Coated article with IR reflecting layer(s) and overcoat for improving solar gain and visible transmission
10745964 ยท 2020-08-18
Assignee
Inventors
- Guowen Ding (Auburn Hills, MI, US)
- Daniel Schweigert (Auburn Hills, MI, US)
- Minh Lee (Auburn Hills, MI, US)
- Brent Boyce (Novi, MI)
Cpc classification
E06B2009/2417
FIXED CONSTRUCTIONS
C03C2217/73
CHEMISTRY; METALLURGY
E06B9/24
FIXED CONSTRUCTIONS
E06B3/6715
FIXED CONSTRUCTIONS
C03C17/3681
CHEMISTRY; METALLURGY
G02B5/208
PHYSICS
C03C17/3642
CHEMISTRY; METALLURGY
C03C17/3618
CHEMISTRY; METALLURGY
C03C2217/734
CHEMISTRY; METALLURGY
International classification
B32B15/04
PERFORMING OPERATIONS; TRANSPORTING
B32B17/06
PERFORMING OPERATIONS; TRANSPORTING
E06B3/67
FIXED CONSTRUCTIONS
Abstract
A coated article includes a low-emissivity (low-E) coating. The low-E coating includes at least one infrared (IR) reflecting layer of a material such as silver, gold, or the like, and a dielectric overcoat designed to increase solar heat gain coefficient (SHGC) of the coated article. A dielectric undercoat may also be designed to increase SHGC of the coated article in certain example embodiments. In certain example embodiments, the overcoat and/or undercoat are designed to increase SHGC while also providing for desirably high visible transmission (TY or T.sub.vis) and desirably low normal emittance (E.sub.n).
Claims
1. A coated article including a coating supported by a glass substrate, the coating comprising: a first dielectric layer; an infrared (IR) reflecting layer comprising silver on the glass substrate, located over at least the first dielectric layer; a contact layer on the glass substrate located over and directly contacting the IR reflecting layer; a multilayer overcoat comprising a dielectric high index layer having a refractive index (n) of at least 2.2, a dielectric medium index layer having a refractive index (n) of from 1.9 to 2.1, and a dielectric low index layer having a refractive index of no greater than 1.7, and wherein the medium index layer is thinner than each of the high and low index layers and is located between and directly contacting the high index layer and the low index layer, and wherein the high index layer comprises an oxide of Bi and Nb, and contains more Nb than Bi; and wherein the coating has a normal emissivity (E.sub.n) of no greater than 0.2.
2. The coated article of claim 1, wherein the low index layer comprises an oxide of silicon.
3. The coated article of claim 1, wherein the overcoat further comprises an outermost layer comprising silicon nitride and/or silicon oxynitride that is located over and directly contacting the low index layer, wherein the outermost layer comprising silicon nitride and/or silicon oxynitride has a thickness of from 50-200 .
4. The coated article of claim 1, wherein the medium index layer comprises an oxide of zinc, and the low index layer comprises an oxide of silicon.
5. The coated article of claim 1, wherein the coated article has an SHGC value of at least 0.60.
6. The coated article of claim 1, wherein the coated article has an SHGC value of at least 0.66.
7. The coated article of claim 1, wherein the coating further comprises a dielectric undercoat between the glass substrate and the IR reflecting layer, wherein the dielectric undercoat comprises the first dielectric layer which is a medium index layer having a refractive index (n) from 1.9 to 2.1 and a second dielectric layer which is a high index layer having a refractive index (n) of at least 2.2, and wherein the first dielectric layer is located between the glass substrate and the second dielectric layer.
8. A coated article including a coating supported by a glass substrate, the coating comprising: a first dielectric layer; an infrared (IR) reflecting layer comprising silver on the glass substrate, located over at least the first dielectric layer; a contact layer on the glass substrate located over and directly contacting the IR reflecting layer; a multilayer overcoat comprising a dielectric high index layer having a refractive index (n) of at least 2.2, a dielectric medium index layer having a refractive index (n) of from 1.9 to 2.1, and a dielectric low index layer having a refractive index of no greater than 1.7, and wherein the medium index layer is located between the high index layer and the low index layer, and wherein the high index layer comprises an oxide of Bi and Nb, and contains more Nb than Bi; a multilayer dielectric undercoat between the glass substrate and the IR reflecting layer, wherein the dielectric undercoat comprises the first dielectric layer which directly contacts the glass substrate and is a medium index layer having a refractive index (n) from 1.9 to 2.1, and a second dielectric layer which is a high index layer having a refractive index (n) of at least 2.2, and wherein in the undercoat the first dielectric layer is located between the glass substrate and the second dielectric layer; and wherein the coating has a normal emissivity (E.sub.n) of no greater than 0.2.
9. A coated article including a coating supported by a glass substrate, the coating comprising: a first dielectric layer; an infrared (IR) reflecting layer comprising silver on the glass substrate, located over at least the first dielectric layer; a contact layer on the glass substrate located over and directly contacting the IR reflecting layer; a multilayer overcoat comprising a dielectric high index layer comprising an oxide of bismuth, and a dielectric low index layer having a refractive index of no greater than 1.7, and wherein the low index layer is located between at least the high index layer comprising the oxide of bismuth and the contact layer, and wherein the high index layer comprises an oxide of Bi and Nb, and contains more Nb than Bi; and wherein the coating has a normal emissivity (E.sub.n) of no greater than 0.2 and a visible transmission of at least 80% measured monolithically.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
(1)
(2)
(3)
(4)
(5)
DETAILED DESCRIPTION OF EXAMPLE EMBODIMENTS OF THE INVENTION
(6) Referring now to the drawings in which like reference numerals indicate like parts throughout the several views.
(7) Coated articles herein may be used in applications such as monolithic windows, IG window units such as residential windows or commercial windows, patio door windows, vehicle windows, and/or any other suitable application that includes single or multiple substrates such as glass substrates. Certain example embodiments of this invention are particularly adapted for residential window and patio door applications where high heat gain and high visible light transmission is desired.
(8) Referring to the
(9) We found that, in order to increase visible transmission and SHGC, the undercoat can be made of two different index materials layers, first layer 2 adjacent the glass is a medium index around n=2 (such as 1.92.1), and the second layer 3 is a high index material such as index n=2.3 (such as 2.22.5), and the overcoat can be made to have a high index layer 21 (n=2.3, such as 2.22.5), then followed by another medium index layer 22, n around 2 (such as 1.92.1), then followed another low index layer 23, such as n<1.7 or <1.6. In such design, it was found that the solar gain was greatly enhanced as was visible transmission in a surprising and unexpected manner.
(10)
(11) High index layers dielectric layers 3 and 21 are preferably of or including a high index metal oxide such as an oxide of titanium (e.g., TiO.sub.x where x is from 1 to 2, more preferably about 2), an oxide of bismuth, or an oxide of niobium. However, other element(s) may be added to these layers. For example one or both of high index dielectric layers 3 and/or 21 may be of or include high index material such as TiZrO.sub.x, YTiO.sub.x, TiSnO.sub.x, TiZnSnO.sub.x, TiNbO.sub.x, or the like. The addition of Zr, Y, Sn, or Nb for example to the titanium oxide is advantageous, for example, in that it results in a difference in atomic radii of Ti and the other metal(s) which causes a disruption in lattice formation and hence impedes the formation of crystals, thereby resulting in a coating that is more thermally stable upon heat treatment such as thermal tempering.
(12) High index layer(s) 3 and/or 21 may also be formed of or including NbBiO.sub.x. In such embodiments, metal content of the NbBiO.sub.x inclusive high index layer may be from 55-99% Nb, more preferably from 60-95% Nb, still more preferably from 70-90% Nb, and from 1-45% Bi, more preferably from 5-40% Bi, still more preferably from 10-30% Bi (atomic %).
(13)
(14)
(15)
(16) In monolithic instances, the coated article includes only one substrate such as glass substrate 1 (see
(17) Other layer(s) below or above the illustrated coatings 25 of
(18) While various thicknesses may be used in different embodiments of this invention, example thicknesses and materials for the respective layers on the glass substrate 1 in the
(19) TABLE-US-00001 TABLE 1 (Example Materials/Thicknesses; FIG. 1-4 Embodiments) Preferred More Layer Range ({acute over ()}) Preferred ({acute over ()}) Example () Si.sub.xN.sub.y or ZnSnO (layer 2) 20-400 50-200 80 TiO.sub.x or BiO.sub.x (layer 3) 30-300 50-300 240 ZnAlO.sub.x (layer 7) 10-230 30-120 40 Ag (layer 9) 60-160 80-140 107 contact (layer 11) 10-60 20-40 26 TiO.sub.x or BiO.sub.x (layer 21) 80-400 160-250 190 ZnO or ZnSnO (layer 22) 20-140 30-80 40 SiO.sub.2 (layer 23) 50-700 150-600 500 Si.sub.xN.sub.y (layer 24) 50-200 80-120 100
(20) In certain example embodiments of this invention, coated articles herein (e.g., see
(21) TABLE-US-00002 TABLE 2 Low-E/Solar Characteristics (Monolithic; non-HT) Characteristic General More Preferred Most Preferred Rs (ohms/sq.): <= 11.0 <= 10 <= 9 E.sub.n: <= 0.2 <= 0.10 <= 0.045 T.sub.vis (%): >= 80 >= 85 >= 90
EXAMPLES
(22) The following examples are provided for purposes of example only, and are not intended to be limiting. The listed thicknesses are approximations and are in units of nm. Refractive index (n) values herein are at 550 nm. Below modeled are a Comparative Example (CE) 1, Example 1 according to the
(23) TABLE-US-00003 TABLE 3 Layer Stacks for CE 1 and Examples 1-2 n @ 550 nm Comparative Index Example 1 Material value Experiment Ex. 1 Ex. 2 SiO2 1.5 0 46 50 ZnSnO 2 0 0 4 ZnAlO 2 36.5 0 0 TiO2 2.3 6 20 19 NiTiNbOx 2.3 2.6 2.6 2.6 Ag 0.1 11 10.7 10.7 ZnAlO 2 4 4 4 TiO2 2.3 31.4 33.6 24 ZnSnO 2 8 glass 1.5 (4 mm)
(24) Optical data for Comparative Example (CE) 1 and Examples 1-2 are as follows. Note that Y refers to visible transmission, that SHGC(2) refers to SHGC when the coating is on surface #2 of a double pane IG unit, that SHGC(3) refers to SHGC when the coating is on surface #3 of a double pane IG unit.
(25) TABLE-US-00004 TABLE 4 Optical Data for CE 1 and Examples 1-2. CE 1 Ex. 1 Ex. 2 Monolithic T Y (%) 89.7 89.9 90.2 Optics (III a* 1.47 1.38 1.44 C, 2 deg b* 1.89 1.09 0.95 obs) Rg Y (%) 5.2 5.5 6.1 a* 2.28 1.95 2.36 b* 8.42 6.06 5.75 Rf Y (%) 4.4 4.4 5.1 a* 2.81 2.31 2.9 b* 7.28 7.06 8.7 A[vis] (100-TT- 5.9 5.7 4.7 Rf) IG Optics (III T Y(%) 81.9 82.1 82.4 C, 2 deg a* 1.93 1.85 1.89 obs) b* 2.09 1.32 1.15 Rg Y (%) 11.9 12.1 12.8 a* 0.36 0.24 0.54 b* 4.48 3.43 3.43 Rf Y(%) 11.8 11.9 12.5 a* 0.84 0.62 0.96 b* 3.53 3.43 4.47 Normal Emissivity (E.sub.n) 0.0356 0.0390 0.0390 Double Tvis (%) 0.819 0.821 0.824 glazing EN Tsol (%) 0.585 0.606 0.616 410- SHGC(3) 0.653 0.676 0.68 673Thermal SHGC(2) 0.607 0.63 0.64 Performance Uval 1.153 1.164 1.165 LSG(3) 1.25 1.21 1.21 LSG(2) 1.35 1.3 1.29 Triple T Y (%) 73.9 74.2 74.8 glazing IG a* 3.14 3.02 3.09 Optics (III b* 3.59 2.12 1.76 C, 2 deg Rg Y (%) 14.8 15.1 16.3 obs) a* 0.61 0.42 0.85 b* 5.5 4.74 5.42 Rf Y (%) 14.8 15.1 16.3 a* 0.61 0.42 0.85 b* 5.5 4.74 5.42 Triple Tvis (%) 0.739 0.742 0.749 glazing EN Tsol (%) 0.465 0.491 0.502 410- SHGC(25) 0.529 0.554 0.563 673Thermal SHGC(52) 0.529 0.554 0.563 Performance Uval 0.592 0.6 0.6 LSG(3) 1.4 1.34 1.33 LSG(2) 1.4 1.34 1.33
(26) It can be seen from the data above that the overcoats provided in Examples 1 and 2 surprisingly and unexpectedly increased both visible transmission (Y or T.sub.vis) and SHGC values of the coated articles, compared to Comparative Example (CE) 1, while maintaining substantially neutral color and low emissivity.
(27) Example 3 according to the
(28) In an example embodiment of this invention, there is provided a coated article including a coating supported by a glass substrate, the coating comprising: a first dielectric layer; an infrared (IR) reflecting layer comprising silver on the glass substrate, located over at least the first dielectric layer; a contact layer on the glass substrate located over and directly contacting the IR reflecting layer; a multilayer overcoat comprising a dielectric high index layer having a refractive index (n) of at least 2.2, a dielectric medium index layer having a refractive index (n) of from 1.9 to 2.1, and a dielectric low index layer having a refractive index of no greater than 1.7, and wherein the medium index layer is thinner than each of the high and low index layers and is located between and directly contacting the high index layer and the low index layer; and wherein the coating has a normal emissivity (E.sub.n) of no greater than 0.2, more preferably no greater than 0.10, still more preferably no greater than 0.045, and the coated article has a visible transmission of at least 80%, more preferably of at least 85%, measured monolithically.
(29) In the coated article of the immediately preceding paragraph, the low index layer may comprise an oxide of silicon such as SiO.sub.2.
(30) In the coated article of any of the preceding two paragraphs, the high index layer may comprise an oxide of titanium such as TiO.sub.2, or an oxide of bismuth.
(31) In the coated article of any of the preceding three paragraphs, the medium index layer may comprise an oxide of zinc such as zinc oxide and/or zinc stannate.
(32) In the coated article of any of the preceding four paragraphs, the overcoat may further comprise an outermost layer comprising silicon nitride and/or silicon oxynitride that is located over and directly contacting the low index layer, wherein the outermost layer comprising silicon nitride and/or silicon oxynitride may have a thickness of from 50-200 , more preferably from 75-150 , and most preferably from 80-120 . Note that all thicknesses discussed herein are physical thicknesses.
(33) In the coated article of any of the preceding five paragraphs, the high index layer may comprise an oxide of titanium and/or bismuth, the medium index layer may comprises an oxide of zinc, and the low index layer may comprise an oxide of silicon.
(34) In the coated article of any of the preceding six paragraphs, the coated article may have, measured monolithically, a visible transmission of at least 85%, more preferably of at least 90%.
(35) In the coated article of any of the preceding seven paragraphs, the coated article may have an SHGC value of at least 0.60, more preferably of at least 0.65, even more preferably of at least 0.66, and most preferably of at least 0.67.
(36) In the coated article of any of the preceding eight paragraphs, the coating may further comprise a dielectric undercoat between the glass substrate and the IR reflecting layer, wherein the dielectric undercoat may comprise the first dielectric layer which may be a medium index layer having a refractive index (n) from 1.9 to 2.1 (more preferably from 1.95 to 2.06) and a second dielectric layer which is a high index layer having a refractive index (n) of at least 2.2 (more preferably of at least 2.25), and wherein the first dielectric layer is located between, and possibly contacting, the glass substrate and the second dielectric layer. In the undercoat, the first dielectric layer may comprises zinc oxide or silicon nitride, and the second dielectric layer may comprises an oxide of titanium and/or bismuth.
(37) In the coated article of any of the preceding nine paragraphs, the coating may further comprise a layer comprising zinc oxide and/or zinc stannate located under and directly contacting the IR reflecting layer. The layer comprising zinc oxide and/or zinc stannate may be located between and directly contacting the IR reflecting layer and second dielectric layer of the undercoat.
(38) In the coated article of any of the preceding ten paragraphs, the contact layer may comprises Ni and/or Cr, and may be of for example NiCr, NiCrO.sub.x, NiTiNbO.sub.x, or NiCrMoO.sub.x.
(39) In the coated article of any of the preceding eleven paragraphs, the coating in certain example embodiments may contain no more than one IR reflecting layer comprising silver. However, in other embodiments, a second IR reflecting layer of or including silver may be located between at least the glass substrate and the first recited IR reflecting layer.
(40) An IG window unit may include the coated article of any of the preceding twelve paragraphs. The IG unit may have a U-value of no greater than 0.30 Btu/h ft F.
(41) In the coated article of any of the preceding thirteen paragraphs, in the overcoat the medium index layer may be at least 50 thinner than each of the high index layer and the low index layer, more preferably the medium index layer may be at least 100 or 140 thinner than each of the high index layer and the low index layer.
(42) In the coated article of any of the preceding fourteen paragraphs, the high index layer(s) may be of or include any of TiO.sub.x, TiZrO.sub.x, YTiO.sub.x, TiSnO.sub.x, TiZnSnO.sub.x, or TiNbO.sub.x.
(43) While the invention has been described in connection with what is presently considered to be the most practical and preferred embodiment, it is to be understood that the invention is not to be limited to the disclosed embodiment, but on the contrary, is intended to cover various modifications and equivalent arrangements included within the spirit and scope of the appended claims.