MIRROR AND METHODS OF MAKING THE SAME
Certain example embodiments of this invention relate to sputtered aluminum second surface mirrors with permanent protective coatings optionally provided thereto, and/or methods of making the same. A mirror coating supported by a substrate may include, for example, first and second dielectric layers sandwiching a metallic or substantially metallic layer including aluminum, and an optional layer including Ni and/or Cr in direct contact with the metallic or substantially metallic layer comprising aluminum. A protective film may be disposed directly over and contacting an outermost layer of the mirror coating, with the protective film having a peel strength of 200-500 cN/20 mm wide strip.
1 . A mirror, comprising:
a glass substrate;
a multilayer thin film coating supported by the substrate, the multilayer thin film coating comprising, in order moving away from the substrate:
a first dielectric layer,
a metallic or substantially metallic layer comprising aluminum, and
a second dielectric layer; and
a protective film disposed directly over and contacting an outermost layer of the multilayer thin film coating, the protective film having a peel strength of 200-500 cN/20 mm wide strip,
wherein the protective film is adapted to survive seven day exposure to an 85 degree C. temperature at 85% relative humidity, as well as seven day exposure to a 49 degree C. temperature at 100% relative humidity.
2 . A mirror comprising:
a substrate;
a multilayer thin film coating supported by the substrate, the multilayer thin film coating comprising a metallic or substantially metallic layer comprising aluminum sandwiched between inner and outer dielectric layers, the inner dielectric layer being located between at least the substrate and the metallic or substantially metallic layer comprising aluminum; and
a protective film disposed directly over and contacting an outermost layer of the multilayer thin film coating.
3 . The mirror of claim 2 , wherein the protective film has a peel strength of 200-500 cN/20 mm wide strip.
4 . The mirror of claim 2 , wherein the protective film is capable of surviving seven day exposure to an 85 degree C. temperature at 85% relative humidity, as well as seven day exposure to a 49 degree C. temperature at 100% relative humidity.
5 . The mirror of claim 2 , wherein a layer comprising Ni and/or Cr is interposed between the metallic or substantially metallic layer comprising aluminum and the outer dielectric layer.
6 . The mirror of claim 2 , wherein the inner and outer dielectric layers each comprise silicon nitride.
7 . The mirror of claim 2 , wherein the inner dielectric layer is less than 100 angstroms thick.
8 . The mirror of claim 2 , wherein a layer comprising NiCr is interposed between the metallic or substantially metallic layer comprising aluminum and the outer dielectric layer, and wherein the layer comprising NiCr is 5-20 angstroms thick.
9 . The mirror of claim 2 , wherein the coated article has a glass side reflectance of at least 76%.
10 . The mirror of claim 2 , wherein the metallic or substantially metallic layer comprising aluminum is 250-650 angstroms thick.
11 . The mirror of claim 2 , wherein the first dielectric layer comprises material selected from one or more of: silicon nitride, silicon oxynitride, aluminum oxide, aluminum oxynitride, zirconium oxide, titanium oxide, yittrium oxide, zinc aluminum oxide, and tin oxide.
12 . The mirror of claim 2 , wherein the second dielectric layer comprises material selected from one or more of: silicon nitride, silicon oxynitride, aluminum oxide, aluminum oxynitride, zirconium oxide, titanium oxide, yittrium oxide, zinc aluminum oxide, and tin oxide.
13 . The mirror of claim 2 , wherein the first and second dielectric layers each comprise material selected from one or more of: silicon nitride, silicon oxynitride, aluminum oxide, aluminum oxynitride, zirconium oxide, titanium oxide, yittrium oxide, zinc aluminum oxide, and tin oxide.
14 . The mirror of claim 2 , wherein the first and/or second dielectric layer(s) comprises silicon oxynitride.
15 . The mirror of claim 2 , wherein the first and/or second dielectric layer(s) comprises zirconium oxide.
16 . The mirror of claim 2 , wherein the first and/or second dielectric layer(s) comprises aluminum oxynitride.
17 . The mirror of claim 2 , wherein the outer dielectric layer is from 10-200 angstroms thick.
18 . A method of making a mirror, the method comprising:
sputter-depositing on a glass substrate a coating comprising at least the following layers in the following order:
a first dielectric layer,
a metallic or substantially metallic layer comprising aluminum, and
a second dielectric layer; and
applying a protective film directly over and contacting an outermost layer of the coating, the protective film having a peel strength of 200-500 cN/20 mm wide strip.
19 . The method of claim 18 , wherein the protective film is adapted to survive seven day exposure to an 85 degree C. temperature at 85% relative humidity, as well as seven day exposure to a 49 degree C. temperature at 100% relative humidity, with no evidence of delamination of the protective film and no evidence of deterioration of the coating.
20 . The method of claim 18 , further comprising:
receiving, at a fabricator location, a coated article made in accordance with the method of claim 18 ; and
cutting the coated article into pieces of one or more respective desired sizes for making mirrors.