High light transmission, low-E sputter coated layer systems and insulated glass units made therefrom

• US 6,132,881 A
• Filed: 09/16/1997
• Issued: 10/17/2000
• Est. Priority Date: 09/16/1997
• Status: Expired due to Term

• Current Assignee: Guardian Glass LLC (KOCH Industries Incorporated)
• Original Assignee: Guardian Industries Corporation (KOCH Industries Incorporated)
• Inventors: Hartig, Klaus W., Lingle, Philip J., Larson, Steven L.
• Primary Examiner(s): LONEY, DONALD J
• Application Number:
  US08/931,356
• Time in Patent Office: 1,127 Days
• Field of Search: 428/34, 428/432, 428/433, 428/434, 428/469, 428/689, 428/699, 428/701, 428/702, 428/215, 428/216, 428/428, 428/472, 428/698, 428/913.3, 359/360, 359/359, 359/584, 359/585, 359/586
• US Class Current: 428/432
• CPC Class Codes: C03C 17/36 at least one coating being a metal
• CPC Class Codes: C03C 17/3613 Coatings of type glass/inorganic compound/metal/inorganic compound/metal/other
• 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 17/3626 one layer at least containing a nitride, oxynitride, boronitride or carbonitride
• 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: Y10T 428/24967 Absolute thicknesses specified

Abstract

A high visible light transmitting, low-E sputter coating system, achieving neutral color and non-mirror-like appearance, useful in 2-pane and 3-pane IG units is achieved by an intermediate layer of silver, an undercoat of a metal oxide or nitride having an index of refraction of 2.35-2.75 and an overcoat of a metal oxide or nitride having an index of refraction of 1.85-2.25.

Claims

1. A glass substrate having a sputter coated layer system thereon which from the glass outwardly consists essentially of:

a) an undercoat layer of a metal oxide or nitride having an index of refraction of 2.35-2.75;

b) a layer of metallic silver; and

c) an overcoat layer of a metal oxide or nitride having an index of refraction of 1.85-2.25;

wherein said layers are of a thickness sufficient such that said glass article has a visible transmittance (T_vis) of at least 84%, a sheet resistance (R_s) of less than or equal to 5.5 ohms/sq., and a normal emissivity (E_n) of less than or equal to 0.065 and wherein said layer system does not include any layer consisting essentially of a sub-stoichiometric metallic oxide located between the substrate and the layer comprised of metallic silver.

2. A glass article according to claim 1, wherein said glass substrate is a monolithic sheet of substantially clear glass.

3. A glass article according to claim 2, wherein said glass article exhibits a substantially neutral, non-purple color and a non-mirror-like reflectance whether viewed from the glass side or the film side.

4. A glass article according to claim 1, wherein said undercoat layer consists essentially of TiO₂ and said overcoat layer consists essentially of SnO₂.

5. A glass article according to claim 4, wherein said layer system further includes a protective layer of a metal oxide between said silver layer and said overcoat layer.

6. A glass article according to claim 5, wherein said protective layer of a metal oxide consists essentially of TiO₂.

7. A glass article according to claims 4 or 5, wherein said layer system further includes a nucleating layer of a metal oxide between said silver layer and said undercoat layer.

8. A glass article according to claim 7, wherein said nucleating layer of a metal oxide consists essentially of ZnO.

9. A glass article according to claim 1, wherein said undercoat layer is a member selected from the group consisting of TiO₂, ZrO₂, PbO, W₂ O₃, SiZrN, SiTiN, and mixtures thereof.

10. A glass article according to claim 9, wherein said overcoat layer is a member selected from the group consisting of ZnO, SnO₂, In₂ O₃, Si₃ N₄ and mixtures thereof.

11. A glass article according to claim 9, which further includes an upper intermediate layer located between said silver layer and said overcoat layer, wherein said upper intermediate layer is selected from an oxide or a nitride of Al, Ti, Zn, Sn, Zr, Cr, Ta, Mg or mixtures thereof.

12. A glass article according to claims 9, 10, or 11, which further includes a lower intermediate layer located between said undercoat layer and said silver layer, wherein said lower intermediate layer is selected from an oxide or nitride of Zn, Ti, Sn, Bi, Si or mixtures thereof.

13. A glass article according to claim 1, wherein said undercoat layer has a thickness of about 160 Å

-320 Å

, said silver layer has a thickness of at least about 165 Å and

said overcoat layer has a thickness of about 350 Å

-700 Å

.

14. A glass article according to claim 3, wherein said layer system from the glass outwardly consists essentially of the following layers and thickness:

space="preserve" listing-type="tabular">______________________________________ Layer Thickness (Å

) ______________________________________ TiO2 160 to 320 Ag 100 to 180 TiO.sub.2 15 or less SnO.sub.2 350 to 700 ______________________________________

15. A glass article according to claim 14, wherein said monolithic glass sheet when consisting of clear glass and measured at a thickness of 2 mm exhibits the following characteristics:

T_vis =84% to 90%

R_s =4.5 to 6.5

E_n =0.04 to 0.07.

16. A glass article according to claim 3, wherein said layer system from the glass outwardly consists essentially of the following layers and thickness:

space="preserve" listing-type="tabular">______________________________________ Layer Thickness (Å

) ______________________________________ TiO2 160 to 320 ZnO ≦

150 Ag 100 to 180 TiO.sub.2 ≦

15 SnO.sub.2 350 to 700 ______________________________________

17. A glass article according to claim 16, wherein said monolithic glass sheet when consisting of clear glass and measured at a thickness of 2 mm exhibits the following characteristics:

T_vis =84% to 90%

R_s =4.5 to 6.5 (ohms/sq.)

E_n =0.04 to 0.07.

18. A glass article according to claim 1, consisting essentially of from the glass substrate outwardly:

space="preserve" listing-type="tabular">______________________________________ Layer Thickness (Å

) ______________________________________ TiO2 290 Ag 165 TiO.sub.2 10 SnO.sub.2 480 ______________________________________

19. A glass article according to claim 1, consisting essentially of from the glass substrate outwardly:

space="preserve" listing-type="tabular">______________________________________ Layer Thickness (Å

) ______________________________________ TiO2 224 ZnO 52 Ag 165 TiO.sub.2 10 SnO.sub.2 480 ______________________________________

20. In an insulating glass unit comprised of at least 2 panes of glass and sealed at their peripheral edges to form an insulating chamber therebetween, the improvement comprising at least one of said panes of glass being a glass sheet according to claims 2, 4, 15, 17, or 19, wherein said layer system on said glass sheet is located within a said insulating chamber wherein said insulating glass unit exhibits the following characteristics:

T_vis =≧

75%

R_outside =≦

15%

R_inside =≦

15%

S.C.=≧

0.60

U_winter =≧

0.26

and wherein T_vis is visible transmittance;

R_outside is visible reflectance as viewed from outside a dwelling;

R_inside is visible reflectance as viewed from inside a dwelling;

S.C. is shading coefficient; and

U_winter is an insulating property.

21. An insulating unit according to claim 20, which exhibits the following characteristics:

T_vis =≧

80%

R_outside =≦

12%

R_inside =≦

12%

S.C.=≧

0.63

U_winter =≦

0.25.

22. An insulating unit according to claim 20, wherein said unit consists of 3-panes of glass having two insulating chambers therebetween, and wherein at least two of said glass sheets is provided with a said layer system.

23. An insulating unit according to claim 22, wherein each of said two insulating chambers has a layer system located therewithin and wherein said insulating unit exhibits the following characteristics:

T_vis =≧

65%

R_outside =≦

15%

R_inside =≦

15%

S.C.=≧

0.50

U_winter =≦

0.16.

24. An insulating unit according to claim 23, which exhibits the following characteristics:

T_vis =≧

70%

R_outside =≦

14%

R_inside =≦

14%

S.C.=≧

0.55

U_winter =≦

0.15.

25. A glass substrate having a sputter coated layer system thereon which from the glass outwardly includes:

a) an undercoat layer having an index of refraction of about 2.35-2.75 selected from the group consisting of TiO₂ ZrO₂, PbO, W₂ O₃, SiZrN, SiTiN, and mixtures thereof;

b) a lower intermediate layer selected from an oxide or nitride of Zn, Ti, Sn, Bi, Si or mixtures thereof;

c) a layer comprised of metallic silver; and

d) an overcoat layer comprised of a metal oxide or nitride having an index of refraction of about 1.85-2.25;

wherein said layers are of a thickness sufficient such that said glass article has a visible transmittance (T_vis) of at least about 84%, a sheet resistance (R_s) of less than or equal to about 5.5 ohms/sq. and a normal emissivity (E_n) of less than or equal to about 0.065 and wherein said layer system does not include any layer consisting essentially of a substoichiometric metallic oxide located between the substrate and the layer comprised of metallic silver.

26. A glass article according to claim 25 wherein said overcoat layer is a member selected from the group consisting of ZnO, SnO₂, In₂ O₃, Si₃ N₄ and mixtures thereof.

27. A glass article according to claim 25 which further includes an upper intermediate layer located between said silver layer and said overcoat layer, wherein said upper intermediate layer is selected from an oxide or a nitride of Al, Ti, Zn, Sn, Zr, Cr, Ta, Mg and mixtures thereof.