Method of making coated articles and coated articles made thereby

• US 7,311,961 B2
• Filed: 03/25/2003
• Issued: 12/25/2007
• Est. Priority Date: 10/24/2000
• Status: Expired due to Term

• Current Assignee: Vitro Flat Glass LLC (Compagnie De Saint-Gobain)
• Original Assignee: PPG Industries Ohio Incorporated (Nouryon BV)
• Inventors: Finley, James J., Thiel, James P.
• Primary Examiner(s): ZACHARIA, RAMSEY E
• Application Number:
  US10/397,001
• Publication Number:
  US 20030228484A1
• Time in Patent Office: 1,736 Days
• Field of Search: 428/166, 428/212, 428/332, 428/336, 428/423.1, 428/426, 428/425.5, 428/437, 428/457, 428/480, 428/522, 428/414, 428/701, 428/702
• US Class Current: 428/212
• 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 17/1055 characterized by the resin layer, i.e. interlayer
• CPC Class Codes: B32B 17/10761 containing vinyl acetal
• CPC Class Codes: C03C 17/34 with at least two coatings having different compositions C03C17/44 takes precedence
• 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 1/105 : Protective coatings
• CPC Class Codes: G02B 1/111 : using layers comprising organic materials
• CPC Class Codes: G02B 1/14 : Protective coatings, e.g. hard coatings
• CPC Class Codes: G02B 5/0808 : having a single reflecting layer G02B5/0883, G02B5/0891 take precedence
• CPC Class Codes: G02B 5/0858 : the reflecting layers comprising a single metallic layer with one or more dielectric layers
• CPC Class Codes: G02B 5/0866 : incorporating one or more organic, e.g. polymeric layers
• 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 156/1043 : Subsequent to assembly
• CPC Class Codes: Y10T 428/12229 : Intermediate article [e.g., blank, etc.]
• CPC Class Codes: Y10T 428/24942 : including components having same physical characteristic in differing degree
• CPC Class Codes: Y10T 428/265 : 1 mil or less
• CPC Class Codes: Y10T 428/31515 : As intermediate layer
• CPC Class Codes: Y10T 428/31551 : Of polyamidoester [polyurethane, polyisocyanate, polycarbamate, etc.]
• CPC Class Codes: Y10T 428/3163 : Next to acetal of polymerized unsaturated alcohol [e.g., formal butyral, etc.]
• CPC Class Codes: Y10T 428/31678 : Of metal
• CPC Class Codes: Y10T 428/31786 : Of polyester [e.g., alkyd, etc.]
• CPC Class Codes: Y10T 428/31935 : Ester, halide or nitrile of addition polymer

Abstract

An article includes a first substrate, a functional coating deposited over at least a portion of the substrate, and a protective coating deposited over the functional coating. The functional coating and the protective coating define a coating stack. A polymeric material is deposited over at least a portion of the protective coating. The protective coating has a refractive index that is substantially the same as the refractive index of the polymeric material.

Claims

1. A laminated article, comprising:

a. a first substrate having a first major surface;

b. a functional coating formed over at least a portion of the first major surface, wherein the functional coating comprises at least one metal oxide-containing coating film and at least one infrared reflective metal film;

c. a protective coating formed over at least a portion of the functional coating, wherein the protective coating consists of a layer comprising a mixture of silica and alumina, wherein the protective coating has a thickness in the range of 300 Å

to 5 microns, and wherein the functional coating and the protective coating define a coating stack;

d. a second substrate; and

e. a polymeric material located between the protective coating and the second substrate, wherein the protective coating has a refractive index in the range of ±

0.2 with respect to the refractive index of the polymeric material.

2. The article as claimed in claim 1, wherein at least one of the first and second substrates is selected from glass, plastic, metal, ceramic, and combinations thereof.

3. The article as claimed in claim 1, wherein the article is an automotive transparency.

4. The article as claimed in claim 1, wherein the functional coating has an emissivity in the range of greater than 0 to 0.1.

5. The article as claimed in claim 1, wherein the protective coating increases the emissivity of the coating stack to be at least 0.3.

6. The article as claimed in claim 1, wherein the protective coating has a refractive index within the range of ±

0.1 with respect to the refractive index of the polymeric material.

7. The article as claimed in claim 1, wherein the polymeric material comprises at least one polymer selected from vinyl resin , polyurethane, polyester, acrylic, and epoxy polymers.

8. The article as claimed in claim 1, wherein the protective coating is of non-uniform thickness.

9. The article as claimed in claim 1, wherein the first and second substrates comprise glass, the functional coating comprises a solar control coating, the polymeric material comprises polyvinyl butyral, and the protective coating has a refractive index in the range of 1.5±

0.1.

10. The article as claimed in claim 1, wherein the protective coating comprises at least one layer comprising 15 wt. % to 70 wt. % alumina and 85 wt. % to 30 wt. % silica.

11. A laminated article, comprising:

a. a first substrate having a first major surface;

b. a functional coating formed over at least a portion of the first major surface, wherein the functional coating comprises at least one metal oxide-containing coating film and at least one infrared reflective metal film;

c. a multilayer protective coating formed over at least a portion of the functional coating to form a coating stack, wherein the protective coating is a multilayer coating comprising a first layer formed over the functional coating and a second layer formed over the first layer, wherein the first and second layers comprise a mixture of alumina and silica and the first layer contains at least 50 wt. % alumina and the second layer contains at least 50 wt. % silica, and wherein the protective coating has a thickness in the range of 300 Å

to 5 microns;

d. a second substrate; and

e. a polymeric material located between the first and second substrates, with the protective coating having a refractive index substantially the same as the refractive index of the polymeric material.

12. The article as claimed in claim 11, wherein the first layer comprises at least 70 wt. % alumina and not more than 30 wt. % silica.

13. The article as claimed in claim 11, wherein the first layer has a thickness in the range of 50 Å

to 1 micron.

14. The article as claimed in claim 11, wherein the first layer has a thickness in the range of 100 Å

to 250 Å

.

15. The article as claimed in claim 11, wherein the second layer comprises at least 70 wt. % silica and not more than 30 wt. % alumina.

16. The article as claimed in claim 11, wherein the second layer has a thickness in the range of 50 Å

to 2,000 Å

.

17. The article as claimed in claim 11, wherein the second layer has a thickness in the range of 300 Å

to 500 Å

.

18. A monolithic article, comprising:

a. a substrate;

b. a functional coating formed over at least a portion of the substrate, wherein the functional coating comprises at least one metal oxide-containing coating film and at least one infrared reflective metal film;

c. a protective coating consisting of a layer comprising a mixture of silica and alumina, formed over at least a portion of the functional coating, wherein the functional coating and the protective coating define a coating stack, and wherein the protective coating has a thickness in the range of 300 Å

to 5 microns; and

d. a polymeric material formed over at least a portion of the protective coating, wherein the protective coating has a refractive index that is substantially the same as the refractive index of the polymeric material.

19. The article as claimed in claim 18, wherein the article is an automotive transparency.

20. The article as claimed in claim 18, wherein the functional coating has an emissivity of 0.1 or less.

21. The article as claimed in claim 18, wherein the protective coating comprises at least one layer comprising 75 wt. % to 85 wt. % alumina and 1 wt. % to 25 wt. % silica.

22. The article as claimed in claim 18, wherein the protective coating has a thickness in the range of 1 micron to 5 microns.

23. The article as claimed in claim 18, wherein the protective coating has a refractive index within ±

0.2 of the refractive index of the interlayer material.

24. The article as claimed in claim 18, wherein the polymeric material comprises polyvinyl butyral.

25. The article as claimed in claim 18, wherein the protective coating has a non-uniform thickness.

26. A monolithic article, comprising:

a. a substrate;

b. a functional coating formed over at least a portion of the substrate, wherein the functional coating comprises at least one metal oxide-containing coating film and at least one infrared reflective metal film;

c. a multilayer protective coating comprising a first layer formed over the functional coating and a second layer formed over at least a portion of the first layer, wherein the first and second layers comprise a mixture of alumina and silica and the first layer contains at least 50 wt. % alumina and the second layer contains at least 50 wt. % silica, wherein the functional coating and the protective coating define a coating stack, and wherein the protective coating has a thickness in the range of 300 Å

to 5 microns; and

d. a polymeric material formed over at least a portion of the protective coating, wherein the protective coating has a refractive index that is substantially the same as the refractive index of the polymeric material.

27. The article as claimed in claim 26, wherein the first layer comprises at least 70 wt. % alumina and not more than 30 wt. % silica.

28. The article as claimed in claim 27, wherein the first layer has a thickness in the range of 50 Å

to 1 micron.

29. The article as claimed in claim 28, wherein the first layer has a thickness in the range of 100 Å

to 250 Å

.

30. The article as claimed in claim 26, wherein the second layer comprises at least 70 wt. % silica and not more than 30 wt. % alumina.

31. The article as claimed in claim 30, wherein the second layer has a thickness in the range of 50 Å

to 2,000 Å

.

32. The article as claimed in claim 31, wherein the second layer has a thickness in the range of 300 Å

to 500 Å

.