Heat treatable coated article with niobium zirconium inclusive IR reflecting layer and method of making same

• US 6,908,679 B2
• Filed: 09/29/2003
• Issued: 06/21/2005
• Est. Priority Date: 04/25/2003
• Status: Expired due to Term

• Current Assignee: Guardian Glass LLC (KOCH Industries Incorporated)
• Original Assignee: Guardian Industries Corporation (KOCH Industries Incorporated)
• Inventors: Stachowiak, Grzegorz, Chonlamaitri, Ratchaneekorn
• Primary Examiner(s): Jones, Deborah
• Assistant Examiner(s): Blackwell-Rudasill, G.
• Application Number:
  US10/672,065
• Publication Number:
  US 20040214013A1
• Time in Patent Office: 631 Days
• Field of Search: 428/428.428, 428/432, 428/433, 428/699, 428/701, 428/702, 428/704
• US Class Current: 428/428
• CPC Class Codes: B32B 17/10174 Coatings of a metallic or dielectric material on a constituent layer of glass or polymer
• CPC Class Codes: C03C 17/3435 comprising a nitride, oxynitride, boronitride or carbonitride
• 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 17/3626 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 17/3649 made of metals other than 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 2217/78 Coatings specially designed to be durable, e.g. scratch-resistant
• CPC Class Codes: C03C 2217/91 Coatings containing at least one layer having a composition gradient through its thickness
• CPC Class Codes: C03C 2218/154 by sputtering
• CPC Class Codes: C23C 14/0084 Producing gradient compositions
• CPC Class Codes: C23C 14/08 Oxides C23C14/10 takes precedence
• CPC Class Codes: C23C 14/185 by cathodic sputtering

Abstract

A coated article is provided so as to include a solar control coating having an infrared (IR) reflecting layer sandwiched between at least a pair of dielectric layers. The IR reflecting layer includes NbZr and/or NbZrO_x in certain embodiments of this invention. The use of such materials as an IR reflecting layer(s) allows the coated article to have good corrosion resistance to alkaline solutions, good mechanical performance such as scratch resistance, and/or good color stability (i.e., a low ΔE* value(s)) upon heat treatment (HT). The coated article may or may not be heat treated in different embodiments of the invention.

Claims

1. A coated article including a layer system supported by a substrate, the layer system comprising:

a first dielectric layer;

a layer comprising an oxide of niobium zirconium (NbZr) provided on the substrate over at least the first dielectric layer;

a second dielectric layer provided on the substrate over at least the layer comprising the oxide of niobium zirconium; and

wherein the coated article has no metallic infrared (IR) reflecting layer comprising Ag or Au.

2. The coated article of claim 1, wherein the layer comprising the oxide of niobium zirconium is sandwiched between and contacts each of the first and second dielectric layers.

4. The coated article of claim 1, wherein at least one of the first and second dielectric layers comprises silicon nitride.

5. The coated article of claim 1, wherein each of the first and second dielectric layers comprises silicon nitride.

8. The coated article of claim 1, wherein the coated article has a visible transmission from about 6 to 80%.

11. The coated article of claim 1, wherein the coated article is a window.

12. The coated article of claim 1, wherein the layer system has a sheet resistance (R_s) of less than 250 ohms/square.

13. The coated article of claim 1, wherein the layer system has a sheet resistance (R_s) of less than 100 ohms/square.

14. The coated article of claim 1, wherein the layer system has a sheet resistance (R_s) of less than 60 ohms/square.

19. The coated article of claim 1, wherein the layer comprising the oxide of niobium zirconium includes from about 0.4 to 15% zirconium.

21. The coated article of claim 1, wherein the coated article is heat treated and has a Δ

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

22. The coated article of claim 1, wherein the coated article is heat treated and has a Δ

E* value (glass side reflective) of no greater than 2.5 after and/or due to heat treatment.

23. The coated article of claim 1, wherein the coated article is heat treated and has a Δ

E* value (glass side reflective) of no greater than 1.5 after and/or due to heat treatment.

24. The coated article of claim 1, wherein the coated article is heat treated and has a Δ

E* value (glass side reflective) of no greater than 1.0 after and/or due to heat treatment.

26. The coated article of claim 1, wherein the coated article comprises an IG window unit, a monolithic window, or a laminated window.

29. The coated article of claim 1, wherein the coated article is not heat treated.

30. The coated article of claim 1, wherein the substrate is a glass substrate.

31. The coated article of claim 1, wherein the layer comprising the oxide of niobium zirconium has an index of refraction “

n”

of from 2.4 to 2.9, an extinction coefficient “

k”

of from 3.3 to 3.8, and comprises from about 0.1 to 60% Zr.

38. The coated article of claim 1, wherein the second dielectric layer over at least the layer comprising the oxide of niobium zirconium comprises nitrogen, and wherein oxygen content in the layer comprising the oxide of niobium zirconium is higher at a location closer to the second dielectric layer than at another location in the layer comprising the oxide of niobium zirconium further from the second dielectric layer.

47. The coated article of claim 1, wherein the coated article has a visible transmission of from about 10-50%.

55. The coated article of claim 1, wherein a contact or nucleation layer is provided between the layer comprising the oxide of niobium zirconium and the first dielectric layer, and/or between the layer comprising the oxide of niobium zirconium and the second dielectric layer.

58. The coated article of claim 1, wherein the coated article is heat treated and has a Δ

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

69. The coated article of claim 1, wherein the layer system consists essentially of the first and second dielectric layers and the layer comprising the oxide of niobium zirconium.

3. A coated article including a layer system supported by a substrate, the layer system comprising:

a first dielectric layer;

a layer comprising an oxide of niobium zirconium (NbZr) provided on the substrate over at least the first dielectric layer;

a second dielectric layer provided on the substrate over at least the layer comprising the oxide of niobium zirconium; and

wherein each of the dielectric layers comprises a nitride and/or a metal oxide.

39. The coated article of claim 3, wherein the layer comprising the oxide of niobium zirconium does not contact any metallic infrared (IR) reflecting layer of Ag or Au.

48. The coated article of claim 3, wherein the coated article has a visible transmission of from about 10-50%.

59. The coated article of claim 3, wherein the coated article is heat treated and has a Δ

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

70. The coated article of claim 3, wherein the layer system consists essentially of the first and second dielectric layers and the layer comprising the oxide of niobium zirconium.

6. A coated article including a layer system supported by a substrate, the layer system comprising:

a first dielectric layer;

a layer comprising an oxide of niobium zirconium (NbZr) provided on the substrate over at least the first dielectric layer;

a second dielectric layer provided on the substrate over at least the layer comprising the oxide of niobium zirconium; and

wherein a contact or nucleation layer is provided between the layer comprising the oxide of niobium zirconium and the first dielectric layer.

40. The coated article of claim 6, wherein the layer comprising the oxide of niobium zirconium does not contact any metallic infrared (IR) reflecting layer of Ag or Au.

60. The coated article of claim 6, wherein the coated article is heat treated and has a Δ

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

7. A coated article including a layer system supported by a substrate, the layer system comprising:

a first dielectric layer;

a layer comprising an oxide of niobium zirconium (NbZr) provided on the substrate over at least the first dielectric layer;

a second dielectric layer provided on the substrate over at least the layer comprising the oxide of niobium zirconium; and

wherein the layer comprising the oxide of niobium zirconium comprises from 0.05 to 10% oxygen.

41. The coated article of claim 7, wherein the layer comprising the oxide of niobium zirconium does not contact any metallic infrared (IR) reflecting layer of Ag or Au.

49. The coated article of claim 7, wherein the coated article has a visible transmission of from about 10-50%.

61. The coated article of claim 7, wherein the coated article is heat treated and has a Δ

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

71. The coated article of claim 7, wherein the layer system consists essentially of the first and second dielectric layers and the layer comprising the oxide of niobium zirconium.

9. A coated article including a layer system supported by a substrate, the layer system comprising:

a first dielectric layer;

a layer comprising an oxide of niobium zirconium (NbZr) provided on the substrate over at least the first dielectric layer;

a second dielectric layer provided on the substrate over at least the layer comprising the oxide of niobium zirconium; and

wherein the coated article has a visible transmission of from about 10-50%.

10. The coated article of claim 9, wherein the coated article has a visible transmission of from about 12-30%.

42. The coated article of claim 9, wherein the layer comprising the oxide of niobium zirconium does not contact any metallic infrared (IR) reflecting layer of Ag or Au.

62. The coated article of claim 9, wherein the coated article is heat treated and has a Δ

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

15. A coated article including a layer system supported by a substrate, the layer system comprising:

a first dielectric layer;

a layer comprising an oxide of niobium zirconium (NbZr) provided on the substrate over at least the first dielectric layer;

a second dielectric layer provided on the substrate over at least the layer comprising the oxide of niobium zirconium; and

wherein the layer comprising the oxide of niobium zirconium is at least partially nitrided.

16. A coated article including a layer system supported by a substrate, the layer system comprising:

a first dielectric layer;

a layer comprising an oxide of niobium zirconium (NbZr) provided on the substrate over at least the first dielectric layer;

a second dielectric layer provided on the substrate over at least the layer comprising the oxide of niobium zirconium; and

wherein the layer comprising the oxide of niobium zirconium comprises (Nb+Zr)_xO_y, where the ratio y/x (i.e., the ratio of oxygen to Nb+Zr) is from 0.03 to 0.20.

17. The coated article of claim 16, wherein the layer comprising the oxide of niobium zirconium comprises (Nb+Zr)_xO_y, where the ratio y/x (i.e., the ratio of oxygen to Nb+Zr) is from 0.05 to 0.15.

43. The coated article of claim 16, wherein the layer comprising the oxide of niobium zirconium does not contact any metallic infrared (IR) reflecting layer of Ag or Au.

50. The coated article of claim 16, wherein the coated article has a visible transmission of from about 10-50%.

63. The coated article of claim 16, wherein the coated article is heat treated and has a Δ

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

72. The coated article of claim 16, wherein the layer system consists essentially of the first and second dielectric layers and the layer comprising the oxide of niobium zirconium.

18. A coated article including a layer system supported by a substrate, the layer system comprising:

a first dielectric layer;

a layer comprising an oxide of niobium zirconium (NbZr) provided on the substrate over at least the first dielectric layer;

a second dielectric layer provided on the substrate over at least the layer comprising the oxide of niobium zirconium; and

wherein in the layer comprising the oxide of niobium zirconium, the ratio of zirconium to niobium (Zr/Nb) is from about 0.004 to 0.50.

44. The coated article of claim 18, wherein the layer comprising the oxide of niobium zirconium does not contact any metallic infrared (IR) reflecting layer of Ag or Au.

51. The coated article of claim 18, wherein the coated article has a visible transmission of from about 10-50%.

64. The coated article of claim 18, wherein the coated article is heat treated and has a Δ

E* value (glass side reflective) of no greater than 2.5 after and/or due to heat treatment.

20. A coated article including a layer system supported by a substrate, the layer system comprising:

a first dielectric layer;

a layer comprising an oxide of niobium zirconium (NbZr) provided on the substrate over at least the first dielectric layer;

a second dielectric layer provided on the substrate over at least the layer comprising the oxide of niobium zirconium; and

wherein the coated article is heat treated and has a Δ

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

45. The coated article of claim 20, wherein the layer comprising the oxide of niobium zirconium does not contact any metallic infrared (IR) reflecting layer of Ag or Au.

52. The coated article of claim 20, wherein the coated article has a visible transmission of from about 10-50%.

56. The coated article of claim 20, wherein a contact or nucleation layer is provided between the layer comprising the oxide of niobium zirconium and the first dielectric layer, and/or between the layer comprising the oxide of niobium zirconium and the second dielectric layer.

73. The coated article of claim 20, wherein the layer system consists essentially of the first and second dielectric layers and the layer comprising the oxide of niobium zirconium.

25. A coated article including a layer system supported by a substrate, the layer system comprising:

a first dielectric layer;

a layer comprising an oxide of niobium zirconium (NbZr) provided on the substrate over at least the first dielectric layer;

a second dielectric layer provided on the substrate over at least the layer comprising the oxide of niobium zirconium; and

wherein the layer system consists essentially of the first and second dielectric layers and the layer comprising the oxide of niobium zirconium.

65. The coated article of claim 25, wherein the coated article is heat treated and has a Δ

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

27. A coated article including a layer system supported by a substrate, the layer system comprising:

a first dielectric layer;

a layer comprising an oxide of niobium zirconium (NbZr) provided on the substrate over at least the first dielectric layer;

a second dielectric layer provided on the substrate over at least the layer comprising the oxide of niobium zirconium; and

wherein at least one of the dielectric layers comprises silicon nitride and includes from 6-20% aluminum and/or stainless steel.

46. The coated article of claim 27, wherein the layer comprising the oxide of niobium zirconium does not contact any metallic infrared (IR) reflecting layer of Ag or Au.

53. The coated article of claim 27, wherein the coated article has a visible transmission of from about 10-50%.

66. The coated article of claim 27, wherein the coated article is heat treated and has a Δ

E* value (glass side reflective) of no greater than 2.5 after and/or due to heat treatment.

74. The coated article of claim 27, wherein the layer system consists essentially of the first and second dielectric layers and the layer comprising the oxide of niobium zirconium.

28. A coated article including a layer system supported by a substrate, the layer system comprising:

a first dielectric layer;

a layer comprising an oxide of niobium zirconium (NbZr) provided on the substrate over at least the first dielectric layer;

a second dielectric layer provided on the substrate over at least the layer comprising the oxide of niobium zirconium; and

wherein the layer comprising the oxide of niobium zirconium does not contact any metallic infrared (IR) reflecting layer of Ag or Au.

54. The coated article of claim 28, wherein the coated article has a visible transmission of from about 10-50%.

57. The coated article of claim 28, wherein a contact or nucleation layer is provided between the layer comprising the oxide of niobium zirconium and the first dielectric layer, and/or between the layer comprising the oxide of niobium zirconium and the second dielectric layer.

67. The coated article of claim 28, wherein the coated article is heat treated and has a Δ

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

68. The coated article of claim 28, wherein the coated article is heat treated and has a Δ

E* value (glass side reflective) of no greater than 2.5 after and/or due to heat treatment.

75. The coated article of claim 28, wherein the layer system consists essentially of the first and second dielectric layers and the layer comprising the oxide of niobium zirconium.

32. A heat treated coated article including a layer system supported by a glass substrate, the layer system comprising:

a layer comprising an oxide of niobium zirconium (NbZr) provided on the glass substrate;

a dielectric layer provided on the substrate over at least the layer comprising the oxide of niobium zirconium; and

wherein the coated article is heat treated and has a Δ

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

33. The coated article of claim 32, wherein the coated article has a Δ

E* value (glass side reflective) of no greater than 2.5 after and/or due to heat treatment.

34. The coated article of claim 32, wherein the coated article has a Δ

E* value (glass side reflective) of no greater than 1.5 after and/or due to heat treatment.

35. The coated article of claim 32, further comprising a layer comprising silicon nitride located between the glass substrate and the layer comprising niobium zirconium.

36. The coated article of claim 32, wherein the layer comprising the oxide of niobium zirconium comprises (Nb+Zr)_xO_y, where the ratio y/x (i.e., the ratio of oxygen to Nb+Zr) is from 0.03 to 0.20.

37. The coated article of claim 36, wherein the layer comprising the oxide of niobium zirconium does not contact any metallic infrared (IR) reflecting layer comprising Ag or Au.