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

• US 9,663,984 B2
• Filed: 12/29/2011
• Issued: 05/30/2017
• 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): Austin, Aaron
• Assistant Examiner(s): FERGUSON, LAWRENCE D
• Application Number:
  US13/339,434
• Publication Number:
  US 20120107572A1
• Time in Patent Office: 1,979 Days
• Field of Search: 428212, 428220, 4284111, 428432, 428434
• 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 coated substrate comprising a substrate and a low-emissivity coating, the substrate having a major surface that bears the low-emissivity coating, the low-emissivity 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 low-emissivity coating comprising, from said major surface outwardly:

a) a first transparent dielectric film region;

b) the first infrared-reflection film region;

c) a first blocker film region deposited as an oxynitride directly on and contiguous to the first infrared-reflection film region;

d) a second transparent dielectric film region;

e) the second infrared-reflection film region;

f) a second blocker film region deposited as an oxynitride directly on and contiguous to the second infrared-reflection film region;

g) a third transparent dielectric film region;

h) the third infrared-reflection film region;

i) a third blocker film region deposited as an oxynitride directly on and contiguous to the first infrared-reflection film region; and

j) a fourth transparent dielectric film region,

wherein the first, second, and third blocker film regions each have a thickness in the range of 3-25 angstroms.

2. The coated substrate of claim 1 wherein the first, second, and third blocker film regions are each deposited as an oxynitride in substoichiometric form.

3. The coated substrate of claim 1 wherein the first, second, and third blocker film regions each have a thickness in the range of 3-18 angstroms.

4. The coated substrate of claim 1 wherein the thickness of at least one of the infrared-reflection film regions is less than 150 angstroms.

5. The coated substrate of claim 1 wherein the low-emissivity coating has a total thickness of greater than 1,750 angstroms.

6. The coated substrate of claim 5 wherein the total thickness of the low-emissivity coating is greater than 2,000 angstroms.