The present invention relates to abrasion resistant glass coatings. More particularly, this invention relates to abrasion resistant glass coatings with a simplified protection layer and methods for forming such coatings.
Abrasion resistant coatings are used on glass in various types of products, such as windows (e.g., on buildings and vehicles), bottles, containers, lenses, photovoltaic devices, and screens for flat-panel displays, touch panels, and climate control systems.
Conventional abrasion resistant glass coatings include an abrasion resistant layer (e.g., an amorphous carbon, such as diamond-like carbon) and several other layers, such as an oxide layer and a nitride layer, formed above the above the abrasion resistant layer. The nitride layer typically provides environmental and chemical durability, and the oxide layer is used as a “pull-up” layer, which can be easily dissolved after tempering, to allow easy removal of the nitride (i.e., the final product may only include the glass and the abrasion resistant layer).
In order to protect the oxide and nitride layers during handling, an additional “top protection film” (TPF), often made of a plastic or polymer, is applied above the nitride layer. The TPF is typically removed before tempering. After tempering, the nitride layer, and the oxide layer are removed (e.g., perhaps using solvents).
To facilitate understanding, identical reference numerals have been used, where possible, to designate identical elements that are common to the figures. The drawings are not to scale and the relative dimensions of various elements in the drawings are depicted schematically and not necessarily to scale.
The techniques of the present invention can readily be understood by considering the following detailed description in conjunction with the accompanying drawings, in which:
A detailed description of one or more embodiments is provided below along with accompanying figures. The detailed description is provided in connection with such embodiments, but is not limited to any particular example. The scope is limited only by the claims, and numerous alternatives, modifications, and equivalents are encompassed. Numerous specific details are set forth in the following description in order to provide a thorough understanding. These details are provided for the purpose of example and the described techniques may be practiced according to the claims without some or all of these specific details. For the purpose of clarity, technical material that is known in the technical fields related to the embodiments has not been described in detail to avoid unnecessarily obscuring the description.
The term “horizontal” as used herein will be understood to be defined as a plane parallel to the plane or surface of the substrate, regardless of the orientation of the substrate. The term “vertical” will refer to a direction perpendicular to the horizontal as previously defined. Terms such as “above”, “below”, “bottom”, “top”, “side” (e.g. sidewall), “higher”, “lower”, “upper”, “over”, and “under”, are defined with respect to the horizontal plane. The term “on” means there is direct contact between the elements. The term “above” will allow for intervening elements.
Embodiments described herein provide a simplified method for protecting abrasion resistant glass coatings, such as during handling and/or before the tempering process. In some embodiments, new materials are used for the protective layer and/or the pull-up layer which may eliminate the need for the use of a “top protection film” (TPF) (e.g., a plastic or polymer), such as during handling, transportation, and/or tempering.
In some embodiments, protective layer includes a titanium-based nitride, such as titanium nitride, titanium-aluminum nitride, titanium-silicon-zirconium nitride, titanium-carbon nitride, titanium-boron nitride, titanium-molybdenum-sulfur nitride, titanium-tungsten-sulfur nitride, or a combination thereof. In some embodiments, the pull-up layer includes titanium oxide, tungsten oxide, zirconium oxide, manganese oxide, molybdenum oxide, or a combination thereof.
The use of these materials in the protective layer and/or the pull-up layer may provide sufficient mechanical durability without the use of the TPF. Thus, manufacturing time and costs may be reduced.
The various layers described below which are formed above the glass body 100 may be formed sequentially (i.e., from bottom to top) above the surface 102 of the glass body 100 using any suitable methods, such as physical vapor deposition (PVD) and/or reactive sputtering. In some embodiments, the layers are formed above the entire glass body 100. However, in some embodiments, the layers may only be formed above isolated portions of the glass body 100. Although the layers may be described as being formed “above” the previous layer (or the glass body), it should be understood that in some embodiments, each layer is formed directly on (and adjacent to) the previously provided/formed component (e.g., layer). In some embodiments, additional layers may be included between the layers, and other processing steps may also be performed between the formation of various layers.
Although not shown, in some embodiments, the surface 102 of the glass body 100 is first cleaned using, for example, any suitable wet cleaning process, as is commonly understood. Referring now to
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In some embodiments, the protective layer 108 is the last layer formed above the glass body 100 (i.e., at least with respect to the abrasion resistant coatings described herein) such that a surface 110 (e.g., an upper surface) of the protective layer 108 remains exposed during subsequent processing steps. That is, in contrast to conventional methods for forming abrasion resistant glass coatings, a TPF is not formed/deposited above the protective layer 108 to protect layers 104, 106, and 108 during handling, transportation, and tempering, as the pull-up layer 106 and the protective layer 108, as described herein, are sufficiently durable. As such, the glass body 100, the abrasion resistant layer 104, the pull-up layer 106, and the protective layer 108 may be considered to form a coated article. However, as described below, the pull-up layer 106 and the protective layer 108 are often removed before the coated article is utilized for its intended purpose.
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At block 1604, an abrasion resistant layer is formed above the glass body. The abrasion resistant layer may be made of amorphous carbon. In some embodiments, the abrasion resistant layer is made of diamond-like carbon (DLC).
At block 1606, a pull-up layer is formed above the abrasion resistant layer. In some embodiments, the pull-up layer is made of an oxide, such as titanium oxide, tungsten oxide, zirconium oxide, manganese oxide, molybdenum oxide, titanium oxide, or a combination thereof.
At block 1608, a protective layer is formed above the pull-up layer. In some embodiments, the protective layer is made of a titanium-based nitride. Examples of titanium-based nitrides includes titanium nitride, titanium-aluminum nitride, titanium-silicon-zirconium nitride, titanium-carbon nitride, titanium-boron nitride, titanium-molybdenum-sulfur nitride, titanium-tungsten-sulfur nitride, and combinations thereof.
Although not shown in
Thus, in some embodiments, a method for forming an abrasion resistant glass coating is provided. A glass body is provided. An abrasion resistant layer is formed above the glass body. The abrasion resistant layer includes an amorphous carbon. A pull-up layer is formed above the abrasion resistant layer. A protective layer is formed above the pull-up layer. The protective layer includes a titanium-based nitride.
In some embodiments, a method for forming an abrasion resistant glass coating is provided. A glass body is provided. An abrasion resistant layer is formed above the glass body. The abrasion resistant layer includes diamond-like carbon. A pull-up layer is formed above the abrasion resistant layer. The pull-up layer includes tungsten oxide, zirconium oxide, manganese oxide, molybdenum oxide, titanium oxide, or a combination thereof. A protective layer is formed above the pull-up layer. The protective layer includes a titanium-based nitride.
In some embodiments, a coated article is provided. The coated article includes a glass body. An abrasion resistant layer is formed above the glass body. The abrasion resistant layer includes an amorphous carbon. An oxide layer is formed above the abrasion resistant layer. A titanium-based nitride layer is formed above the oxide layer.
Although the foregoing examples have been described in some detail for purposes of clarity of understanding, the invention is not limited to the details provided. There are many alternative ways of implementing the invention. The disclosed examples are illustrative and not restrictive.
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Entry |
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V.S. Veerasamy et al.; Diamondlike Amorphous Carbon Coatings for Large Areas of Glass; Jan. 1, 2003; Elsevier; Unknown, Thin Solid Films 442 (2003) 1-10. |
Number | Date | Country | |
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20150158762 A1 | Jun 2015 | US |