Protective layers for optical coatings

a protective layer and optical coating technology, applied in coatings, transportation and packaging, chemical instruments and processes, etc., can solve the problems of optical coatings that are often damaged, adhesive films run the risk of removing parts of optical coatings, and silver based low-emissivity coatings in particular have been plagued with corrosion problems, so as to reduce the number and severity of scratches

Inactive Publication Date: 2005-11-24
AFG IND INC
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  • Summary
  • Abstract
  • Description
  • Claims
  • Application Information

AI Technical Summary

Benefits of technology

[0016] Use of the temporary carbon protective layer when manufacturing a transparent article having an optical coating significantly reduces the number and severity of scratches introduced into the optical coating by the manufacturing process. Because the carbon layer is removed during tempering, the carbon layer does not affect the optical properties of the optical coating. While the SPB layer is not removed during tempering and may affect the optical properties of an

Problems solved by technology

Optical coatings are frequently damaged during shipping and handling by scratching and by exposure to corrosive environments.
Silver based low-emissivity coatings in particular have been plagued with corrosion problems since their introduction into the fenestration marketplace decades ago.
However, a number of problems are associated with using adhesive films and polymer films as protective layers on optical coatings.
When an adhesive film is pulled away from an optical coating, the adhesive film runs the risk of removing portions of the optical coating.
Even if porti

Method used

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  • Protective layers for optical coatings
  • Protective layers for optical coatings
  • Protective layers for optical coatings

Examples

Experimental program
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Effect test

example 1

[0064] FIGS. 5(1)-5(4) are optical microscope photographs showing the significant decrease in scratches that results according to the present invention by depositing a temporary carbon protective layer on an optical coating before tempering, and then removing the carbon protective layer by tempering in a reactive atmosphere. Each sample had the same optical coating. The optical coating included multiple layers of Zn, Ag, and NiCr, along with an outermost layer of 36 nm thick Si. A carbon protective layer 1 nm thick was deposited on the optical coatings of the samples shown in FIGS. 5(1) and 5(2), but not on the optical coatings of the samples shown in FIGS. 5(3) and 5(4). The samples were then scratched under the same conditions using the same commercial abrasion wheel (a TABER® wheel). FIGS. 5(1) and 5(2) show different areas of carbon protected samples representative of the worst scratching. The scratch in FIG. 5(1) is about 10-15 nm wide. FIGS. 5(1) and 5(3) show scratched sample...

example 2

[0066]FIG. 6 shows nine samples (numbered 1 through 9) comparing the effect of different carbon protective layer thicknesses on scratches remaining on optical coatings after tempering. Each sample had the same optical coating. The optical coating included multiple layers of Zn, Ag, and NiCr, along with an outermost layer of 36 nm thick Si. Carbon protective layers of various thicknesses were deposited on the samples as shown in the following Table 1. Samples 1-2 contained no carbon protective layer.

TABLE 1SAMPLECARBON THICKNESS (nm)1none2none3141.251.86575810915

[0067] The samples were scratched under the same conditions using the same commercial abrasion wheel (a TABER® wheel). The nine samples were each tempered in air at 730° C. for four minutes. FIG. 6 shows Samples 1-9 after the tempering.

[0068] As shown in FIG. 6, Samples 3-9, which included temporary carbon protective layers, had significantly fewer scratches after tempering in air than did Samples 1-2, which did not includ...

example 3

[0069] Individual protective layers of various SPB materials and carbon were deposited onto identical optical coatings on glass. The protective layers were scratched under the same conditions using the same commercial abrasion wheel (a TABER® wheel). Table 2 shows the relative abilities of individual SPB materials and of carbon to lessen scratch damage.

TABLE 2PROTECTIVE LAYER(SPB or C)THICKNESS (nm)DAMAGE (%)unprotected (standard)—100SiO2260TiN230TiO2230ZnO210C110C10 2

[0070] In Table 1, the “% Damage” is the approximate number of scratches per unit length perpendicular to the direction of the abrasive tool.

[0071] Table 2 shows that an SPB layer can help to prevent scratching and scratch propagation on handling, even without a protective carbon layer. Combined, the SPB and C layers can have an even greater effect in inhibiting scratches. The thicknesses of each SPB and C layer can be varied as needed.

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Abstract

An optical coating on a transparent substrate is provided with a temporary layer of carbon as protection during manufacturing against scratches and corrosive environments. When the optical coating and/or substrate are tempered in an atmosphere reactive to carbon, such as air, the layer of carbon is removed as a carbon-containing gas. For an optical coating with a brittle, glassy, outermost layer furthest from the substrate, additional protection is provided by a scratch propagation blocker layer between the outermost layer and the carbon protective layer.

Description

BACKGROUND OF THE INVENTION [0001] 1. Field of the Invention [0002] This invention relates to protective layers applied to optical coatings on transparent substrates. In particular, the invention relates to the use of a temporary protective layer of carbon. In addition, the invention relates to a scratch propagation blocker (SPB) protective layer applied to the outermost layer of various optical coatings. [0003] 2. Discussion of the Background [0004] Optical coatings are deposited on transparent substrates to reflect or otherwise alter the transmission of some or all of the radiation incident on the substrates. For example, the optical coating of a mirror is designed to reflect visible light. Low-emissivity optical coatings are designed to reduce the transmission of infrared radiation. Optical coatings generally include two or more different layers each having a thickness in a range of from less than 1 nm to over 500 nm. [0005] Optical coatings are frequently damaged during shipping...

Claims

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Application Information

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IPC IPC(8): C03C17/34C03C17/00C03C17/36
CPCC03C17/3435C03C17/3441C03C17/36C03C17/3618C03C17/3626C03C17/3634Y10T428/265C03C17/366C03C2217/78C03C2218/355Y10T428/24942Y10T428/24975Y10T428/30C03C17/3644
Inventor HUKARI, KYLE W.MASCHWITZ, PETER A.DANNENBERG, RAND D.
Owner AFG IND INC
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