Coated article with low-E coating having low visible transmission
10196303 ยท 2019-02-05
Assignee
Inventors
- Francis Wuillaume (Plymouth, MI)
- Muhammad Imran (Hamilton, NJ, US)
- Afonso Kreling (Rio de Janeiro, BR)
- Brent Boyce (Novi, MI)
Cpc classification
G02B1/10
PHYSICS
G02B5/0875
PHYSICS
C03C17/3626
CHEMISTRY; METALLURGY
C03C17/3681
CHEMISTRY; METALLURGY
C23C30/00
CHEMISTRY; METALLURGY
G02B5/208
PHYSICS
C03C17/3639
CHEMISTRY; METALLURGY
Y10T428/2495
GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
C23C28/3455
CHEMISTRY; METALLURGY
C03C17/3652
CHEMISTRY; METALLURGY
International classification
B32B15/04
PERFORMING OPERATIONS; TRANSPORTING
C23C30/00
CHEMISTRY; METALLURGY
G02B1/10
PHYSICS
B32B17/06
PERFORMING OPERATIONS; TRANSPORTING
C23C28/00
CHEMISTRY; METALLURGY
Abstract
This invention relates to a coated article including a low-emissivity (low-E) coating. In certain example embodiments, the low-E coating is provided on a substrate (e.g., glass substrate) and includes at least first and second infrared (IR) reflecting layers (e.g., silver based layers) that are spaced apart by contact layers (e.g., NiCr based layers) and a dielectric layer of or including a material such as silicon nitride. In certain example embodiments, the coated article has a low visible transmission (e.g., no greater than 50%, more preferably no greater than about 40%, and most preferably no greater than about 39%).
Claims
1. A coated article including a coating supported by a glass substrate, the coating comprising: first and second infrared (IR) reflecting layers comprising silver, the first IR reflecting layer being located closer to the glass substrate than is the second IR reflecting layer; a first contact layer comprising NiCr and containing from 0-10% oxygen (atomic %) located over and directly contacting the first IR reflecting layer comprising silver; a dielectric layer comprising silicon nitride; a second contact layer comprising NiCr located over and directly contacting the layer comprising silicon nitride, so that the layer comprising silicon nitride is located between the second contact layer comprising NiCr and the glass substrate; wherein the dielectric layer comprising silicon nitride is the only dielectric layer located between the first and second contact layers comprising NiCr; the second IR reflecting layer comprising silver located over and directly contacting the second contact layer comprising NiCr; a third contact layer comprising NiCr and comprising 0-5% oxygen located over and directly contacting the second IR reflecting layer; and wherein the second IR reflecting layer comprising silver is at least 10 angstroms () thinner than the first IR reflecting layer comprising silver, and wherein the coated article has a visible transmission of no greater than 50%.
2. The coated article of claim 1, wherein the second IR reflecting layer comprising silver is at least 20 angstroms () thinner than the first IR reflecting layer comprising silver.
3. The coated article of claim 1, wherein the coated article is thermally tempered.
4. The coated article of claim 1, wherein the coated article is not thermally tempered.
5. The coated article of claim 1, wherein the first and second contact layers comprising NiCr are nitrided.
6. The coated article of claim 1, further comprising another layer comprising silicon nitride located over and directly contacting the third contact layer comprising NiCr, and wherein the third contact layer comprising NiCr is located between and directly contacting the second IR reflecting layer and the another layer comprising silicon nitride.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
(1)
(2)
(3)
DETAILED DESCRIPTION OF EXAMPLE EMBODIMENTS OF THE INVENTION
(4) Coated articles herein may be used in applications such as IG window units, laminated window units (e.g., for use in vehicle or building applications), vehicle windows, monolithic architectural windows, residential windows, and/or any other suitable application that includes single or multiple glass substrates.
(5) In certain example embodiments of this invention, the coating includes a double-silver stack, although this invention is not so limited in all instances. Referring to
(6) In order to increase durability, along with optics and thermal properties, and avoid significant structural changes before and after HT, coated articles according to certain example embodiments of this invention have a center dielectric layer 14 of or including silicon nitride and lower contact layers 7, 17 are based on NiCr (as opposed to ZnO). It has also been found that using metallic or substantially metallic NiCr (possibly partly nitrided) for layer(s) 7, 11, 17 and/or 21 improves chemical, mechanical and environmental durability (compared to using ZnO lower contact layers below silver and/or highly oxided NiCr upper contact layers above silver). It has also been found that sputter-depositing silicon nitride inclusive layer 14 in an amorphous state, so that it is amorphous in both as-coated and HT states, helps with overall stability of the coating. For example, 5% HCl at 65 degrees C. for one hour will remove the coating of U.S. Pat. No. 7,521,096, whereas the coating shown in
(7) In certain example embodiments of this invention such as
(8)
(9) In monolithic instances, the coated article includes only one glass substrate 1 as illustrated in
(10)
(11) In certain example embodiments of this invention, one, two, three, or all four of contact layers 7, 11, 17, 21 may be of or include NiCr (any suitable ratio or Ni:Cr), and may or may not be nitrided (NiCrN.sub.x). In certain example embodiments, one, two, three or all four of these NiCr inclusive layers 7, 11, 17, 21 is substantially or entirely non-oxidized. In certain example embodiments, one, two, three or all four of NiCr based layers 7, 11, 17, 21 may comprise from 0-10% oxygen, more preferably from 0-5% oxygen, and most preferably from 0-2% oxygen (atomic %). In certain example embodiments, one, two, three or all four of these layers 7, 11, 17, 21 may contain from 0-20% nitrogen, more preferably from 1-15% nitrogen, and most preferably from about 1-12% nitrogen (atomic %). While NiCr is a preferred material for the absorption layers 4 and 25, it is possible that other materials may instead or additionally be used. For example, NiCr based layers 7, 11, 17 and/or 21 may or may not be doped with other material(s) such as stainless steel, Mo, or the like. It has been found that the use of NiCr based contact layer(s) 7 and/or 17 under the silver-based IR reflecting layer(s) 9, 19 improves durability of the coated article (compared to if layers 7 and 17 were instead of ZnO).
(12) Dielectric layers 3, 14, and 24 may be of or include silicon nitride in certain embodiments of this invention. Silicon nitride layers 3, 14 and 24 may, among other things, improve heat-treatability of the coated articles and protect the other layers during optional HT, e.g., such as thermal tempering or the like. One or more of the silicon nitride of layers 3, 14, 24 may be of the stoichiometric type (i.e., Si.sub.3N.sub.4), or alternatively of the Si-rich type of silicon nitride in different embodiments of this invention. The presence of free Si in a Si-rich silicon nitride inclusive layer 3 and/or 14 may, for example, allow certain atoms such as sodium (Na) which migrate outwardly from the glass 1 during HT to be more efficiently stopped by the Si-rich silicon nitride inclusive layer(s) before they can reach silver and damage the same. Thus, it is believed that the Si-rich Si.sub.xN.sub.y can reduce the amount of damage done to the silver layer(s) during HT in certain example embodiments of this invention thereby allowing sheet resistance (R.sub.s) to decrease or remain about the same in a satisfactory manner. Moreover, it is believed that the Si-rich Si.sub.xN.sub.y in layers 3, 14 and/or 24 can reduce the amount of damage (e.g., oxidation) done to the silver and/or NiCr during HT in certain example optional embodiments of this invention. In certain example embodiments, when Si-rich silicon nitride is used, the Si-rich silicon nitride layer (3, 14 and/or 24) as deposited may be characterized by Si.sub.xN.sub.y layer(s), where x/y may be from 0.76 to 1.5, more preferably from 0.8 to 1.4, still more preferably from 0.82 to 1.2. Any and/or all of the silicon nitride layers discussed herein may be doped with other materials such as stainless steel or aluminum in certain example embodiments of this invention. For example, any and/or all silicon nitride layers discussed herein may optionally include from about 0-15% aluminum, more preferably from about 1 to 10% aluminum, in certain example embodiments of this invention. The silicon nitride may be deposited by sputtering a target of Si or SiAl, in an atmosphere having argon and nitrogen gas, in certain embodiments of this invention. Small amounts of oxygen may also be provided in certain instances in the silicon nitride layers.
(13) Infrared (IR) reflecting layers 9 and 19 are preferably substantially or entirely metallic and/or conductive, and may comprise or consist essentially of silver (Ag), gold, or any other suitable IR reflecting material. IR reflecting layers 9 and 19 help allow the coating to have low-E and/or good solar control characteristics. The IR reflecting layers may, however, be slightly oxidized in certain embodiments of this invention.
(14) Other layer(s) below or above the illustrated coating may also be provided. Thus, while the layer system or coating is on or supported by substrate 1 (directly or indirectly), other layer(s) may be provided therebetween. Thus, for example, the coating of
(15) While various thicknesses and materials may be used in layers in different embodiments of this invention, example thicknesses and materials for the respective layers on the glass substrate 1 in the
(16) TABLE-US-00001 Example Materials/Thicknesses; FIG. 1 Embodiment Layer Preferred More Preferred Glass (1-10 mm thick) Range ({acute over ()}) ({acute over ()}) Example () Si.sub.xN.sub.y (layer 3) 100-500 250-450 339 NiCr or NiCrN (layer 7) 10-45 {acute over ()} 15-30 {acute over ()} 18-25 Ag (layer 9) 90-165 {acute over ()} 110-145 {acute over ()} 128 NiCr or NiCrN (layer 11) 10-45 {acute over ()} 15-30 {acute over ()} 18-25 Si.sub.xN.sub.y (layer 14) 300-1400 {acute over ()} 400-1200 {acute over ()} 700-990 NiCr or NiCrN (layer 17) 5-22 {acute over ()} 6-14 {acute over ()} 7-11 Ag (layer 19) 50-115 {acute over ()} 60-95 {acute over ()} 79 NiCr or NiCrN (layer 21) 8-30 {acute over ()} 10-20 {acute over ()} 11-18 Si.sub.3N.sub.4 (layer 24) 100-500 {acute over ()} 150-290 {acute over ()} 200-260 ZrO.sub.2 (layer 27) 25-150 {acute over ()} 35-80 {acute over ()} 50
(17) In certain example embodiments of this invention, coated articles herein may have the following optical and solar characteristics set forth in Table 2 when measured monolithically (before and/or after optional HT). The sheet resistances (R.sub.s) herein take into account all IR reflecting layers (e.g., silver layers 9, 19).
(18) TABLE-US-00002 Optical/Solar Characteristics (Monolithic) Characteristic General More Preferred Most Preferred R.sub.s (ohms/sq.): <=5.0 <=4.0 <=3.0 E.sub.n: <=0.08 <=0.05 <=0.04 T.sub.vis (Ill. C 2): 10-60% 20-42% 27-39%
(19) In certain example laminated embodiments of this invention, coated articles herein which have been optionally heat treated to an extent sufficient for tempering, and which have been coupled to another glass substrate to form an IG unit, may have the above recited Optical/Solar characteristics in a structure as shown in
(20) The following examples are provided for purposes of example only, and are not intended to be limiting unless specifically claimed.
Examples 1-3
(21) The following Examples 1-3 were made via sputtering coatings on 4 mm thick clear/transparent glass substrates so as to have approximately the layer stacks set forth below. The layer thicknesses below for the examples are in units of angstroms ({acute over ()}), from the glass substrate moving outwardly.
(22) TABLE-US-00003 Layer Example 1 Example 2 Example 3 Si.sub.xN.sub.y (layer 3) 339 343 326 NiCr (layer 7) 20 {acute over ()} 40 {acute over ()} 14 Ag (layer 9) 128 {acute over ()} 122 {acute over ()} 148 NiCr (layer 11) 22 {acute over ()} 22 {acute over ()} 22 Si.sub.xN.sub.y (layer 14) 880 {acute over ()} 958 {acute over ()} 960 NiCr (layer 17) 8 {acute over ()} 8 {acute over ()} 8 Ag (layer 19) 79 {acute over ()} 79 {acute over ()} 79 NiCr (layer 21) 14 {acute over ()} 14 {acute over ()} 14 Si.sub.3N.sub.4 (layer 24) 235 {acute over ()} 268 {acute over ()} 238 ZrO.sub.2 (layer 27) 50 {acute over ()} 50 {acute over ()} 50
(23) Set forth below are the optical characteristics of Examples 1-3 measured in a laminated structure with two glass substrates as shown in
(24) TABLE-US-00004 Monolithic Characteristic Ex. 1 Ex. 2 Ex. 3 T.sub.vis (or TY)(Ill. C 2): 39.3% 33.7% 37.1% a*.sub.t (Ill. C 2): 5.5 5.5 4.3 b*.sub.t (Ill. C 2): 1.3 +2.8 +2.8 R.sub.fY (Ill. C, 2 deg.): 13.4% 18.9% 22.5% a*.sub.f (Ill. C, 2): 9.5 15.5 18.1 b*.sub.f (Ill. C, 2): 23.3 17.2 11.0 R.sub.gY (Ill. C, 2 deg.): 18.3 22.6% 26.0% a*.sub.g (Ill. C, 2): +1.1 4.4 4.0 b*.sub.g (Ill. C, 2): 8.6 4.7 5.4 E* (transmissive): 2.8 2.6 2.7 E* (glass side refl.): 4.4 4.3 3.6
(25) It can be seen from the above the examples above that the coated articles measured monolithically had desirable visible transmission (e.g., in the range of from about 20-42% measured monolithically), and had fairly neutral glass side reflective color. In particular, a*.sub.g (glass side reflective a* color) was in a desirable range of from about 5 to +3, and b*.sub.g (glass side reflective b* color) was in a desirable range of from about 10 to +2. These are desirable characteristics, especially when the coated article is to be put in an IG window unit as shown in
(26) Set forth below are the optical characteristics of IG window units including the coated articles of Examples 1-3, namely when the coated articles are located in IG window units as shown in
(27) TABLE-US-00005 IG Unit Characteristic Ex. 1 Ex. 2 Ex. 3 T.sub.vis (or TY)(Ill. C 2): 33.4% 29.5% 35.1% a*.sub.t (Ill. C 2): 1.05 1.58 0.8 b*.sub.t (Ill. C 2): 7.83 7.3 7.13 R.sub.fY (Ill. C, 2 deg.): 24.7% 29.1% 32.7% a*.sub.f (Ill. C, 2): 17.97 18.3 17.42 b*.sub.f (Ill. C, 2): 2.75 8.19 12.65 R.sub.gY (Ill. C, 2 deg.): 22% 23.3% 29% a*.sub.g (Ill. C, 2): 2.66 0.98 2.48 b*.sub.g (Ill. C, 2): 8.12 5.01 8.35
(28) Set forth below are the optical characteristics of laminated window units including the coated articles of Examples 1-3, namely when the coated articles are located in laminated window units as shown in
(29) TABLE-US-00006 Laminated Window Unit Characteristic Ex. 1 Ex. 2 Ex. 3 T.sub.vis (or TY)(Ill. C 2): 38.5% 33.7% 40.5% a*.sub.t (Ill. C 2): 6.15 5.48 3.9 b*.sub.t (Ill. C 2): 1.42 2.73 2.72 R.sub.fY (Ill. C, 2 deg.): 13.2% 18.8% 22.2% a*.sub.f (Ill. C, 2): 9.84 15.61 17.57 b*.sub.f (Ill. C, 2): 22.98 17.14 8.74 R.sub.gY (Ill. C, 2 deg.): 18% 22.6% 25.4% a*.sub.g (Ill. C, 2): 0.62 4.34 3.66 b*.sub.g (III. C, 2): 8.49 4.64 7.41
(30) In certain example embodiments of this invention, there is provided a coated article including a coating supported by a glass substrate, the coating comprising: first 9 and second 19 infrared (IR) reflecting layers comprising silver, the first IR reflecting layer 9 being located closer to the glass substrate 1 than is the second IR reflecting layer 19; a first contact layer comprising NiCr 11 located over and directly contacting the first IR reflecting layer comprising silver 9; a dielectric layer comprising silicon nitride 14 located over and directly contacting the first contact layer comprising NiCr 11; a second contact layer comprising NiCr 17 located over and directly contacting the layer comprising silicon nitride 14; the second IR reflecting layer comprising silver 19 located over and directly contacting the second contact layer comprising NiCr 17; and wherein the second IR reflecting layer comprising silver 19 is at least 10 angstroms (A) thinner than the first IR reflecting layer comprising silver 9, and wherein the coated article has a visible transmission of no greater than 50% (e.g., measured monolithically and/or in a laminated window structure).
(31) In the coated article of the immediately preceding paragraph, the first contact layer comprising NiCr may be from about 10-40 thick, more preferably from about 15-30 thick, and most preferably from about 18-25 thick.
(32) In the coated article of any of the preceding two paragraphs, said first contact layer comprising NiCr may be from 8-22 thicker than the second contact layer comprising NiCr, more preferably said first contact layer comprising NiCr may be from 10-18 thicker than the second contact layer comprising NiCr.
(33) In the coated article of any of the preceding three paragraphs, the second contact layer comprising NiCr may be from about 5-22 thick, more preferably from about 6-14 thick, and most preferably from about 7-11 thick.
(34) In the coated article of any of the preceding four paragraphs, the second IR reflecting layer comprising silver may be at least 20 angstroms () thinner (more preferably at least 40 angstroms thinner) than the first IR reflecting layer comprising silver.
(35) In the coated article of any of the preceding five paragraphs, the dielectric layer comprising silicon nitride 14 may be amorphous.
(36) In the coated article of any of the preceding six paragraphs, the first contact layer comprising NiCr and/or the second contact layer comprising NiCr may be substantially metallic or metallic and contain no more than about 5% (atomic %) oxygen.
(37) In the coated article of any of the preceding seven paragraphs, said first and/or second contact layer may further contain nitrogen (e.g., from about 1-10%, atomic %, nitrogen).
(38) In the coated article of any of the preceding eight paragraphs, said coated article may have a visible transmission of from about 20-40% (more preferably from about 27-39%) measured monolithically.
(39) The coated article of any of the preceding nine paragraphs may or may not be heat treated (e.g., thermally tempered). When heat treated, the coated article may have a glass side reflective E* value of no greater than 4.6 (more preferably no greater than 3.6, and possibly from 3.0 to 4.6) due to the heat treatment.
(40) In the coated article of any of the preceding ten paragraphs, the coating may further include another dielectric layer 24 comprising silicon nitride located over at least the second IR reflecting layer 19. The another dielectric layer 24 comprising silicon nitride may be from 150-290 thick. An overcoat comprising zirconium oxide 27 may be located over and directly contacting the another dielectric layer comprising silicon nitride 24.
(41) In the coated article of any of the preceding eleven paragraphs, the coating may further include a bottom layer comprising silicon nitride 3 located on and directly contacting the glass substrate 1, and another contact layer comprising NiCr 7 located between and directly contacting the bottom layer comprising silicon nitride 3 and the first IR reflecting layer comprising silver 9.
(42) In the coated article of any of the preceding twelve paragraphs, the first IR reflecting layer comprising silver may be from 110-145 thick.
(43) In the coated article of any of the preceding thirteen paragraphs, the second IR reflecting layer comprising silver may be from 60-95 thick.
(44) In the coated article of any of the preceding fourteen paragraphs, the coating may have a sheet resistance of less than or equal to 4.0 ohms/square.
(45) The coated article of any of the preceding fifteen paragraphs, when heat treated, may have a transmissive E* value of from 2.0 to 3.2.
(46) The coated article of any of the preceding sixteen paragraphs may be provided in an IG window unit, or in a laminated window unit in which the coated substrate is laminated to another glass substrate.
(47) 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.