METHOD OF MAKING COATED ARTICLE INCLUDING ANTI-REFLECTION COATING AND PRODUCTS CONTAINING THE SAME

• US 20130194670A1
• Filed: 12/13/2012
• Published: 08/01/2013
• Est. Priority Date: 01/30/2012
• Status: Abandoned Application

• Current Assignee: Guardian Glass LLC (KOCH Industries Incorporated)
• Original Assignee: Guardian Industries Corporation (KOCH Industries Incorporated)
• Inventors: BLACKER, Richard, LIANG, Liang, LOVELL, Chris, LEWIS, Mark A.
• Application Number:
  US13/713,990
• Publication Number:
  US 20130194670A1
• Time in Patent Office: Days
• US Class Current: 359/601
• CPC Class Codes: B05D 5/063 Reflective effect B05D5/067 takes precedence
• CPC Class Codes: B82Y 30/00 Nanotechnology for materials or surface science, e.g. nanocomposites
• CPC Class Codes: C03C 1/008 for the production of films or coatings
• CPC Class Codes: C03C 17/007 containing a dispersed phase, e.g. particles, fibres or flakes, in a continuous phase
• CPC Class Codes: C03C 17/3417 all coatings being oxide coatings
• CPC Class Codes: C03C 2217/213 SiO2
• CPC Class Codes: C03C 2217/73 Anti-reflective coatings with specific characteristics
• CPC Class Codes: C03C 2217/732 made of a single layer
• CPC Class Codes: C03C 2217/91 Coatings containing at least one layer having a composition gradient through its thickness
• CPC Class Codes: C03C 2218/113 by sol-gel processes
• CPC Class Codes: C03C 2218/116 by spin-coating, centrifugation
• CPC Class Codes: C23C 18/1212 Zeolites, glasses
• CPC Class Codes: C23C 18/1225 Deposition of multilayers of inorganic material
• CPC Class Codes: C23C 18/1245 Inorganic substrates other than metallic
• CPC Class Codes: C23C 18/1254 Sol or sol-gel processing
• CPC Class Codes: C23C 18/127 Preformed particles
• CPC Class Codes: C23C 18/1283 Control of temperature, e.g. gradual temperature increase, modulation of temperature
• CPC Class Codes: G02B 1/11 Anti-reflection coatings
• CPC Class Codes: G02B 2207/107 Porous materials, e.g. for reducing the refractive index
• CPC Class Codes: G02B 2207/109 Sols, gels, sol-gel materials

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.

Claims

1. A method of making an anti-reflection coating, the method comprising:

forming a first layer having a first porosity on a glass substrate; and

forming a second layer having a second porosity over and contacting the first layer;

wherein the second porosity is greater than the first porosity, and

wherein the first and/or second porosities are formed by at least one of;

(a) forming the first and/or second layer(s) from a sol comprising combustible carbon-inclusive structures, and heating the layer comprising the combustible carbon-inclusive structures to a temperature sufficient to cause the carbon-based structures to combust, leaving pores where the structures were previously located such that a porosity of the layer(s) arises from said pores,

(b) forming the first and/or second layer(s) from a sol comprising mesoporous nanoparticles such that the porosity is attributable to pores arising from gaps between the individual nanoparticles and pores within the nanoparticles themselves,

(c) forming the first and/or second layer(s) from a sol comprising geometrically packed nanoparticles, wherein the porosity arises from spaces between the individual nanoparticles and/or agglomerates of nanoparticles, and/or

(d) forming the first and/or second layers from a surfactant-inclusive sol comprising micelles, and removing at least some of the micelles, leaving pores where the micelles were previously located such that a porosity of the layer(s) arises from said pores.

2. The method of claim 1, wherein the first and second porosities are formed by the geometric packing of nanoparticles.

3. The method of claim 2, wherein the first layer comprises substantially spherical nanoparticles, and the second layer comprises elongated substantially cylindrical nanoparticles.

4. The method of claim 1, wherein the coated article has a Tqe % gain as compared to an uncoated glass substrate of at least about 3.3%.

5. The method of claim 1, wherein the first and/or second porosities are formed at least by (a).

6. The method of claim 5, wherein the first and second porosities are formed by (a).

7. The method of claim 1, wherein the first and/or second porosities are formed at least by (b).

8. The method of claim 7, wherein the first and second porosities are formed by (b).

9. The method of claim 1, wherein one of the first and/or second porosities is formed by (a), and the other by (b).

10. The method of claim 1, wherein one of the first and/or second porosities is formed by (a), and the other by (c).

11. The method of claim 1, wherein one of the first and/or second porosities is formed by (b), and the other by (c).

12. The method of claim 1, wherein the anti-reflection coating has a thickness of from about 50 to 200 nm.

13. The method of claim 1, wherein each layer is dried at a temperature of at least about 300 degrees C. after it is deposited on the substrate.

14. A coated article comprising:

a glass substrate; and

an anti-reflection coating disposed over the glass substrate, wherein the anti-reflection coating comprises at least first and second layers;

wherein the first and/or second layers of the coating comprise at least one of;

(a) a matrix comprising fullerene structures and silica, (b) mesoporous nanoparticles, (c) a matrix comprising micelles and silica, and (d) elongated and/or substantially spherical nanoparticles.

19. The coated article of claim 14, wherein the first and second layers comprise (a).

20. The coated article of claim 14, wherein the first and second layers comprise (b).

21. The coated article of claim 14, wherein the first layer comprises (c) and the second layer comprises (d).

22. The coated article of claim 21, wherein the nanoparticles of (d) are elongated nanoparticles having a diameter of from about 2 to 20 nm and a length of from about 30 to 150 nm.

15. The coated article of claim 15, wherein the first layer comprises (d).

16. The coated article of claim 15, wherein the second layer comprises (d).

17. The coated article of claim 16, wherein the first layer comprises substantially spherical nanoparticles.

18. The coated article of claim 17, wherein the second layer comprises elongated nanoparticles having a diameter of from about 2 to 20 nm and a length of from about 30 to 150 nm.