Coated article

[0001] This application is a partial continuation (CIP) of US Patent Applications Nos. 12/923082, filed August 31, 2010, and 12/662894, the latter of which is a partial continuation (CIP) of application 12/659196, filed February 26, 2010 , the contents of each of which are hereby incorporated into this description by reference.

TECHNICAL FIELD OF THE INVENTION

[0002] Certain exemplary embodiments of the present invention relate to articles including anti-condensation and / or energy saving (low-E) coatings and / or methods of making them. More specifically, certain exemplary embodiments of the present invention relate to articles including anti-condensation and / or energy saving coatings that are exposed to the outside environment and / or methods of making them. In certain exemplary embodiments, anti-condensation and / or energy efficient coatings may remain functional in the external environment and may also have a low hemispherical emissivity such that the glass surface is more likely to retain heat from the interior, thereby reducing (and sometimes completely eliminating) the presence of condensate on it. Articles in certain exemplary embodiments may be, for example, skylights, vehicle windows or windshields, insulating glass units (IG), vacuum insulating glass units (VIG), refrigerator / freezer doors, and / or the like.

BACKGROUND AND SUMMARY OF EXEMPLARY EMBODIMENTS OF THE INVENTION

[0003] As is known, moisture condenses on skylights, refrigerator / freezer doors, vehicle windows, and other glass products. The accumulation of condensation on skylights reduces the aesthetic appeal of lighting. Likewise, condensation build-up on refrigerator / freezer doors in supermarkets or the like sometimes makes it difficult for shoppers to quickly and easily identify the products they are looking for. Condensation on cars is often an annoying inconvenience in the morning when the driver often has to clean off frost or ice and / or operate the vehicle's defroster and / or windshield wipers to ensure driving safety. Moisture and fog on the windshield often create this inconvenience, although they can also pose potentially more serious safety hazards when the driver is driving through hilly terrain, when there is a sudden drop in temperature, etc.

[0004] A variety of anti-condensation products have been developed over the years to solve these and / or other problems in a wide variety of applications. For example, see US Patent Nos. 6,818,309; 6606833; 6144017; 6052965; 4910088, the entire content of each of which is hereby incorporated by reference into this description. As mentioned above, certain approaches use active heating elements to reduce condensation, such as in vehicle windscreen heaters, forced-heated refrigerator / freezer doors, etc. Unfortunately, these proactively intervening technical solutions take up time to service the vehicle and thus only resolve the problem once it has arisen. In the case of refrigerator / freezer doors, such active solutions can be costly and / or energy inefficient.

[0005] Some attempts have been made to apply a thin film anti-condensation coating to glass. These attempts primarily involve pyrolytic deposition of a fluorine-doped tin oxide (FTO) coating with a thickness of 4000-6000 angstroms (400-600 nm) on the outer surface (eg, surface 1) of glass, such as a skylight, for example. Although pyrolytic deposition methods are known as forming "hard coatings", unfortunately, FTO scratches quite easily, changes color over time and suffers from other disadvantages.

[0006] Thus, it will be understood that there is a need in the art for articles including improved thin film anti-condensation and / or energy efficient coatings and / or methods for making them.

[0007] One aspect of certain exemplary embodiments relates to anti-condensation and / or energy efficient coatings that are suitable to be exposed to the external environment, and / or methods of making them. The external environment, in certain exemplary situations, can be outside and / or inside a vehicle or building (as opposed to, for example, a more protected area between adjacent substrates).

[0008] Yet another aspect of certain exemplary embodiments relates to anti-condensation and / or energy-efficient coatings that have a low surface layer resistance and a low hemispherical emissivity such that the glass surface is more likely to retain heat from the inner region, thereby reducing (and sometimes completely eliminating) the presence of condensation on it.

[0009] Yet another further aspect of certain exemplary embodiments relates to coated articles having an anti-condensation and / or energy saving coating formed on an outer surface and one or more energy saving coatings formed on one or more corresponding inner surfaces of the article. In certain exemplary embodiments, the anti-condensation coating can be thermally quenched (e.g., at a temperature of at least 580 degrees Celsius for at least about 2 minutes, more preferably at least about 5 minutes) or annealed (e.g., at a lower temperature than required for hardening).

[0010] Articles in certain exemplary embodiments may be, for example, skylights, vehicle windows or windshields, IG units, vacuum insulated glass units (VIG), refrigerator / freezer doors, and / or the like.

[0011] Certain exemplary embodiments of the present invention relate to a skylight including: first and second substantially parallel, spaced apart glass plates; a plurality of spacers positioned to assist in maintaining the first and second plates in a substantially parallel relationship spaced apart from each other; an edge seal jointly sealing the first and second plates; and an anti-condensation coating provided on the outer surface of the first plate facing the environment, external with respect to the glazed roof, the anti-condensation coating comprising the following layers from the first plate: a layer comprising silicon nitride and / or silicon oxynitride, a layer comprising a transparent conductive oxide (TCO), a layer comprising silicon nitride, and a layer comprising at least one of zirconium oxide, zirconium nitride, alumina and aluminum nitride, and anti-condensation the coating has a hemispherical emissivity of less than 0.23 and a surface resistance of the layer of less than 30 ohms / square. In certain exemplary embodiments of the present invention, the TCO may be comprised of or include ITO (Indium Tin Oxide) or the like.

[0012] Certain exemplary embodiments of the present invention relate to a skylight. A first and a second substantially parallel, spaced apart glass plates are created. A plurality of spacers are positioned to assist in maintaining the first and second plates in a substantially parallel relationship spaced apart from each other. The edge seal assists in sealing the first and second plates together. An anti-condensation coating is provided on the outer surface of the first plate facing the environment, external to the glazed roof. The anti-condensation coating includes the following thin-film layers deposited in the following order from the first wafer: a silicon-containing barrier layer, a first silicon-containing contact layer, a layer including a transparent conductive oxide (TCO), a second silicon-containing contact layer, and a zirconium oxide layer. The anti-condensation coating has a hemispherical emissivity of less than 0.23 and a layer surface resistance of less than 30 ohms / square.

[0013] Certain exemplary embodiments of the present invention relate to a coated article comprising: a coating supported by a plate, the coating being an anti-condensation coating including the following layers, counting from the first plate: a layer comprising silicon nitride and / or silicon oxynitride, a layer comprising a transparent conductive oxide (TCO), a layer comprising silicon nitride, and a layer comprising at least one or more of zirconium oxide, zirconium nitride, alumina and aluminum nitride, moreover, the anti-condensation coating is placed on the outer surface of the plate in such a way that the anti-condensation coating is exposed to the external environment, and the anti-condensation coating has a hemispherical emissivity of less than 0.23 and a layer surface resistance of less than 30 ohms / square.

[0014] Certain exemplary embodiments of the present invention relate to a coated article including a plate supported coating. The coating is an anti-condensation coating including the following thin film layers deposited in the following order from the first wafer: a silicon-containing barrier layer, a first silicon-containing contact layer, a layer including a transparent conductive oxide (TCO), a second silicon-containing contact layer, and a zirconium oxide layer. The anti-condensation coating is placed on the outer surface of the plate in such a way that the anti-condensation coating faces the external environment. The anti-condensation coating has a hemispherical emissivity of less than 0.23 and a layer surface resistance of less than 30 ohms / square.

[0015] According to certain exemplary embodiments, the external environment is within a building or vehicle. According to certain exemplary embodiments, the external environment is an external environment. In certain exemplary embodiments, the energy saving coating is provided on a plate opposite to the anti-condensation coating.

[0016] In certain exemplary embodiments, the coated article may be embedded in a skylight, window, IG unit, VIG, refrigerator / freezer door, and / or vehicle window or windshield. An anti-condensation coating can be provided, for example, on the first surface and / or the fourth surface of IG or VIG insulating glass units.

[0017] In certain exemplary embodiments, a method of manufacturing an insulating glass unit (IGU) is provided. Create the first glass plate. On the first major surface of the first glass plate, directly or indirectly, a plurality of layers are disposed, the plurality of layers including, in order, counting from the first glass plate: a first layer comprising silicon oxynitride having a refractive index of 1.5-2.1; a layer comprising ITO having a refractive index of 1.7-2.1, and a second layer comprising silicon oxynitride having a refractive index of 1.5-2.1. The first glass plate with a plurality of layers disposed thereon is heat treated. The second glass plate is disposed in a substantially parallel relative position, spaced from the first glass plate so that the first major surface of the first glass plate faces opposite to the second glass plate. The first and second glass plates are sealed in conjunction with each other.

[0018] According to certain exemplary embodiments, the first and second layers including silicon oxynitride have refractive indices of 1.7-1.8 and / or the layer including ITO has a refractive index of 1.8-1.93.

[0019] According to certain exemplary embodiments, said heat treatment includes laser annealing, exposure to NIR-SWIR radiation (in the far-short wave infrared region) and / or heating in an oven.

[0020] In certain exemplary embodiments, a method of manufacturing an insulating glass unit (IGU) is provided. Create the first glass plate. On the first major surface of the first glass plate, a plurality of layers are disposed directly or indirectly, the plurality of layers being included, in order from the first glass plate: a first layer including silicon oxynitride, a layer including ITO, and a second layer including silicon oxynitride. The first glass plate with a plurality of layers disposed thereon is heat treated. The second glass plate is disposed in a substantially parallel relative position, spaced from the first glass plate so that the first major surface of the first glass plate faces opposite to the second glass plate. After said heat treatment, the first plate with multiple layers on the first major surface of the first glass plate has a hemispherical emissivity of less than or equal to about 0.20 and a surface resistance of the layer of less than or equal to about 20 ohms / square.

[0021] In certain exemplary embodiments, an insulating glass unit (IGU) is provided. IGU includes the first glass plate. On the first major surface of the first glass plate, a plurality of layers are deposited directly or indirectly by vacuum deposition, the plurality of layers being included in order from the first glass plate: a first layer comprising silicon oxynitride having a refractive index of 1.5-2.1, a layer including ITO having a refractive index of 1.7-2.1 and a second layer including silicon oxynitride having a refractive index of 1.5-2.1. The second glass plate is disposed in a substantially parallel relationship, spaced from the first glass plate, in an assembled state with the first major surface of the first glass plate facing away from the second glass plate. An edge seal bonds and seals the first and second glass plates to each other. The first glass plate with a plurality of layers disposed thereon is heat treated. After said heat treatment, the first plate with multiple layers on the first major surface of the first glass plate has a hemispherical emissivity of less than or equal to about 0.20 and a surface resistance of the layer of less than or equal to about 20 ohms / square.

[0022] The features, aspects, advantages, and exemplary embodiments described herein may be combined to implement other additional embodiments.

BRIEF DESCRIPTION OF DRAWINGS

[0023] These and other features and advantages may be better and more fully understood by reference to the following detailed description of exemplary illustrative embodiments in conjunction with the drawings, in which:

[0024] FIG. 1 is a coated article including an anti-condensation coating in accordance with one exemplary embodiment;

[0025] FIG. 2 is an insulating glass unit including an anti-condensation coating (for example, in any embodiment of the present invention, such as the embodiment of FIG. 1 and / or FIG. 6) placed on the outermost surface facing the outside atmosphere, in accordance with one exemplary embodiment;

[0026] FIG. 3 shows an insulating glass unit including an anti-condensation coating (for example, according to any embodiment of the present invention, such as the embodiment of FIG. 1 and / or FIG. 6) disposed on the innermost surface facing the interior environment , in accordance with one exemplary embodiment;

[0027] FIG. 4 is an insulating glass unit including an anti-condensation coating (for example, according to any embodiment of the present invention, such as the embodiment of FIG. 1 and / or FIG. 6), disposed on the outermost and innermost surfaces of the insulating glass unit, in accordance with one exemplary embodiment;

[0028] FIG. 5 is a graph illustrating the performance of an exemplary embodiment of a given anti-condensation article and an uncoated glass plate as temperature, humidity, and dew point vary over an 18 hour time period;

[0029] FIG. 6 illustrates a coated article including an anti-condensation coating in accordance with one exemplary embodiment of the present invention;

[0030] FIG. 7 illustrates a coated article including an anti-condensation coating in accordance with one exemplary embodiment; and

[0031] FIG. 8 is a schematic view of a system including an infrared (IR) heater, in accordance with certain exemplary embodiments.

DETAILED DESCRIPTION OF EXEMPLARY EMBODIMENTS OF THE INVENTION

[0032] Referring now more specifically to the accompanying drawings, like reference numbers designate like parts in several views.

[0033] Certain exemplary embodiments of the present invention relate to thin film anti-condensation coatings that are exposed to the environment. In certain exemplary embodiments, such coatings have a low hemispherical emissivity, which helps the glass surface to retain heat from the inside. For example, in a skylight and / or in other exemplary window applications in buildings, the glass surface retains more heat from the interior of the building. In exemplary vehicle applications, the windshield retains more heat from the interior of the vehicle. This helps to reduce (and sometimes even prevent) the initial formation of condensation. As mentioned above, such anti-condensation coatings can be provided on surfaces (or multiple surfaces) facing the environment in certain exemplary situations. As such, anti-condensation coatings, in certain exemplary embodiments, may be strong enough to withstand such conditions.

[0034] FIG. 1 illustrates a coated article including an anti-condensation coating in accordance with one exemplary embodiment. The exemplary embodiment according to FIG. 1 includes a glass plate 1 carrying a multilayer thin-film anti-condensation coating 3. The anti-condensation coating 3 has a low hemispherical emissivity. In certain exemplary embodiments, the hemispherical emissivity is less than 0.25, more preferably less than 0.23, even more preferably less than 0.2, and sometimes even less than 1.0-1.5. This is achieved by creating a thin, transparent, conductive oxide layer 5 (TCO) in such a way that a predominantly low surface resistance of the layer is ensured. In the example of FIG. 1, the TCO layer 5 is composed of indium tin oxide (ITO). A layer surface resistivity of 10-30 ohms / square will generally be sufficient to achieve the desired hemispherical emissivity values. Certain exemplary embodiments described herein provide a layer surface resistance of 13-27 ohms / square, with the example below achieving a layer surface resistance of 17 ohms / square. In certain exemplary situations, it is possible to select the TCO 5 such that the surface resistance of the layer falls to no more than 5 ohms / square, although such a low value is not required in all embodiments of the present invention. 6 illustrates a coated article including similar layers, except that in the embodiment of FIG. 6, layers 11 and 13 are not present. In the embodiment of FIG. 6, the silicon oxynitride-containing layer 9b can be both a silicon-containing barrier layer and a lower contact layer, and is made up of a combination of layers 9b and 11 in the embodiment of FIG. In the embodiments of FIGS. 1 and 6, the top cover layer 7 may be composed of zirconium oxide, alumina, aluminum nitride and / or aluminum oxynitride, or include them in exemplary embodiments of the present invention. In certain exemplary embodiments, layers 9a, 9b, and 11, consisting of or including silicon nitride and / or silicon oxynitride, may be doped with aluminum (e.g., about 0.5 to 5% Al), as is known in the art to the target was conductive during the vacuum deposition of the layer.

[0035] With reference to FIGS. 1 and 6, the TCO layer 5 is protected from the environment by a zirconium oxide layer 7. A silicon-containing barrier layer 11 may be provided between the TCO layer 5 and the wafer 1, also to help protect the TCO layer 5 from sodium migration, for example. In the example of FIG. 1, the silicon-containing barrier layer 11 is silicon nitride, and the silicon nitride barrier layer 11 is formed adjacent to the titanium oxide layer 13. The silicon nitride barrier layer 11 and the titanium oxide layer 13 contribute to the optical performance of the entire article. It will be appreciated that a multi-layer low / high / low stacking system can be used to improve the optical performance of the final product in certain exemplary situations. In certain exemplary embodiments, the silicon nitride barrier layer 11 may be oxidized, for example, such that the layer is silicon oxynitride. In other words, in certain exemplary embodiments, the layer 11 may consist of, for example, or include silicon oxynitride. In certain exemplary embodiments, a barrier layer comprising silicon nitride (e.g., Si₃N₄ or with other suitable stoichiometric ratios) can replace the silicon-containing barrier layer 11 and the titanium oxide layer 13 in the example of FIG.

[0036] Additional silicon-containing layers 9a and 9b may be sandwiched with the TCO layer 5. As shown in the example of FIG. 1, the upper silicon-containing layer 9a is a silicon nitride layer, while the lower silicon-containing layer 9b is a silicon oxynitride layer. It will be understood that any suitable combination of silicon with oxygen and / or nitrogen can be used in various embodiments of the present invention.

[0037] The following table provides exemplary physical thicknesses and thickness ranges for the exemplary embodiment of FIG.

<tables num="1"><table frame="all"><tgroup rowsep="1" colsep="1" cols="3"><colspec colname="c1" colwidth="53mm" /><colspec colname="c2" colwidth="58mm" /><colspec colname="c3" colwidth="54mm" /><tbody><row><entry rowsep="1" colsep="1" /><entry align="center" rowsep="1" colsep="1"><b>Approximate thickness range (nm)</b></entry><entry align="center" rowsep="1" colsep="0"><b>Approximate thickness (nm)</b></entry></row><row><entry rowsep="1" colsep="1">ZrOx (7)</entry><entry align="center" rowsep="1" colsep="1">2-15</entry><entry align="center" rowsep="1" colsep="0">7</entry></row><row><entry rowsep="1" colsep="1">Sinx (9a)</entry><entry align="center" rowsep="1" colsep="1">10-50</entry><entry align="center" rowsep="1" colsep="0">30</entry></row><row><entry rowsep="1" colsep="1">ito (5)</entry><entry align="center" rowsep="1" colsep="1">75-175</entry><entry align="center" rowsep="1" colsep="0">130</entry></row><row><entry rowsep="1" colsep="1">sioxny (9b)</entry><entry align="center" rowsep="1" colsep="1">10-50</entry><entry align="center" rowsep="1" colsep="0">35</entry></row><row><entry rowsep="1" colsep="1">Tiox (13)</entry><entry align="center" rowsep="1" colsep="1">2-10</entry><entry align="center" rowsep="1" colsep="0">3,5</entry></row><row><entry rowsep="0" colsep="1">sinx (11)</entry><entry align="center" rowsep="0" colsep="1">10-20</entry><entry align="center" rowsep="0" colsep="0">13</entry></row></tbody></tgroup></table></tables>

[0038] The thicknesses of the layers 9b, 5, 9a and 7 in the embodiment of FIG. 6 are similar to these, and the above table also applies to these layers. However, in the embodiment of FIG. 6, the silicon nitride and / or silicon oxynitride layer 9b may be thicker, for example from about 10-200 nm in thickness, more preferably from about 10-100 nm in thickness. As indicated above, other TCOs may be used instead of, or in addition to, ITO. For example, certain exemplary embodiments may provide an ITO / Ag / ITO sandwich package. Certain exemplary embodiments may include zinc oxide, aluminum-doped zinc oxide (AZO), p-type alumina, Ag doped or undoped, FTO, and / or the like. When Ag is introduced into a multilayer stack system as TCO, layers including Ni and / or Cr can be placed directly adjacent (in contact with) Ag. In certain exemplary embodiments, each layer in a multilayer stack system may be formed by vacuum deposition. In certain exemplary embodiments, one or more layers may be deposited using various methods. For example, when fluorine-doped tin oxide (FTO) is introduced as the TCO layer 5, it can be performed by pyrolytic deposition (for example, using a precursor combustion method in an open atmosphere or chemical vapor deposition (CVD)).

[0039] In certain exemplary embodiments, a layer of diamond-like carbon (DLC) may be created directly above and in contact with the zirconium oxide. In certain exemplary situations, this can help create a more robust coating with a hydrophilic nature. Hydrophilic coatings typically have a contact angle of less than or equal to 10 degrees. The vacuum sprayed zirconium oxide tends to have a contact angle of less than about 20 degrees. However, the formation of DLC on top of the zirconium oxide promotes its wettability and creates a harder layer. When quenched, for example, a zirconia / DLC laminated stack achieves a wetting angle of less than or equal to about 15 degrees. Thus, a coating with a hydrophilic nature that is resistant to external influences can be obtained. It should be noted that this layer can be formed in steps that form a zirconium nitride layer followed by a DLC layer, which, when quenched, will form a zirconium oxide layer followed by a DLC layer. For example, see Applicant's patent document No. 12/320664, which describes a heat-treatable coated article including DLC ​​and / or zirconium in its coating. The entire content of this application is hereby incorporated into this description by reference.

[0040] In addition or alternatively, in certain exemplary embodiments, a thin hydrophilic and / or photocatalytic coating may be formed over the zirconium oxide. Such a layer may include anatase TiO₂, BiO, BiZr, BiSn, SnO and / or any other suitable material. Such a layer can also promote wettability and / or impart self-cleaning properties to the article.

[0041] In certain exemplary embodiments, the protective layer 7 of zirconium oxide may be replaced with aluminum oxide and / or aluminum oxynitride. In addition, in certain exemplary embodiments, the layer 7 may be initially deposited in a multilayer form so as to include a first layer consisting of or including zirconium nitride directly onto the silicon nitride containing layer 9a and a second layer consisting of diamond-like carbon (DLC) or including it. Then, when a heat treatment is desired (e.g., heat quenching performed at a temperature (s) of at least about 580 degrees Celsius), the coated article is heat treated and the overlying DLC-containing layer burns out during the heat treatment and contains zirconium nitride the layer is converted to zirconium oxide, thereby resulting in a heat treated coated article having a heat treated multilayer stack, where layer 7 consists of or includes zirconium oxide (eg see FIGS. 1 and 6).

[0042] Although not shown in the examples of Fig. 1 or Fig. 6, a silver-based energy-saving coating can be provided on the glass plate opposite to the anti-condensation coating 3. For example, the silver-based energy saving coating can be any of the energy saving coatings described in Serial Nos. 12/385234; 12/385802; 12/461792; 12/591611; and 12/654594, the entire contents of which are hereby incorporated by reference into this specification. Of course, other energy saving coatings commercially available on the market from the applicant of the present invention and / or other energy saving coatings may also be used in connection with various embodiments of the present invention. When the coated article is quenched, it can be passed through a face down quenching furnace. In other words, when the coated article is quenched, the anti-condensation coating can face the rollers of the roller table.

[0043] In certain exemplary embodiments, visible light transmittance may be high when an anti-condensation coating is applied. For example, in certain exemplary embodiments, the visible light transmittance will preferably be at least about 50%, more preferably at least about 60%, even more preferably at least about 65%. In certain exemplary embodiments, the visible light transmittance may be 70%, 80%, or even higher.

[0044] The coated article shown in Fig. 1 or Fig. 6 may be incorporated into an insulating glass unit (IG). For example, FIG. 2 illustrates an insulating glass unit including an anti-condensation coating disposed on the outermost surface facing the outside atmosphere, in accordance with one exemplary embodiment. The insulating glass unit (IG) in the example of FIG. 2 includes first and second substantially parallel glass plates 1 and 21 spaced apart from each other. These plates define a gap, or gap, 22 between them. The first and second plates 1 and 21 are sealed using an edge seal 23, and multiple struts 25 help maintain the distance between the first and second plates 1 and 21. The first plate 1 carries an anti-condensation cover 3. As will be understood from the exemplary embodiment of FIG. 2, the anti-condensation cover 3 is exposed to the outside environment. This is a departure from common practice where energy efficient coatings are generally protected from the external environment. The configuration according to FIG. 2 is made possible by the strength of the anti-condensation coating 3.

[0045] Although not shown in FIG. 2, similarly to that described above, an energy saving coating (eg, a silver based energy saving coating) may be provided on the inner surface of one of the first and second plates 1 and 21. In other words, although not shown in FIG. 2, an energy saving coating may be provided on the surface 2 or surface 3 of the IG unit shown in FIG.

[0046] When the exemplary embodiment of FIG. 2 is presented in connection with a skylight application, for example, the outer plate 1 can be hardened and the inner plate 21 can be laminated, for example, for safety reasons. This may be true for other products in the Insulating Glass (IG) range as well depending on the desired application. In addition, it will be understood that the IG structure shown in the example of FIG. 2 may be used in connection with applications in common vertical and common horizontal orientations. In other words, the IG structure shown in the example of FIG. 2 can be used in refrigerator / freezer doors that are either mostly vertical or mostly horizontal.

[0047] In certain exemplary embodiments, the gap, or gap, 22 between the first and second plates 1 and 21 may be evacuated and / or filled with an inert gas (such as argon), and the edge seal 23 may provide a seal, for example the formation of a vacuum insulating glass unit (VIG).

[0048] Fig. 2 shows an insulating glass unit (IG) having two glass plates. However, the exemplary anti-condensation coatings described herein may be used in connection with articles that include first, second, and third substantially parallel and spaced apart glass plates (also sometimes referred to as "triple-glazed insulating glass units"). The anti-condensation coating can be placed on surface 1 (the outermost surface exposed to the environment), and the energy saving coating can be placed on one or more inner surfaces (other than surface 1 and surface 6). For example, in various embodiments of the present invention, an anti-condensation coating can be placed on surface 1, and energy-saving coatings can be placed on surfaces 2 and 5, 3 and 5, etc. Such triple glazed products in various embodiments of the present invention may be insulating glass units (IG) containing three glasses or plates, triple vacuum insulating glass units (VIG) containing three glasses or plates, etc.

[0049] As noted above, certain exemplary embodiments may be used in connection with windshields, windows, mirrors, and / or the like in vehicles. The hemispherical emissivity of the outer glass surfaces of the vehicle is typically greater than about 0.84. However, by reducing the hemispherical emissivity to the above (and / or other) ranges, the glass surface can retain more heat coming from inside the vehicle. This, in turn, may result in a reduction or elimination of condensation on the glass surface when a moving vehicle moves from a colder to a warmer climate (for example, in hilly areas), a reduction or elimination of condensation and / or frost on glass when parking and leaving overnight, etc. An anti-condensation coating for vehicle applications can be provided on the side of the glass that is external to the vehicle cab.

[0050] A zirconium oxide topcoat is preferred for vehicle glass applications because it has a relatively low coefficient of friction. More specifically, this low coefficient of friction makes it easier to move the glass up and down.

[0051] Certain exemplary embodiments may be used in connection with any suitable vehicle, including, for example, automobiles; trucks; trains; boats, ships and other vessels; aircraft; tractors and other production equipment, etc. In vehicle mirror applications, the optical performance of the coating can be adjusted so that no "double reflection" occurs.

[0052] The inventors also envisioned that the anti-condensation coating in certain exemplary embodiments could be used to help meet the so-called "0.30 / 0.30 standard". In short, 0.30 / 0.30-standard refers to a U-value (resistance to convection through a window) less than or equal to 0.30 and a solar heat gain coefficient (SHGC) less than or equal to 0.30. Under current US law, an investment tax credit would be granted to companies producing windows, skylights, doors, etc. that meet these criteria.

[0053] FIG. 3 illustrates an insulating glass unit including an anti-condensation coating (eg, see the coating of FIG. 1 and / or FIG. 6) disposed on the innermost surface facing an interior environment, in accordance with one exemplary embodiment. The exemplary embodiment of FIG. 3 is similar to the exemplary embodiment of FIG. 2, except that the exemplary embodiment of FIG. 3 has an anti-condensation coating 3 disposed on surface 4, which is the outer surface of the inner glass plate 1 that faces, inside the room rather than into the external environment.

[0054] In certain exemplary embodiments, the inner plate 1 may be annealed (rather than quenched). The anti-condensation coating may remain the same or substantially the same as among the exemplary embodiments of FIGS. 2 and 3, although the modifications described above in connection with FIGS. 1, 2 and / or 6 may also be made in connection with with an embodiment similar to FIG. 3. One change that could be made is to increase the thickness of the ITO to achieve the desired U-value. In such cases where the ITO is thicker, the thicknesses of the other layers can also be adjusted so that the desired optical properties are achieved. Additional layers can also be added to achieve the desired optical properties. Other structural elements remain the same as in Figures 2 and 3, and similar modifications can be made to them.

[0055] When the anti-condensation coating 3 is placed on the surface 4 as shown in FIG. 3, the U-value can be determined to be 0.29. When an additional energy saving coating is provided on the surface 2 of the IG unit, the U-value was found to drop to 0.23. Certain exemplary embodiments may also provide an SHGC value of less than or equal to 0.30, thereby helping to meet the 0.30 / 0.30 standard.

[0056] In products with low U-values ​​(for example, IG or VIG insulating glass units with anti-condensation coating on the surface 4, two- and three-layer VIG, etc.) condensation can be a problem, for example, when the glass does not heat up due to coatings with low emissivity. One solution to this problem is presented in FIG. 4, which shows an insulating glass unit including anti-condensation coatings placed on the outermost and innermost surfaces of the insulating glass unit, in accordance with one exemplary embodiment. In the example of FIG. 4, first and second plates 1a and 1b are shown. First and second anti-condensation coatings 3a and 3b are placed on surfaces 1 and 4, respectively. In certain exemplary embodiments, additional energy saving coatings may also be provided on one or both of the inner surfaces (surfaces 2 and / or 3). In this way, it is possible to create a product that exhibits a U-value reduction and has anti-condensation characteristics.

[0057] FIG. 5 is a graph illustrating the performance of an exemplary embodiment of a given anti-condensation product, and an uncoated glass plate, as temperature, humidity, and dew point change over an 18 hour time period. Each of the images in FIG. 5 has a “cross-hatched” pattern printed on it to help demonstrate the presence or absence of condensation. As can be seen from FIG. 5, virtually no condensation occurs on those samples that were obtained in accordance with one exemplary embodiment. In contrast, the comparative example, which includes pyrolytically precipitated FTO, exhibits some condensation occurring in the first observation period, and the condensation rate rises sharply during the second and third observation periods, and decreases slightly in the fourth observation period. Indeed, the “cross-hatched” picture is much more blurry in the second observation period, and barely visible during the third. A sample of uncoated glass shows significant condensation during all observation periods. The “cross-hatched” picture in the second and third observation periods cannot be visible. The example of FIG. 5 thereby demonstrates that the exemplary embodiments described herein provide excellent performance when compared with this comparative example and bare glass.

[0058] FIG. 7 illustrates a coated article including an anti-condensation coating in accordance with one exemplary embodiment. The multilayer stack in the example of FIG. 7 is similar to the previously described exemplary multilayer stacks in that it includes a TCO layer 5 sandwiched between the first and second silicon-containing layers 9a and 9b. In the exemplary embodiment of FIG. 7, the first and second silicon-containing layers 9a and 9b include silicon oxynitride. The first and second layers 9a and 9b, containing silicon oxynitride, sandwich enclose the TCO layer 5 including ITO. The approximate thicknesses and refractive indices of each of the layers are given in the table, which are as follows:

<tables num="1"><table frame="all"><tgroup rowsep="1" colsep="1" cols="6"><colspec colname="c1" colwidth="20mm" /><colspec colname="c2" colwidth="27mm" /><colspec colname="c3" colwidth="27mm" /><colspec colname="c4" colwidth="28mm" /><colspec colname="c5" colwidth="38mm" /><colspec colname="c6" colwidth="26mm" /><tbody><row><entry rowsep="1" colsep="1" /><entry align="center" rowsep="1" colsep="1"><b>Approximate thickness range (nm)</b></entry><entry align="center" rowsep="1" colsep="1"><b>Approximate thickness (nm)</b></entry><entry align="center" rowsep="1" colsep="1"><b>Approximate range of refractive indices</b></entry><entry align="center" rowsep="1" colsep="1"><b>Preferred refractive index range</b></entry><entry align="center" rowsep="1" colsep="0"><b>Approximate refractive index</b></entry></row><row><entry rowsep="1" colsep="1">sioxnx</entry><entry align="center" rowsep="1" colsep="1">30-100</entry><entry align="center" rowsep="1" colsep="1">60</entry><entry align="center" rowsep="1" colsep="1">1,5-2,1</entry><entry align="center" rowsep="1" colsep="1">1,7-1,8</entry><entry align="center" rowsep="1" colsep="0">1,75</entry></row><row><entry rowsep="1" colsep="1">ITO</entry><entry align="center" rowsep="1" colsep="1">95-160</entry><entry align="center" rowsep="1" colsep="1">105</entry><entry align="center" rowsep="1" colsep="1">1,7-2,1</entry><entry align="center" rowsep="1" colsep="1">1,8-1,93</entry><entry align="center" rowsep="1" colsep="0">1,88</entry></row><row><entry rowsep="1" colsep="1">sioxny</entry><entry align="center" rowsep="1" colsep="1">30-100</entry><entry align="center" rowsep="1" colsep="1">65</entry><entry align="center" rowsep="1" colsep="1">1,5-2,1</entry><entry align="center" rowsep="1" colsep="1">1,7-1,8</entry><entry align="center" rowsep="1" colsep="0">1,75</entry></row><row><entry rowsep="0" colsep="1">Glass</entry><entry align="center" rowsep="0" colsep="1">It does not matter</entry><entry align="center" rowsep="0" colsep="1">It does not matter</entry><entry align="center" rowsep="0" colsep="1">It does not matter</entry><entry align="center" rowsep="0" colsep="1">It does not matter</entry><entry align="center" rowsep="0" colsep="0">It does not matter</entry></row></tbody></tgroup></table></tables>

[0059] In various embodiments of the present invention, other variations of this multi-layer stack are possible. Such options may include, for example, the use of partially and fully oxidized and / or nitride layers for the first and / or second silicon-containing layers, the addition of a protective topcoat including ZrOx, the addition of one or more layers to match the index (for example, including TiOx) between glass a wafer and a second silicon-containing layer, etc. For example, certain exemplary embodiments may provide for an exemplary multilayer stack modified relative to FIG. 7 so as to replace the top layer including SiOxNy with a layer of SiN, add a layer including ZrOx (e.g., to potentially increase strength), or not only replace the top layer. layer containing SiOxNy with a layer of SiN, but also add a layer containing ZrOx, etc. Thus, it will be understood that the possible modifications listed here can be made in any combination or sub-combination.

[0060] Modifications can also be made to meet the so-called "R5 window" characteristic (U-value across the glass &lt;0.225) with a low emissivity (eg, &lt;0.20). To meet these standards, the TCO layer thickness can be increased. The table below shows the ITO design thicknesses and performance measurements. It will be understood that the silicon-containing layers can also be adjusted to maintain acceptable optical properties, and / or that dielectric layers such as titanium oxide containing layers can be added. It should be noted that the glass plates are intended to be 3 mm thick clear glass plates, that an energy efficient coating is provided on surface 2, and that IGU versions provide a ½ inch (12.7 mm) gap filled with a mixture of approximately 90% Ar and 10% air.

<tables num="1"><table frame="all"><tgroup rowsep="1" colsep="1" cols="8"><colspec colname="c1" colwidth="27mm" /><colspec colname="c2" colwidth="23mm" /><colspec colname="c3" colwidth="23mm" /><colspec colname="c4" colwidth="20mm" /><colspec colname="c5" colwidth="20mm" /><colspec colname="c6" colwidth="19mm" /><colspec colname="c7" colwidth="19mm" /><colspec colname="c8" colwidth="15mm" /><tbody><row><entry rowsep="1" colsep="1" /><entry namest="c2" nameend="c3" align="center" rowsep="1" colsep="1"><b>Monolithic glass</b></entry><entry namest="c4" nameend="c5" align="center" rowsep="1" colsep="1"><b>Insulating glass unit</b></entry><entry rowsep="1" colsep="0" /><entry rowsep="1" colsep="0" /><entry rowsep="1" colsep="0" /></row><row><entry align="center" rowsep="1" colsep="1"><b>Emissivity</b></entry><entry align="center" rowsep="1" colsep="1"><b>Visible transmittance</b></entry><entry align="center" rowsep="1" colsep="1"><b>Visible reflectance</b></entry><entry align="center" rowsep="1" colsep="1"><b>Visible transmittance</b></entry><entry align="center" rowsep="1" colsep="1"><b>Visible reflectance, inside</b></entry><entry align="center" rowsep="1" colsep="1"><b>U-value, center of glass (COG)</b></entry><entry align="center" rowsep="1" colsep="1"><b>Indium Tin Oxide (ITO) Layer Thickness</b></entry><entry align="center" rowsep="1" colsep="0"><b>U-value improvement percentage</b></entry></row><row><entry align="center" rowsep="1" colsep="1">0.84 (Uncoated)</entry><entry align="center" rowsep="1" colsep="1">It does not matter</entry><entry align="center" rowsep="1" colsep="1">It does not matter</entry><entry align="center" rowsep="1" colsep="1">69,3</entry><entry align="center" rowsep="1" colsep="1">12,6</entry><entry align="center" rowsep="1" colsep="1">0,247</entry><entry align="center" rowsep="1" colsep="1">0</entry><entry align="center" rowsep="1" colsep="0">It does not matter</entry></row><row><entry align="center" rowsep="1" colsep="1">0,20</entry><entry align="center" rowsep="1" colsep="1">87,5</entry><entry align="center" rowsep="1" colsep="1">8,5</entry><entry align="center" rowsep="1" colsep="1">67,4</entry><entry align="center" rowsep="1" colsep="1">12,4</entry><entry align="center" rowsep="1" colsep="1">0,205</entry><entry align="center" rowsep="1" colsep="1">130</entry><entry align="center" rowsep="1" colsep="0">17,0%</entry></row><row><entry align="center" rowsep="1" colsep="1">0,15</entry><entry align="center" rowsep="1" colsep="1">86,2</entry><entry align="center" rowsep="1" colsep="1">8,5</entry><entry align="center" rowsep="1" colsep="1">66,4</entry><entry align="center" rowsep="1" colsep="1">12,4</entry><entry align="center" rowsep="1" colsep="1">0,200</entry><entry align="center" rowsep="1" colsep="1">195</entry><entry align="center" rowsep="1" colsep="0">19,0%</entry></row><row><entry align="center" rowsep="1" colsep="1">0,10</entry><entry align="center" rowsep="1" colsep="1">85,0</entry><entry align="center" rowsep="1" colsep="1">8,5</entry><entry align="center" rowsep="1" colsep="1">65,5</entry><entry align="center" rowsep="1" colsep="1">12,4</entry><entry align="center" rowsep="1" colsep="1">0,194</entry><entry align="center" rowsep="1" colsep="1">260</entry><entry align="center" rowsep="1" colsep="0">21,5%</entry></row><row><entry align="center" rowsep="0" colsep="1">0,05</entry><entry align="center" rowsep="0" colsep="1">80,0</entry><entry align="center" rowsep="0" colsep="1">8,5</entry><entry align="center" rowsep="0" colsep="1">61,6</entry><entry align="center" rowsep="0" colsep="1">12,0</entry><entry align="center" rowsep="0" colsep="1">0,188</entry><entry align="center" rowsep="0" colsep="1">520</entry><entry align="center" rowsep="0" colsep="0">23,9%</entry></row></tbody></tgroup></table></tables>

[0061] The exemplary embodiment of FIG. 7 is advantageously very strong, for example after heat treatment, even if it does not include a topcoat layer containing ZrOx or the like. Therefore, it was found suitable for use as a so-called surface coating 4. As you know, the fourth surface of an insulating glass unit (IGU), for example, is the surface farthest from the sun (and thus usually facing the interior of the room). Thus, the exemplary sandwich pouch of FIG. 7 is particularly well suited for use in an assembly such as that shown in FIG. It will also be understood that the exemplary embodiment of FIG. 7 is suitable for use in conjunction with other glazing applications where it forms the innermost surface facing the interior of the room (eg, on the surface 6 of a triple IGU, etc.).

[0062] As mentioned above, the exemplary multilayer stack of FIG. 7 may be heat treated in certain exemplary embodiments. Such heat treatment can be performed using an infrared (IR) heater, a chamber or other furnace, laser annealing, etc. Further details of the exemplary heat treatment are provided below. The following two tables include specifications for the monolithic multilayer stack of FIG. 7 after IR heat treatment and after heat treatment in a conveyor oven (eg, 650 degrees Celsius), respectively.

Technical characteristics of monolithic annealed glass (after IR treatment)

<tables num="1"><table frame="all"><tgroup rowsep="1" colsep="1" cols="2"><colspec colname="c1" colwidth="102mm" /><colspec colname="c2" colwidth="38mm" /><tbody><row><entry rowsep="1" colsep="1">Glass thickness (mm)</entry><entry align="center" rowsep="1" colsep="0">2.8 mm</entry></row><row><entry rowsep="1" colsep="1" /><entry rowsep="1" colsep="0" /></row><row><entry align="left" rowsep="1" colsep="1">T</entry><entry align="center" rowsep="1" colsep="0">88,49</entry></row><row><entry align="left" rowsep="1" colsep="1">a * Transmittance</entry><entry align="center" rowsep="1" colsep="0">-0,56</entry></row><row><entry align="left" rowsep="1" colsep="1">b * Transmittance</entry><entry align="center" rowsep="1" colsep="0">0,22</entry></row><row><entry align="left" rowsep="1" colsep="1">L * Transmittance</entry><entry align="center" rowsep="1" colsep="0">95,36</entry></row><row><entry align="left" rowsep="1" colsep="1">Rg</entry><entry align="center" rowsep="1" colsep="0">9,11</entry></row><row><entry align="left" rowsep="1" colsep="1">a * Glass side</entry><entry align="center" rowsep="1" colsep="0">-0,4</entry></row><row><entry align="left" rowsep="1" colsep="1">b * Glass side</entry><entry align="center" rowsep="1" colsep="0">-1,13</entry></row><row><entry align="left" rowsep="1" colsep="1">L * Glass side</entry><entry align="center" rowsep="1" colsep="0">36,20</entry></row><row><entry align="left" rowsep="1" colsep="1">Rf</entry><entry align="center" rowsep="1" colsep="0">9,10</entry></row><row><entry align="left" rowsep="1" colsep="1">a * Film side</entry><entry align="center" rowsep="1" colsep="0">-0,72</entry></row><row><entry align="left" rowsep="1" colsep="1">b * Film side</entry><entry align="center" rowsep="1" colsep="0">-1,13</entry></row><row><entry align="left" rowsep="1" colsep="1">L * Film side</entry><entry align="center" rowsep="1" colsep="0">36,17</entry></row><row><entry align="left" rowsep="1" colsep="1">Color rendering index (CRI)</entry><entry align="center" rowsep="1" colsep="0">97,91</entry></row><row><entry align="left" rowsep="1" colsep="1">T-Turbidity</entry><entry align="center" rowsep="1" colsep="0">0,12</entry></row><row><entry rowsep="1" colsep="1" /><entry rowsep="1" colsep="0" /></row><row><entry align="left" rowsep="1" colsep="1">Surface roughness</entry><entry align="center" rowsep="1" colsep="0">1,8</entry></row><row><entry rowsep="1" colsep="1" /><entry rowsep="1" colsep="0" /></row><row><entry align="left" rowsep="1" colsep="1">Surface layer resistance</entry><entry align="center" rowsep="1" colsep="0">17-19</entry></row><row><entry align="left" rowsep="0" colsep="1">Hemispherical emissivity</entry><entry align="center" rowsep="0" colsep="0">0.20 or 0.21</entry></row></tbody></tgroup></table></tables>

Technical characteristics of monolithic tempered glass (in a conveyor oven at a temperature of 650 ° C)

<tables num="1"><table frame="all"><tgroup rowsep="1" colsep="1" cols="2"><colspec colname="c1" colwidth="102mm" /><colspec colname="c2" colwidth="38mm" /><tbody><row><entry rowsep="1" colsep="1">T</entry><entry align="center" rowsep="1" colsep="0">88,10</entry></row><row><entry rowsep="1" colsep="1">ΔE (from annealing to quenching)</entry><entry align="center" rowsep="1" colsep="0">0,37</entry></row><row><entry align="left" rowsep="1" colsep="1">a * Transmittance</entry><entry align="center" rowsep="1" colsep="0">-0,60</entry></row><row><entry align="left" rowsep="1" colsep="1">b * Transmittance</entry><entry align="center" rowsep="1" colsep="0">0,54</entry></row><row><entry align="left" rowsep="1" colsep="1">L * Transmittance</entry><entry align="center" rowsep="1" colsep="0">95,20</entry></row><row><entry align="left" rowsep="1" colsep="1">Rg</entry><entry align="center" rowsep="1" colsep="0">9,08</entry></row><row><entry rowsep="1" colsep="1">ΔE (from annealing to quenching)</entry><entry align="center" rowsep="1" colsep="0">1,04</entry></row><row><entry align="left" rowsep="1" colsep="1">a * Glass side</entry><entry align="center" rowsep="1" colsep="0">-0,26</entry></row><row><entry align="left" rowsep="1" colsep="1">b * Glass side</entry><entry align="center" rowsep="1" colsep="0">-2,16</entry></row><row><entry align="left" rowsep="1" colsep="1">L * Glass side</entry><entry align="center" rowsep="1" colsep="0">36,14</entry></row><row><entry align="left" rowsep="1" colsep="1">Rf</entry><entry align="center" rowsep="1" colsep="0">9,06</entry></row><row><entry align="left" rowsep="1" colsep="1">ΔE (from annealing to quenching)</entry><entry align="center" rowsep="1" colsep="0">1,16</entry></row><row><entry align="left" rowsep="1" colsep="1">a * Film side</entry><entry align="center" rowsep="1" colsep="0">-0,69</entry></row><row><entry align="left" rowsep="1" colsep="1">b * Film side</entry><entry align="center" rowsep="1" colsep="0">-2,28</entry></row><row><entry align="left" rowsep="1" colsep="1">L * Film side</entry><entry align="center" rowsep="1" colsep="0">36,10</entry></row><row><entry align="left" rowsep="1" colsep="1">Color rendering index (CRI)</entry><entry align="center" rowsep="1" colsep="0">97,91</entry></row><row><entry align="left" rowsep="1" colsep="1">T-Turbidity</entry><entry align="center" rowsep="1" colsep="0">0,12</entry></row><row><entry rowsep="1" colsep="1" /><entry rowsep="1" colsep="0" /></row><row><entry align="left" rowsep="1" colsep="1">Surface roughness</entry><entry align="center" rowsep="1" colsep="0">1,8</entry></row><row><entry rowsep="1" colsep="1" /><entry rowsep="1" colsep="0" /></row><row><entry align="left" rowsep="1" colsep="1">Surface layer resistance (using NAGY instrument)</entry><entry align="center" rowsep="1" colsep="0">17-19</entry></row><row><entry align="left" rowsep="0" colsep="1">Hemispherical emissivity</entry><entry align="center" rowsep="0" colsep="0">0.19 or 0.20</entry></row></tbody></tgroup></table></tables>

[0063] As shown above, the exemplary embodiment of FIG. 7 may be heat treated using, for example, an infrared (IR) heater, a chamber or other furnace, a laser annealing process, and so on. A post-deposition heat treatment step may be preferred to promote recrystallization of the ITO layer and to help achieve desired emissivities and optical characteristics (eg, including those described above). In one exemplary method, the glass can be heated to a temperature of about 400 degrees Celsius to help achieve these goals. In certain exemplary embodiments, the temperature of the glass will not exceed 470 degrees Celsius to help reduce the likelihood of permanent (or at least transient) stress variations in the glass.

[0064] In certain exemplary embodiments, an array of laser diodes may be used in connection with the laser annealing process. It has been found that an array of laser diodes with the following parameters advantageously helps to reduce the surface resistance of the layer to about 20 ohms / square (for example, from about 65 ohms / square in a state immediately after deposition), helps to achieve a substantially uniform coating appearance. and helps in achieving the above characteristic values:

- Laser power - 1 kW

- Radiation wavelength - 975 nm

- Scanning speed - 75 mm / s

- Spot size - nominally 12.5 mm × 2 mm

[0065] In certain exemplary embodiments, a furnace having multiple zones may also be used for heat treatment. Zone temperature, conveying speed, temperature gradient (eg top / bottom), aspiration, regulation of heating elements (eg along the oven), cooling air settings (eg pressure and flow gradient), and / or other factors can be adjusted to help achieve the desired performance characteristics. In certain exemplary embodiments, a ten-zone oven may be used to perform heat treatment. A partial subset of zones can facilitate the ITO recrystallization process, while other zones can provide slow cooling of the plate before it leaves the furnace. In one example using a ten zone furnace, zones 1-3 were shown to be active during the ITO recrystallization process, heating the coating to nearly 400 degrees Celsius, while the rest of the furnace helped to slowly cool the glass before it exited the air cooling section. It will be understood that in certain exemplary situations it would be desirable to maintain a low outlet temperature to help reduce the likelihood of cracking. Indeed, glass is very susceptible to thermal cracking within the temperature range, including the re-annealing process, especially at temperatures above 200 degrees Celsius.

[0066] Additional parameters influencing thermal cracking include temperature differences across the glass thickness as well as the temperature difference along its surface. The latter has been found to have a strong effect on thermal cracking for coated plates. The temperatures of the upper and lower surfaces of the uncoated glass leaving the furnace were almost identical, and the vast majority of clean glass withstands the annealing process after the initial profile of parameters (feed rate, zone temperature, cooling air, no gradient) has been established. However, the top surface of the coated article exiting the oven was measured more than 250 degrees Fahrenheit (121 ° C) higher. This is because heat is lost faster when transferred to the rollers by conduction than by radiative transfer from the coated top surface.

[0067] However, by detecting and understanding this difference, and adjusting the heating and cooling, this difference can be reduced and, in turn, help to reduce the likelihood of cracking. The approximate profile parameters of the furnace for glass with a thickness of 3.2 mm and 2.3 mm are shown in the tables below, respectively.

Furnace profile for glass 3.2 mm

<tables num="1"><table frame="all"><tgroup rowsep="1" colsep="1" cols="12"><colspec colname="c1" colwidth="14mm" /><colspec colname="c2" colwidth="23mm" /><colspec colname="c3" colwidth="13mm" /><colspec colname="c4" colwidth="13mm" /><colspec colname="c5" colwidth="13mm" /><colspec colname="c6" colwidth="13mm" /><colspec colname="c7" colwidth="13mm" /><colspec colname="c8" colwidth="13mm" /><colspec colname="c9" colwidth="13mm" /><colspec colname="c10" colwidth="13mm" /><colspec colname="c11" colwidth="13mm" /><colspec colname="c12" colwidth="13mm" /><tbody><row><entry namest="c1" nameend="c2" rowsep="1" colsep="1" /><entry namest="c3" nameend="c12" align="center" rowsep="1" colsep="0"><b>Zone</b></entry></row><row><entry align="center" rowsep="1" colsep="1"><b>Bake</b></entry><entry align="center" rowsep="1" colsep="1"><b>Temperature (° F)</b></entry><entry align="center" rowsep="1" colsep="1"><b>1</b></entry><entry align="center" rowsep="1" colsep="1"><b>2</b></entry><entry align="center" rowsep="1" colsep="1"><b>3</b></entry><entry align="center" rowsep="1" colsep="1"><b>4</b></entry><entry align="center" rowsep="1" colsep="1"><b>5</b></entry><entry align="center" rowsep="1" colsep="1"><b>6</b></entry><entry align="center" rowsep="1" colsep="1"><b>7</b></entry><entry align="center" rowsep="1" colsep="1"><b>8</b></entry><entry align="center" rowsep="1" colsep="1"><b>9</b></entry><entry align="center" rowsep="1" colsep="0"><b>10</b></entry></row><row><entry morerows="1" align="left" rowsep="1" colsep="1">Top</entry><entry align="left" rowsep="1" colsep="1">Set value</entry><entry align="center" rowsep="1" colsep="1">771.1 ° C</entry><entry align="center" rowsep="1" colsep="1">771.1 ° C</entry><entry align="center" rowsep="1" colsep="1">771.1 ° C</entry><entry align="center" rowsep="1" colsep="1">0</entry><entry align="center" rowsep="1" colsep="1">0</entry><entry align="center" rowsep="1" colsep="1">0</entry><entry align="center" rowsep="1" colsep="1">0</entry><entry align="center" rowsep="1" colsep="1">0</entry><entry align="center" rowsep="1" colsep="1">0</entry><entry align="center" rowsep="1" colsep="0">0</entry></row><row><entry align="left" rowsep="1" colsep="1">Actual value</entry><entry align="center" rowsep="1" colsep="1">772.2 ° C</entry><entry align="center" rowsep="1" colsep="1">783.3 ° C</entry><entry align="center" rowsep="1" colsep="1">783.9 ° C</entry><entry align="center" rowsep="1" colsep="1">502.8 ° C</entry><entry align="center" rowsep="1" colsep="1">396.2 ° C</entry><entry align="center" rowsep="1" colsep="1">367.2 ° C</entry><entry align="center" rowsep="1" colsep="1">296.1 ° C</entry><entry align="center" rowsep="1" colsep="1">288.3 ° C</entry><entry align="center" rowsep="1" colsep="1">307.2 ° C</entry><entry align="center" rowsep="1" colsep="0">305 ° C</entry></row><row><entry morerows="1" align="left" rowsep="1" colsep="1">Bottom</entry><entry align="left" rowsep="1" colsep="1">Set value</entry><entry align="center" rowsep="1" colsep="1">771.1 ° C</entry><entry align="center" rowsep="1" colsep="1">771.1 ° C</entry><entry align="center" rowsep="1" colsep="1">771.1 ° C</entry><entry align="center" rowsep="1" colsep="1">0</entry><entry align="center" rowsep="1" colsep="1">371.1 ° C</entry><entry align="center" rowsep="1" colsep="1">371.1 ° C</entry><entry align="center" rowsep="1" colsep="1">371.1 ° C</entry><entry align="center" rowsep="1" colsep="1">371.1 ° C</entry><entry align="center" rowsep="1" colsep="1">371.1 ° C</entry><entry align="center" rowsep="1" colsep="0">371.1 ° C</entry></row><row><entry align="left" rowsep="0" colsep="1">Actual value</entry><entry align="center" rowsep="0" colsep="1">760 ° C</entry><entry align="center" rowsep="0" colsep="1">781.1 ° C</entry><entry align="center" rowsep="0" colsep="1">777.2 ° C</entry><entry align="center" rowsep="0" colsep="1">440.6 ° C</entry><entry align="center" rowsep="0" colsep="1">415.6 ° C</entry><entry align="center" rowsep="0" colsep="1">395 ° C</entry><entry align="center" rowsep="0" colsep="1">387.8 ° C</entry><entry align="center" rowsep="0" colsep="1">233.9 ° C</entry><entry align="center" rowsep="0" colsep="1">365.6 ° C</entry><entry align="center" rowsep="0" colsep="0">373.9 ° C</entry></row></tbody></tgroup></table></tables>

[0068] In connection with this exemplary heating profile, the following parameters were used:

- Feed rate: 60 ft / min (18.3 m / min)

- Aspiration: 0

- Alignment (zones 1-3): 5-10 (50%) - center, all others 100%

- Primary cooling: set value = 0 and damper closed

- Medium level cooling: 1 ”H2O, set value = 0 and damper open

- Aftercooler: 1 ”H2O, set value = 0 and damper open

Furnace profile for glass 2.3 mm

<tables num="1"><table frame="all"><tgroup rowsep="1" colsep="1" cols="12"><colspec colname="c1" colwidth="14mm" /><colspec colname="c2" colwidth="23mm" /><colspec colname="c3" colwidth="13mm" /><colspec colname="c4" colwidth="13mm" /><colspec colname="c5" colwidth="13mm" /><colspec colname="c6" colwidth="13mm" /><colspec colname="c7" colwidth="13mm" /><colspec colname="c8" colwidth="13mm" /><colspec colname="c9" colwidth="13mm" /><colspec colname="c10" colwidth="13mm" /><colspec colname="c11" colwidth="13mm" /><colspec colname="c12" colwidth="13mm" /><tbody><row><entry namest="c1" nameend="c2" rowsep="1" colsep="1" /><entry namest="c3" nameend="c12" align="center" rowsep="1" colsep="0"><b>Zone</b></entry></row><row><entry align="center" rowsep="1" colsep="1"><b>Bake</b></entry><entry align="center" rowsep="1" colsep="1"><b>Temperature (° F)</b></entry><entry align="center" rowsep="1" colsep="1"><b>1</b></entry><entry align="center" rowsep="1" colsep="1"><b>2</b></entry><entry align="center" rowsep="1" colsep="1"><b>3</b></entry><entry align="center" rowsep="1" colsep="1"><b>4</b></entry><entry align="center" rowsep="1" colsep="1"><b>5</b></entry><entry align="center" rowsep="1" colsep="1"><b>6</b></entry><entry align="center" rowsep="1" colsep="1"><b>7</b></entry><entry align="center" rowsep="1" colsep="1"><b>8</b></entry><entry align="center" rowsep="1" colsep="1"><b>9</b></entry><entry align="center" rowsep="1" colsep="0"><b>10</b></entry></row><row><entry morerows="1" align="left" rowsep="1" colsep="1">Top</entry><entry align="left" rowsep="1" colsep="1">Set value</entry><entry align="center" rowsep="1" colsep="1">771.1 ° C</entry><entry align="center" rowsep="1" colsep="1">771.1 ° C</entry><entry align="center" rowsep="1" colsep="1">771.1 ° C</entry><entry align="center" rowsep="1" colsep="1">0</entry><entry align="center" rowsep="1" colsep="1">0</entry><entry align="center" rowsep="1" colsep="1">0</entry><entry align="center" rowsep="1" colsep="1">0</entry><entry align="center" rowsep="1" colsep="1">0</entry><entry align="center" rowsep="1" colsep="1">0</entry><entry align="center" rowsep="1" colsep="0">0</entry></row><row><entry align="left" rowsep="1" colsep="1">Actual value</entry><entry align="center" rowsep="1" colsep="1">772.2 ° C</entry><entry align="center" rowsep="1" colsep="1">783.3 ° C</entry><entry align="center" rowsep="1" colsep="1">783.9 ° C</entry><entry align="center" rowsep="1" colsep="1">502.8 ° C</entry><entry align="center" rowsep="1" colsep="1">377.8 ° C</entry><entry align="center" rowsep="1" colsep="1">339.4 ° C</entry><entry align="center" rowsep="1" colsep="1">284.4 ° C</entry><entry align="center" rowsep="1" colsep="1">273.3 ° C</entry><entry align="center" rowsep="1" colsep="1">283.3 ° C</entry><entry align="center" rowsep="1" colsep="0">298.9 ° C</entry></row><row><entry morerows="1" align="left" rowsep="1" colsep="1">Bottom</entry><entry align="left" rowsep="1" colsep="1">Set value</entry><entry align="center" rowsep="1" colsep="1">771.1 ° C</entry><entry align="center" rowsep="1" colsep="1">771.1 ° C</entry><entry align="center" rowsep="1" colsep="1">771.1 ° C</entry><entry align="center" rowsep="1" colsep="1">0</entry><entry align="center" rowsep="1" colsep="1">315.6 ° C</entry><entry align="center" rowsep="1" colsep="1">315.6 ° C</entry><entry align="center" rowsep="1" colsep="1">315.6 ° C</entry><entry align="center" rowsep="1" colsep="1">315.6 ° C</entry><entry align="center" rowsep="1" colsep="1">315.6 ° C</entry><entry align="center" rowsep="1" colsep="0">315.6 ° C</entry></row><row><entry align="left" rowsep="0" colsep="1">Actual value</entry><entry align="center" rowsep="0" colsep="1">782.2 ° C</entry><entry align="center" rowsep="0" colsep="1">781.1 ° C</entry><entry align="center" rowsep="0" colsep="1">777.2 ° C</entry><entry align="center" rowsep="0" colsep="1">440.6 ° C</entry><entry align="center" rowsep="0" colsep="1">340 ° C</entry><entry align="center" rowsep="0" colsep="1">320.6 ° C</entry><entry align="center" rowsep="0" colsep="1">322.2 ° C</entry><entry align="center" rowsep="0" colsep="1">196.7 ° C</entry><entry align="center" rowsep="0" colsep="1">316.7 ° C</entry><entry align="center" rowsep="0" colsep="0">316.1 ° C</entry></row></tbody></tgroup></table></tables>

[0069] In connection with this exemplary heating profile, the following parameters were used:

- Feed rate: 70 ft / min (21.3 m / min)

- Aspiration: 0

- Alignment (zones 1-3): 5-10 (50%) - center, all others 100%

- Primary cooling: 1 ”H2O, top only, set value = 0 and damper open

- Medium level cooling: set value = 0 and damper closed

- Aftercooler: 1 ”H2O, set value = 0 and damper open

[0070] As a further option, in certain exemplary embodiments, infrared (IR) radiation with a variable wavelength may be used for heat treatment. Exemplary methods are set forth in US Patent Publication No. 12/923082, filed Aug. 31, 2010, the entire contents of which are hereby incorporated by reference. The TCO layer can be preferably and selectively heat treated using, for example, specially tuned near infrared radiation — short wave infrared (NIR-SWIR). In certain exemplary embodiments, selective heating of the coating can be achieved using IR emitters with maximum output powers and spectral wavelengths where the ITO exhibits significant absorption but where the wafer (eg glass) has reduced or minimal absorption. In certain exemplary embodiments, the coating will preferably be heated, thereby improving its properties, while at the same time the temperatures of the underlying plate will be kept low.

[0071] By preferentially heating the coating using the wavelength-controlled high intensity infrared (IR) methods described herein, heat treatment of the ITO layer is possible at lower plate temperatures and / or for shorter heating times than would be required using conventional routes. Preferred heating is achieved by using infrared (IR) wavelengths that are much more absorbed by the coating than by the plate. High-intensity infrared (IR) radiation can be delivered, for example, using quartz lamps or laser emitters.

[0072] In the case of laser emitters, laser diode arrays have advantages, for example, due to their lower operating cost compared to other common types of lasers (and the availability of output radiation in the region of about 800-1050 nm (for example, 940 nm), with spectral characteristics of the coverage). However, in various embodiments, excimer, CO₂-, YAG (solid state neodymium), quartz and other types of lasers and / or lamps. For example, it should be noted that 810 nm is common with some diode lasers (and in general can be used, for example, in connection with low-E type coatings) and that 1032 nm is common with some YAGs. -lasers. Furthermore, in addition, other lasers (e.g., CO₂- and other lasers) for very fast heating of glass and thus indirect heating of the coating. In certain exemplary embodiments, electromagnetic radiation may be focused into a rectangular beam with a very high aspect ratio covering the width of the glass. The glass can move on the conveyor in a direction perpendicular to the long axis of the rectangle. In certain exemplary embodiments, a "step and repeat" method may be used, for example, to irradiate smaller sections in a controlled manner such that the entire plate is ultimately irradiated. In addition, other sizes and / or shapes may be used including, for example, substantially square shapes, round shapes, etc.

[0073] In general, it has been found that higher power densities are preferred as they allow shorter heating times and higher temperature gradients from the coating through the bulk of the wafer. For shorter heating times, less heat is transferred from the coating through the glass by conduction and a lower temperature can be maintained.

[0074] FIG. 8 is a schematic view of a system including an infrared (IR) heater in accordance with certain exemplary embodiments. An exemplary system of FIG. 8 includes an apparatus 102 for applying physical vapor deposition of a coating of one or more thin film layers on a wafer, such as by vacuum deposition. An infrared (IR) heater 104 is located downstream of the coater 102. In certain exemplary embodiments, a room temperature vacuum deposition apparatus may be used to deposit ITO onto a glass plate. The conveyor system 106 moves the wafer through the coater 102 where the layer or stack is deposited and to the infrared (IR) heater 104. In turn, the infrared (IR) heater 104 is configured to focus the NIR-SWIR radiation on the coated wafer on it. The wavelength of the IR radiation is chosen so as to preferentially heat the coating or a particular layer in the coating, for example, relative to the plate and / or any other layers in the multilayer coating.

[0075] While certain exemplary embodiments have been described as including an IR heater downstream of the coater, it will be appreciated that in other exemplary embodiments, the coater may be housed within the vacuum chamber of the coater. In addition, in certain exemplary embodiments, IR thermal treatment may be performed at any time after the layer to be heat treated or activated has been deposited. For example, in certain exemplary embodiments, IR heat treatment may be performed immediately after deposition of the ITO layer, whereas in certain exemplary embodiments, IR heat treatment may be performed only when all layers in the stack have been deposited. In certain exemplary embodiments, multiple IR thermal treatments may be performed at different times during the deposition process.

[0076] In certain exemplary embodiments, a short wave infrared (SWIR) oven including quartz lamps may be used. Peak IR radiation with a wavelength of 1.15 μm can be applied to heat the coating. This wavelength was determined by analyzing the spectral characteristics of the coating and glass plate, although other wavelengths are of course possible. Indeed, an approximate range of 0.8-2.5 μm wavelengths for heating has been determined. More preferably, the IR range is 1 to 2 µm. For example, the methods described in US Patent Application No. 12 / 923,082 can also be used to establish optimal or preferred IR ranges for heat treatment of other coatings (eg, other TCO, metal, etc. coatings) on glass.

[0077] The power density of the SWIR furnace is 10.56 kW / ft² (113.5 kW / m²) (lamp output 80 W / in. (31.5 W / cm)) when mounted 1 in. (25.4 mm) in the center). Heating times can vary from 12-130 seconds, for example at 12-second intervals. The heating elements can be positioned about 4 inches (101.6 mm) from the glass surface, although in various exemplary embodiments of the present invention, the heating elements can be raised or lowered.

[0078] By accurately matching the target infrared (IR) wavelengths that are absorbed by the coating, a large thermal gradient can be created between the coating and the bulk of the wafer. Since the amount of heat in the coating is very small compared to glass, glass essentially acts as a cooling mechanism. The increase in temperature in the bulk of the glass is mainly attributed to direct heat transfer as a result of absorption of IR radiation rather than through conduction from the coating.

[0079] It was found that the final crystallinity of the film is achieved only after 48-60 seconds of heating, although, of course, shorter or longer periods of time are possible.

[0080] The initial level of ITO oxidation on the samples used here was optimized for low surface resistance of the layer after quenching (which causes additional ITO oxidation). It is likely that there is an optimum level for ITO heat treatment using NIR radiation. When the initial ITO oxidation level is optimized for NIR heating, it should be possible to significantly reduce the required heating level. In theory, this time should be reduced to 48-60 seconds required for recrystallization using such a heating process. Additional reduction in heating time can be achieved by optimizing power density ratios versus heating duration.

[0081] The IR heating method described herein generally preferentially heats the ITO in the coating so that the glass plate remains below its glass transition temperature, which for float glass is about 480 degrees Celsius. The glass plate is preferably kept below 450 degrees Celsius, and more preferably below 425 degrees Celsius. In certain exemplary embodiments, where the maximum radiation with a wavelength of 1.15 μm is exposed for 108 seconds, the surface resistance of the exemplary coating layer is about one third of that immediately after deposition, and the emissivity and absorption coefficients accordingly fall to about half of their values. occurring after deposition. Meanwhile, the temperature of the plate only peaks at around 400 degrees Celsius, which is much lower than its glass transition temperature.

[0082] Near infrared (NIR) spectrum includes infrared (IR) radiation having a wavelength of 0.75-1.4 μm, and a short wave infrared (SWIR) region mainly includes IR radiation having a wavelength of 1.4 -3 microns. Certain exemplary embodiments can generally operate within these wavelength ranges. The temperature of the plate preferably does not exceed 480 degrees Celsius, more preferably 450 degrees Celsius, even more preferably 425 degrees Celsius, and sometimes 400 degrees Celsius as a result of such NIR-SWIR heating.

[0083] While certain exemplary embodiments have been described herein as relating to anti-condensation coatings, the coatings described herein may be used in connection with other applications. For example, the exemplary coatings described herein may be applied in connection with refrigerator / freezer, and / or other commercial applications, skylights, etc.

[0084] In certain exemplary embodiments, after heat treatment or activation using the methods described herein, the coated article may be sent to the manufacturer or to other locations, for example, for further processing, such as cutting, dimensioning, insertion into additional articles. (e.g. insulating glass unit, skylight, vehicle, glazing, etc.). Preferably, cracking or catastrophic damage to the heat treated coated article will not result from changes in the glass caused by the heat treatment process.

[0085] "Peripheral" and "edge" seals here do not mean that the seals are located exclusively at the perimeter or edge of the product, but instead mean that the seal is at least partially located on the edge of at least one plate of the product, or near it (for example, within about two inches (50.8 mm). Likewise, an “edge” as used herein is not limited to the absolute edge of the glass plate, but may also include a portion at or near the very edge of the plate (s) (eg, within about two inches (50.8 mm).

[0086] As used herein, the terms "on", "supported by something," and the like, should not be construed to mean that two elements are directly conjugate to each other, unless otherwise specifically stated. In other words, the first layer can be said to be "on" or "supported" by the second layer, even if one or more layers are interposed therebetween.

[0087] It will be understood that certain exemplary embodiments may include one or more additional energy efficient coatings on the surface of one or more glass plates facing the air gap therebetween (e.g., surfaces 2 and / or 3 in an IGU; surfaces 2, 3, 4 and / or 5 in a 3-layer IGU, etc.). An energy-saving coating on surface 4, placed on, for example, clean glass, can improve the overall U-value of the window, for example by reflecting infrared heat radiation back into the room. In certain exemplary embodiments, the glass may be uncoated float glass with a thickness of 2.3 to 6 mm in certain exemplary embodiments. In such embodiments, the hemispherical emissivity can be reduced to 0.3 and the surface resistance of the layer to 30 ohms / square. Preferably, the emissivity can be reduced to 0.23-0.30 and the surface resistance of the layer to 30 ohms / square, and sometimes the emissivity can be reduced to less than or equal to about 0.2 and the surface resistance of the layer to less than or equal to 20 ohms / square.

[0088] While the invention has been described in connection with what is currently considered the most practical and preferred embodiment, it should be understood that the invention should not be limited to the disclosed embodiment, but, on the contrary, is intended to encompass various modifications and equivalent constructions within the meaning and scope of the claims of the appended claims.