US2003228476A1PendingUtilityA1

Methods of changing the visible light transmittance of coated articles and coated articles made thereby

47
Priority: Oct 22, 2001Filed: Apr 24, 2003Published: Dec 11, 2003
Est. expiryOct 22, 2021(expired)· nominal 20-yr term from priority
Inventors:Harry BuhayJames J. FinleyJames P. ThielJohn Lehan
C23C 14/08C03C 17/366C03C 17/42C03C 17/36G02B 5/208C23C 14/3414B32B 17/10174B32B 17/10036C03C 17/3644Y10T428/266C03C 17/3639C03C 17/3652C03C 17/38C03C 17/3618G02B 5/0808C23C 14/5806G02B 5/0875C03C 17/3417B32B 17/10761C03C 17/3681C03C 2217/78Y10T428/265G02B 1/111
47
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Claims

Abstract

A method is provided for changing the visible light transmittance of a coated article having a functional coating having at least one anti-reflective material and at least one infrared reflective material. The anti-reflective material includes an alloying material capable of combining or alloying with the infrared reflective material. A protective coating is deposited over the functional coating to prevent or retard the diffusion of atmospheric gas and/or vapor into the functional coating. The coated article is heated to a temperature sufficient to cause at least some of the alloying material to combine with at least some of the infrared reflective material to form a substance having a different visible light transmittance than the infrared reflective material.

Claims

exact text as granted — not AI-modified
What is claimed is:  
     
         1 . A method of changing the visible light transmittance of a coated article, comprising: 
 providing a substrate having a functional coating, the functional coating comprising at least one anti-reflective material and at least one infrared reflective material, wherein the anti-reflective material includes an alloying material capable of combining with the infrared reflective material;    depositing a protective coating over the functional coating, the protective coating preventing or retarding the diffusion of atmospheric gas and/or vapor into the functional coating; and    heating the coated article to a temperature sufficient to cause at least some of the alloying material to combine with at least some of the infrared reflective material to form a combination having a different visible light transmittance than the infrared reflective material.    
     
     
         2 . The method of  claim 1 , wherein the anti-reflective material includes at least one of tin, antimony, bismuth, indium, or combinations thereof.  
     
     
         3 . The method of  claim 1 , wherein the alloying material is selected from tin, antimony, bismuth, indium, or combinations thereof.  
     
     
         4 . The method of  claim 1 , wherein the infrared reflective material includes at least one of gold, copper, silver, or mixtures or combinations thereof.  
     
     
         5 . The method of  claim 1 , wherein the protective coating includes at least one metal oxide selected from aluminum oxide, silicon oxide, and mixtures thereof.  
     
     
         6 . The method of  claim 1 , including forming the protective coating to a thickness in the range of greater than 100 Å to less than 10 microns.  
     
     
         7 . The method of  claim 1 , wherein the protective coating has a refractive index in the range of 1.4 to 1.8.  
     
     
         8 . The method of  claim 1 , including forming the protective coating to a thickness of greater than or equal to 1 micron.  
     
     
         9 . The method of  claim 1 , including forming the protective coating to a thickness of less than or equal to 5 microns.  
     
     
         10 . The method of  claim 1 , wherein the protective coating comprises 0 wt. % to 100 wt. % alumina and 100 wt. % to 0 wt. % silica.  
     
     
         11 . The method of  claim 1 , wherein the protective coating comprises at least 35 wt. % alumina.  
     
     
         12 . The method of claim, wherein the protective coating comprises 50 wt. % to 75 wt. % alumina and 25 wt. % to 50 wt. % silica.  
     
     
         13 . The method of  claim 1 , wherein the protective coating comprises 15 wt. % to 70 wt. % alumina and 85 wt. % to 30 wt. % silica.  
     
     
         14 . The method of  claim 1 , wherein the protective coating comprises 75 wt. % to 85 wt. % alumina and 15 wt. % to 25 wt. % silica.  
     
     
         15 . The method of  claim 1 , wherein the protective coating comprises a first layer formed over the functional coating and a second layer formed over the first layer, wherein the first layer comprises 50 wt. % to 100 wt. % alumina and 50 wt. % to 0 wt. % silica, and the second layer comprises 50 wt. % to 100 wt. % silica and 50 wt. % to 0 wt. % alumina.  
     
     
         16 . The method of  claim 15 , wherein the first layer comprises 70 wt. % to 100 wt. % alumina and 30 wt. % to 0 wt. % silica.  
     
     
         17 . The method of  claim 16 , wherein the first layer has a thickness in the range of 50 Å to 1 micron.  
     
     
         18 . The method of  claim 16 , wherein the first layer has a thickness in the range of 100 Å to 250 Å.  
     
     
         19 . The method of  claim 15 , wherein the second layer comprises 70 wt. % to 100 wt. % silica and 30 wt. % to 0 wt. % alumina.  
     
     
         20 . The method of  claim 19 , wherein the second layer has a thickness in the range of 50 Å to 2,000 Å.  
     
     
         21 . The method of  claim 19 , wherein the second layer has a thickness in the range of 300 Å to 500 Å.  
     
     
         22 . The method of  claim 1 , wherein the protective coating provides an oxygen permeability of less than or equal to 1.5 cubic cm of oxygen gas at a thickness of one mil for 100 square inches over a period of twenty-four hours under an oxygen partial pressure differential of one atmosphere at 23° C. and a relative humidity of zero.  
     
     
         23 . The method of  claim 1 , further including depositing an alloy prevention layer adjacent the infrared reflective layer, the alloy prevention layer configured to prevent or reduce combination of the infrared reflective material with the alloying material.  
     
     
         24 . The method of  claim 23 , wherein the alloy prevention layer is at least partially crystalline.  
     
     
         25 . The method of  claim 24 , wherein the alloy prevention layer includes at least one of zinc oxide, titania, and zirconia.  
     
     
         26 . A method of making a coated article, comprising: 
 providing a substrate having a functional coating, the functional coating comprising at least one anti-reflective layer and at least one infrared reflective layer, wherein the anti-reflective layer includes an alloying material capable of combining with the material of the infrared reflective layer;    depositing an alloy prevention layer adjacent the infrared reflective layer, the alloy prevention layer configured to prevent or reduce combination of the infrared reflective material with the alloying material;    depositing a protective coating over the functional coating; and    heating the article.    
     
     
         27 . The method of  claim 26 , wherein the anti-reflective material includes at least one of tin, antimony, bismuth, indium, or combinations thereof.  
     
     
         28 . The method of  claim 26 , wherein the alloying material is selected from tin, antimony, bismuth, indium, or combinations thereof.  
     
     
         29 . The method of  claim 26 , wherein the infrared reflective material includes at least one of gold, copper, silver, or mixtures or combinations thereof.  
     
     
         30 . The method of  claim 26 , wherein the protective coating includes at least one metal oxide selected from aluminum oxide, silicon oxide, and mixtures thereof.  
     
     
         31 . The method of  claim 26 , including forming the protective coating to a thickness in the range of greater than 100 Å to less than 10 microns.  
     
     
         32 . The method of  claim 26 , wherein the protective coating comprises 0 wt. % to 100 wt. % alumina and 100 wt. % to 0 wt. % silica.  
     
     
         33 . The method of  claim 26 , wherein the protective coating comprises a first layer formed over the functional coating and a second layer formed over the first layer, wherein the first layer comprises 50 wt. % to 100 wt. % alumina and 50 wt. % to 0 wt. % silica, and the second layer comprises 50 wt. % to 100 wt. % silica and 50 wt. % to 0 wt. % alumina.  
     
     
         34 . The method of  claim 26 , wherein the alloy prevention layer is at least partially crystalline.  
     
     
         35 . The method of  claim 34 , wherein the alloy prevention layer includes at least one of zinc oxide, titania, and zirconia  
     
     
         36 . A coated article, comprising: 
 a substrate;    a functional coating deposited over at least a portion of the substrate, comprising: 
 at least on anti-reflective layer;  
 at least one alloy prevention layer deposited over at least a portion of the anti-reflective layer; and  
 at least one infrared reflective layer deposited over at least a portion of the alloy prevention layer, wherein the anti-reflective layer includes an alloying material capable of combining with the infrared reflective layer; and  
   a protective coating deposited over at least a portion of the infrared reflective layer.    
     
     
         37 . The article of  claim 36 , wherein the anti-reflective layer includes at least one of tin, antimony, bismuth, indium, or combinations thereof.  
     
     
         38 . The article of  claim 36 , wherein the alloying material is selected from tin, antimony, bismuth, indium, or combinations thereof.  
     
     
         39 . The article of  claim 36 , wherein the infrared reflective layer includes at least one of gold, copper, silver, or mixtures or combinations thereof.  
     
     
         40 . The article of  claim 36 , wherein the protective coating includes a metal oxide selected from aluminum oxide, silicon oxide, and mixtures thereof.  
     
     
         41 . The article of  claim 36 , wherein the protective coating has a thickness in the range of greater than 100 Å to less than 10 microns.  
     
     
         42 . The article of  claim 36 , wherein the protective coating has a refractive index in the range of 1.4 to 1.8.  
     
     
         43 . The article of  claim 36 , wherein the article is an automotive transparency.  
     
     
         44 . The article of  claim 36 , wherein the protective coating comprises 0 wt. % to 100 wt. % alumina and 100 wt. % to 0 wt. % silica.  
     
     
         45 . The article of  claim 36 , wherein the protective coating comprises 50 wt. % to 75 wt. % alumina and 25 wt. % to 50 wt. % silica.  
     
     
         46 . The article of  claim 36 , wherein the protective coating comprises a first layer formed over the functional coating and a second layer formed over the first layer, wherein the first layer comprises 50 wt. % to 100 wt. % alumina and 50 wt. % to 0 wt. % silica, and the second layer comprises 50 wt. % to 100 wt. % silica and 50 wt. % to 0 wt. % alumina.  
     
     
         47 . The article of  claim 36 , wherein the alloy prevention layer is adjacent the infrared reflective layer and is at least partially crystalline.  
     
     
         48 . The article of  claim 36 , wherein the alloy prevention layer includes at least one of zinc oxide, titania, and zirconia.  
     
     
         49 . A coated article, comprising: 
 a substrate;    a functional coating deposited over at least a portion of the substrate, the functional coating comprising:    an anti-reflective layer;    an infrared reflective layer deposited over at least a portion of the antireflective layer, wherein the anti-reflective layer contains a material capable of alloying with the material of the infrared reflective layer; and a protective coating deposited over at least a portion of the infrared reflective layer.    
     
     
         50 . The article of  claim 49 , wherein the anti-reflective layer includes at least one of tin, antimony, bismuth, indium, or combinations thereof.  
     
     
         51 . The article of  claim 49 , wherein the alloying material is selected from tin, antimony, bismuth, indium, or combinations thereof.  
     
     
         52 . The article of  claim 49 , wherein the infrared reflective layer includes at least one of gold, copper, silver, or mixtures or combinations thereof.  
     
     
         53 . The article of  claim 49 , wherein the protective coating includes a metal oxide selected from aluminum oxide, silicon oxide, and mixtures thereof.  
     
     
         54 . The article of  claim 49 , wherein the protective coating has a thickness in the range of greater than 100 Å to less than 10 microns.  
     
     
         55 . The article of  claim 49 , wherein the article is an automotive transparency.  
     
     
         56 . The article of  claim 49 , wherein the protective coating comprises 0 wt. % to 100 wt. % alumina and 100 wt. % to 0 wt. % silica.  
     
     
         57 . The article of  claim 49 , wherein the protective coating comprises 50 wt. % to 75 wt. % alumina and 25 wt. % to 50 wt. % silica.  
     
     
         58 . The article of  claim 49 , wherein the protective coating comprises a first layer formed over the functional coating and a second layer formed over the first layer, wherein the first layer comprises 50 wt. % to 100 wt. % alumina and 50 wt. % to 0 wt. % silica, and the second layer comprises 50 wt. % to 100 wt. % silica and 50 wt. % to 0 wt. % alumina.  
     
     
         59 . The article of  claim 49 , further including at least one alloy prevention layer deposited over at least a portion of the anti-reflective layer.  
     
     
         60 . The article of  claim 59 , wherein the alloy prevention layer is at least partially crystalline.  
     
     
         61 . The article of  claim 60 , wherein the alloy prevention layer includes at least one of zinc oxide, titania, and zirconia.

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