc oxide on the glass substrate over at least the layer comprising DLC, wherein said protective film comprising zinc oxide is formed using at least one sputtering target comprising zinc that is sputtered in an atmosphere including at least carbon gas;

heat treating the glass substrate with the layer comprising DLC and the protective film thereon so that during the heat treating the protective film prevents significant burnoff of the layer comprising DLC, wherein the heat treating comprises heating the glass substrate to temperature(s) sufficient for thermal tempering, heat strengthening, and/or heat bending; and

exposing the protective film to a release liquid and removing at least part of the protective film during and/or after said heat treating.

25. The method of claim 24, wherein the atmosphere in which the target is sputtered comprising carbon, oxygen and argon gas.