Method of making a coated article including DLC and FAS

• US 6,531,182 B2
• Filed: 06/20/2001
• Issued: 03/11/2003
• Est. Priority Date: 05/03/1999
• Status: Expired due to Fees

• Current Assignee: Guardian Glass LLC (KOCH Industries Incorporated)
• Original Assignee: Guardian Industries Corporation (KOCH Industries Incorporated)
• Inventors: Petrmichl, Rudolph Hugo, Veerasamy, Vijayen S.
• Primary Examiner(s): CHEN, BRET P
• Application Number:
  US09/884,142
• Publication Number:
  US 20010044030A1
• Time in Patent Office: 629 Days
• Field of Search: 427/249.7, 427/533, 427/535, 427/577, 427/255.7, 427/249.15
• US Class Current: 427/249.7
• CPC Class Codes: B05D 5/083 involving the use of fluoropolymers
• CPC Class Codes: B08B 17/06 by giving articles subject to fouling a special shape or arrangement
• CPC Class Codes: B08B 17/065 the surface having a microscopic surface pattern to achieve the same effect as a lotus flower
• CPC Class Codes: B32B 17/1033 Laminated safety glass or glazing containing temporary protective coatings or layers
• CPC Class Codes: B60S 1/54 using gas, e.g. hot air
• CPC Class Codes: B60S 1/58 for rear windows
• CPC Class Codes: C03C 17/22 with other inorganic material C03C17/34, C03C17/44 take precedence
• CPC Class Codes: C03C 17/3441 comprising carbon, a carbide or oxycarbide
• CPC Class Codes: C03C 17/3482 comprising silicon, hydrogenated silicon or a silicide
• CPC Class Codes: C03C 17/36 at least one coating being a metal
• CPC Class Codes: C03C 17/3634 one layer at least containing carbon, a carbide or oxycarbide
• 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 17/42 at least one coating of an organic material and at least one non-metal coating
• CPC Class Codes: C03C 2217/282 Carbides, silicides
• CPC Class Codes: C03C 2217/76 Hydrophobic and oleophobic coatings
• CPC Class Codes: C03C 2217/78 Coatings specially designed to be durable, e.g. scratch-resistant
• CPC Class Codes: C03C 2218/151 by vacuum evaporation
• CPC Class Codes: C03C 2218/31 Pre-treatment
• CPC Class Codes: C03C 23/0075 Cleaning of glass specially adapted to plate glass B08B11/00
• CPC Class Codes: C03C 3/076 : with 40% to 90% silica, by weight C03C3/045 takes precedence
• CPC Class Codes: C23C 16/26 : Deposition of carbon only
• 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: Y10T 428/24983 : Hardness
• CPC Class Codes: Y10T 428/30 : Self-sustaining carbon mass or layer with impregnant or other layer
• CPC Class Codes: Y10T 428/31663 : As siloxane, silicone or silane

Abstract

A substrate is coated with a coating system including diamond-like carbon (DLC) and at least one fluoro-alkyl silane (FAS) compound. In certain embodiments, a method of making a coated article includes providing a substrate; and forming a coating system on said substrate in a manner such that the coating system includes each of diamond-like carbon (DLC) and at least one fluoro-alkyl silane (FAS) compound.

Claims

1. A method of making a coated article, the method comprising:

providing a substrate;

depositing a first DLC inclusive layer on the substrate using a first gas including silicon (Si);

depositing a second DLC inclusive layer on the substrate over the first DLC inclusive layer using a second gas different than the first gas; and

applying a FAS inclusive layer over said second DLC inclusive layer.

2. The method of claim 1, further comprising depositing the second DLC inclusive layer so as to include ta-C, and applying the FAS inclusive layer so that the resulting article has an initial contact angle θ

of at least about 80 degrees.

3. The method of claim 1, wherein said first gas includes a silane compound and said second gas includes a hydrocarbon.

4. The method of claim 1, wherein said first gas comprises at least one of tetramethylsilane, trimethyldisilane, tetraethoxysilane, hexamethyldisiloxane, and dichlorodimethylsilane.

5. The method of claim 1, wherein the second gas comprises C₂H₂.

6. The method of claim 1, wherein the first layer is deposited in direct contact with the substrate using at least plasma ion beam deposition, and wherein said FAS inclusive layer is applied so as to be in direct or indirect contact with said second DLC inclusive layer.

7. The method of claim 1, further comprising depositing an intermediate layer such that the intermediate layer is located between a) the substrate, and b) the first and second DLC inclusive layers.

8. The method of claim 1, further comprising depositing the first and second DLC inclusive layers such that the first DLC inclusive layer includes substantially more Si than the second DLC inclusive layer.

9. A method of making a coated article comprising:

providing a substrate; and

forming a coating system on said substrate such that the coating system includes each of diamond-like carbon (DLC) and at least one fluoro-alkyl silane (FAS) compound.

10. The method of claim 9, wherein the coating system includes at least one DLC inclusive layer and at least one FAS inclusive layer.

11. The method of claim 10, wherein the FAS inclusive layer is applied on a surface of the DLC inclusive layer within about 60 minutes after formation of the DLC inclusive layer on the substrate.

12. The method of claim 10, further comprising the step of heating the FAS inclusive layer after its formation on the substrate in order to increase its durability.