High infrared reflection coatings, thin film coating deposition methods and associated technologies

• US 8,088,473 B2
• Filed: 02/09/2011
• Issued: 01/03/2012
• Est. Priority Date: 10/11/2005
• Status: Active Grant

• Current Assignee: Cardinal CG Company (Cardinal Glass Industries Incorporated)
• Original Assignee: Cardinal CG Company (Cardinal Glass Industries Incorporated)
• Inventors: Hartig, Klaus
• Primary Examiner(s): Sample, David
• Assistant Examiner(s): FERGUSON, LAWRENCE D
• Application Number:
  US13/023,582
• Publication Number:
  US 20110128617A1
• Time in Patent Office: 328 Days
• Field of Search: 428/212, 428/220, 428/411.1, 428/432, 428/434
• US Class Current: 428/212
• CPC Class Codes: C03C 17/36 at least one coating being a metal
• CPC Class Codes: C03C 17/3613 Coatings of type glass/inorganic compound/metal/inorganic compound/metal/other
• CPC Class Codes: C03C 17/3626 one layer at least containing a nitride, oxynitride, boronitride or carbonitride
• CPC Class Codes: C03C 17/3639 Multilayers containing at least two functional metal layers
• CPC Class Codes: C03C 17/3642 the multilayer coating containing a metal layer
• 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 2217/211 SnO2
• CPC Class Codes: C03C 2217/216 ZnO
• CPC Class Codes: C03C 2217/78 Coatings specially designed to be durable, e.g. scratch-resistant
• CPC Class Codes: C03C 2218/153 by plasma-enhanced cvd
• CPC Class Codes: C03C 2218/154 by sputtering
• CPC Class Codes: C03C 2218/156 by magnetron sputtering
• CPC Class Codes: C23C 14/086 of zinc, germanium, cadmium, indium, tin, thallium or bismuth
• CPC Class Codes: C23C 14/185 by cathodic sputtering
• CPC Class Codes: C23C 14/35 by application of a magnetic field, e.g. magnetron sputtering C23C14/3457 takes precedence
• CPC Class Codes: C23C 14/568 Transferring the substrates through a series of coating stations C23C14/562 takes precedence
• CPC Class Codes: E06B 2009/2417 Light path control; means to control reflection
• CPC Class Codes: E06B 3/6715 : specially adapted for increased thermal insulation or for controlled passage of light E06B3/66323 takes precedence; coating of glass pains C03C17/00; devices or arrangements for controlling the intensity, colour, phase, polarisation or direction of light G02F1/00
• CPC Class Codes: E06B 9/24 : Screens or other constructions affording protection against light, especially against sunshine; Similar screens for privacy or appearance; Slat blindsoperating, guiding or securing devices or arrangements for roll-type closures E06B9/56; free-hanging flexible screens A47H23/00
• 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: G02B 5/26 : Reflecting filters G02B5/28 takes precedence
• CPC Class Codes: Y02B 80/22 : Glazing, e.g. vaccum glazing
• CPC Class Codes: Y10T 428/24612 : Composite web or sheet
• CPC Class Codes: Y10T 428/24942 : including components having same physical characteristic in differing degree
• CPC Class Codes: Y10T 428/2495 : Thickness [relative or absolute]
• CPC Class Codes: Y10T 428/24975 : No layer or component greater than 5 mils thick
• CPC Class Codes: Y10T 428/31504 : Composite [nonstructural laminate]

Abstract

The invention provides low-emissivity coatings that are highly reflective of infrared radiation. The coating includes three infrared-reflection film regions, which may each comprise silver.

Claims

1. A substrate having a major surface that bears a low-emissivity coating, the coating comprising a first infrared-reflection film region having a thickness, a second infrared-reflection film region having a thickness, and a third infrared-reflection film region having a thickness, the coating comprising, from said major surface outwardly:

a) a first transparent dielectric film region;

b) the first infrared-reflection film region;

c) a second transparent dielectric film region;

d) the second infrared-reflection film region;

e) a third transparent dielectric film region;

f) the third infrared-reflection film region;

g) a fourth transparent dielectric film region;

wherein the substrate is a glass sheet that is part of a multiple-pane insulating glass unit that includes at least one other glass sheet, the multiple-pane insulating glass unit having a between-pane space, the low-emissivity coating being exposed to the between-pane space, wherein the first, second, and third infrared-reflection film regions each comprise silver, wherein the coating has a first reflection-region ratio equal to the thickness of the first infrared-reflection film region over the thickness of the second infrared-reflection film region, the coating has a second reflection-region ratio equal to the thickness of the second infrared-reflection film region over the thickness of the third infrared-reflection film region, the three infrared-reflection film regions have a combined thickness of greater than 450 angstroms and the coated substrate has a spectral transmission curve with a peak transmission located in the visible wavelength range and a halfwidth of between 175 nm and 300 nm and yet the multiple-pane insulating glass unit has a visible transmittance of greater than 0.6 together with a solar heat gain coefficient of between 0.25 and 0.29 and a visible-thermal efficiency ratio of between 2 and 2.5, the visible-thermal efficiency ratio being defined as the insulating glass unit'"'"'s visible transmittance divided by the multiple-pane insulating glass unit solar heat gain coefficient, wherein together with the combined thickness of the three infrared-reflection film regions being greater than 450 angstroms the coating includes three or more nitride or oxynitride films, the second transparent dielectric film region comprises at least three transparent dielectric layers, and the third transparent dielectric film region comprises at least three transparent dielectric layers.

2. The substrate of claim 1 wherein the visible-thermal efficiency ratio is about 2.44.

3. The substrate of claim 1 wherein the visible transmission of the multiple-pane insulating glass unit is greater than 65%.

4. The substrate of claim 1 wherein the coated substrate has an emissivity of less than 0.023.

5. The substrate of claim 4 wherein the emissivity is less than 0.015.

6. The substrate of claim 1 wherein the first, second, and third infrared-reflection film regions are silver layers each consisting essentially of silver, and wherein these three silver layers are the only silver layers in the coating.

7. The substrate of claim 1 wherein said three or more nitride or oxynitride films include at least one nitride or oxynitride film having a thickness of less than 150 angstroms and at least one nitride or oxynitride film having a thickness of greater than 150 angstroms.

8. The substrate of claim 7 wherein said nitride or oxynitride film having a thickness of greater than 150 angstroms has a thickness of greater than 175 angstroms.

9. The substrate of claim 7 wherein said nitride or oxynitride film having a thickness of greater than 150 angstroms is either located between the first and second infrared-reflection film regions or between the second and third infrared-reflection film regions.

10. The substrate of claim 1 wherein the halfwidth is less than 290 nm and greater than 175 nm.

11. The substrate of claim 1 wherein the combined thickness of the three infrared-reflection film regions is greater than 460 angstroms.

12. The substrate of claim 1 wherein the thickness of the third infrared-reflection film region is greater than the thickness of the second infrared-reflection film region, and the thickness of the second infrared-reflection film region is greater than the thickness of the first infrared-reflection film region.

13. The substrate of claim 1 wherein at least one of said first and second reflection region ratios is less than 0.85.

14. The substrate of claim 1 wherein said three or more nitride or oxynitride films include at least three films comprising silicon nitride and/or silicon oxynitride.

15. The substrate of claim 7 wherein said nitride or oxynitride film having a thickness of less than 150 angstroms has a thickness of less than 125 angstroms.

16. The substrate of claim 1 wherein the solar heat gain coefficient is about 0.27.

17. The substrate of claim 1 wherein both glass sheets are clear soda-lime glass.