METHOD OF MAKING COATED ARTICLE INCLUDING ANTI-REFLECTION COATING WITH DOUBLE COATING LAYERS INCLUDING MESOPOROUS MATERIALS, AND PRODUCTS CONTAINING THE SAME
First Claim
1. A method of making an anti-reflection coating, the method comprising:
- forming a first intermediate layer on a glass substrate by wet-applying a sol comprising at least silica and a surfactant on a glass substrate;
initially heating the glass substrate with the first intermediate layer thereon to a first temperature, and subsequently heating the glass substrate with the first intermediate layer thereon to a second temperature, wherein the second temperature is higher than the first temperature;
forming a second intermediate layer by wet-applying a sol comprising nanoparticles over and contacting the first intermediate layer; and
curing the first and second intermediate layers so as to form an anti-reflection coating comprising at least first and second layers having first and second porosities from the first and second intermediate layers, respectively,wherein the second porosity is greater than the first porosity.
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Abstract
Certain examples relate to a method of making an antireflective (AR) coating supported by a glass substrate. The anti-reflection coating may include porous metal oxide(s) and/or silica, and may be produced using a sol-gel process. The pores may be formed and/or tuned in each layer respectively in such a manner that the coating ultimately may comprise a porous matrix, graded with respect to porosity. The gradient in porosity may be achieved by forming first and second layers using one or more of (a) nanoparticles of different shapes and/or sizes, (b) porous nanoparticles having varying pore sizes, and/or (c) compounds/materials of various types, sizes, and shapes that may ultimately be removed from the coating post-deposition (e.g., carbon structures, micelles, etc., removed through combustion, calcination, ozonolysis, solvent-extraction, etc.), leaving spaces where the removed materials were previously located.
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Citations
22 Claims
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1. A method of making an anti-reflection coating, the method comprising:
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forming a first intermediate layer on a glass substrate by wet-applying a sol comprising at least silica and a surfactant on a glass substrate; initially heating the glass substrate with the first intermediate layer thereon to a first temperature, and subsequently heating the glass substrate with the first intermediate layer thereon to a second temperature, wherein the second temperature is higher than the first temperature; forming a second intermediate layer by wet-applying a sol comprising nanoparticles over and contacting the first intermediate layer; and curing the first and second intermediate layers so as to form an anti-reflection coating comprising at least first and second layers having first and second porosities from the first and second intermediate layers, respectively, wherein the second porosity is greater than the first porosity. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, 20, 21)
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22. A coated article comprising:
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a glass substrate; and an anti-reflection coating disposed over the glass substrate, the anti-reflection coating comprising first and second layers, the first layer having a first porosity and the second layer having a second porosity, wherein the first layer comprises mesoporous silica, and has a refractive index of from about 1.39 to 1.49, and the second layer comprises elongated nanoparticles comprising silica and has a refractive index of from about 1.27 to 1.37, wherein the second porosity is greater than the first porosity, and wherein an average broadband (400-1200 nm) Tqe % gain as compared to an uncoated glass substrate is at least about 3.0%.
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Specification