Method of making coated articles having an oxygen barrier coating and coated articles made thereby

• US 6,962,759 B2
• Filed: 04/24/2003
• Issued: 11/08/2005
• 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, GWENDOLYN
• Application Number:
  US10/422,095
• Publication Number:
  US 20040023038A1
• Time in Patent Office: 929 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: 428/699
• CPC Class Codes: B32B 17/00 Layered products essentially comprising sheet glass, or glass, slag, or like fibres
• 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 17/10761 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: Y02T 50/60 : Efficient propulsion technologies, e.g. for aircraft
• CPC Class Codes: Y10T 428/265 : 1 mil or less

Abstract

An article includes a substrate, a functional coating deposited over at least a portion of the substrate, and a protective (barrier) coating deposited over at least a portion of the functional coating. The barrier coating is stable to oxygen-containing gases and limits the transmission of oxygen-containing gases to materials over which it is deposited when subjected to conditioning steps such as heating, bending, and/or tempering.

Claims

1. An article, comprising:

a substrate;

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

a barrier coating comprising a first layer formed over the functional coating and a second layer formed over 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 80 wt. to 95 wt. silica and 5 wt. to 20 wt. alumina,

wherein the barrier coating is stable to oxygen-containing gases and limits the transmission of oxygen-containing gases to materials over which it is deposited when subjected to conditioning comprising one or more of heating, bending, and tempering.

2. The article of claim 1, wherein the substrate is an oxygen barrier.

3. The article of claim 1, wherein the substrate includes at least one other barrier coating formed over at least a portion of the substrate and wherein the functional coating is formed over the at least one other barrier coating.

4. The article of claim 1, wherein the barrier coating has a refractive index in the range of 1.4 to 1.8.

5. The article of claim 1, wherein the substrate is selected from glass, plastic, and ceramic.

6. The article of claim 1, wherein the article is an automotive transparency.

7. The article of claim 1, wherein the article is selected from the group of comprising a window, a single pane of glass, a window with multiple panes of glass, an aircraft transparency, and a motor vehicle transparency.

8. The article of claim 1, wherein the substrate has a thickness in the range of 0.2 mm to 20 mm.

9. The article of claim 1, wherein the functional coating has an emissivity of 0.1 or less.

10. The article of claim 1, wherein the barrier coating increases the emissivity of the coating stack by at least a factor of two with respect to the emissivity of the functional coating.

11. The article of claim 1, wherein the barrier coating increases the emissivity of the coating stack by a factor in the range of 2 to 20 compared to the emissivity of the functional coating.

12. The article of claim 1, wherein the functional coating has an emissivity of less than or equal to 0.1 and the coating stack has an emissivity of greater than or equal to 0.5.

13. The article of claim 1, wherein the emissivity of the coating stack is 0.5 to 0.8.

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

15. The article of claim 1, wherein the first layer comprises 50 wt. % to 60 wt. % alumina and 40 wt. % to 50 wt. % silica.

16. The article of claim 1, wherein the first layer comprises 55 wt. % alumina and 45 wt. % silica.

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

to 1,000 Å

.

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

to 200 Å

.

19. The article of claim 1, wherein the first layer has a thickness of 125 Å

.

20. The article of claim 15, wherein the first layer has a thickness in the range of 50 Å

to 400 Å

.

21. The article of claim 16, wherein the first layer has a thickness of 200 Å

.

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

to 2,000 Å

.

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

to 1,000 Å

.

24. The article of claim 1, wherein the second layer has a thickness of 500 Å

.

25. The article of claim 1, wherein the barrier coating provides an oxygen permeability of less than or equal to 1.5 cubic cm of oxygen gas at a thickness of one mil for 100 square inches over a period of twenty-four hours under an oxygen partial pressure differential of one atmosphere at 23°

C. and a relative humidity of zero.

26. The article of claim 1, wherein the barrier coating is solar absorbing in at least one of the UV, IR, or visible regions of the electromagnetic spectrum.

27. The article of claim 1, wherein the article is a monolithic transparency.