Coated articles having a protective coating and cathode targets for making the coated articles

• US 6,916,542 B2
• Filed: 04/24/2003
• Issued: 07/12/2005
• Est. Priority Date: 10/22/2001
• Status: Expired due to Term

• Current Assignee: Vitro Flat Glass LLC (Compagnie De Saint-Gobain)
• Original Assignee: PPG Industries Ohio Incorporated (Nouryon BV)
• Inventors: Lehan, John P., Thiel, James P., Finley, James J., Buhay, Harry
• Primary Examiner(s): Jones, Deborah
• Assistant Examiner(s): Blackwell-Rudasill, G.
• Application Number:
  US10/422,094
• Publication Number:
  US 20040023080A1
• Time in Patent Office: 810 Days
• Field of Search: 428/428, 428/432, 428/433, 428/434, 428/446, 428/697, 428/698, 428/699, 428/701, 428/702, 428/704
• US Class Current: 428/432
• CPC Class Codes: B32B 17/10036 comprising two outer glass sheets
• CPC Class Codes: B32B 17/10174 Coatings of a metallic or dielectric material on a constituent layer of glass or polymer
• CPC Class Codes: B32B 17/10229 Metallic layers sandwiched by dielectric layers
• CPC Class Codes: B32B 17/10761 containing vinyl acetal
• CPC Class Codes: C03C 17/3417 all coatings being oxide coatings
• 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 17/3644 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 17/38 at least one coating being a coating of an organic material
• 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 2217/78 Coatings specially designed to be durable, e.g. scratch-resistant
• CPC Class Codes: C23C 14/08 Oxides C23C14/10 takes precedence
• CPC Class Codes: C23C 14/3414 Metallurgical or chemical aspects of target preparation, e.g. casting, powder metallurgy
• CPC Class Codes: C23C 14/5806 Thermal treatment
• CPC Class Codes: G02B 1/111 using layers comprising organic materials
• CPC Class Codes: G02B 5/0808 having a single reflecting layer G02B5/0883, G02B5/0891 take precedence
• CPC Class Codes: G02B 5/0875 : the reflecting layers comprising two or more metallic 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: Y10T 428/265 : 1 mil or less

Abstract

An article includes a substrate, a functional coating deposited over the substrate, and a protective coating deposited over the functional coating. The functional coating and the protective coating define a coating stack. The protective coating provides the coating stack with an emissivity value higher than the emissivity value of the functional coating alone. The protective coating can have a thickness in the range of greater than 100 Å to less than or equal to 10 microns and a refractive index in the range of 1.4 to 2. The protective coating can include a first layer formed over the functional coating and a second layer formed over the first layer. The first layer can include 50 wt. % to 100 wt. % alumina and 50 wt. % to 0 wt. % silica, and the second layer can include 50 wt. % to 100 wt. % silica and 50 wt. % to 0 wt. % alumina. An alternating current power supply and cathode target system includes a cathode target including aluminum in the range of 5 wt. % to 100 wt. % and silicon in the range of 0 wt. % to 95 wt. %.

Claims

1. An article, comprising:

a substrate;

a functional coating deposited over at least a portion of the substrate; and

a protective coating deposited over at least a portion of the functional coating,

wherein the functional coating and the protective coating define a coating stack,

wherein the protective coating provides the coating stack with an emissivity higher than the emissivity of the functional coating alone,

wherein the protective coating has a thickness in the range of greater than 100 Å

to less than or equal to 10 microns and the protective coating has a refractive index in the range of 1.4 to 2, and

wherein the protective coating comprises a first layer formed over at least a portion of the functional coating and a second layer formed over at least a portion of the first layer, wherein the first layer comprises 50 wt. % to 99 wt. % alumina and 50 wt. % to 1 wt. % silica, and the second layer comprises 50 wt. % to 99 wt. % silica and 50 wt. % to 1 wt. % alumina.

2. The article of claim 1, wherein the article is a motor vehicle transparency.

4. The article of claim 1, wherein the first layer has a thickness in the range of 50 Å

to 1 micron.

5. The article of claim 1, wherein the first layer has a thickness in the range of 100 Å

to 250 Å

.

6. The article of claim 1, wherein the second layer comprises 70 wt. % to 99 wt. % silica and 30 wt. % to 1 wt. % alumina.

7. The article of claim 1, wherein the second layer has a thickness in the range of 50 Å

to 2,000 Å

.

8. The article of claim 1, wherein the second layer has a thickness in the range of 300 Å

to 500 Å

.

3. The article of claim , wherein the first layer comprises 70 wt. % to 99 wt. % alumina and 30 wt. % to 1 wt. % silica.

9. A monolithic transparency, comprising:

a glass substrate;

a functional coating deposited over at least a portion of the glass substrate; and

a protective coating deposited over at least a portion of the functional coating to form a coating stack, the protective coating comprising aluminum oxide having a thickness in the range of 1 micron to 10 microns, and

wherein the protective coating comprises a first layer formed over at least a portion of the functional coating and a second layer formed over at least a portion of the first layer, wherein the first layer comprises 50 wt. % to 99 wt. % alumina and 50 wt % to 1 wt. % silica, and the second layer comprises 50 wt % to 99 wt. % silica and 50 wt. % to 1 wt. % alumina.

10. An article, comprising:

a substrate;

at least one solar infrared reflective dielectric functional coating deposited over at least a portion of the substrate; and

a protective coating deposited over at least a portion of the functional coating,

wherein the protective coating has a thickness in the range of greater than 100 Å

to less than 10 microns and has a refractive index in the range of 1.4 to 1.8, and

wherein the protective coating comprises a first layer formed over at least a portion of the functional coating and a second layer formed over at least a portion of the first layer, wherein the first layer comprises 50 wt. % to 99 wt. % alumina and 50 wt. % to 1 wt. % silica, and the second layer comprises 50 wt. % to 99 wt. % silica and 50 wt. % to 1 wt. % alumina.