Method of making coated articles having an oxygen barrier coating and coated articles made thereby
View Patent ↗An article includes a substrate, a functional coating deposited over at least a portion of the substrate, and a protective (barrier) coating deposited over at least a portion of the functional coating. The barrier coating is stable to oxygen-containing gases and limits the transmission of oxygen-containing gases to materials over which it is deposited when subjected to conditioning steps such as heating, bending, and/or tempering.
1. An article, comprising:
a substrate;
a functional coating deposited over at least a portion of the substrate; and
a barrier coating comprising 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 99 wt. % alumina and 50 wt. % to 1 wt. % silica, and the second layer comprises 80 wt. to 95 wt. silica and 5 wt. to 20 wt. alumina,
wherein the barrier coating is stable to oxygen-containing gases and limits the transmission of oxygen-containing gases to materials over which it is deposited when subjected to conditioning comprising one or more of heating, bending, and tempering.
2. The article of claim 1 , wherein the substrate is an oxygen barrier.
3. The article of claim 1 , wherein the substrate includes at least one other barrier coating formed over at least a portion of the substrate and wherein the functional coating is formed over the at least one other barrier coating.
4. The article of claim 1 , wherein the barrier coating has a refractive index in the range of 1.4 to 1.8.
5. The article of claim 1 , wherein the substrate is selected from glass, plastic, and ceramic.
6. The article of claim 1 , wherein the article is an automotive transparency.
7. The article of claim 1 , wherein the article is selected from the group of comprising a window, a single pane of glass, a window with multiple panes of glass, an aircraft transparency, and a motor vehicle transparency.
8. The article of claim 1 , wherein the substrate has a thickness in the range of 0.2 mm to 20 mm.
9. The article of claim 1 , wherein the functional coating has an emissivity of 0.1 or less.
10. The article of claim 1 , wherein the barrier coating increases the emissivity of the coating stack by at least a factor of two with respect to the emissivity of the functional coating.
11. The article of claim 1 , wherein the barrier coating increases the emissivity of the coating stack by a factor in the range of 2 to 20 compared to the emissivity of the functional coating.
12. The article of claim 1 , wherein the functional coating has an emissivity of less than or equal to 0.1 and the coating stack has an emissivity of greater than or equal to 0.5.
13. The article of claim 1 , wherein the emissivity of the coating stack is 0.5 to 0.8.
14. The article of claim 1 , wherein the first layer comprises 70 wt. % to 99 wt. % alumina and 30 wt. % to 1 wt. % silica.
15. The article of claim 1 , wherein the first layer comprises 50 wt. % to 60 wt. % alumina and 40 wt. % to 50 wt. % silica.
16. The article of claim 1 , wherein the first layer comprises 55 wt. % alumina and 45 wt. % silica.
17. The article of claim 1 , wherein the first layer has a thickness in the range of 50 Å to 1,000 Å.
18. The article of claim 1 , wherein the first layer has a thickness in the range of 50 Å to 200 Å.
19. The article of claim 1 , wherein the first layer has a thickness of 125 Å.
20. The article of claim 15 , wherein the first layer has a thickness in the range of 50 Å to 400 Å.
21. The article of claim 16 , wherein the first layer has a thickness of 200 Å.
22. The article of claim 1 , wherein the second layer has a thickness in the range of 50 Å to 2,000 Å.
23. The article of claim 1 , wherein the second layer has a thickness in the range of 300 Å to 1,000 Å.
24. The article of claim 1 , wherein the second layer has a thickness of 500 Å.
25. The article of claim 1 , wherein the barrier 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.
26. The article of claim 1 , wherein the barrier coating is solar absorbing in at least one of the UV, IR, or visible regions of the electromagnetic spectrum.
27. The article of claim 1 , wherein the article is a monolithic transparency.