Coated article with sequentially activated low-E coating, and/or method of making the same
View Patent ↗Certain example embodiments relate to coated articles with sequentially activated low-E coatings, and/or methods of making the same. In certain example embodiments, one or more infrared reflecting layers is/are activated via a non-equilibrium preconditioning activation that uses photons with specific frequencies/frequency ranges, followed by a more equilibrium thermal activation. The preconditioning activation aids in rearranging the silver atoms to energetically favorable positions, while helping to avoid their unwanted agglomeration. The more equilibrium thermal stage of activation aids in aligning the chemical potentials of the layers of the stack and in further densification of the preconditioned silver layer. Doing so, in turn, helps to reduce the likelihood of stresses building-up in the coating, the formation of point and dimensional defects, other unwanted efficiency-reducing phenomena, and/or the like. Advantageously, emissivity can be lowered to a value lower than that achievable using conventional thermal, flash, and laser scanning, approaches alone.
1. A method of making a coated article including a multilayer thin film coating supported by a glass substrate, the method comprising:
sputter-depositing a first silver-based layer, directly or indirectly, on the glass substrate;
sputter-depositing at least one dielectric layer, directly or indirectly, on the first silver-based layer;
sputter-depositing a second silver-based layer, directly or indirectly, on the at least one dielectric layer;
adjusting resistivity levels of the first and second silver-based layers through flash light source exposure in at least one wavelength range and subsequently performing thermal activation; and
wherein the adjusting comprises preconditioning the silver based layers via flash light source exposure in at least first and second different wavelength ranges, the first wavelength range preferentially transmitting energy to the first silver based layer and the second wavelength range preferentially transmitting energy to the second silver based layer, and thereafter performing thermal activation comprising a thermal treatment that is performed after all of the silver based layers have been deposited, directly or indirectly, on the glass substrate.
2. The method of claim 1 , wherein the flash light source exposure in the at least one wavelength range preferentially transmits energy to one of the first and second silver-based layers and cause a rearrangement of silver atoms therein to a desired orientation relating to emissivity.
3. The method of claim 1 , wherein the flash light source exposure is performed after both the first and second silver-based layers have been sputter-deposited, the flash light source exposure in the at least one wavelength range preferentially transmitting energy to the first silver-based layer.
4. The method of claim 1 , wherein the adjusting of resistivity levels includes flash light source exposure in first and second wavelength ranges that are different from one another, the flash light source exposure being performed after both the first and second silver-based layers have been sputter-deposited.
5. The method of claim 4 , wherein the flash light source exposures generate the first and second wavelength ranges by using time-separated sub-pulses of different waveforms.
6. The method of claim 4 , wherein the first wavelength range has a maximum intensity in a first area proximate to a maximum absorptivity of the first silver-based layer and the second wavelength range has a maximum intensity in a second area that is remote from the first area and where the absorptivity of the first silver-based layer is less than one-half of its maximum.
7. The method of claim 1 , further comprising thermally heating the substrate with the first and second silver-based layers sputter-deposited thereon in the thermal activation, following the flash light source exposure, wherein:
the adjusting of resistivity levels includes flash light source exposure in first and second wavelength ranges that are different from one another;
the flash light source exposures generate the first and second wavelength ranges by using time-separated sub-pulses of different waveforms;
the first wavelength range has a maximum intensity in a first area proximate to a maximum absorptivity of the first silver-based layer and the second wavelength range has a maximum intensity in a second area that is remote from the first area and where the absorptivity of the first silver-based layer is less than one-half of its maximum; and
the flash light source exposures preferentially transmit energy to the first and second silver-based layers, respectively, and cause rearrangements of silver atoms therein to desired crystallinities.
8. The method of claim 1 , wherein the flash light source exposure comprises treatment with photons with energies of 0.82-3.55 eV.
9. The method of claim 1 , wherein the thermal activation comprises treatment at a temperature(s) of 400-650 degrees C.
10. The method of claim 1 , wherein the emissivity of the coating, following the flash light exposure and thermal activation is 0.011 or lower.
11. A method of making a coated article including a multilayer thin film coating supported by a glass substrate, the method comprising:
sputter-depositing a first silver-based layer, directly or indirectly, on the glass substrate;
sputter-depositing at least one dielectric layer, directly or indirectly, on the first silver-based layer;
sputter-depositing a second silver-based layer, directly or indirectly, on the at least one dielectric layer;
adjusting resistivity levels of the first and second silver-based layers through radiation source exposure in at least one wavelength range; and
wherein the adjusting comprises preconditioning the silver based layers via flash light source exposure in at least first and second different wavelength ranges, the first wavelength range preferentially transmitting energy to the first silver based layer and the second wavelength range preferentially transmitting energy to the second silver based layer.