Photocatalytic window and method of making same

• US 7,846,492 B2
• Filed: 04/27/2006
• Issued: 12/07/2010
• Est. Priority Date: 04/27/2006
• Status: Expired due to Fees

• Current Assignee: Guardian Glass LLC (KOCH Industries Incorporated)
• Original Assignee: Guardian Industries Corporation (KOCH Industries Incorporated)
• Inventors: Thomsen, Scott V., Nunez-Regueiro, Jose, Veerasamy, Vijayen S.
• Primary Examiner(s): TUROCY, DAVID P
• Application Number:
  US11/412,120
• Publication Number:
  US 20070254164A1
• Time in Patent Office: 1,685 Days
• Field of Search: 427/249.7, 427/372.2, 427/255.31, 427/248.1
• US Class Current: 427/165
• 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 17/3423 at least one of the coatings comprising a suboxide
• CPC Class Codes: C03C 17/3435 comprising a nitride, oxynitride, boronitride or carbonitride
• CPC Class Codes: C03C 17/3441 comprising carbon, a carbide or oxycarbide
• CPC Class Codes: C03C 17/36 at least one coating being a metal
• CPC Class Codes: C03C 17/3621 one layer at least containing a fluoride
• CPC Class Codes: C03C 17/3626 one layer at least containing a nitride, oxynitride, boronitride or carbonitride
• CPC Class Codes: C03C 17/3634 one layer at least containing carbon, a carbide or oxycarbide
• CPC Class Codes: C03C 17/3644 the metal being silver
• CPC Class Codes: C03C 17/3681 the multilayer coating being used in glazing, e.g. windows or windscreens
• CPC Class Codes: C03C 2204/02 Antibacterial glass, glaze or enamel
• CPC Class Codes: C03C 2217/212 TiO2
• CPC Class Codes: C03C 2217/22 ZrO2
• CPC Class Codes: C03C 2217/425 consisting of a porous layer
• CPC Class Codes: C03C 2217/479 Metals
• CPC Class Codes: C03C 2217/71 Photocatalytic coatings
• CPC Class Codes: C03C 2217/75 Hydrophilic and oleophilic coatings
• CPC Class Codes: C03C 2217/78 Coatings specially designed to be durable, e.g. scratch-resistant
• CPC Class Codes: C03C 2218/322 Oxidation
• CPC Class Codes: C03C 2218/328 : Partly or completely removing a coating
• CPC Class Codes: C03C 2218/355 : Temporary coating

Abstract

Certain example embodiments of this invention relate to a photocatalytic coated article and a method of making the same. In certain example embodiments, a coated article includes a zirconium nitride and/or oxide inclusive layer before heat treatment (HT). The coated article is heat treated so that following heat treatment (e.g., thermal tempering) a zirconium oxide based layer is provided. A photocatalytic layer (e.g., of an oxide of titanium) may be formed over zirconium oxide based layer following heat treatment.

Claims

1. A method of making a heat treated coated article, the method comprising:

providing a coating supported by a glass substrate, the coating comprising a zirconium nitride based layer;

thermally tempering the glass substrate with the zirconium nitride based layer thereon, so that the tempering causes the zirconium nitride based layer to transform into a layer comprising zirconium oxide (Zr_xO_y) where y/x is from about 1.2 to 2.5; and

following said tempering, forming a photocatalytic layer comprising anatase TiO₂ on the glass substrate over and directly contacting the layer comprising zirconium oxide (Zr_xO_y), wherein the photocatalytic layer is initially deposited in a wet form including titania colloids in solution,

wherein deposition of the photocatalytic layer in wet form causes the photocatalytic layer to have a nano-porosity sufficient to cause a refractive index of the photocatalytic layer to substantially match a refractive index of the layer comprising zirconium oxide.

2. The method of claim 1, wherein y/x is from about 1.4 to 2.1.

3. The method of claim 1, wherein the titania colloids make up from about 0.1 to 2% of the wet coating initially formed in making the photocatalytic layer.

4. The method of claim 1, wherein the photocatalytic layer further comprises silver particles and is an outermost layer of the coated article.

5. The method of claim 1, wherein the photocatalytic layer is formed in a manner so that its refractive index does not differ by more than 0.1 from the refractive index of the layer comprising zirconium oxide (Zr_xO_y).

6. The method of claim 1, wherein the photocatalytic layer comprising anatase TiO₂ has a refractive index of from about 1.75 to 2.15.

7. The method of claim 1, wherein the photocatalytic layer comprising anatase TiO₂ has a refractive index of from about 1.85 to 2.15.

8. The method of claim 1, wherein the photocatalytic layer comprising anatase TiO₂ has a refractive index of from about 1.90 to 2.10.

9. The method of claim 1, wherein the zirconium nitride based layer further comprises fluorine and/or carbon.

10. The method of claim 1, wherein the layer comprising zirconium oxide further comprises fluorine and/or carbon.

11. The method of claim 1, wherein prior to the tempering, the coating further comprises a layer comprising diamond-like carbon located between the glass substrate and the zirconium nitride based layer.

12. The method of claim 1, wherein prior to the tempering, the coating further comprises a layer comprising diamond-like carbon located on the glass substrate over at least the zirconium nitride based layer.

13. The method of claim 1, wherein the layer comprising zirconium oxide comprises a nanocrystalline cubic lattice structure.

14. The method of claim 1, wherein the layer comprising zirconium oxide comprises from about 50 to 70% oxygen.

15. The method of claim 1, wherein the tempered coated article has a visible transmission of at least 70%.

16. The method of claim 1, wherein the titania colloids in the wet form are doped with Zn cations.

17. The method of claim 1, further comprising disposing Ag simultaneously with the wet form including titania colloids such that the photocatalytic layer comprises both TiO₂ and Ag.

18. The method of claim 17, wherein the wet form includes both titania colloids and silver particles, the silver particles being sized so as to fit between the TiO₂ particles in the photocatalytic layer.

19. The method of claim 18, wherein the photocatalytic layer comprises 1-10% silver.

20. A method of making a heat treated coated article, the method comprising:

providing a coating supported by a glass substrate, the coating comprising a silver-inclusive layer and a zirconium nitride based layer over the silver-inclusive layer;

thermally tempering the glass substrate with the silver-inclusive layer and the zirconium nitride based layer thereon, so that the tempering causes the zirconium nitride based layer to transform into a layer comprising zirconium oxide (Zr_xO_y) where y/x is from about 1.2 to 2.5; and

following said tempering, forming a photocatalytic layer comprising anatase TiO₂ on the glass substrate over the layer comprising zirconium oxide (Zr_xO_y), wherein the photocatalytic layer is initially deposited in a wet form including titania colloids in solution,

wherein deposition of the photocatalytic layer in wet form causes the photocatalytic layer to have a nano-porosity sufficient to cause a refractive index of the photocatalytic layer to substantially match a refractive index of the layer comprising zirconium oxide,

wherein the layer comprising zirconium oxide and the photocatalytic layer have a porosity selected so as to permit silver particles to migrate therethrough over time in providing an anti-fungal and/or an anti-bacterial function(s).

21. A method of making a heat treated coated article, the method comprising:

providing a coating supported by a glass substrate, the coating comprising a zirconium nitride based layer;

thermally tempering the glass substrate with the zirconium nitride based layer thereon, so that the tempering causes the zirconium nitride based layer to transform into a layer comprising zirconium oxide (Zr_xO_y) where y/x is from about 1.2 to 2.5; and

following said tempering, forming a photocatalytic layer comprising anatase TiO₂ on the glass substrate over the layer comprising zirconium oxide (Zr_xO_y), wherein the photocatalytic layer is initially deposited in a wet form including titania colloids in solution,

wherein deposition of the photocatalytic layer in wet form causes the photocatalytic layer to have a nano-porosity sufficient to cause a refractive index of the photocatalytic layer to substantially match a refractive index of the layer comprising zirconium oxide,

wherein either (a) a silica-based primer is disposed between the layer comprising zirconium oxide and the photocatalytic layer, or (b) the wet form used to deposit the photocatalytic layer also includes an acidic catalyzed silica.