Coated articles

• US 5,821,001 A
• Filed: 02/27/1997
• Issued: 10/13/1998
• Est. Priority Date: 04/25/1996
• Status: Expired due to Term

• Current Assignee: Vitro Flat Glass LLC (Compagnie De Saint-Gobain)
• Original Assignee: PPG Industries Incorporated (Nouryon BV)
• Inventors: Arbab, Mehran, Miller, Larry A., Criss, Russell C.
• Primary Examiner(s): ACHUTAMURTHY, PONNATHAPURA N
• Application Number:
  US08/807,352
• Time in Patent Office: 593 Days
• Field of Search: 428/623, 428/630, 428/632, 428/633, 428/670
• US Class Current: 428/623
• 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 17/3639 Multilayers containing at least two functional metal layers
• CPC Class Codes: C03C 17/3642 the multilayer coating containing a metal layer
• 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 2217/78 Coatings specially designed to be durable, e.g. scratch-resistant
• 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 1/116 including electrically conducting layers
• CPC Class Codes: G02B 5/208 for use with infrared or ultraviolet radiation, e.g. for separating visible light from infrared and/or ultraviolet radiation
• CPC Class Codes: G02B 5/282 reflecting for infrared and transparent for visible light, e.g. heat reflectors, laser protection
• CPC Class Codes: Y10T 428/12549 Adjacent to each other
• CPC Class Codes: Y10T 428/12597 Noncrystalline silica or noncrystalline plural-oxide component [e.g., glass, etc.]
• CPC Class Codes: Y10T 428/12611 Oxide-containing component
• CPC Class Codes: Y10T 428/12618 Plural oxides
• CPC Class Codes: Y10T 428/12875 Platinum group metal-base component

Abstract

Multilayer high transmittance, low emissivity coatings on transparent substrates feature a special antireflective base film of at least two parts on the substrate-near side of a metallic, reflective film. A first of the two parts is in contact with the metallic film. This first film-part has crystalline properties for causing the metallic film to deposit in a low resistivity configuration. The second of the two film-parts supports the first part and is preferably amorphous. Coated articles of the invention also feature, in combination with the above-mentioned base film or independently thereof, a newly discovered, particularly advantageous subrange of thicker primer films for coated glass that can be thermally processed for tempering, heat strengthening, or bending.

Claims

1. A high transmittance, low emissivity coated article comprising:

a. a transparent, nonmetallic substrate;

b. a dielectric, antireflective base film overlying the substrate, the base film including a zinc-tin oxide support film-part overlying the substrate and a crystalline metal-contacting film-part selected from the group consisting of indium tin oxide, zinc-aluminum oxide, zinc oxide and mixtures thereof overlying the support film-part;

c. a metallic reflective film deposited on the crystalline metal-contacting film-part of the base film, the metallic film having two levels of electrical resistivity, one level being lower than the other;

d. a primer film overlying the metallic reflective film; and

e. a dielectric, antireflective film overlying the primer film;

wherein the metal-contacting film-part directs said metallic film to the lower of said two levels.

2. A coated article as claimed in claim 1 further comprising an exterior protective overcoat layer overlying the dielectric antireflective film.

3. A coated article as claimed in claim 2 wherein the transparent, nonmetallic substrate is glass, the support film-part is a zinc stannate film, the crystalline metal-contacting film-part is a zinc oxide film, the metallic reflective film is a silver film, the primer film is deposited as titanium metal having a thickness in the range of about 22 to 30 Angstroms, the dielectric, antireflective film is a zinc stannate film, and the exterior protective overcoat layer is a titanium oxide film.

27. The article according to claim 1 wherein said base film is deposited on said substrate.

4. A high transmittance, low emissivity coated article comprising:

a. a transparent, nonmetallic substrate;

b. a first dielectric, antireflective base film overlying the substrate, the first base film including a zinc-tin oxide support film-part overlying the substrate and a crystalline metal-contacting film part selected from the group consisting of indium tin oxide, zinc-aluminum oxide and zinc oxide overlying the support film-part;

c. a first metallic reflective film deposited on the crystalline metal-contacting film-part of the first base film, the metallic film having two levels of electrical resistivity, one level being lower than the other;

d. a first primer film overlying the first metallic reflective film;

e. a second dielectric, antireflective base film overlying the first primer film, the second base film including a zinc-tin oxide support film-part overlying the first primer film and a crystalline metal-contacting film-part selected from the group consisting of indium tin oxide, zinc aluminum oxide and zinc oxide overlying the support film-part;

f. a second metallic reflective film deposited on the crystalline metal-contacting film-part of the second base film, the metallic film having two levels of electrical resistivity, one level being lower than the other;

g. a second primer film overlying the second metallic reflective film; and

h. a dielectric, antireflective film overlying the second primer film;

wherein the metal-contacting film-part of the first base film directs the first metallic film to the lower of said two levels and the metal-contacting film-part of the second base film directs the second metallic film to the lower of said two levels.

5. A coated article as claimed in claim 4 further comprising an exterior protective overcoat layer overlying the dielectric, antireflective film.

6. A coated article as claimed in claim 5 wherein the transparent, nonmetallic substrate is glass, the support film-part of the first base film is a zinc stannate film, the crystalline metal-contacting film-part of the first base film is a zinc oxide film;

the first metallic reflective film is a silver film, the first primer film is deposited as titanium metal having a thickness of 22 to 30 Angstroms, the support film-part of the second base film is a zinc stannate film, the crystalline metal-contacting film-part of the second base film is a zinc oxide film, the second metallic reflective film is a silver film, the second primer film is deposited as titanium metal having a thickness of 22 to 30 Angstroms, the dielectric, antireflective film deposited on the second primer film is a zinc stannate film, and the exterior protective overcoat layer is a titanium oxide film.

28. The article according to claim 4 wherein said first base film is deposited on said substrate.

7. A high transmittance, low emissivity coated article comprising:

a. a transparent, nonmetallic substrate;

b. a first dielectric, antireflective base film overlying the substrate, the first base film including a zinc-tin oxide support film-part overlying the substrate and a crystalline metal-contacting film-part selected from the group consisting of indium tin oxide, zinc-aluminum oxide and zinc oxide overlying the support film-part;

c. a first metallic reflective film deposited on the crystalline metal-contacting film-part of the first base film, the metallic film having two levels of electrical resistivity, one level being lower than the other;

d. a first primer film overlying the first metallic reflective film;

e. a second dielectric, antireflective base film overlying the first primer film, the second base film including a crystalline metal-contacting film-part selected from the group consisting of indium tin oxide, zinc aluminum oxide and zinc oxide overlying a support film-part, wherein the support film-part is further comprised of a first layer of a zinc oxide film overlying the first primer film and a second layer of a zinc stannate film overlying the first layer of said support film-part;

f. a second metallic reflective film deposited on the crystalline metal-contacting film-part of the second base film, the metallic film having two levels of electrical resistivity, one level being lower than the other;

g. a second primer film overlying the second metallic reflective film; and

h. a dielectric, antireflective film overlying the second primer film wherein the dielectric, antireflective film includes a first layer of a zinc oxide film overlying the primer film and a second layer of a zinc stannate film overlying the first zinc oxide layer of the dielectric, antireflective film;

wherein the metal-contacting film-part of the first base film directs the first metallic film to the lower of said two levels and the metal-contacting film-part of the second base film directs the second metallic film to the lower of said two levels.

8. A coated article as claimed in claim 7 further comprising an exterior protective overcoat layer overlying the dielectric antireflective film.

9. A coated article as claimed in claim 8 wherein the transparent, nonmetallic substrate is glass, the support film-part of the first base film is a zinc stannate film, the crystalline metal-contacting film-part of the first base film is a zinc oxide film, the first metallic reflective film is a silver film, the first primer film is deposited as titanium metal having a thickness of 8 to 12 Angstroms, the second metallic reflective film is a silver film, the second primer film is deposited as titanium metal having a thickness of 8 to 12 Angstroms, and the exterior protective overcoat layer is a titanium oxide film.

29. The article according to claim 7 wherein said first base film is deposited on said substrate.

10. A method for making a high transmittance, low emissivity coated article comprising the steps of:

a. selecting a transparent, nonmetallic substrate;

b. depositing a dielectric, antireflective base film over the substrate, the base film including a zinc-tin oxide support film-part overlying the substrate and a crystalline metal-contacting film-part selected from the group consisting of indium tin oxide, zinc-aluminum oxide and zinc-oxide overlying the support film-part;

c. depositing a metallic reflective film on the crystalline metal-contacting film-part of the base film, the metallic film having two levels of electrical resistivity, one level being lower than the other;

d. depositing a primer film over the metallic reflective film; and

e. depositing a dielectric, antireflective film over the primer film;

wherein the metal-contacting film-part directs said metallic film to the lower of said two levels.

11. A method according to claim 10 further comprising the step of depositing an exterior protective overcoat layer over the dielectric antireflective film.

12. A method according to claim 11 wherein the transparent, nonmetallic substrate is glass, the support film-part is a zinc stannate film, the crystalline metal-contacting film-part is a zinc oxide film, the metallic reflective film is a silver film, the primer film is deposited as titanium metal having a thickness of 22 to 30 Angstroms, the dielectric, antireflective film is a zinc stannate film, and the exterior protective overcoat layer is a titanium oxide film.

19. The method of claim 10 further comprising the step of subjecting the coated article to a heat treatment.

20. The method of claim 19 wherein the nonmetallic substrate is glass and said heat treatment is a tempering heat treatment to temper said glass substrate.

30. The method according to claim 10 wherein said base film is deposited on said substrate.

13. A method for making a high transmittance, low emissivity coated article comprising the steps of:

a. selecting a transparent, nonmetallic substrate;

b. depositing a first dielectric, antireflective base film over the substrate, the first base film including a zinc-tin oxide support film-part overlying the substrate and a crystalline metal-contacting film-part selected from the group consisting of indium tin oxide, zinc aluminum oxide and zinc oxide overlying the support film-part;

c. depositing a first metallic reflective film on the crystalline metal-contacting film-part of the first base film, the metallic film having two levels of electrical resistivity, one level being lower than the other;

d. depositing a first primer film on the first metallic reflective film;

e. depositing a second dielectric, antireflective base film over the first primer film, the second base film including a zinc-tin oxide support film-part overlying the first primer film and a crystalline metal-contacting film-part selected from the group consisting of indium tin oxide, zinc-aluminum oxide and zinc oxide overlying the support film-part;

f. depositing a second metallic reflective film on the crystalline metal-contacting film-part of the second base film, the metallic film having two levels of electrical resistivity, one level being lower than the other;

g. depositing a second primer film over the second metallic reflective film; and

h. depositing a dielectric, antireflective film over the second primer film;

wherein the metal-contacting film-part of the first base film directs the first metallic film to the lower of said two levels and the metal-contacting film-part of the second base film directs the second metallic film to the lower of said two levels.

14. A method according to claim 13 further comprising the step of depositing an exterior protective overcoat layer over the dielectric, antireflective film.

15. A method according to claim 14 wherein the transparent, nonmetallic substrate is glass, the support film-part of the first base film is a zinc stannate film, the crystalline metal-contacting film-part of the first base film is a zinc oxide film;

the first metallic reflective film is a silver film, the first primer film is deposited as titanium metal having a thickness of 22 to 30 Angstroms, the support film-part of the second base film is a zinc stannate film, the crystalline metal-contacting film-part of the second base film is a zinc oxide film, the second metallic reflective film is a silver film, the second primer film is deposited as titanium metal having a thickness of 22 to 30 Angstroms, the dielectric, antireflective film deposited on the second primer film is a zinc stannate film, and the exterior protective overcoat layer is a titanium oxide film.

21. The method of claim 13 further comprising the step of subjecting the coated article to a heat treatment.

22. The method of claim 21 wherein the nonmetallic substrate is glass and said heat treatment is a heat treatment to temper said glass substrate.

31. The method of claim 13 wherein said first base film is deposited on said substrate.

16. A method for making a high transmittance, low emissivity coated article comprising the steps of:

a. selecting a transparent, nonmetallic substrate;

b. depositing a first dielectric, antireflective base film over the substrate, the first base film including a zinc-tin oxide support film-part overlying the substrate and a crystalline metal-contacting film-part selected from the group consisting of indium tin oxide, zinc-aluminum oxide and zinc oxide overlying the support film part;

c. depositing a first metallic reflective film on the crystalline metal-contacting film-part of the first base film, the metallic film having two levels of electrical resistivity, one level being lower than the other;

d. depositing a first primer film over the first metallic reflective film;

e. depositing a second dielectric, antireflective base film over the first primer film, the second dielectric antireflective base film including a crystalline metal-contacting film-part selected from the group consisting of indium tin oxide, zinc-aluminum oxide and zinc oxide overlying a support film-part, wherein the support film-part is further comprised of a first layer of a zinc oxide film overlying the first primer film and a second layer of a zinc stannate film overlying the first layer of said support film-part;

f. depositing a second metallic reflective film on the crystalline metal-contacting film-part of the second base film, the metallic film having two levels of electrical resistivity, one level being lower than the other;

g. depositing a second primer film over the second metallic reflective film; and

h. depositing a dielectric, antireflective film over the second primer film wherein the dielectric, antireflective film includes a first layer of a zinc oxide film deposited over the primer film and a second layer of a zinc stannate film deposited on the first zinc oxide layer of the dielectric, antireflective film;

wherein the metal-contacting film-part of the first base film directs the first metallic film to the lower of said two levels and the metal-contacting film-part of the second base film directs the second metallic film to the lower of said two levels.

17. A method according to claim 16 further comprising the step of depositing an exterior protective overcoat layer over the dielectric antireflective film.

18. A method according to claim 17 wherein the transparent, nonmetallic substrate is glass, the support film-part of the first base film is a zinc stannate film, the crystalline metal-contacting film-part of the first base film is a zinc oxide film, the first metallic reflective film is a silver film, the first primer film is deposited as titanium metal having a thickness of 8 to 12 Angstroms, the second metallic reflective film is a silver film, the second primer film is deposited as titanium metal having a thickness of 8 to 12 Angstroms, and the exterior protective overcoat layer is a titanium oxide film.

32. The method of claim 16 wherein said first base film is deposited on said substrate.

23. A high transmittance, low emissivity coated article comprising:

a. a transparent, nonmetallic substrate;

b. a dielectric, antireflective base film overlying the substrate, the base film including a support film-part overlying said substrate and a crystalline metal-contact film-part overlying the support film-part; and

c. a metallic-reflective film on the crystalline metal-contact film-part, the metallic film having two levels of electrical resistivity, one level being lower than the other;

wherein the support film-part is chemically and thermally more durable than said crystalline metal-contact film-part, said support film-part bonding said crystalline metal-contact film-part to said substrate and wherein said crystalline metal-contact film-part directs said metallic film to the lower of said two resistivity levels.

24. The high transmittance, low emissivity coated article of claim 23 wherein said base film having said metallic reflective film deposited thereon is included on a multi-layer stack deposited on said substrate.

25. The article of claim 23 wherein the support film-part includes an oxide of zinc and tin.

26. The article of claim 24 wherein the metal-contact film-part is selected from the group consisting of indium tin oxide, zinc-aluminum oxide and zinc oxide.

33. A high transmittance, low emissivity coated article comprising:

a. a transparent, nonmetallic substrate;

b. a first dielectric, antireflective base film overlying the substrate, the first base film including a zinc-tin oxide support film-part overlying the substrate and a crystalline metal-contacting film part selected from the group consisting of indium tin oxide, zinc-aluminum oxide and zinc oxide overlying the support film-part;

c. a first metallic reflective film deposited on the crystalline metal-contacting film-part of the first base film, the metallic film having two levels of electrical resistivity, one level being lower than the other;

d. a first primer film overlying the first metallic reflective film;

e. a second dielectric, antireflective base film overlying the first primer film;

f. a second metallic reflective film overlying the second base film;

g. a second primer film overlying the second metallic reflective film; and

h. a dielectric, antireflective film overlying the second primer film;

wherein the metal-contacting film-part of the first base film directs the first metallic film to the lower of said two levels.

34. The coated article according to claim 33 wherein the first base film is deposited on the substrate.

35. A high transmittance, low emissivity coated article comprising:

a. a transparent, nonmetallic substrate;

b. a first dielectric, antireflective base film overlying the substrate;

c. a first metallic reflective film overlying the first base film;

d. a first primer film overlying the first metallic reflective film;

e. a second dielectric, antireflective base film overlying the first primer film, the second base film including a zinc-tin oxide support film-part overlying the first primer film and a crystalline metal-contacting film-part selected from the group consisting of indium tin oxide, zinc aluminum oxide and zinc oxide overlying the support film-part;

f. a second metallic reflective film deposited on the crystalline metal-contacting film-part of the second base film, the metallic film having two levels of electrical resistivity, one level being lower than the other;

g. a second primer film overlying the second metallic reflective film; and

h. a dielectric, antireflective film overlying the second primer film;

wherein the metal-contacting film-part of the second base film directs the second metallic film to the lower of said two levels.

36. A method for making a high transmittance, low emissivity coated article comprising the steps of:

a. selecting a transparent, nonmetallic substrate;

b. depositing a first dielectric, antireflective base film on the substrate, the first base film including a zinc-tin oxide support film-part overlying the substrate and a crystalline metal-contacting film-part selected from the group consisting of indium tin oxide, zinc aluminum oxide and zinc oxide overlying the support film-part;

c. depositing a first metallic reflective film on the crystalline metal-contacting film-part of the first base film, the metallic film having two levels of electrical resistivity, one level being lower than the other;

d. depositing a first primer film over the first metallic reflective film;

e. depositing a second dielectric, antireflective base film over the first primer film;

f. depositing a second metallic reflective film over the second base film;

g. depositing a second primer film over the second metallic reflective film; and

h. depositing a dielectric, antireflective film over the second primer film;

wherein the metal-contacting film-part of the first base film directs the first metallic film to the lower of said two levels.

37. The method according to claim 36 wherein the first base film is deposited on the substrate.

38. A method for making a high transmittance, low emissivity coated article comprising the steps of:

a. selecting a transparent, nonmetallic substrate;

b. depositing a first dielectric, antireflective base film over the substrate;

c. depositing a first metallic reflective film over the first base film;

d. depositing a first primer film over the first metallic reflective film;

e. depositing a second dielectric, antireflective base film over the first primer film, the second base film including a zinc-tin oxide support film-part overlying the first primer film and a crystalline metal-contacting film-part selected from the group consisting of indium tin oxide, zinc-aluminum oxide and zinc oxide overlying the support film-part;

f. depositing a second metallic reflective film on the crystalline metal-contacting film-part of the second base film, the metallic film having two levels of electrical resistivity, one level being lower than the other;

g. depositing a second primer film over the second metallic reflective film; and

h. depositing a dielectric, antireflective film over the second primer film;

wherein the metal-contacting film-part of the second base film directs the second metallic film to the lower of said two levels.