Coated article with IR reflecting layer and method of making same

• US 7,597,962 B2
• Filed: 06/07/2005
• Issued: 10/06/2009
• Est. Priority Date: 06/07/2005
• Status: Expired due to Fees

• Current Assignee: Guardian Glass LLC (KOCH Industries Incorporated)
• Original Assignee: Centre Luxembourgeois de Recherches pour le Verre et la Ceramique SA, Guardian Industries Corporation (KOCH Industries Incorporated)
• Inventors: Dietrich, Anton, Blacker, Richard, Kriltz, Uwe, Butz, Jochen
• Primary Examiner(s): XU, LING X
• Application Number:
  US11/146,274
• Publication Number:
  US 20060275613A1
• Time in Patent Office: 1,582 Days
• Field of Search: 428/428, 428/432, 428/698, 428/697, 428/699, 428/701, 428/702, 428/704
• US Class Current: 428/432
• CPC Class Codes: C03C 17/36 at least one coating being a metal
• CPC Class Codes: C03C 17/3626 one layer at least containing a nitride, oxynitride, boronitride or carbonitride
• 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: C23C 14/0089 in metallic mode
• CPC Class Codes: C23C 14/086 of zinc, germanium, cadmium, indium, tin, thallium or bismuth
• CPC Class Codes: C23C 14/3414 Metallurgical or chemical aspects of target preparation, e.g. casting, powder metallurgy
• CPC Class Codes: Y10T 428/31 Surface property or characteristic of web, sheet or block
• CPC Class Codes: Y10T 428/315 Surface modified glass [e.g., tempered, strengthened, etc.]

Abstract

A coated article is provided with at least one infrared (IR) reflecting layer (e.g,. silver based). In certain example embodiments, silicon nitride, zinc oxide, and an oxide of Ni and/or Cr are provided under the IR reflecting layer. It has been found that improved thermal stability may be realized upon heat treatment. In certain example instances, the silicon nitride may be replaced with tin oxide.

Claims

1. A heat treated coated article including a coating supported by a glass substrate, the coating comprising:

a dielectric layer;

a layer comprising silicon nitride;

a layer comprising zinc oxide over and directly contacting the layer comprising silicon nitride;

a layer comprising an oxide of Ni and/or Cr over and directly contacting the layer comprising zinc oxide;

an infrared (IR) reflecting layer comprising silver on the glass substrate, located over and directly contacting the layer comprising an oxide of Ni and/or Cr;

another layer comprising an oxide of Ni and/or Cr located over and directly contacting the IR reflecting layer comprising silver;

a layer comprising a metal oxide located over and directly contacting the another layer comprising the oxide of Ni and/or Cr;

a layer comprising silicon nitride located over the layer comprising the metal oxide; and

wherein the layer comprising zinc oxide is formed using a ceramic target comprising zinc oxide so that the IR reflecting layer comprising silver has a specific resistivity (SR) of no greater than 4.2 microohms·

cm and the coating has a sheet resistance of no greater than 3.8 ohms/square.

2. The coated article of claim 1, wherein the coated article includes only one layer comprising silver.

3. The coated article of claim 1, wherein the dielectric layer comprises titanium oxide.

4. The coated article of claim 1, wherein the dielectric layer comprises tin oxide.

5. The coated article of claim 1, further comprising a layer comprising tin oxide provided between the dielectric layer and the layer comprising silicon nitride.

6. The coated article of claim 1, wherein the coating has a sheet resistance (R_s) of no greater than 3.4 ohms/square.

7. The coated article of claim 1, wherein the coated article is an insulating glass (IG) window unit.

8. The coated article of claim 1, wherein the coated article is an insulating glass (IG) window unit, the IG window unit comprising said glass substrate and another glass substrate spaced therefrom, and wherein the IG window unit has a U-value of no greater than 1.25 W/(m²K).

9. The coated article of claim 8, wherein the IG window unit has a U-value of no greater than 1.15 W/(m²K).

10. The coated article of claim 9, wherein the IG window unit has a U-value of no greater than 1.1 W/(m²K).

11. The coated article of claim 9, wherein the IG window unit has a visible transmission of at least 70%.

12. The coated article of claim 1, wherein the coated article has a Δ

E* value (transmissive and/or film side reflective) of no greater than 4.0 due to heat treatment.

13. The coated article of claim 1, wherein the coated article has a Δ

E* value (transmissive and/or film side reflective) of no greater than 3.0 due to heat treatment.

14. The coated article of claim 1, wherein the layer comprising zinc oxide is doped with from about 0.5 to 3% P and/or B.

15. The coated article of claim 1, wherein the layer comprising zinc oxide is doped with from about 0.5 to 3% F and/or B.

20. The coated article of claim 15, further comprising:

another layer comprising an oxide of Ni and/or Cr located over and directly contacting the IR reflecting layer comprising silver;

a layer comprising a metal oxide located over and directly contacting the another layer comprising the oxide of Ni and/or Cr; and

a dielectric layer located over the layer comprising the metal oxide.

16. A coated article including a coating supported by a glass substrate, the coating comprising, from the glass substrate outwardly:

a layer comprising silicon nitride or tin oxide;

a layer comprising zinc oxide over and directly contacting the layer comprising silicon nitride or tin oxide;

a layer comprising an oxide of Ni and/or Cr over and directly contacting the layer comprising zinc oxide;

an infrared (IR) reflecting layer comprising silver over and directly contacting the layer comprising an oxide of Ni and/or Cr;

a dielectric layer; and

wherein the IR reflecting layer comprising silver has a specific resistivity (SR) of no greater than 4.5 microohms.cm and the coating has a sheet resistance of no greater than 3.8 ohms/square, and wherein the layer comprising zinc oxide is doped with F and/or B.

17. The coated article of claim 16, further comprising a layer comprising a metal oxide located between the glass substrate and the layer comprising silicon nitride or tin oxide.

18. The coated article of claim 16, wherein the coated article is not heat treated and the layer comprising the oxide of Ni and/or Cr is substoichiometric.

19. The coated article of claim 16, wherein the coated article is heat treated.

21. The coated article of claim 16, wherein the coated article has only one IR reflecting layer comprising silver, is thermally tempered, and has a sheet resistance of no greater than 3.4 ohms/square.

22. The coated article of claim 16, wherein the layer comprising zinc oxide is doped with from about 0.5 to 3% F and/or B.