Heat reflecting fenestration products with color corrective and corrosion protective layers

• US 6,007,901 A
• Filed: 12/04/1997
• Issued: 12/28/1999
• Est. Priority Date: 12/04/1997
• Status: Expired due to Term

• Current Assignee: Eastman Performance Films, LLC (Eastman Chemical Company)
• Original Assignee: CPFilms Inc. (Eastman Chemical Company)
• Inventors: Spraker, Ronald, Maschwitz, Peter
• Primary Examiner(s): TURNER, ARCHENE A
• Application Number:
  US08/984,977
• Time in Patent Office: 754 Days
• Field of Search: 428/216, 428/336, 428/428, 428/432, 428/698, 428/701, 428/702, 359/580, 359/585, 359/586
• US Class Current: 428/216
• 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 17/3647 in combination with other metals, silver being more than 50%
• 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 17/38 at least one coating being a coating of an organic material
• CPC Class Codes: Y10T 428/24975 No layer or component greater than 5 mils thick
• CPC Class Codes: Y10T 428/265 1 mil or less

Abstract

A heat reflecting fenestration composite is provided which includes in sequence: (a) a substantially transparent substrate; (b) a first outer dielectric layer; (c) an infrared reflecting metal layer; (d) a color correcting metal layer comprising a metal different from the infrared reflecting metal layer; (e) a protective metal layer comprising a metal different from the infrared reflecting metal layer and different from the color correcting layer; and (f) a second outer dielectric layer. The dielectric layers are typically indium oxide, indium zinc oxide, indium tin oxide or mixtures thereof. Preferably, the composite also includes additional layers of infrared reflecting metal layer, color correcting metal, protective metal and dielectric. Also preferably, the composite comprises a top layer of glass or transparent polymeric plastic. The infrared reflecting metal layer is typically silver, gold, copper or alloys thereof. The color correcting metal layer typically has a refractive index in the visible light range between about 0.6 and about 4 and has an extinction coefficient for light in the visible light range between about 1.5 and about 7. Metals such as chromium, cobalt, nickel, zinc, palladium, indium, tin, antimony, platinum, bismuth and alloys thereof can be used in the color correcting metal layer, with indium being preferred. The protective metal layer is made from a metal whose oxide is substantially non-optically absorbing, such as aluminum, titanium, zirconium, niobium, hafnium, tantalum, tungsten and alloys thereof, with titanium being preferred. The color correcting and protective metal layers can also be disposed on both sides of the infrared reflecting metal layer. Such composites provide a heat reflecting fenestration structure having exception degradation resistant properties and visible light transmission reduction properties, without excessive reflectance.

Claims

1. A heat reflecting fenestration composite comprising in sequence:

(a) a substantially transparent first substrate;

(b) a first outer dielectric layer;

(c) an infrared reflecting metal layer;

(d) a color correcting metal layer comprising a metal different from the infrared reflecting metal layer;

(e) a protective metal layer comprising a metal different from the infrared reflecting metal layer and different from the color correcting layer;

(f) a subcomposite comprising;

(i) a subcomposite inner dielectric layer;

(ii) a subcomposite infrared reflecting metal layer;

(iii) a subcomposite color correcting metal layer comprising a metal different from the subcomposite infrared reflecting metal layer; and

(iv) a subcomposite protective metal layer comprising a metal different from the subcomposite infrared reflecting metal layer and different from the subcomposite color correcting layer;

(g) a second outer dielectric layer; and

(h) a substantially transparent second substrate;

wherein the heat reflective substrate transmits 40-60% of light within the visible wavelengths and has a reflectance of less than 15%; and

wherein the color of both transmitted and reflected light from the heat reflecting fenestration product is either neutral or is slightly blueish or slightly greenish in color.

2. The heat reflecting fenestration composite of claim 1 wherein the outer dielectric layers have an index of refraction between about 1.9 and about 2.5.

3. The heat reflecting fenestration composite of claim 1 wherein the outer dielectric layers have a thickness between about 0.15 quarter wave optical thickness and about 1 quarter wave optical thickness.

4. The heat reflecting fenestration composite of claim 1 wherein the outer dielectric materials are selected from the group of dielectric materials consisting of (i) oxides of magnesium, indium, tin, indium and tin, tantalum, yttrium, niobium, tungsten, zinc, bismuth, titanium and mixtures thereof and (ii) nitrides of silicon and aluminum.

5. The heat reflecting fenestration composite of claim 1 wherein the subcomposite inner dielectric layer has an index of refraction between about 1.4 and about 2.5, is chosen from the group of dielectric materials consisting of (i) oxides of magnesium, indium, tin, indium and tin, tantalum, yttrium, niobium, tungsten, zinc, bismuth, titanium and mixtures thereof, (ii) nitrides of silicon and aluminum, and (iii) polymeric materials, and has a thickness between about 0.3 quarter wave optical thickness and about 2 quarter wave optical thickness.

6. The heat reflecting fenestration composite of claim 1 wherein the dielectric layers are chosen from the group of dielectric materials consisting of indium oxide, indium zinc oxide, indium tin oxide and mixtures thereof.

7. The heat reflecting fenestration composite of claim 1 wherein the infrared reflecting metal layer has a thickness between about 7 nm and about 25 nm.

8. The heat reflecting fenestration composite of claim 1 wherein the infrared reflecting metal layers are chosen from the list of metals consisting of silver, gold, copper and alloys thereof.

9. The heat reflecting fenestration composite of claim 1 wherein the infrared reflecting metal layers comprise silver.

10. The heat reflecting fenestration composite of claim 1 wherein the infrared reflecting metal layers consist essentially of a silver/copper alloy wherein the percentage of copper within the alloy is between 3 and about 20 weight percent.

11. The heat reflecting fenestration composite of claim 1 wherein the infrared reflecting metal layers consist essentially of a silver/copper alloy wherein the percentage of copper within the alloy is between about 5 and about 10 weight percent.

12. The heat reflecting fenestration composite of claim 1 wherein the color correcting metal layers have a refractive index in the visible light wave range between about 0.6 and about 4.

13. The heat reflecting fenestration composite of claim 1 wherein the index of refraction for the color correcting metal layers generally increase with increasing wave lengths for light waves having a wave length between about 400 nm and about 750 mm.

14. The heat reflecting fenestration composite of claim 1 wherein the color correcting metal layers have an extinction coefficient for light in the visible range of between about 1.5 and about 7.

15. The heat reflecting fenestration composite of claim 1 wherein the color correcting metal layers have a thickness between about 2 nm and about 15 nm.

16. The heat reflecting fenestration composite of claim 1 wherein the color correcting metal layers are chosen from the group of metals consisting of chromium, cobalt, nickel, zinc, palladium, indium, tin, antimony, platinum, bismuth and alloys thereof.

17. The heat reflecting fenestration composite of claim 1 wherein the color correcting metal layers consist essentially of indium.

18. The heat reflecting fenestration composite of claim 1 wherein the protective metal layers consist substantially of a metal whose oxide is substantially non-optically absorbing.

19. The heat reflecting fenestration composite of claim 1 wherein the protective metal layers have a thickness between about 1 nm and about 5 nm.

20. The heat reflecting fenestration composite of claim 1 wherein the protective metal layers are chosen from the list of metals consisting of aluminum, titanium, zirconium, niobium, hafnium, tantalum, tungsten and alloys thereof.

21. The heat reflecting fenestration composite of claim 1 wherein the protective metal layers consist essentially of titanium.

22. The heat reflecting fenestration composite of claim 1 wherein each infrared reflecting metal layer is sandwiched between a pair of color correcting metal layers comprising metals different from the respective infrared reflecting metal layer and wherein each color correcting metal layer is contiguous with a protective metal layer comprising a metal different from the infrared reflecting and metal layers and different from the color correcting metal layers.

23. The heat reflecting fenestration composite of claim 1 wherein the number of subcomposites is two.

24. The heat reflecting fenestration composite of claim 1 wherein the substantially transparent second substrate is disposed contiguous with the second outer dielectric layer.

25. The heat reflecting fenestration composite of claim 1 wherein the composite transmits less than about 7% of the infrared energy in light having a wavelength greater than about 1500 nm.

26. The heat reflecting fenestration composite of claim 1 wherein the combined thicknesses of the infrared reflecting metal layer and the color correcting metal layer is to more than 24 nm.

27. The heat reflecting fenestration composite of claim 1 wherein the combined thicknesses of the infrared reflecting metal layer and the color correcting metal layer is 10-24 nm.

28. The heat reflecting fenestration composite of claim 1 wherein the combined thicknesses of the infrared reflecting metal layer, the color correcting metal layer and the protecting metal layer is no more than 29 nm.

29. The heat reflecting fenestration composite of claim 1 wherein the combined thicknesses of the infrared reflecting metal layer, the color correcting metal layer and the protecting metal layer is 10.5-29 nm.

30. The heat reflecting fenestration composite of claim 1 wherein the combined thicknesses T₁ of the infrared reflecting metal layer, the color correcting metal layer and the protecting metal layer is different than the combined thickness T₂ of the subcomposite infrared reflecting metal layer, the subcomposite color correcting metal layer and the subcomposite protecting metal layer, and wherein T₁ and T₂ are in a ratio to one another of about 1.2.

31. A heat reflecting fenestration composite comprising in sequence:

(a) a substantially transparent first substrate;

(b) a first outer dielectric layer;

(c) an infrared reflecting metal layer comprising silver;

(d) a color correcting metal layer comprising a metal chosen from the group of metals consisting of chromium, cobalt, nickel, zinc, palladium, indium, tin, antimony, platinum, bismuth and alloys thereof;

(e) a protective metal layer comprising a metal chosen from the group of metals consisting of aluminum, titanium, zirconium, niobium, hafnium, tantalum, tungsten and alloys thereof;

(f) a subcomposite comprising;

(i) a subcomposite inner dielectric layer;

(ii) a subcomposite infrared reflecting metal layer comprising silver;

(iii) a subcomposite color correcting metal layer comprising a metal chosen from the group of metals consisting of chromium, cobalt, nickel, zinc, palladium, indium, tin, antimony, platinum, bismuth and alloys thereof;

(iv) a subcomposite protective metal layer comprising a metal chosen from the group of metals consisting of aluminum, titanium, zirconium, niobium, hafnium, tantalum, tungsten and alloys thereof;

(g) a second outer dielectric layer; and

(h) a substantially transparent second substrate disposed contiguous with the second outer dielectric layer;

wherein the dielectric layers are chosen from the group of dielectric materials consisting of indium oxide, indium zinc oxide, indium tin oxide and mixtures thereof;

wherein the heat reflective substrate transmits 40-60% of light within the visible wavelengths and has a reflectance of less than 15%;

wherein the color of both transmitted and reflected light from the heat reflect substrate is either neutral or is blue or green in color; and

wherein the composite transmits less than about 7% of the infrared energy in light having a wavelength greater than about 1500 nm.

32. A heat reflecting fenestration composite comprising in sequence:

(a) a substantially transparent substrate;

(b) a first outer dielectric layer;

(c) an infrared reflecting metal layer;

(d) a color correcting metal layer comprising a metal different from the infrared reflecting metal layer;

(e) a protective metal layer comprising a metal different from the infrared reflecting metal layer and different from the color correcting layer;

(f) a subcomposite comprising;

(i) a subcomposite inner dielectric layer;

(ii) a subcomposite infrared reflecting metal layer;

(iii) a subcomposite color correcting metal layer comprising a metal different from the subcomposite infrared reflecting metal layer; and

(iv) a subcomposite protective metal layer comprising a metal different from the subcomposite infrared reflecting metal layer and different from the subcomposite color correcting layer; and

(g) a second outer dielectric layer;

wherein the combined thickness T₁ of the infrared reflecting metal layer, the color correcting metal layer and the protecting metal layer is different than the combined thickness T₂ of the subcomposite infrared reflecting metal layer, the subcomposite color correcting metal layer and the subcomposite protecting metal layer, and wherein T₁ and T₂ are in a ratio to one another of about 1.2.