Photocatalytically-activated self-cleaning article and method of making same
First Claim
1. A photocatalytically-activated self-cleaning article of manufacture comprising:
- a substrate having at least one surface; and
a photocatalytically-activated self-cleaning coating deposited over the surface of the substrate at a thickness of less than 1,000 Angstroms by a process selected from the group consisting of chemical vapor deposition, magnetron sputtered vacuum deposition and spray pyrolysis, wherein said photocatalytically-activated self-cleaning coating comprises one layer of a multilayer stack of coatings deposited over the substrate wherein said photocatalytically-activated self-cleaning coating is a layer other than the uppermost layer of said multilayer stack.
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Abstract
A method and article are disclosed wherein a substrate is provided with a photocatalytically-activated self-cleaning surface by forming a photocatalytically-activated self-cleaning coating on the substrate by spray pyrolysis chemical vapor deposition or magnetron sputter vacuum deposition. The coating has a thickness of at least about 500 Angstroms to limit sodium-ion poisoning to a portion of the coating facing the substrate. Alternatively, a sodium ion diffusion barrier layer is deposited over the substrate prior to the deposition of the photocatalytically-activated self-cleaning coating to prevent sodium ion poisoning of the photocatalytically-activated self-cleaning coating. The substrate includes glass substrates, including glass sheet and continuous float glass ribbon.
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Citations
51 Claims
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1. A photocatalytically-activated self-cleaning article of manufacture comprising:
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a substrate having at least one surface; and a photocatalytically-activated self-cleaning coating deposited over the surface of the substrate at a thickness of less than 1,000 Angstroms by a process selected from the group consisting of chemical vapor deposition, magnetron sputtered vacuum deposition and spray pyrolysis, wherein said photocatalytically-activated self-cleaning coating comprises one layer of a multilayer stack of coatings deposited over the substrate wherein said photocatalytically-activated self-cleaning coating is a layer other than the uppermost layer of said multilayer stack. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12)
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13. A photocatalytically active coated article comprising:
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a glass substrate having an air side major surface having sodium ions therein and an opposite major surface having tin diffused therein defined as a tin side major surface; and a coating over the air side major surface, said coating comprising a photocatalytically-active titanium dioxide layer having a first surface and an opposite surface defined as a second surface with the second surface adjacent the air side major surface of the glass substrate and the second surface of the coating having sodium ions diffused therein from the air side major surface of the glass substrate, wherein the photocatalytically-active titanium dioxide layer comprises a combination of anatase phase and amorphous phase of titanium dioxide and said layer has a thickness ranging from about 100 to about 1000 Angstroms.
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14. A photocatalytically active coated article comprising:
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a glass substrate having an air side major surface and an opposite major surface having tin therein defined as a tin side major surface; and a coating over the air side major surface, said coating comprising a photocatalytically-active titanium dioxide layer having a first surface and an opposite surface defined as a second surface with the second surface adjacent the air side major surface of the glass substrate, wherein (a) the photocatalytically-active titanium dioxide layer comprises a combination of anatase phase and an amorphous phase of titanium dioxide, (b) said layer has a thickness ranging from about 100 to about 1000 Angstrom, (c) said tin side major surface has tin diffused therein characteristic of glass formed by pulling molten glass in the form of a glass ribbon across a molten tin bath while cooling the glass ribbon, (d) said photocatalytically-active titanium dioxide layer was deposited by chemical vapor deposition in the tin bath and this coated glass is exposed to ultraviolet radiation, and (e) said photocatalytically active titanium dioxide layer has a photocatalytically active self-cleaning reaction rate of at least about 2 ×
10−
3 cm−
1 min−
1. - View Dependent Claims (15, 16, 17, 18, 19, 20, 21, 22, 23, 24, 25, 26, 27, 28, 29, 30, 31, 32, 33, 34, 35, 36, 37)
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38. A photocatalytically-activatable self-cleaning article of manufacture comprising:
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a glass substrate having a first major surface and an opposite major surface defined as a second major surface, the first major surface having tin diffused therein characteristic of being formed by pulling molten glass in the form of a glass ribbon across a molten tin bath while cooling the glass ribbon, and a photocatalytically-activatable self-cleaning metal oxide coating having a thickness of less than 1,000 Angstroms over the second major surface capable of having a photocatalytically-activated self-cleaning reaction rate of at least about 2×
10−
3 cm1 min−
1, where the metal oxide coating was deposited by chemical vapor deposition at a temperature in the range of at least 400–
800°
C. - View Dependent Claims (39, 40, 41, 42, 43, 44)
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45. A photocatalytically-activatable coated glass comprising:
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a glass substrate having an air side major surface and a tin side major surface having been formed in a tin bath of a float glass process; a coating over the air side major surface, said coating comprising a photocatalytically-activatable titanium dioxide layer having a first surface and a second surface with the second surface adjacent the air side major surface, wherein the photocatalytically-activatable titanium dioxide layer comprises anatase titanium dioxide and said layer has a thickness ranging from about 100 to about 1000 Angstroms; and wherein the coated glass comprises an interlayer between the photocatalytically-activatable layer second surface and the air side major surface of the substrate, said interlayer comprising amorphous silicon oxide.
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46. A photocatalytically-active coated glass comprising:
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a glass substrate having an air side major surface and a tin side major surface having been formed in a tin bath of a float glass process; a coating over the air side major surface of the substrate, said coating comprising a photocatalytically-active titanium dioxide layer having a first surface and a second surface with the second surface adjacent the air side major surface wherein the photocatalytically-active titanium dioxide layer comprises anatase titanium dioxide having a thickness of less than 1000 Angstroms, and an interlayer between the second surface of the photocatalytically-active layer and the air side major surface of the substrate, said interlayer comprising amorphous silicon oxide, wherein said tin side major surface has tin diffused therein characteristic of being formed from a glass ribbon floated in a molten tin bath; wherein said photocatalytically-active titanium dioxide layer was deposited by chemical vapor deposition in said tin bath and exposed to ultraviolet radiation, and further wherein said photocatalytically-active titanium dioxide layer has a photocatalytically-active self-cleaning reaction rate of at least about 2×
10−
3 cm−
1 min−
1. - View Dependent Claims (47, 48)
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49. A photocatalytically-active coated glass comprising:
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a glass substrate having an air side major surface and a tin side major surface, the tin side major surface having tin oxide characteristic of glass formed by pulling molten glass in the form of a glass ribbon across a molten tin bath while cooling the glass ribbon; and a coating over the air side major surface, said coating comprising a photocatalytically-active titanium dioxide layer having a first surface and a second surface with the second surface adjacent the air side major surface, wherein said layer (a) has a thickness ranging from about 100 to about 1000 Angstroms, (b) was deposited by chemical vapor deposition in said tin bath and exposed to ultraviolet radiation, and (c) has a photocatalytically-active self-cleaning reaction rate of at least 2×
10−
3 cm−
1 min−
1.
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50. A photocatalytically active coated glass comprising:
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a glass substrate having an air side major surface and a tin side major surface, the tin side major surface having tin oxide therein characteristic of glass formed by pulling molten glass in the form of a glass ribbon across a molten tin while cooling the glass ribbon; a sodium ion diffusion barrier layer over said air side major surface, and a coating over the sodium ion diffusion barrier layer, said coating comprising a photocatalytically-active titanium dioxide layer having a first surface and a second surface with the second surface adjacent the sodium ion diffusion barrier layer, wherein the photocatalytically active titanium dioxide layer has a thickness ranging from about 100 to about 1000 Angstroms, was deposited by chemical vapor deposition in said tin bath, and has a photocatalytically active self-cleaning reaction rate of at least about 9.95×
10−
1 cm1 −
min−
1. - View Dependent Claims (51)
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Specification