Graded photocatalytic coatings
First Claim
1. A substrate bearing a photocatalytic coating comprising, in sequence outwardly:
- a) a first graded film region having a substantially continuously decreasing concentration of a first transparent dielectric material and a substantially continuously increasing concentration of a second transparent dielectric material;
b) a second graded film region having a substantially continuously decreasing concentration of the second transparent dielectric material and a substantially continuously increasing concentration of a third transparent dielectric material, the third transparent dielectric material comprising a photocatalyst; and
wherein the coating consists essentially of film regions of different transparent dielectric materials interlocked by continuous transition, and the coating does not include any discrete film interfaces, the coating comprising a homogenous intermediate film region that is bounded by and gradually transitions into the first and second graded film regions, the homogenous intermediate film region having a thickness and comprising said second transparent dielectric material, the homogenous intermediate film region having a composition that is substantially uniform across its thickness.
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Abstract
The invention provides graded photocatalytic coatings. In one aspect, the invention provides a substrate carrying a photocatalytic coating that includes a first graded film region and a second graded film region. The first graded film region has a substantially continuously decreasing concentration of a first transparent dielectric material and a substantially continuously increasing concentration of a second transparent dielectric material. The second graded film region has a substantially continuously decreasing concentration of the second transparent dielectric material and a substantially continuously increasing concentration of a third transparent dielectric material. In certain embodiments, the first transparent dielectric material comprises silicon dioxide, the second transparent dielectric material comprises zirconium oxide, and the third transparent dielectric material comprises titanium oxide. The invention also provides methods and equipment for depositing graded photocatalytic coatings.
325 Citations
36 Claims
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1. A substrate bearing a photocatalytic coating comprising, in sequence outwardly:
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a) a first graded film region having a substantially continuously decreasing concentration of a first transparent dielectric material and a substantially continuously increasing concentration of a second transparent dielectric material; b) a second graded film region having a substantially continuously decreasing concentration of the second transparent dielectric material and a substantially continuously increasing concentration of a third transparent dielectric material, the third transparent dielectric material comprising a photocatalyst; and wherein the coating consists essentially of film regions of different transparent dielectric materials interlocked by continuous transition, and the coating does not include any discrete film interfaces, the coating comprising a homogenous intermediate film region that is bounded by and gradually transitions into the first and second graded film regions, the homogenous intermediate film region having a thickness and comprising said second transparent dielectric material, the homogenous intermediate film region having a composition that is substantially uniform across its thickness. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18)
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19. A substrate bearing a photocatalytic coating comprising, in sequence outwardly:
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a) a first graded film region having a substantially continuously decreasing concentration of silicon dioxide and a substantially continuously increasing concentration of zirconium oxide; b) a second graded film region having a substantially continuously decreasing concentration of zirconium oxide and a substantially continuously increasing concentration of titanium oxide; and wherein the coating consists essentially of film regions of different transparent dielectric materials interlocked by continuous transition, and the coating does not include any discrete film interfaces, each graded film region extending between two homogenous film regions of different composition, each graded film region having a thickness of greater than about 10 angstroms but less than about 75 angstroms. - View Dependent Claims (20, 21, 22, 23, 25)
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24. A substrate bearing a graded photocatalytic coating, the graded photocatalytic coating comprising at least one graded film region having a composition that transitions, with increasing distance from the substrate, from one transparent dielectric material to another, the graded photocatalytic coating having an exterior photocatalytic film-side visible reflectance of less than about 13%;
- wherein the coating consists essentially of film regions of different transparent dielectric materials interlocked by continuous transitions, the coating has a total thickness of less than about 150 angstroms, and the graded film region has a thickness of greater than about 10 angstroms but less than about 75 angstroms.
- View Dependent Claims (26, 27, 28)
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29. A substrate bearing a graded photocatalytic coating, the coating being deposited over a major surface of the substrate and comprising at least one graded film region having a composition that transitions, with increasing distance from the substrate, from one transparent dielectric material to another, wherein at least one of these transparent dielectric materials comprises titania, the graded film region having a thickness of greater than about 10 angstroms but less than about 75 angstroms;
- wherein the coating consists essentially of film regions of different transparent dielectric materials interlocked by continuous transition.
- View Dependent Claims (30, 31, 32, 33, 34, 35, 36)
Specification