CN106164717A - 一种用于绝缘玻璃窗单元灰色外观的具较低可见光透射率涂层的涂层制品 - Google Patents

一种用于绝缘玻璃窗单元灰色外观的具较低可见光透射率涂层的涂层制品 Download PDF

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CN106164717A
CN106164717A CN201380079930.4A CN201380079930A CN106164717A CN 106164717 A CN106164717 A CN 106164717A CN 201380079930 A CN201380079930 A CN 201380079930A CN 106164717 A CN106164717 A CN 106164717A
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coated article
layer
reflecting layer
infrared reflecting
contact
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CN106164717B (zh
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哈特穆特·诺尔
马库斯·弗兰克
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Guardian Europe SARL
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Glass And Luxembourg Of Ceramic Research Co Ltd Center
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    • CCHEMISTRY; METALLURGY
    • C03GLASS; MINERAL OR SLAG WOOL
    • C03CCHEMICAL COMPOSITION OF GLASSES, GLAZES OR VITREOUS ENAMELS; SURFACE TREATMENT OF GLASS; SURFACE TREATMENT OF FIBRES OR FILAMENTS MADE FROM GLASS, MINERALS OR SLAGS; JOINING GLASS TO GLASS OR OTHER MATERIALS
    • C03C17/00Surface treatment of glass, not in the form of fibres or filaments, by coating
    • C03C17/34Surface treatment of glass, not in the form of fibres or filaments, by coating with at least two coatings having different compositions
    • C03C17/36Surface treatment of glass, not in the form of fibres or filaments, by coating with at least two coatings having different compositions at least one coating being a metal
    • C03C17/3602Surface treatment of glass, not in the form of fibres or filaments, by coating with at least two coatings having different compositions at least one coating being a metal the metal being present as a layer
    • C03C17/3681Surface treatment of glass, not in the form of fibres or filaments, by coating with at least two coatings having different compositions at least one coating being a metal the metal being present as a layer the multilayer coating being used in glazing, e.g. windows or windscreens
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B32LAYERED PRODUCTS
    • B32BLAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B17/00Layered products essentially comprising sheet glass, or glass, slag, or like fibres
    • B32B17/06Layered products essentially comprising sheet glass, or glass, slag, or like fibres comprising glass as the main or only constituent of a layer, next to another layer of a specific material
    • B32B17/10Layered products essentially comprising sheet glass, or glass, slag, or like fibres comprising glass as the main or only constituent of a layer, next to another layer of a specific material of synthetic resin
    • B32B17/10005Layered products essentially comprising sheet glass, or glass, slag, or like fibres comprising glass as the main or only constituent of a layer, next to another layer of a specific material of synthetic resin laminated safety glass or glazing
    • B32B17/10165Functional features of the laminated safety glass or glazing
    • B32B17/10174Coatings of a metallic or dielectric material on a constituent layer of glass or polymer
    • B32B17/10201Dielectric coatings
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B32LAYERED PRODUCTS
    • B32BLAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B17/00Layered products essentially comprising sheet glass, or glass, slag, or like fibres
    • B32B17/06Layered products essentially comprising sheet glass, or glass, slag, or like fibres comprising glass as the main or only constituent of a layer, next to another layer of a specific material
    • B32B17/10Layered products essentially comprising sheet glass, or glass, slag, or like fibres comprising glass as the main or only constituent of a layer, next to another layer of a specific material of synthetic resin
    • B32B17/10005Layered products essentially comprising sheet glass, or glass, slag, or like fibres comprising glass as the main or only constituent of a layer, next to another layer of a specific material of synthetic resin laminated safety glass or glazing
    • B32B17/10165Functional features of the laminated safety glass or glazing
    • B32B17/10174Coatings of a metallic or dielectric material on a constituent layer of glass or polymer
    • B32B17/1022Metallic coatings
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B32LAYERED PRODUCTS
    • B32BLAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B17/00Layered products essentially comprising sheet glass, or glass, slag, or like fibres
    • B32B17/06Layered products essentially comprising sheet glass, or glass, slag, or like fibres comprising glass as the main or only constituent of a layer, next to another layer of a specific material
    • B32B17/10Layered products essentially comprising sheet glass, or glass, slag, or like fibres comprising glass as the main or only constituent of a layer, next to another layer of a specific material of synthetic resin
    • B32B17/10005Layered products essentially comprising sheet glass, or glass, slag, or like fibres comprising glass as the main or only constituent of a layer, next to another layer of a specific material of synthetic resin laminated safety glass or glazing
    • B32B17/10165Functional features of the laminated safety glass or glazing
    • B32B17/10174Coatings of a metallic or dielectric material on a constituent layer of glass or polymer
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    • B32B17/10229Metallic layers sandwiched by dielectric layers
    • BPERFORMING OPERATIONS; TRANSPORTING
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    • B32B7/00Layered products characterised by the relation between layers; Layered products characterised by the relative orientation of features between layers, or by the relative values of a measurable parameter between layers, i.e. products comprising layers having different physical, chemical or physicochemical properties; Layered products characterised by the interconnection of layers
    • B32B7/02Physical, chemical or physicochemical properties
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    • C03C17/001General methods for coating; Devices therefor
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    • C03C17/3435Surface treatment of glass, not in the form of fibres or filaments, by coating with at least two coatings having different compositions with at least two coatings of inorganic materials at least one of the coatings being a non-oxide coating comprising a nitride, oxynitride, boronitride or carbonitride
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    • C03C17/3602Surface treatment of glass, not in the form of fibres or filaments, by coating with at least two coatings having different compositions at least one coating being a metal the metal being present as a layer
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    • C03C17/36Surface treatment of glass, not in the form of fibres or filaments, by coating with at least two coatings having different compositions at least one coating being a metal
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    • C03C17/3626Surface treatment of glass, not in the form of fibres or filaments, by coating with at least two coatings having different compositions at least one coating being a metal the metal being present as a layer one layer at least containing a nitride, oxynitride, boronitride or carbonitride
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    • C03C17/00Surface treatment of glass, not in the form of fibres or filaments, by coating
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    • Y10T428/2495Thickness [relative or absolute]
    • Y10T428/24967Absolute thicknesses specified

Abstract

本发明涉及一种含有低辐射(low‑E)涂层的涂层制品。在示例性实施例中,低辐射涂层被配置在基片(例如,玻璃基片)上,并包括:至少第一和第二红外(IR)反射层(例如,银基层),通过接触层(例如,基于镍铬的层)和含有类似氮化硅材料的介质层被隔开。在示例性实施例中,涂层制品具有较低的可见光透射率(例如,不超过60%,更优选是约55%以下,且最优选是约50%以下)。

Description

一种用于绝缘玻璃窗单元灰色外观的具较低可见光透射率涂 层的涂层制品
本发明涉及一种涂层制品,包括低辐射(low-E)涂层。使涂层的玻璃制品具有理想的灰色玻璃侧反射着色而无需灰色的玻璃基片。在一些实施例中,低辐射涂层被配置在基片上(例如,玻璃基片),并包括:至少第一和第二红外(IR)反射层(例如,银基层),通过接触层(例如,基于镍铬的层)和含有类似氮化硅材料的介质层被隔开。在一些示例性实施例中,涂层制品(例如,单片形式和/或以绝缘玻璃窗单元形式)具有较低的可见光透射率(例如,不超过55%,更优选是约50%以下,更优选是约45%以下,且最优选是约40%以下)。在示例性实施例中,涂层制品可被热处理(例如,热回火和/或热弯曲),并被设计成热处理(HT)时基本上热稳定,由于热处理其ΔE*值(玻璃侧反射)不超过5.0,且更优选是不超过4.5,且最优选是不超过4.1。根据本发明的示例性实施例的涂层制品可用于绝缘玻璃(IG)窗单元、车窗或其他类型的窗中。
发明背景
涂层制品在现有技术中被应用于窗,例如绝缘玻璃(IG)窗单元,车窗,和/或类似等。通常在一些情况下,将涂层制品热处理(例如,热回火,热弯曲和/或热强化)从而目的在于回火、弯曲、或类似等。涂层的热处理(HT)通常需要使用至少580摄氏度的温度,更优选是至少约600摄氏度,甚至更优选是至少620摄氏度。该高温(例如,5-10分钟以上)经常会使涂层分裂和/或恶化,或是以不可预知的方式改变。因此,最好是涂层能够承受这样的热处理(例如,热回火),如果需要的话,以一种不会明显损害涂层的预知方式。
在一些情况下,涂层物品设计师试图将所需的可见光透射率、所需的颜色、低辐射(或辐射率)、以及低片电阻(Rs)相结合。低辐射(low-E)和低片电阻特性使该涂层制品阻挡大量的红外辐射,从而来减少车辆或建筑物内部不理想的热量。
美国专利No.7,521,096公开了一种低辐射涂层,在银基红外反射层之下使用氧化锌(ZnO)接触层,以及在底部的银(Ag)基红外反射层之上使用NiCrOx接触层,随后为中心氧化锡(SnO2)介质层,其内容被纳入此处作为参考。虽然银基红外反射层下面的氧化锌层提供良好的结构性能有助于银的增长,但是在一些情况下发现氧化锌会降低涂层的化学性,环境及机械耐久性。
美国专利No.5,557,462公开了一种具有SiN/NiCr/Ag/NiCr/SiN/NiCr/Ag/NiCr/SiN层堆栈的低辐射涂层。然而,“462专利”的涂层制品针对至少63%的高可见光透射率被设计。在“462专利的第3栏,第12-15行,指出可见光透射率低于70%(单片涂层制品)和低于63%(绝缘玻璃窗单元)都是不可取的。因此,“462专利直接背离了可见光透射率低于63%的涂层制品。此外,如美国专利No.8,173,263中仔细说明的,由于‘462专利的涂层制品在热处理时片电阻(RS)从约3-5上升至10,并产生雾霾,且玻璃侧反射ΔE*值不理想,超过5.0,因此不能被热处理。
因此,需要提供一种涂层,具有以下特性中一个、两个、三个或四个:(i)较低的可见光透射率,(ii)较好的耐久性,(iii)理想的着色,和/或(iv)热处理时较好的热稳定性,从而实现玻璃侧反射ΔE*值不超过5.0,更优选是不超过4.5。此外,需要一种含有涂层的绝缘玻璃窗单元,所述涂层具较低的太阳能系数(SF),和/或较低的外反射率,例如不超过12%,更优选是约11%以下,甚至更优选是约10%以下,且最优选是约9%以下。参照有关计算绝缘玻璃单元的太阳能系数和可见光透射率的EN 410。
在ASTM2244-93以及Hunter等人的有关外观测量报告The Measurement ofAppearance 2nd Ed.Cptr.9,第162页及以下等[John Wiley&Sons,1987]内容中说明了本技术领域中的ΔE*(以及ΔE),根据各种各种技术来确定该值。如本技术领域中所使用的,ΔE*(以及ΔE)是适当地表现热处理之后或由于热处理制品中的反射率和/或透射率中的变化(或不足之处)的方法。ΔE可通过"ab"技术被计算,或是通过Hunter技术(被指定使用下标的"H")。ΔE对应于Hunter Lab L,a,b标度(或是Lh,ah,bh)。相似的,ΔE*对应于CIE LAB标度L*,a*,b*。对于本发明的目的两者都十分实用并相同。例如,上述参考的Hunter等人的报告中,称为L*,a*,b*标度的直角坐标/标度技术(CIELAB 1976)可被使用,其中,L*为(CIE1976)明度单位;a*为(CIE 1976)红绿色单位;b*为(CIE 1976)黄蓝色单位,且L*o a*o b*o和L*1a*1b*1之间的差距ΔE*为:ΔE*=[(ΔL*)2+(Δa*)2+(Δb*)2]1/2,其中,ΔL*=L*1–L*o;Δa*=a*1–a*o;Δb*=b*1–b*o。其中下标的"o"表示热处理之前的涂层(涂层制品),下标的"1"表示热处理之后的涂层(涂层制品),且使用的数字(例如a*,b*,L*)由上述的(CIELAB 1976)L*,a*,b*坐标技术被计算。例如,当玻璃侧反射ΔE*值被测量时,然后玻璃侧反射a*,b*和L*值被测量。以相似的方法,ΔE可利用上述用于ΔE*的等式被计算,即,ΔE*=[(ΔL*)2+(Δa*)2+(Δb*)2]1/2,使用Hunter Lab值ah,bh,Lh来替换a*,b*,L*。此外,当在本发明的范围内,转换成采用如上定义的相同概念ΔE*的任何其他技术被计算时,ΔE*的定量数值相同。
U值(有时称为U系数)用于测量类似墙、地板、窗户或屋顶的建筑构件的热损耗。其也可被称作为整体传热合作效率,并测量建筑部分传热的效果。其表示U值越高建筑外围的热性能越差。较低的U值通常表示绝缘水平高。换句话说,U值用于测量房屋或建筑热量散失的效果。U值越低,产品则能更好地保持建筑内部的热量。除非另有说明,在所述的U值以W/m2K的单位被测量。参照关于计算U值的EN 673。
发明的示例性实施例概述
本发明涉及一种涂层制品,包括低辐射(low-E)涂层,使涂层的玻璃制品具有理想的灰色玻璃侧反射着色,而无需灰色的玻璃基片。在一些实施例中,低辐射涂层被配置在基片上(例如,玻璃基片),并包括:至少第一和第二红外(IR)反射层(例如,银基层),通过接触层(例如,基于镍铬的层)和含有类似氮化硅材料的介质层被隔开。在一些示例性实施例中,涂层制品具有较低的可见光透射率(例如,不超过55%,更优选是约50%以下,更优选是约45%以下,且最优选是约40%以下,在绝缘玻璃单元中和/或单片地被测量)。在示例性实施例中,涂层制品可被热处理(例如,热回火和/或热弯曲),并被设计成热处理(HT)时基本上热稳定,由于热处理其ΔE*值(玻璃侧反射)不超过5.0,且更优选是不超过4.5,且最优选是不超过4.1。该较低的ΔE*值示出经肉眼观察涂层制品在热处理之前和之后几乎具有相同的透射性和颜色特性。根据本发明的示例性实施例的涂层制品可用于绝缘玻璃(IG)窗单元、车窗或其他类型的窗中。
优选是提供一种涂层制品,具有以下特性中一个、两个、三个或四个:(i)较低的可见光透射率,(ii)较好的耐久性,(iii)理想的灰色玻璃侧着色,和(iv)热处理时的热稳定性,从而实现玻璃侧反射ΔE*值不超过5.0,更优选是不超过4.5。此外,优选是提供一种含有涂层的绝缘玻璃窗单元,所述涂层具有以下特性中的一个、两个、或三个:(a)较低的太阳能系数(SF),例如不超过33%,更优选是约31%以下,甚至更优选是约29%以下,且甚至更优选是约27%以下;(b)较低的外反射率,例如不超过12%,更优选是约11%以下,甚至更优选是约10%以下,且最优选是约9%以下;(c)外反射灰色着色。
在本发明的示例性实施例中,提供一种绝缘玻璃(IG)窗单元,包括:含有涂层的涂层制品,所述涂层由第一玻璃基片支撑;所述第一玻璃基片与其上的所述涂层被耦合至第二玻璃基片,其之间具有间隙,且其中,所述第一玻璃基片被用来配置在所述绝缘玻璃窗单元的外部/外侧,且所述第二玻璃基片被用来配置在所述绝缘玻璃窗单元的内部/内侧,位于安装有或将要安装所述绝缘玻璃窗单元的建筑的内部附近,且其中,所述涂层位于所述第一玻璃基片的主要表面上,与所述基片之间的所述间隙相对,其中,由所述第一玻璃基片支撑的所述涂层包括:含有银的第一和第二红外(IR)反射层,所述第一红外反射层比所述第二红外反射层更靠近所述玻璃基片;含有镍铬的第一接触层,位于所述含有银的第一红外反射层之上并直接与其接触;含有氮化硅的介质层,位于所述含有镍铬的第一接触层之上并直接与其接触;第二接触层,位于所述含有氮化硅的介质层之上并直接与其接触;所述含有银的第二红外反射层,位于所述第二接触层之上并直接与其接触;含有镍铬的第三接触层,位于所述第二红外反射层之上并直接与其接触;另一个含有氮化硅的介质层,位于所述含有镍铬的第三接触层之上并直接与其接触,其中,所述含有银的第二红外反射层比所述含有银的第一红外反射层至少厚 其中,所述绝缘玻璃窗单元的可见光透射率不超过50%,且外侧可见光反射率不超过12%,且其中,从外侧观察时,所述绝缘玻璃窗单元的外观为灰色或深灰色,且其中,所述绝缘玻璃窗单元的所述第一和第二玻璃基片为透明而不灰色的玻璃基片。
在本发明的示例性实施例中,提供一种含有涂层的涂层制品,所述涂层由玻璃基片支撑,所述涂层包括:含有银的第一和第二红外(IR)反射层,所述第一红外反射层比所述第二红外反射层更靠近所述玻璃基片;含有镍铬的第一接触层,位于所述含有银的第一红外反射层之上并直接与其接触;含有氮化硅的介质层,位于所述含有镍铬的第一接触层之上并直接与其接触;含有镍铬的第二接触层,位于所述含有氮化硅的介质层之上并直接与其接触;所述含有银的第二红外反射层,位于所述含有镍铬的第二接触层之上并直接与其接触;含有镍铬的第三接触层,位于所述第二红外反射层之上并直接与其接触;另一个含有氮化硅的介质层,位于所述含有镍铬的第三接触层之上并直接与其接触,其中,所述含有银的第二红外反射层比所述含有银的第一红外反射层至少厚两倍,且其中,所述涂层制品被单片测量的可见光透射率不超过55%,被单片测量的玻璃侧可见光反射率不超过11%。
附图简要说明
图1是示出根据本发明的示例性实施例的涂层制品的横截面图。
图2是示出根据本发明的示例性实施例的配置在绝缘玻璃窗单元中的图1的涂层制品的横截面图。
本发明示例性实施例的具体说明
在此所述的涂层制品,可用于类似绝缘玻璃窗单元,层压窗单元(例如,用于在车辆或建筑应用)、车辆窗、单片的建筑窗、住宅窗,和/或任何其他包括单个或多个玻璃基片的合适的窗应用中。
在一些实施例中,含有涂层制品的绝缘玻璃窗单元的外侧(玻璃侧)将为灰色或深灰色的颜色,且涂层能使绝缘玻璃窗单元实现较低的可见光透射率、较低的太阳能系数、较低的外侧可见光反射率、低辐射、较低的传热系数。在一些实施例中,当在涂层制品中使用透明基片玻璃来制备绝缘玻璃窗单元的外侧物时,可通过外反射的灰色着色在绝缘玻璃窗单元中实现非常低的外反射率。因此,没有必要使用灰色基片玻璃来用于上述的外侧效果。透明玻璃较便宜,并相比灰色基片玻璃具有更好的实用性。虽然在本发明的示例性实施例中可使用灰色玻璃基片,但优选是使用透明或中和色的玻璃基片,并可通过涂层设计来实现所需的灰色着色而无需灰色玻璃。虽然在此所述的涂层制品可被热处理(例如,热回火),但是根据本发明的实施例的涂层制品不需要被热处理,或可以是热处理或非热处理中的任何一个。
在本发明的一些示例性实施例中,该涂层包括双银堆栈。参考图1,例如,在本发明的一些实施例,提供了一种含有涂层30的涂层制品,所述涂层30由玻璃基片1支撑,包括:含有银或主要由银构成的第一红外(IR)反射层9和第二红外反射层19,第一红外反射层9比第二红外反射层19更靠近玻璃基片1;含有镍铬的第一接触层7,位于含有银的第一红外反射层9之下并直接与其接触,第二接触层11位于含有银的第一红外反射层9之上并直接与其接触;含有氮化硅的透明介质层14,位于含有镍铬的第二接触层11之上并直接与其接触;含有镍铬的第三接触层17,位于含有氮化硅的层14之上并直接与其接触;含有银的第二红外反射层19,位于含有镍铬的第三接触层17之上并直接与其接触;含有镍铬的第四接触层21,位于第二红外反射层19之上并直接与其接触,其中,含有银的第二红外反射层19与含有银的第一红外反射层9至少一样厚。在一些优选的实施例中发现,当含有银的第二红外反射层19比含有银的第一红外反射层9更厚时可实现令人惊讶的有益效果,更优选是,第二红外反射层19比含有银的第一红外反射层9至少厚(更优选是至少厚甚至更优选是至少厚进一步更优选是至少厚此外更优选是至少厚最优选是至少厚)。如图1所示,图1中的涂层包括三个含有氮化硅的透明介质层3、14和24。此外,涂层可选择性地包括含有氧化锆和/或氮氧化锆的外层(未示图),该选择性的外层可位于基于氮化硅的层24之上并直接与其接触。在一些实施例中,该含有氧化锆和/或氮氧化锆的外层27可能比红外反射层9,19中的一个或两个更薄。在本发明的一些实施例中,各含有银的红外反射层9、19与含有氧化锆和/或氮氧化锆的选择性外层相比,可以是至少厚两倍,更优选是至少厚三倍。在本发明的一些示例性实施例中,涂层30仅包括2个含有银或类似等的红外反射层9、19。
为了提高耐久性,以及光学和热学性能,并在热处理之前和之后避免较大的结构性转变,根据本发明的一些实施例的涂层制品具备含有氮化硅的中心介质层14和基于镍铬的下接触层7、17(相对于ZnO)。此外还发现使用金属或基本金属的镍铬(可能部分被氮化)来用于层7、11、17和/或21可提高化学、机械、和环境的耐久性(相比在银之下使用氧化锌的下接触层和/或在银之上使用高氧化的镍铬上接触层)。在此还发现,在非晶质状态下,溅射沉积含有氮化硅的层14,从而使半涂层和热处理状态下都为非晶质,可有助于涂层的整体稳定性。例如,美国专利No.7,521,096中的涂层,经1小时65摄氏度下的5%HCl将会被除去,然而图1中所示的涂层以及在此所述的示例将通过该HCl测试。在高温高湿的环境下,与两天曝光后的‘096专利中的涂层相比,十天曝光后的图1所示的涂层以及在此所述的示例则损害更少。对于那些用于“砖洗”的高腐蚀性化学物质,用于抗腐蚀的切边不需要在示例性实施例和层压示例中被执行。此外发现,使顶部银基红外反射层19比底部银基红外反射层9更厚时可提高涂层光学特性。由于ΔE*值相对较低,该涂层可以是半涂层或被热处理。例如,当涂层30位于绝缘玻璃窗单元的表面#2(如图2所示)时,由于热处理玻璃侧反射ΔE*值较低,示出在热处理(如热回火)之前和之后经肉眼观察几乎具有相同的透射率和颜色特征,因此作为半涂层或被热处理不会严重影响其光学特性。
在本发明的一些实施例中,如图1,热处理或非热处理的涂层制品具有多个红外反射层(例如,两个隔开的银基层9和19)可实现小于或等于5.0的片电阻(RS)(更优选是小于或等于4.0欧姆/平方)。“热处理”和“热处理”的术语表示加热到足够的温度,以实现玻璃制品的热回火、热弯曲、和/或热强化。该定义包括,例如,至少约580摄氏度的温度下在烤炉或加热炉中加热涂层制品,更优选是至少约600摄氏度,以足够的时间允许回火、弯曲、和/或热强化。在一些情况下,热处理可以是至少约4分钟或5分钟。在本发明的不同实施例中,涂层制品可被热处理或也可以不热处理。
图1是根据本发明的非限制性示例实施例的涂层制品的侧横截面图。该涂层制品包括:基片1(例如,透明、绿色、青铜色、灰色、或蓝绿色的玻璃基片,厚度约为1.0-12.0毫米,更优选是厚度约为4-8毫米);和低辐射涂层(或层系统)30,直接或间接地配置在基片1上。涂层(或层系统)30包括,例如:底部介质氮化硅层3,其可以是Si3N4,或是富硅型的氮化硅来减少灰霾,或是本发明的不同实施例中任何其他合适的化学计量氮化硅;下接触层7(其接触底部红外反射层9);导电的优选是金属或基本金属的第一红外(IR)反射层9;上接触层11(其接触层9);基于和/或含有氮化硅的介质层14;下接触层17(其接触红外反射层19);导电的优选是金属或基本金属的第二红外反射层19;上接触层21(其接触层19);透明的氮化硅介质层24,其可以是Si3N4,富硅型来减少雾霾,或是本发明的不同实施例中任何其他合适的化学计量氮化硅。“接触”层11、7、17和21分别接触红外反射层(例如,,银基层)。上述层3-24用来制备低辐射(即低辐射率)涂层30,配置在玻璃基片1上。在本发明的一些实施例中,层3-24可溅射沉积在基片1上,各层根据需要通过使用一个或多个目标在真空中被溅射沉积(溅射目标可以是陶瓷或金属)。金属或基本金属的层(例如,层7、9、11、17、19和21)可在含有氩气的氛围中被溅射,其中氮化层(例如,层3、7、11、14、17、21和24)可在含有氮氩混合气体的氛围中被溅射。在本发明的不同实施例中,接触层7、11、17和21可被氮化或也可以不被氮化。
在单片的情况下,如图1所示,涂层制品仅包括一个玻璃基片1。然而,在此所述的单片涂层制品可用于类似层压的汽车挡风玻璃、绝缘玻璃窗单元等装置中。用于绝缘玻璃窗单元时,绝缘玻璃窗单元可包括2个隔开的玻璃基片。示例性的绝缘玻璃窗单元被示出并说明,例如美国专利文件No.2004/0005467中所公开的内容,其被纳入此处作为参考。图2示出含有图1中所示的涂层玻璃基片1的示例性绝缘玻璃窗单元,通过隔离片、密封胶40或类似等被耦合到另一个玻璃基片2,其之间被定义有间隙50。绝缘玻璃窗单元实施例中基片之间的间隙50在一些情况下被填入气体,例如氩气(Ar)。示例性绝缘玻璃单元可包括一对被隔开的玻璃基片1、2,厚度分别为3-4毫米,在示例性例子中,其中一个被涂有在此所述的涂层30,基片之间的间隔50可约为5-30毫米,更优选是约为10-20毫米,且最优选是约为16毫米。在示例性例子中,低辐射涂层30可面对间隙配置在任一基片的内表面(虽然在图2中涂层被示出面对间隔50位于基片1内部主要表面上,但是也可以是面对间隔50位于基片2的内部主要表面上)。无论是基片1或基片2可以是建筑外墙的绝缘玻璃窗单元的最外层基片(例如,图2中基片1是最接近外墙的基片,且涂层30被配置在绝缘玻璃窗单元的表面#2上)。在本发明的优选实施例中,涂层30被配置在如图2所示的绝缘玻璃窗单元的表面#2上。
在本发明的示例性实施例中,接触层7、11、17、21中的一个、两个、三个或四个可包括镍铬(任何合适的Ni对Cr比例),可被氮化或是也可以不被氮化(NiCrNx)。在一些实施例中,含有镍铬的层7、11、17、21中的一个、两个、三个或四个为基本或完全非氧化的。在一些实施例中,层7、11、17和21可能都是金属镍铬或基本金属镍铬(尽管其他微量元素可能存在)。在一些实施例中,基于镍铬的层7、11、17、21中的一个、两个、三个或四个可含有0-10%的氧气,更优选是0-5%的氧气,最优选是0-2%的氧气(原子百分比)。在一些实施例中,层7、11、17、21中的一个、两个、三个或四个可含有0-20%的氮气,更优选是1-15%的氮气,最优选是约12%的氮气(原子百分比)。基于镍铬的层7、11、17和/或21可以或也可以不掺杂其他物质,如不锈钢、钼等。在此发现,在银基红外反射层9、19下使用基于镍铬的接触层7和/或17可提高涂层制品的耐久性(与使用氧化锌的层7和17相比)。而且,令人惊讶地发现,由于与镍铬构成的层7、11、17和21相比,添加超微量氧气会造成不良雾霾以及降低耐久性,因此将层7、11、17、21制备成基本上由镍铬构成,来提高耐久性。
本发明的特定实施例中,介质层3、14、24可以是或包含氮化硅。氮化硅层3、14和24可位于其他物质之前,提高涂层制品的热处理性,并在选择性热处理期间保护其他层,例如热回火等。在本发明的不同实施例中,氮化硅层中3、14、24一个或多个可以是化学计量式(即,Si3N4),或者富硅型氮化硅。例如,富硅型氮化硅层3和/或14中存在的自由硅,可使热处理过程中从玻璃基片1中向外迁移的类似钠(Na)的特定原子,在达到银和损害银之前经富硅型氮化硅层被更有效地制止。因此,在本发明的选择性示例实施例中,富硅型SixNy可减少热处理过程中对于银层的损害,使片电阻(Rs)减少或以符合要求的方式保持不变。此外,在本发明的选择性示例实施例中,层3、14和/或24中的富硅型SixNy可减少热处理过程中对于银和/或镍铬的损害(例如,氧化)。在一些实施例中,当使用富硅型氮化硅时,沉积的富硅型氮化硅层(3、14和/或24)可以是SixNy层特征,其中X/Y可以是0.76-1.5,更优选是0.8-1.4,且更优选是0.82-1.2。在本发明的示例性实施例中,在此所述的氮化硅层中的任何一个和/或所有可掺杂其他材料,如不锈钢或铝。例如,在本发明的示例性实施例中,在此所述的氮化硅层3、14、24中的任何一个和/或所有可选择性地包括约0-15%的铝,更优选是约1-10%的铝。在本发明的示例性实施例中,氮化硅层3、14、24可通过在氩气和氮气的氛围中溅射硅或硅铝目标被沉积。在一些情况下,也可在氮化硅层中提供少量的氧气。
红外线(IR)反射层19和9优选是基本或完全金属的和/或导电的,并可包括或基本上由银(Ag)、金、或任何其他合适的红外反射材料构成。红外反射层9和19使涂层具有低辐射和/或良好的太阳能控制特性。
还可在示出的涂层之下或之上提供其他层。因此,虽然层系统或涂层位于基片1“上”或由基片1(直接或间接地)“支撑”,但其他层也可配置在其之间。因此,例如,即使层3和基片1之间配置有其他层,图1中的涂层也可被视为位于基片1“上”或由基片1“支撑”。此外,在不脱离本发明实施例的整个思想范围下,在一些实施例中,示出的涂层中的特定层可被去除,且在本发明的其他实施例中,各种层之间可添加其他层,或是各种层可与分开部分之间添加的其他层断开。作为另一个示例,涂有氧化锆的层也可配置在涂层30中。
在本发明的不同实施例中,层中可使用各种厚度和材料,以下示出针对图1实施例中的玻璃基片1上的层的示例性厚度和材料,从玻璃基片开始向外(物理厚度被列举):
示例性材料/厚度;图1实施例
含有银的第二红外反射层19至少与含有银的第一红外反射层9一样厚。在一些优选的实施例中,发现可实现更惊人的有效结果,含有银的第二红外反射层19比含有银的第一红外反射层9更厚,更优选是,第二红外反射层19比含有银的第一红外反射层9至少厚更优选是至少厚甚至更优选是至少厚更优选是至少厚更优选是至少厚最优选是至少厚在一些示例性实施例中,含有银的第二红外反射层19比含有银的第一红外反射层9至少厚两倍。在此所述的所有厚度均为物理厚度。
选择性的实施例包括:含有氧化锆和/或氮氧化锆的外层(未显示),与涂层30中含有银的红外反射层9、19中的每一个相比,该外层可以是更薄。在该实施例中,与含有氧化锆和/或氮氧化锆的外层相比,红外反射层9和19中的每一个可能至少厚两倍,更优选是至少厚三倍。
在示例性实施例中,中心基于氮化硅的层14,厚度大于其他基于氮化硅的层3和24中的每一个,优选是至少为更优选是至少为最优选是至少为此外,在一些示例性实施例中,氮化硅层3、14和24中的每一个,厚度至少为银基红外反射层9和19中一个或两个的2倍以上。
涂层30提供良好的耐久性,并与单个基于银的低辐射涂层相比,具有较低的玻璃侧和外侧可见光反射率。
在本发明的示例性实施例中,当涂层制品被单片测量时(选择性地热处理前和/或后)可具有以下的光学和太阳能特性。在此,片电阻(Rs)被涉及所有的红外反射层(例如,银层9、19)。应注意,“热处理前”表示被退火,但在所述的类似热回火的高温热处理前。此外,应注意,En表示正常辐射率,Tvis表示可见光透射率,RgY表示玻璃侧可见光反射率,且下标“g”的a*和b*值分别为玻璃侧反射的a*和b*颜色值。
光学/太阳能特性(单片–热处理前)
光学/太阳能特性(单片–热处理后)
从上面可以看出,热处理(例如,热回火)稍微增加了涂层制品的可见光透射率。
在本发明的示例性绝缘玻璃窗实施例中,涂层制品选择性地被热处理,从而在一定程度上充分回火,并被耦合至另一个玻璃基片来形成绝缘玻璃单元,在如图2所示的结构中可具有以下所述的光学/太阳能特性,(例如,两个玻璃片的厚度分别约为3.5-6毫米的透明玻璃,具有约为13-16毫米的间隙,其之间填充有90/10的氩气/空气)。
光学/太阳能特性(绝缘玻璃单元–非热处理)
光学/太阳能特性(绝缘玻璃单元–热处理)
以下本发明的示例仅作为示例被提供,除了特别声明,其并不局限于此。
示例1-3
以下示例1-3通过将涂层溅射在6毫米厚的透明玻璃基片上被制备,从而使层厚度大约具有以上表中“示例”栏中所示出的层厚度。
以下示出示例1-3的光学性能,针对如图1所示的单片涂层制品被测量。下表中所有的测量值为热处理前。请注意,“f”表示薄膜反射率,即,涂层制品的薄膜侧的反射率,而“g”表示玻璃侧反射率。除非另有说明,光学元件采用Ill.C,2deg.观察器。
单片(热处理前)
从上面的示例可以看出,被单片测量的涂层制品具有理想的较低可见光透射率,并具有理想的较低玻璃侧可见光反射率和理想的玻璃侧反射颜色值。玻璃侧可见光反射率(RgY)较好,其低于10%,更优选是不超过9%。特别是如图2所示当涂层制品被放置在绝缘玻璃窗单元中时都为理想的特性。
单片(热处理后)
从上面的示例可以看出,被单片测量的涂层制品具有理想的较低可见光透射率(Tvis或TY),并具有理想的较低玻璃侧可见光反射率(RgY),并有相当理想的玻璃侧反射颜色。玻璃侧可见光反射率较好,其低于10%。特别是如图2所示当涂层制品被放置在绝缘玻璃窗单元中时都为理想的特性,从而涂层最终位于绝缘玻璃窗单元的表面#2上。
如图2所示,示例1-3中的涂层制品被放置在绝缘玻璃窗单元中,其中玻璃基片1的厚度为6毫米,是Guardian公司的ExtraClear玻璃,玻璃基片2的厚度为4毫米,是Guardian公司的ExtraClear玻璃,间隙50的厚度为16毫米,且间隙50被填入90%的氩气和10%的空气。以下示出含有示例1-3中涂层制品的绝缘玻璃窗单元的光学特性,即,如图2所示,涂层制品被放置在绝缘玻璃窗单元中(位于绝缘玻璃窗单元的表面#2上,从而玻璃侧反射值自外侧被示出)。以下表示出绝缘玻璃窗单元中涂层制品的非热处理和热处理的信息。“非热处理”指的是绝缘玻璃单元中被退火的涂层制品和玻璃基片,而“热处理”指的是绝缘玻璃单元中被热回火的涂层制品和玻璃基片。绝缘玻璃单元在外观上为灰色/深灰色,且该外观可被实现而不使用灰色玻璃基片(而是使用透明玻璃基片,但由于涂层设计仍然可实现灰色外观)。绝缘玻璃单元还可理想地实现较低的可见光透射率、较低的外侧可见光反射率、低外的U值、和较低的太阳能系数。
绝缘玻璃单元(非热处理)
绝缘玻璃单元(热处理)
虽然参照最实用和优选的实施例对本发明进行了说明,但是应理解,本发明并不局限于所述实施例,相反可进行各种修改和等效的配置,修改将由后附的权利要求范围定义。

Claims (34)

1.一种含有涂层的涂层制品,所述涂层由玻璃基片支撑,所述涂层包括:
含有银的第一和第二红外IR反射层,所述第一红外反射层比所述第二红外反射层更靠近所述玻璃基片;
含有镍铬的第一接触层,位于所述含有银的第一红外反射层之上并直接与其接触;
含有氮化硅的介质层,位于所述含有镍铬的第一接触层之上并直接与其接触;
含有镍铬的第二接触层,位于所述含有氮化硅的介质层之上并直接与其接触,
所述含有银的第二红外反射层,位于所述含有镍铬的第二接触层之上并直接与其接触;
含有镍铬的第三接触层,位于所述第二红外反射层之上并直接与其接触;
另一个含有氮化硅的介质层,位于所述含有镍铬的第三接触层之上并直接与其接触,
其中,所述含有银的第二红外反射层比所述含有银的第一红外反射层至少厚两倍,且
其中,所述涂层制品被单片测量的可见光透射率不超过55%,被单片测量的玻璃侧可见光反射率不超过11%。
2.根据权利要求1所述的涂层制品,其中,所述涂层制品被单片测量的玻璃侧可见光反射率不超过10%。
3.根据上述权利要求中任何一项所述的涂层制品,其中,所述涂层制品被单片测量的玻璃侧可见光反射率不超过9%。
4.根据上述权利要求中任何一项所述的涂层制品,其中,所述涂层制品被单片测量的玻璃侧可见光反射率不超过8%。
5.根据上述权利要求中任何一项所述的涂层制品,其中,所述含有银的第二红外反射层比所述含有银的第一红外反射层至少厚
6.根据上述权利要求中任何一项所述的涂层制品,其中,所述含有银的第二红外反射层比所述含有银的第一红外反射层至少厚
7.根据上述权利要求中任何一项所述的涂层制品,其中,所述涂层制品被单片测量的可见光透射率不超过50%。
8.根据上述权利要求中任何一项所述的涂层制品,其中,所述涂层制品被单片测量的可见光透射率不超过45%。
9.根据上述权利要求中任何一项所述的涂层制品,其中,位于所述含有镍铬的第一接触层之上并直接与其接触的所述含有氮化硅的介质层为非晶质。
10.根据上述权利要求中任何一项所述的涂层制品,其中,所述含有镍铬的第一接触层为基本金属或金属,并含有不超过5%原子百分比的氧气。
11.根据上述权利要求中任何一项所述的涂层制品,其中,所述含有镍铬的第一、第二和第三接触层分别为基本金属或金属,并含有不超过5%原子百分比的氧气。
12.根据上述权利要求中任何一项所述的涂层制品,其中,所述第一、第二和/或第三接触层含有氮。
13.根据上述权利要求中任何一项所述的涂层制品,其中,所述涂层制品被单片测量的可见光透射率为25-55%。
14.根据上述权利要求中任何一项所述的涂层制品,其中,所述涂层制品没有被热回火,且被单片测量的可见光透射率为35-45%。
15.根据权利要求1-13中任何一项所述的涂层制品,其中,所述涂层制品被热回火。
16.根据权利要求15所述的涂层制品,其中,所述涂层制品被热处理,且由于热处理,玻璃侧反射ΔE*值不超过5.0。
17.根据权利要求15-16中任何一项所述的涂层制品,其中,所述涂层制品被热处理,且被单片测量的可见光透射率为35-50%。
18.根据上述权利要求中任何一项所述的涂层制品,其中,所述含有银的第一红外反射层的厚度为且所述含有银的第二红外反射层的厚度为
19.根据上述权利要求中任何一项所述的涂层制品,其中,所述涂层进一步包括含有氧化锆的外层。
20.根据上述权利要求中任何一项所述的涂层制品,其中,所述涂层的片电阻Rs小于或等于4.0欧姆/平方。
21.根据上述权利要求中任何一项所述的涂层制品,其中,所述涂层进一步包括另一个含有镍铬的接触层,位于所述含有银的第一红外反射层之下并直接与其接触。
22.根据上述权利要求中任何一项所述的涂层制品,其中,所述涂层进一步包括含有氮化硅的介质层,位于所述玻璃基片之上并与其直接接触。
23.一种绝缘玻璃窗单元,包括上述权利要求中任何一项所述的涂层制品,以及被耦合至所述涂层制品的另一个玻璃基片。
24.根据权利要求23所述的绝缘玻璃窗单元,其中,从外侧观察时,所述绝缘玻璃窗单元的外观为灰色或深灰色,且其中,所述绝缘玻璃窗单元的所述玻璃基片为透明而不灰色的玻璃基片。
25.一种绝缘玻璃IG窗单元,包括:
含有涂层的涂层制品,所述涂层由第一玻璃基片支撑;
所述第一玻璃基片与其上的所述涂层被耦合至第二玻璃基片,其之间具有间隙,且其中,所述第一玻璃基片被用来配置在所述绝缘玻璃窗单元的外部/外侧,且所述第二玻璃基片被用来配置在所述绝缘玻璃窗单元的内部/内侧,位于安装有或将要安装所述绝缘玻璃窗单元的建筑内部附近,且其中,所述涂层位于所述基片之间所述间隙对面的所述第一玻璃基片的主要表面,
其中,由所述第一玻璃基片支撑的所述涂层包括:
含有银的第一和第二红外IR反射层,所述第一红外反射层比所述第二红外反射层更靠近所述玻璃基片;
含有镍铬的第一接触层,位于所述含有银的第一红外反射层之上并直接与其接触;
含有氮化硅的介质层,位于所述含有镍铬的第一接触层之上并直接与其接触;
第二接触层,位于所述含有氮化硅的介质层之上并直接与其接触,
所述含有银的第二红外反射层,位于所述第二接触层之上并直接与其接触;
含有镍铬的第三接触层,位于所述第二红外反射层之上并直接与其接触;
另一个含有氮化硅的介质层,位于所述含有镍铬的第三接触层之上并直接与其接触,
其中,所述含有银的第二红外反射层比所述含有银的第一红外反射层至少厚
其中,所述绝缘玻璃窗单元的可见光透射率不超过50%,且外侧可见光反射率不超过12%,且
其中,从外侧观察时,所述绝缘玻璃窗单元的外观为灰色或深灰色,且其中,所述绝缘玻璃窗单元的所述第一和第二玻璃基片为透明而非灰色的玻璃基片。
26.根据权利要求25所述的绝缘玻璃窗单元,其中,所述第二接触层含有镍铬。
27.根据权利要求25-26中任何一项所述的绝缘玻璃窗单元,其中,所述绝缘玻璃窗单元的外侧可见光反射率不超过10%。
28.根据权利要求25-27中任何一项所述的绝缘玻璃窗单元,其中,所述含有银的第二红外反射层比所述含有银的第一红外反射层至少厚
29.根据权利要求25-28中任何一项所述的绝缘玻璃窗单元,其中,所述含有银的第二红外反射层比所述含有银的第一红外反射层至少厚两倍。
30.根据权利要求25-29中任何一项所述的绝缘玻璃窗单元,其中,所述玻璃基片被热回火。
31.根据权利要求25-30中任何一项所述的绝缘玻璃窗单元,其中,所述含有银的第一红外反射层的厚度为且所述含有银的第二红外反射层的厚度为
32.根据权利要求25-31中任何一项所述的绝缘玻璃窗单元,其中,所述涂层进一步包括含有氧化锆的外层。
33.根据权利要求25-32中任何一项所述的绝缘玻璃窗单元,其中,所述涂层的片电阻Rs小于或等于4.0欧姆/平方。
34.根据权利要求25-33中任何一项所述的绝缘玻璃窗单元,其中,所述涂层进一步包括另一个含有镍铬的接触层,位于所述含有银的第一红外反射层之下并直接与其接触。
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