Low-E matchable coated articles, and methods

• US 6,730,352 B2
• Filed: 05/16/2003
• Issued: 05/04/2004
• Est. Priority Date: 09/13/2001
• Status: Expired due to Term

• Current Assignee: Guardian Glass LLC (KOCH Industries Incorporated)
• Original Assignee: Guardian Industries Corporation (KOCH Industries Incorporated)
• Inventors: Stachowiak, Grzegorz
• Primary Examiner(s): Jones, Deborah
• Assistant Examiner(s): Piziali, Andrew T
• Application Number:
  US10/439,169
• Publication Number:
  US 20030194489A1
• Time in Patent Office: 354 Days
• Field of Search: 428/428, 428/432, 428/448, 428/673, 428/697, 428/698, 428/699, 428/701, 428/702, 428/34, 428/689, 428/704, 427/162, 427/163.1, 427/165
• US Class Current: 427/165
• 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 17/3626 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: C03C 2217/78 Coatings specially designed to be durable, e.g. scratch-resistant
• CPC Class Codes: Y10T 428/12896 Ag-base component
• CPC Class Codes: Y10T 428/265 1 mil or less

Abstract

A heat treatable coated article including an infrared (IR) reflecting layer (e.g., of or including Ag), the coated article being able to attain a ΔE* (glass side) no greater than about 3.5, more preferably no greater than 3.0, and even more preferably no greater than 2.6, following or due to heat treatment (e.g., thermal tempering). Accordingly, low-E (i.e., low emissivity) coated articles of certain embodiments of this invention appear from the glass side thereof visually similar to the naked eye both before and after heat treatment. Good matchability characteristics (i.e., low ΔE* values) combined with good durability can be achieved by controlling to what extent barrier layer(s) in contact with the IR reflecting layer are nitrided and to what thickness(es) they are sputtered. Optionally, certain embodiments of this invention relate to coated articles that also have high visible transmission and/or good durability. Coated articles herein may be used in the context of insulating glass (IG) window units, vehicle windows, or any other suitable applications. In certain embodiments of this invention, an exemplary layer stack includes: glass/Si₃N₄/NiCrN_x/Ag/NiCrN_x/Si₃N₄. Other materials may instead be used without departing from the scope and/or spirit of the instant invention which is a low-E matchable and/or durable product.

Claims

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

depositing a layer system on a glass substrate, the layer system including an infrared (IR) reflecting metal layer located between and in contact with first and second barrier layers that are at least partially nitrided,

controlling nitrogen gas flow during sputtering of at least one of the barrier layers so that the nitrogen gas flow is from 0-16 sccm/kW, and

heat treating the substrate with the layer system thereon so that due to said heat treating the resulting substrate with the layer system thereon has a Δ

E* value (glass side) no greater than 3.5.

2. The method of claim 1, wherein the nitrogen gas flow is from 4-12 sccm/kW.

3. The method of claim 2, wherein the nitrogen gas flow is from 6-10 sccm/kW.

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

depositing a layer system on a glass substrate, a layer system including at least one infrared reflecting layer located between and in contact with first and second barrier layers;

controlling nitrogen gas flow during sputtering of at least one of the barrier layers so that the nitrogen gas flows from 0-16 sccm/kW; and

heat treating the substrate with the layer system thereon so that the resulting substrate with the layer system thereon has a Δ

E* value (glass side reflective) no greater than 3.5.

5. The method of claim 4, wherein the nitrogen gas flow is from 4-12 sccm/kW.