Heads-up display and coating therefor

Abstract

To provide a HUD system that projects an image visible to drivers wearing polarized sunglasses and / or that reduces or eliminates ghosting.SOLUTION: A laminate includes: a first ply having a first surface and a second surface, where the first surface is an outer surface of the laminate; a second ply having a third surface facing the second surface and a fourth surface opposite the third surface, where the fourth surface is an inner surface of the laminate; an interlayer between the plies; and an enhanced p-polarized reflective coating positioned over at least a portion of a surface of the plies. When the laminate is contacted with radiation having p-polarized radiation at an angle of 60° relative to the normal of the laminate, the laminate exhibits an LTA of at least 70% and a reflectivity of the p-polarized radiation of at least 10%. A display system and a method of projecting an image in a heads-up display is also disclosed.SELECTED DRAWING: Figure 7

Description

[Technical Field]

[0001] CROSS-REFERENCE TO RELATED APPLICATIONS This application claims priority to and the full benefit of U.S. Patent Application No. 16 / 111,496, filed August 24, 2018, and U.S. Provisional Patent Application No. 62 / 552,467, filed August 31, 2017, the disclosures of which are incorporated herein by reference.

[0002] The present invention relates to a laminate having improved reflectivity for P-polarized radiation, a display system for projecting images, and a method for projecting images in a head-up display. [Background technology]

[0003] Conventional automotive head-up displays (HUDs) use an electromagnetic radiation source within the dashboard to project light onto the windshield, which reflects it back to the driver's eyes, creating a virtual image of vehicle data, allowing the driver to access information about the vehicle's operation without taking their eyes off the road. For electromagnetic radiation typically found in conventional vehicles that reflects off the windshield at an angle, and for typical unpolarized light sources such as light-emitting diodes (LEDs), the reflected light is primarily S-polarized, with far less of the light being P-polarized. In an extreme example, when the angle of incidence of the electromagnetic radiation on the windshield is the Brewster angle of the air-glass interface (approximately 57°), the P-polarized light reflectance is zero percent.

[0004] Light (primarily S-polarized) from a radiation source reflects off both the innermost and outermost surfaces of the windshield due to the refractive index mismatch between air and glass. This creates two reflected images, one on each surface. The multiple images created within a HUD are a phenomenon known as "ghosting," and eliminating or minimizing the presence of "ghosting" is a goal of HUD technology. A traditional method of eliminating ghosting is by using a wedge-shaped vinyl layer between the inner and outer glass laminates of the windshield to adjust the alignment of the two glass laminates to line up with the two reflected images. This wedge-shaped vinyl adds cost to the windshield and adds complexity to its manufacturing.

[0005] It may also be desirable to provide solar control, heat generation, and / or antenna functionality to the windshield by applying a coating to at least one of the glass laminates. This additional coating creates a third reflectance mismatch in the windshield and a third reflected image on the HUD system, which causes a third reflection that is difficult to offset with a wedge-shaped vinyl layer.

[0006] Another problem with conventional HUD systems stems from the fact that many drivers wear polarized sunglasses to reduce glare from the road and other sources while driving. Typical polarized sunglasses function by blocking S-polarized radiation; P-polarized radiation can pass through polarized sunglasses. However, as discussed above, in conventional HUD systems, it is primarily S-polarized radiation that reflects off the windshield to form the HUD image, with very little P-polarized radiation reflected off the windshield surface. This is especially true when the windshield is typically positioned at an angle close to the Brewster's angle at the air-glass interface. Thus, a driver wearing conventional polarized sunglasses may be unable to see the HUD image, which is formed primarily by S-polarized radiation.

[0007] Accordingly, there is a need in the art for a system and / or component that reduces or eliminates one or more of these problems. For example, it would be desirable to provide a HUD system that projects an image that is viewable by drivers wearing polarized sunglasses and / or that reduces or eliminates ghosting. [Prior art documents] [Patent documents]

[0008] [Patent Document 1] U.S. Patent No. 6,265,076 [Patent Document 2] U.S. Patent No. 6,570,709 Summary of the Invention

[0009] The present invention is directed to a laminate, such as a windshield, having improved reflectivity for P-polarized radiation. The laminate includes a first layer having a first surface (Side No. 1) that is the exterior surface of the laminate and a second surface (Side No. 2) opposite the first surface, and a second layer having a third surface (Side No. 3) facing the second surface and a fourth surface (Side No. 4) opposite the third surface and that is the interior surface of the laminate. An intermediate layer is disposed between the first and second layers. An improved P-polarized reflective coating of the present invention is disposed on at least a portion of at least one of the first and / or second layers. When the laminate is contacted with radiation from a radiation source having P-polarized radiation at an angle of 60° relative to the normal to the laminate, the laminate exhibits a luminous transmittance (LTA) of at least 70% using Standard Illuminant A and a reflectance of P-polarized radiation of at least 5%, e.g., at least 10%.

[0010] The improved P-polarized reflective coating may include multiple layers. The improved P-polarized reflective coating may be positioned on at least a portion of the second or third surface. The improved P-polarized reflective coating may include a base layer positioned on at least a portion of one of the surfaces, a first metal functional layer positioned on at least a portion of the base layer, a first sacrificial metal layer positioned on at least a portion of the first metal functional layer, a first phase adjustment layer positioned on at least a portion of the first sacrificial metal layer, a second metal functional layer positioned on at least a portion of the first phase adjustment layer, a second sacrificial metal layer positioned on at least a portion of the second metal functional layer, a topcoat layer positioned on at least a portion of the second sacrificial metal layer, and an overcoat positioned on at least a portion of the topcoat layer. The improved P-polarized reflective coating may further include a second phase adjustment layer positioned on at least a portion of the second sacrificial metal layer, a third metal functional layer positioned on at least a portion of the second phase adjustment layer, a third sacrificial metal layer positioned on at least a portion of the third metal functional layer, a topcoat layer positioned on at least a portion of the third sacrificial metal layer, and an overcoat positioned on at least a portion of the topcoat layer.

[0011] The base layer may include a first layer comprising a metal alloy oxide layer and a second base layer layer positioned on the first base layer layer and including an oxide layer. The first base layer layer may include a zinc oxide / tin alloy, particularly zinc stannate. The second base layer layer may include a metal oxide layer, particularly zinc oxide. In one example, the base layer may have a thickness in the range of 300 to 500 angstroms, preferably 350 to 430 angstroms. In another example, the base layer may have a thickness in the range of 350 to 550 angstroms, preferably 420 to 500 angstroms.

[0012] The first and / or second phase adjustment layers may include a first layer including an oxide layer, a second layer positioned on the first layer of the first and / or second phase adjustment layers, the second layer including a metal alloy oxide layer, and a third layer positioned on the second layer of the first and / or second phase adjustment layers, the third layer including an oxide layer. The first and / or second phase adjustment layers and / or the third layer of the first and / or second phase adjustment layers may include a metal oxide layer, particularly zinc oxide. The second layer of the first and / or second phase adjustment layers may include a zinc oxide / tin alloy, particularly zinc stannate. In one example, the first phase adjustment layer may have a thickness in the range of 700 to 1,100 angstroms, preferably 850 to 1,050 angstroms. In another example, the first phase adjustment layer may have a thickness in the range of 600 to 1000 angstroms, preferably 675 to 875 angstroms, and the second phase adjustment layer may have a thickness in the range of 500 to 1000 angstroms, preferably 600 to 850 angstroms.

[0013] The first, second, and / or third metal functional layers may comprise at least one noble or semi-noble metal, in particular silver, gold, platinum, palladium, osmium, iridium, rhodium, ruthenium, copper, mercury, rhenium, aluminum, and combinations thereof, more preferably metallic silver. The first metal functional layer may have a thickness in the range of 10 to 200 angstroms, preferably 50 to 150 angstroms. The first metal functional layer may have a thickness in the range of 10 to 150 angstroms, preferably 50 to 110 angstroms. The second metal functional layer may have a thickness in the range of 10 to 150 angstroms, preferably 50 to 125 angstroms. The second metal functional layer may have a thickness in the range of 10 to 100 angstroms, preferably 50 to 75 angstroms. The third metal functional layer may have a thickness in the range of 50 to 200 Angstroms, preferably 75 to 150 Angstroms.

[0014] The first, second and / or third sacrificial metal layer may comprise at least one of titanium, niobium, tungsten, nickel, chromium, iron, tantalum, zirconium, aluminum, silicon, indium, tin, zinc, molybdenum, hafnium, bismuth, vanadium, manganese and combinations thereof, preferably titanium. The first, second and / or third sacrificial metal layer may have a thickness in the range of 10 to 50 angstroms, preferably 20 to 40 angstroms, more preferably 25 to 35 angstroms.

[0015] The topcoat layer may include a first layer including an oxide layer and a second layer positioned on the first layer of the topcoat layer, the second layer including a metal alloy oxide layer. The first layer of the topcoat layer may include a metal oxide layer, particularly zinc oxide. The second layer of the topcoat layer may include a zinc oxide / tin alloy, particularly zinc stannate. The topcoat layer may have a thickness in the range of 300 to 400 angstroms, preferably 340 to 375 angstroms. The topcoat layer may have a thickness in the range of 275 to 450 angstroms, preferably 300 to 415 angstroms.

[0016] The overcoat may comprise a silica-alumina combination coating. The overcoat may have a thickness in the range of 100 to 1,000 angstroms, preferably 600 to 800 angstroms.

[0017] The laminate 12 may further include an anti-reflective coating positioned on at least a portion of the first surface or the fourth surface. The anti-reflective coating may be positioned on at least a portion of the first surface or the fourth surface. The first layer and the second layer may be non-parallel to each other. The intermediate layer may be a wedge-shaped intermediate layer. The intermediate layer may be a layer of uniform thickness. The intermediate layer may include polyvinyl butyral (PVB). The laminate may exhibit a total reflectance of up to 60%, preferably up to 55%, and more preferably up to 52%, when contacted with radiation from a radiation source at an angle of 60° relative to the normal of the laminate. The laminate may be an automotive laminate.

[0018] The present invention is also directed to a display system for projecting an image, comprising a laminate having improved reflectivity for P-polarized radiation. The laminate comprises a first layer having a first surface that is the exterior surface of the laminate and a second surface opposite the first surface; a second layer having a third surface facing the second surface and a fourth surface opposite the third surface and that is the interior surface of the laminate; an intermediate layer positioned between the first and second layers; and an improved P-polarized reflective coating positioned on at least a portion of at least one surface of the first and / or second layers. When the laminate is in contact with radiation from a radiation source having P-polarized radiation at an angle of 60° relative to the normal to the laminate, the laminate exhibits a luminous transmittance (LTA) of at least 70% using Standard Illuminant A and a reflectance of P-polarized radiation of at least 10%. The display system also includes a radiation source that emits radiation having P-polarized radiation and is directed toward the laminate.

[0019] The system may further include a polarizing filter positioned between the radiation source and the laminate and configured to pass at least a portion of the P-polarized radiation. The polarizing filter may filter at least a portion of the S-polarized radiation emitted from the radiation source. The polarizing filter may filter substantially all of the S-polarized radiation emitted from the radiation source. The radiation source may emit radiation directed at the laminate such that an image is projected onto an area inside the laminate. The image may be at least one of a static image or a dynamic image. The image may include color. The image may be an image in a head-up display. The laminate may be an automotive laminate, such as a windshield for an automobile. The improved P-polarized reflective coating may be positioned on at least a portion of the second surface or the third surface. The improved P-polarized reflective coating may be positioned on at least a portion of the first surface or the fourth surface. A modified P-polarized reflective coating may be positioned on at least a portion of the fourth surface, and a radiation source directed at the stack may be positioned at an angle relative to the stack, such that the radiation contacts the first surface at an angle approximately equal to the Brewster angle of the first surface-air interface.

[0020] The present invention is also directed to a method for projecting an image in a head-up display, comprising providing a laminate having improved reflectivity for P-polarized radiation. The laminate comprises: a first layer having a first surface that is an exterior surface of the laminate and a second surface opposite the first surface; a second layer having a third surface facing the second surface and a fourth surface opposite the third surface and that is an interior surface of the laminate; an intermediate layer disposed between the first and second layers; and an improved P-polarized reflective coating positioned on at least a portion of at least one surface of the first and / or second layers. When the laminate is contacted with radiation from a radiation source having P-polarized radiation at an angle of 60° relative to the normal to the laminate, the laminate exhibits a luminous transmittance (LTA) of at least 70% using Standard Illuminant A and a reflectance of P-polarized radiation of at least 10%. The laminate also comprises directing a radiation source emitting radiation having P-polarized radiation toward the laminate such that an image is projected onto an area inside the laminate.

[0021] These and other features and characteristics of the present invention, and its method of operation and function of the associated elements of construction, combination of parts and economy of manufacture, will become more apparent from a consideration of the following description and the appended claims, which refer to all the accompanying drawings, which form a part of this specification, such that corresponding parts in the different drawings are designated by reference characters. It is to be expressly understood, however, that the drawings are for purposes of illustration and description only and are not intended as a limiting description of the invention. As used in the specification and claims, the singular forms "a," "an," and "the" include plural referents unless the context clearly dictates otherwise. [Brief explanation of the drawings]

[0022] [Figure 1] FIG. 1 is a perspective view (not to scale) of a display system including a stack and a radiation source. [Figure 2A] 1A-1C are side views (not to scale) of various example stacks having modified P-polarized reflective coatings. [Figure 2B] 1A-1C are side views (not to scale) of various example stacks having modified P-polarized reflective coatings. [Figure 2C] 1A-1C are side views (not to scale) of various example stacks having modified P-polarized reflective coatings. [Figure 2D] 1A-1C are side views (not to scale) of various example stacks having modified P-polarized reflective coatings. [Figure 2E] 1A-1C are side views (not to scale) of various example stacks having modified P-polarized reflective coatings. [Figure 2F] 1A-1C are side views (not to scale) of various example stacks having modified P-polarized reflective coatings. [Figure 3A] FIG. 1 is a side view (not to scale) of an improved P-polarized reflective coating disposed on a substrate and including two metal functional layers. [Figure 3B] FIG. 1 is a side view (not to scale) of an improved P-polarized reflective coating disposed on a substrate and including two metal functional layers. [Figure 4A] FIG. 1 is a side view (not to scale) of an improved P-polarized reflective coating disposed on a substrate and including three metallic functional layers. [Figure 4B] FIG. 1 is a side view (not to scale) of an improved P-polarized reflective coating disposed on a substrate and including three metallic functional layers. [Figure 5A] FIG. 1 is a side view (not to scale) of a laminate comprising two plies and having a wedge-shaped intermediate layer. [Figure 5B] FIG. 1 is a side view (not to scale) of a laminate comprising two plies and having a continuous thickness intermediate layer. [Figure 6] FIG. 1 is a perspective view (not to scale) of a stack having an improved P-polarized reflective coating on its fourth surface and a radiation source positioned such that radiation from the radiation source contacts the first surface of the stack at the Brewster angle of the first surface-air interface. [Figure 7]FIG. 1 is a perspective view (not to scale) of a test setup in which radiation from a radiation source contacts the laminate at an angle of 60° relative to the normal to the laminate. DETAILED DESCRIPTION OF THE INVENTION

[0023] For purposes of the following description, the terms "end," "upper," "lower," "right," "left," "vertical," "horizontal," "top," "bottom," "lateral," "longitudinal," and derivatives thereof, shall refer to the present invention as oriented in the drawings. However, unless expressly specified to the contrary, it will be understood that the present invention may contemplate various alternative modifications and process sequences. It will also be understood that the specific devices and processes illustrated in the accompanying drawings or described in the following specification are merely exemplary embodiments or aspects of the present invention. Specific dimensions and other physical characteristics relating to the embodiments or aspects disclosed herein are not to be considered as limiting.

[0024] For purposes of the following detailed description, it will be understood that the present invention may assume various alternative modifications and process sequences, unless otherwise specified. Also, except for all working examples, or unless otherwise stated, all numbers used in the specification and claims will be understood to be modified in all instances by the term "about." Accordingly, unless indicated to the contrary, the numerical parameters set forth in the following specification and appended claims are approximations that may vary depending upon the desired properties obtained by the present invention. At the very least, and not as an attempt to limit the application of the doctrine of equivalents to the scope of the claims, each numerical parameter should at least be construed in light of the number of reported significant digits and by applying ordinary rounding techniques.

[0025] It should be understood that all numerical ranges recited herein are intended to include all subranges subsumed therein. For example, a range of "1 to 10" is intended to include all subranges between (and including) the stated minimum of 1 and the stated maximum of 10, i.e., having a minimum of 1 or greater and a maximum of 10 or less.

[0026] With respect to coating layers described herein, the term "on" means that the coating layer is further from the substrate on which it is positioned. For example, a second layer positioned "on" a first layer means that the second layer is positioned further from the substrate than the first layer. The second layer may be in direct contact with the first layer. Alternatively, one or more layers may be positioned between the first and second layers.

[0027] The term "film" refers to an area having a distinct structure. A "layer" may include one or more "films." A "coating" may include one or more "layers."

[0028] The term "polymer" or "polymeric" includes oligomers, homopolymers, copolymers and terpolymers, which are polymers formed from two or more types of monomers or polymers, for example.

[0029] The term "ultraviolet radiation" means electromagnetic radiation having a wavelength in the range of 100 nm to less than 300 nm. The term "visible light radiation" means electromagnetic radiation having a wavelength in the range of 380 nm to 780 nm. The term "infrared radiation" means electromagnetic radiation having a wavelength in the range of greater than 780 nm to 100,000 nm. The term "solar infrared radiation" means electromagnetic radiation having a wavelength in the range of 1,000 nm to 3,000 nm. The term "thermal infrared radiation" means electromagnetic radiation having a wavelength in the range of greater than 3,000 nm to 20,000 nm.

[0030] The terms "metal" and "metal oxide" include silicon and silica, respectively, and also include metals and metal oxides as originally recognized, even though silicon is not traditionally considered a metal.

[0031] "At least" means "more than or equal to." "Less than" means "less than or equal to."

[0032] The term "including" is synonymous with "comprises."

[0033] A "reference laminate" is defined as a laminate having two 2 mm clear float glass sheets separated by a 0.76 mm layer of PVB with an improved P-polarized reflective coating on face No. 3. "Reference laminate values" refer to the reported values, such as LTA and reflectance, measured for the laminate using the test apparatus shown in Figure 7.

[0034] The discussion of the present invention may refer to certain features as "particularly" or "preferably," within certain limitations (e.g., "preferably," "more preferably," or "even more preferably," within certain limitations). It will be understood that the invention is not limited to these particular or preferred limitations, but rather encompasses the full scope of the present disclosure. [Example]

[0035] Display System Referring to FIG. 1, a display system 10 according to the present invention is shown. The display system 10 may be a head-up display (HUD) in a vehicle, such as a head-up display in an automobile or aircraft. However, the display system 10 is not limited to head-up displays in vehicles and may be any type of display that projects an image. Non-limiting examples of displays that may be considered "display systems" include advertising, promotional, or informational displays, etc. The display system 10 may project an image that is visible to humans (e.g., in the visible spectrum). Alternatively, the display system 10 may project an image in the non-visible region of the electromagnetic spectrum.

[0036] Continuing with reference to FIG. 1 , display system 10 may include stack 12 and radiation source 14. Radiation source 14 may emit electromagnetic radiation 16. Radiation source 14 may emit radiation 16 across the entire radiation spectrum or across only a portion thereof (e.g., the visible spectrum, ultraviolet radiation, infrared radiation, etc., and combinations thereof). Radiation source 14 may emit white light as radiation 16. Radiation 16 may include S-polarized radiation and / or P-polarized radiation. "S-polarized radiation" means that radiation 16 has an electric field perpendicular to the plane of incidence. "P-polarized radiation" means that radiation 16 has an electric field along the plane of incidence. "Angle of incidence" is defined as the angle between a ray of radiation incident on a surface and a line normal to the surface at the point of incidence. Radiation source 14 may emit radiation 16 directed toward stack 12 such that radiation 16 contacts stack 12 at at least one point.

[0037] 1 , display system 10 may further include polarizing filter 18. Polarizing filter 18 may be positioned between radiation source 14 and stack 12. Polarizing filter 18 may pass at least a portion of P-polarized and / or S-polarized radiation. Polarizing filter 18 may pass only P-polarized radiation. Polarizing filter 18 may filter at least a portion of S-polarized radiation, preventing the filtered portion from passing. Polarizing filter 18 may filter substantially all of S-polarized radiation, preventing substantially all of S-polarized radiation from passing. Substantially all, in this context, means that polarizing filter 18 filters at least 95% of S-polarized radiation, e.g., at least 97%, at least 99%, or 100% of S-polarized radiation.

[0038] 1 , radiation source 14 may emit radiation 16 away from stack 12 such that at least a portion of radiation 16 is reflected from stack 12 and directed toward a user's eye 20. The portion of the radiation that is not reflected from stack 12 may be refracted, absorbed, or otherwise transmitted by stack 12. The user may be wearing polarized sunglasses 21, and radiation 16 directed toward the user's eye 20 may be directed toward polarized sunglasses 21. Polarized sunglasses 21 may filter S-polarized radiation such that at least a portion of the S-polarized radiation cannot pass through.

[0039] Continuing to refer to FIG. 1 , when radiation source 14 emits radiation 16 directed toward stack 12, an image is projected onto an area inside stack 12, and the image may be viewable by a user's eye 20. The image of display system 10 may be static or dynamic. The image may include color, and may be a monochromatic or multicolor image. The image may be an image within a HUD. The HUD may be a HUD within an automobile or other vehicle. In this example, stack 12 may be a windshield or another stack 12 within a vehicle, and radiation source 14 may be directed toward stack 12 to display an image so that the driver (or other user) can view the image while operating the vehicle. Laminate

[0040] 1 and 2A-2F, various examples of laminates 12 of the present invention are shown. The laminate 12 may include a first layer 22 having a first surface 24 (surface No. 1) and an opposing second surface 26 (surface No. 2). The laminate 12 may also include a second layer 28 having a third surface 30 (surface No. 3) and an opposing fourth surface 32 (surface No. 4). This surface numbering follows conventions in the art. The second surface 26 may face the third surface 30, and an intermediate layer 34 may be positioned between the second surface 26 and the third surface 30. Referring to FIG. 1, the first surface 24 may be the outer surface of the laminate 12, and the fourth surface 32 may be the inner surface of the laminate 12. If laminate 12 is a vehicle windshield, first side 24 may be the side closest to the sun, and fourth side 32 may be the side closest to the interior of the vehicle. Thus, fourth side 32 may be the side of laminate 12 closest to a radiation source 14 located inside the vehicle and directed at laminate 12.

[0041] The first layer 22 and / or the second layer 28 may be transparent or translucent to visible radiation. "Transparent" means having a transmittance of visible radiation from greater than 0% to 100%. Alternatively, the layer may be translucent. "Translucent" means diffusing visible radiation so that objects opposite the viewer cannot be clearly seen. Examples of suitable materials include, but are not limited to, plastic substrates (such as acrylic polymers such as polyacrylates, polyalkyl methacrylates such as polymethyl methacrylate, polyethyl methacrylate, and polypropyl methacrylate, polyurethanes, polycarbonates, polyalkyl terephthalates such as polyethylene terephthalate (PET), polypropylene terephthalate, and polybutylene terephthalate, polysiloxane-containing polymers, copolymers of any of the monomers used to prepare them, or mixtures of any of these), ceramic substrates, glass substrates, or mixtures or combinations of any of the above. For example, layers 22 and 28 may comprise conventional soda-lime silicate glass, borosilicate glass, or lead glass. The glass may be clear glass. "Clear glass" means untinted or uncolored glass. Alternatively, the glass may be tinted or otherwise colored glass. The glass may be annealed or heat-treated glass. As used herein, the term "heat-treated" means tempered or at least partially tempered. The glass may be of any type, such as conventional float glass, and of any configuration, having any optical properties, for example, any values ​​of visible radiation transmittance, ultraviolet radiation transmittance, infrared radiation transmittance, and / or total solar energy transmittance. "Float glass" means glass formed by a conventional float process in which molten glass is deposited onto a molten metal bath and controllably cooled to form a float glass ribbon.

[0042] First and / or second layers 22 and / or 28 may be, for example, clear float glass or tinted or colored glass. Layers 22 and 28 may be of any desired dimensions, for example, length, width, shape, or thickness. Non-limiting examples of glass that may be used in the practice of the present invention include clear glass, Starphire®, Solargreen®, Solextra®, GL-20®, GL-35™, Solarbronze®, Solargray® glass, Pacifica® glass, SolarBlue® glass, and Optiblue® glass, all commercially available from Vitro Architectural Glass of Pittsburgh, Pennsylvania.

[0043] The other of the first layer 22 and the second layer 28 may be any of the materials previously described for the first layer 22 and / or the second layer 28. The first layer 22 and the second layer 28 may be the same as or different from one another. The first and second layers 22 and 28 may each be, for example, clear float glass or tinted or colored glass, or one layer 22 or 28 may be clear glass and the other layer 22 or 28 may be colored glass.

[0044] 2A-2F, stack 12 may also include a modified P-polarization reflective coating 36 positioned on at least a portion of one of surfaces 24, 26, 30, and 32 of layers 22 and 28. In FIG. 2A, modified P-polarization reflective coating 36 is positioned on first surface 24. In FIG. 2B, modified P-polarization reflective coating 36 is positioned on second surface 22. In FIG. 2C, modified P-polarization reflective coating 36 is positioned on third surface 30. In FIG. 2D, modified P-polarization reflective coating 36 is positioned on fourth surface 32.

[0045] 2E and 2F, stack 12 may include additional coating layers in addition to modified P-polarized reflective coating 36. Stack 12 may also include an anti-reflective coating 38 positioned on one of surfaces 24, 26, 30, and 32 of layers 22 and 28. As shown in FIGS. 2E and 2F, 38 may also be positioned on fourth surface 32 when modified P-polarized reflective coating 36 is positioned on second surface 26 (FIG. 2E) or third surface 30 (FIG. 2F). Improved P-polarized reflective coating

[0046] 3A and 3B, the modified P-polarized reflective coating 36 may be a dual metal functional layer modified P-polarized reflective coating 36. In the dual metal functional layer modified P-polarized reflective coating 36, a base layer 44 may be positioned on a substrate 42 (the substrate 42 being one of the aforementioned surfaces 24, 26, 30, and 32). A first metal functional layer 46 may be positioned on the base layer 44. A first sacrificial metal layer 48 may be positioned on the first metal functional layer 46. A first phase adjustment layer 50 may be positioned on the first sacrificial metal layer 48. A second metal functional layer 52 may be positioned on the first phase adjustment layer 50. A second sacrificial metal layer 54 may be positioned on the second metal functional layer 52. A topcoat layer 56 may be positioned on the second sacrificial metal layer 54. An overcoat 58 may be positioned on the topcoat layer 56.

[0047] 3B , at least one of the layers of the improved P-polarized reflective coating 36 in the dual metal functional layer improved P-polarized reflective coating 36 may include multiple layers. The base layer 44 may include a first film 66 and a second film 68. The first film 66 may be positioned on the substrate 42, and the second film 68 may be positioned on the first film 66. The first phase adjustment layer 50 may include a first film 70, a second film 72, and a third film 74. The first film 70 may be positioned on the first sacrificial metal layer 48. The second film 72 may be positioned on the first film 70, and the third film 74 may be positioned on the second film 72. The topcoat layer 56 may include a first film 76 and a second film 78. The first film 76 may be positioned on the second sacrificial metal layer 54, and the second film 78 may be positioned on the first film 76.

[0048] 4A and 4B, the improved P-polarized reflective coating 36 is a triple-metal functionally improved reflective coating 36 that includes several additional layers compared to the dual-metal functional layer improved P-polarized reflective coating 36 of FIGS. 3A and 3B. The triple-metal functionally improved P-polarized reflective coating 36 may further include a second phase adjustment layer 60 positioned on the second sacrificial metal layer 54 (compared to the dual-metal functional layer improved P-polarized reflective coating 36). A third metal functional layer 62 may be positioned on the second phase adjustment layer 60. A third sacrificial metal layer 64 may be positioned on the third metal functional layer 62. The topcoat layer 56 and overcoat layer 58 (described above) may be positioned on the third sacrificial metal layer 64.

[0049] Referring to FIG. 4B , at least one of the layers of the triple-metal functional layer modified P-polarized reflective coating 36 may include multiple layers. The second phase adjustment layer 60 of the triple-metal functional layer modified P-polarized reflective coating 36 may have multiple layers in addition to those described for the dual-metal functional layer modified P-polarized reflective coating 36 ( FIG. 3B ). The second phase adjustment layer 60 may include a first film 80, a second film 82, and a third film 84. The first film 80 may be positioned on the second sacrificial metal layer 54. The second film 82 may be positioned on the first film 80, and the third film 84 may be positioned on the second film 82. In the previously described multi-layer topcoat layer 56, the first film 76 may be positioned on the third sacrificial metal layer 64.

[0050] Based on this disclosure, it will be understood that additional repeating coating portions are within the scope of the present invention. For example, this disclosure also contemplates the addition of additional phase adjustment layers, metal functional layers, and / or sacrificial metal layers (e.g., to form a quadruple, quintuple, etc. metal functional layer-enhanced P-polarized reflective coating 36).

[0051] The modified P-polarized reflective coating 36 may be a conductive low-emissivity coating that allows visible wavelength energy to pass through the coating but reflects longer wavelength solar infrared energy. "Low-emissivity" means an emissivity of less than 0.4, e.g., less than 0.3, e.g., less than 0.2, e.g., less than 0.1, e.g., 0.05 or less.

[0052] The modified P-polarized reflective coating 36, when applied to the substrate 42, may neutralize the substrate 42, such that the reflectance of the a* and / or b* values ​​is between -2 and 2, according to the 1976 CIELAB color system established by the International Commission on Illumination. The substrate 42 may have a low external reflectance, such that the reflectance is 30% or less, e.g., 15% or less, when the substrate 42 is viewed at an angle perpendicular to the substrate 42.

[0053] The improved P-polarized reflective coating 36 may be deposited on the substrate 42 by any conventional method. Examples of such methods include conventional chemical vapor deposition (CVD) and / or physical vapor deposition (PVD). Examples of CVD processes include spray pyrolysis. Examples of PVD processes include electron beam evaporation (such as magnetron sputter deposition (MSVD)) and vacuum sputtering. Other coating methods, such as, but not limited to, sol-gel deposition, may also be used. In one non-limiting example, the improved P-polarized reflective coating 36 may be deposited by MSVD.

[0054] The modified P-polarized reflective coating 36 may be deposited on part or all of the substrate 42. In some examples, the modified P-polarized reflective coating 36 may be deposited on a first large area of ​​the substrate 42, and then a portion of the first large area may be "removed" so that the modified P-polarized reflective coating 36 is positioned on a second, narrower area that is a subset of the first large area. 1. Base Layer

[0055] The base layer 44 may include one or more non-metallic layers. For example, the base layer 44 may include a dielectric or semiconductor material. For example, the base layer 44 may include an oxide, a nitride, an oxynitride, and / or a mixture thereof. Examples of suitable materials for the base layer 44 include oxides, nitrides, or oxynitrides of titanium, hafnium, zirconium, niobium, zinc, bismuth, lead, indium, tin, and mixtures thereof. These may contain small amounts of other materials, such as manganese in bismuth oxide or tin in indium oxide. Metal alloy or metal mixture oxides, such as oxides containing zinc and tin (e.g., zinc stannate), oxides of indium-tin alloys, silicon nitride, aluminum silicon nitride, or aluminum nitride, may also be used. Doped metal oxides, such as antimony- or indium-doped tin oxide or nickel- or boron-doped silicon oxide, may also be used. Examples of specific materials may include zinc oxide, tin oxide, silicon nitride, aluminum silicon nitride, nickel silicon nitride, chromium silicon nitride, antimony-doped tin oxide, aluminum-doped zinc oxide, indium-doped zinc oxide, titanium oxide, and / or mixtures thereof. Base layer 44 may include a single material. Alternatively, base layer 44 may include multiple materials and / or multiple layers.

[0056] Base layer 44 may allow for adjustment of constructive and destructive optical interference of electromagnetic radiation that is partially reflected from and partially transmitted through various interface boundaries of the layers of modified P-polarized reflective coating 36. Base layer 44 may also provide chemical and / or mechanical protection for other layers of modified P-polarized reflective coating 36, such as metal functional layers 46, 52, and 62.

[0057] If high visible light transmission is desired, base layer 44 acts as an anti-reflection layer, anti-reflecting metallic functional layers 46, 52, and 62 to reduce the overall visible light reflectance and / or improve the visible light transmission of modified P-polarized reflective coating 36. Materials with a refractive index of about 2 are particularly useful for anti-reflection of metallic functional layers 46, 52, and 62.

[0058] In the illustrated exemplary modified P-polarized reflective coating 36, a base layer 44 may be positioned on at least a portion of a substrate 42 (which may be one of surfaces 24, 26, 30, and 32 of one of layers 22 and 28). The base layer 44 may be a single layer or may include one or more films of the antireflective and / or dielectric materials described above. The base layer 44 may be transparent to visible light.

[0059] As mentioned above, the base layer 44 may include a metal oxide, a mixture of metal oxides, and / or a metal alloy oxide. For example, the base layer 44 may include an oxide of zinc and tin.

[0060] The base layer 44 may have a thickness within a range of 300 to 550 angstroms. For example, the base layer 44 may have a thickness within a range of 300 to 500 angstroms, 350 to 430 angstroms, or 375 to 430 angstroms. For example, the base layer 44 may have a thickness within a range of 350 to 550 angstroms, 400 to 500 angstroms, or 420 to 490 angstroms.

[0061] The base layer 44 may include a multi-film structure having a first film 66 and / or a second film 68. The first film 66 may be, for example, a metal alloy oxide film. The second film 68 may be, for example, a metal oxide film or a mixed oxide film. The second film 68 may be positioned on the first film 66.

[0062] The first film 66 may be a zinc / tin alloy oxide. "Zinc / tin alloy oxide" refers to both a true alloy and a mixture of oxides. The zinc / tin alloy oxide may be obtained by magnetron sputtering vacuum deposition from a zinc and tin cathode. The cathode may contain zinc and tin in ratios of 5 wt.% to 95 wt.% zinc and 95 wt.% to 5 wt.% tin, for example, 10 wt.% to 90 wt.% zinc and 90 wt.% to 10 wt.% tin. However, other ratios of zinc to tin may also be used. An exemplary metal alloy oxide for the first film 42 is Zn 2 O 3 , where "x" varies from greater than 0 to less than 1. X Sn 1-X O 2-X (Equation 1). For example, "x" may be greater than 0, or any fractional or decimal number between greater than 0 and less than 1. The stoichiometric form of Equation 1 is "Zn2SnO4," commonly referred to as zinc stannate. A zinc stannate layer may be sputter-deposited from a cathode having 52 wt.% zinc and 48 wt.% tin in the presence of oxygen. For example, first film 66 may include zinc stannate.

[0063] The second film 68 may include a metal oxide film. For example, the second film 68 may include zinc oxide. Zinc oxide may be deposited from a tin cathode containing other materials to improve the sputtering characteristics of the cathode. For example, a tin cathode may include a small amount (e.g., up to 10 wt.%, e.g., up to 5 wt.%) of tin to improve sputtering. Thus, the resulting zinc oxide film may include a small percentage of tin oxide, e.g., up to 10 wt.% tin oxide, e.g., up to 5 wt.% tin oxide. A coating layer deposited from a zinc cathode having up to 10 wt.% tin is referred to herein as a "zinc oxide film," even if a small amount (e.g., up to 10 wt.%) of tin oxide is present. It is believed that the tin in the cathode primarily forms tin oxide in the zinc oxide second film 68. 2. Metallic functional layer

[0064] At least one of the metal functional layers 46, 52 and 62 may be a continuous metal layer. A "continuous" metal layer means an unbroken or unseparated layer, such as a homogeneous layer.

[0065] Metallic functional layers 46, 52 and 62 provide reflectivity of electromagnetic radiation in at least a portion of the infrared radiation region of the electromagnetic spectrum, for example, in the solar infrared radiation region and / or in the thermal infrared radiation region of the electromagnetic spectrum.

[0066] Examples of materials useful for the metallic functional layers 46, 52, and 62 include noble or near-noble metals. Examples of such metals include silver, gold, platinum, palladium, osmium, iridium, rhodium, ruthenium, copper, mercury, rhenium, aluminum, and combinations thereof. For example, one or more of the metallic functional layers 46, 52, and 62 may comprise metallic silver.

[0067] The first metal functional layer 46 is positioned on the base layer 44 and may comprise any of the above metals. For example, the first metal functional layer 46 may comprise silver. The first metal functional layer 46 may be a continuous layer.

[0068] The first metal function layer 46 may be a continuous layer having a thickness in the range of 10 to 200 angstroms. For example, the first metal function layer 46 may have a thickness in the range of 10 to 200 angstroms or 50 to 150 angstroms. For example, the first metal function layer 46 may have a thickness in the range of 10 to 150 angstroms or 50 to 125 angstroms.

[0069] A second metal function layer 52 may be positioned on the first phase adjustment layer 50. The second metal function layer 52 may be a continuous layer comprising silver.

[0070] The second metal function layer 52 may be a continuous layer having a thickness in the range of 10 to 150 angstroms. For example, the second metal function layer 52 may have a thickness in the range of 10 to 150 angstroms or 50 to 125 angstroms. For example, the second metal function layer 52 may have a thickness in the range of 10 to 100 angstroms, 50 to 75 angstroms, or 65 to 75 angstroms.

[0071] The third metal function layer 62 may comprise any of the materials described above for the first or second metal function layers 46 or 52. For example, the third metal function layer 70 may comprise silver. The third metal function layer 70 may be a continuous layer positioned on the second phase adjustment layer 60.

[0072] For example, the third metal function layer 62 may be a continuous layer having a thickness in the range of 50-200 Angstroms, 75-150 Angstroms, or 60-140 Angstroms.

[0073] The metal function layer 46, the second metal function layer 52, and the optional third metal function layer 62 have a combined thickness. The combined thickness may be in the range of 100-350 angstroms, 150-300 angstroms, or 175-275 angstroms. For embodiments including only the first and second metal function layers 46 and 52, the combined thickness may be in the range of 150-250 angstroms, 175-225 angstroms, 175-215 angstroms, or 178-211 angstroms. For embodiments including the first, second, and third metal function layers 46, 52, and 62, the combined thickness may be in the range of 225-325 angstroms, 240-300 angstroms, 250-280 angstroms, or 253-275 angstroms. 3. Sacrificial Metal Layer

[0074] The sacrificial metal layers 48, 54, and 64 may be positioned in direct contact with the corresponding underlying metal functional layers 46, 52, and 62. The sacrificial metal layers 48, 54, and 64 may protect the corresponding underlying metal functional layers 46, 52, and 62 during coating processes and / or subsequent processing, such as thermal tempering. The sacrificial metal layers 48, 54, and 64 may be deposited as metals. Some or all of the sacrificial metal layers 48, 54, and 64 may oxidize during subsequent processing, such as deposition of the upper phase adjustment layers 50 and 60 or the topcoat layer 56, and / or thermal tempering. If an oxide or nitride material is used for the upper phase adjustment layers 50 and 60 or the topcoat layer 56, the sacrificial metal layers 48, 54, and 64 may comprise an oxygen-forming (oxophillic) or nitrogen-forming (nitrophillic) material, respectively. The sacrificial metal layers 48, 54, and 64 do not all have to be the same material. The sacrificial metal layers 48, 54 and 64 do not have to be the same thickness.

[0075] Examples of materials useful for the sacrificial metal layers 48, 54 and 64 include titanium, niobium, tungsten, nickel, chromium, iron, tantalum, zirconium, aluminum, silicon, indium, tin, zinc, molybdenum, hafnium, bismuth, vanadium, manganese, and combinations thereof.

[0076] A first sacrificial metal layer 48 may be positioned on the first metal functional layer 46. The first sacrificial metal layer 48 may be a single film or multiple film layers. The first sacrificial metal layer 48 may include any of the materials described above. For example, the first sacrificial metal layer 48 may include titanium.

[0077] A second sacrificial metal layer 54 may be positioned on the second metal functional layer 52. The second sacrificial metal layer 54 may include any of the materials described above for the first sacrificial metal layer 48. For example, the second sacrificial metal layer 54 may include titanium.

[0078] A third sacrificial metal layer 64 may be positioned on the third metal functional layer 62. The third sacrificial metal layer 64 may include any of the materials described above for the first or second sacrificial metal layers 48 or 54. For example, the third sacrificial metal layer 64 may include titanium.

[0079] The sacrificial metal layers 48, 54, and 64 may have the same or different thicknesses, such as within the range of 10-50 angstroms, e.g., 20-40 angstroms or 25-35 angstroms. The thickness of the sacrificial metal layers may be selected to provide sufficient protection to the underlying functional metal layers (e.g., preferably such that the sacrificial metal oxidizes to protect the underlying metal functional layers during deposition of the upper layers). 4. Phase Adjustment Layer

[0080] The phase adjustment layers 50 and 60 may be non-metallic layers. For example, the phase adjustment layers 50 and 60 may comprise a dielectric or semiconductor material. For example, the phase adjustment layers 50 and 60 may comprise an oxide, nitride, oxynitride, and / or a mixture thereof. Examples of materials suitable for the phase adjustment layers 50 and 60 include oxides, nitrides, or oxynitrides of titanium, hafnium, zirconium, niobium, zinc, bismuth, lead, indium, tin, and mixtures thereof. These may contain small amounts of other materials, such as manganese in bismuth oxide or tin in indium oxide. Metal alloy or metal mixture oxides may also be used, such as oxides containing zinc and tin (e.g., zinc stannate), oxides of indium-tin alloys, silicon nitride, aluminum silicon nitride, or aluminum nitride. Doped metal oxides, such as antimony- or indium-doped tin oxide or nickel- or boron-doped silicon oxide, may also be used. Examples of specific materials may include zinc oxide, tin oxide, silicon nitride, aluminum silicon nitride, nickel silicon nitride, chromium silicon nitride, antimony-doped tin oxide, aluminum-doped zinc oxide, indium-doped zinc oxide, titanium oxide, and / or mixtures thereof.

[0081] Phase adjustment layers 50 and 60 may comprise a single material. Alternatively, phase adjustment layers 50 and 60 may comprise multiple materials and / or multiple layers. Different phase adjustment layers 50 and 60 may comprise the same material or different materials. Phase adjustment layers 50 and 60 may have the same thickness or different thicknesses.

[0082] The phase adjustment layers 50 and 60 may allow for adjustment of the constructive and destructive optical interference of electromagnetic radiation that is partially reflected from and partially transmitted through various interface boundaries of the layers of the modified P-polarized reflective coating 36. By varying the thickness and / or composition of the phase adjustment layers 50 and 60, the overall reflectivity, transmittance, and / or absorptivity of the modified P-polarized reflective coating 36 may be altered to change the solar control performance, thermal infrared insulation performance, color, and / or aesthetics of the modified P-polarized reflective coating 36. The phase adjustment layers 50 and 60 may also provide chemical and / or mechanical protection for the other layers of the modified P-polarized reflective coating 36, such as the metal functional layers 46, 52, and 62.

[0083] When high visible light transmission is desired, the phase adjusting layers 50 and 60 function as anti-reflection layers, anti-reflecting the metallic functional layers 46, 52, and 62 to reduce the overall visible light reflectance and / or increase the visible light transmission of the modified P-polarized reflective coating 36. Materials with a refractive index of about 2 are particularly useful for anti-reflection of the metallic functional layers 46, 52, and 62.

[0084] A first phase adjustment layer 50 may be positioned on the first sacrificial metal layer 48. The first phase adjustment layer 50 may include one or more of the materials and / or films described above.

[0085] The first phase adjustment layer 50 may have a thickness in the range of 600 to 1,100 angstroms. For example, the first phase adjustment layer 50 may have a thickness in the range of 700 to 1,100 angstroms, such as 850 to 1,050 angstroms, such as 675 to 1,050 angstroms, or such as 689 to 1,048 angstroms. For example, the first phase adjustment layer 50 may have a thickness in the range of 600 to 1,000 angstroms, such as 675 to 875 angstroms, or such as 689 to 866 angstroms. For example, the first phase adjustment layer 50 may have a thickness in the range of 825 to 1,100 angstroms, such as 850 to 1,075 angstroms, such as 875 to 1,050 angstroms, or such as 879 to 1,048 angstroms.

[0086] The first phase adjustment layer 50 may be a single layer or a multi-layer structure. For example, the first phase adjustment layer 50 may include a first film 70, a second film 72, and a third film 74.

[0087] For example, the first film 70 may include a metal oxide film, or may include a zinc oxide film.

[0088] For example, the second film 72 may include a metal alloy oxide film. For example, the second film 72 may include a zinc stannate film.

[0089] For example, the third film 74 may include a metal oxide film. For example, the third film 56 may include a zinc oxide film.

[0090] An optional second phase adjustment layer 60 may be positioned on the second sacrificial metal layer 54. The second phase adjustment layer 60 may include any of the materials and / or layers described above for the first phase adjustment layer 50. For example, the second phase adjustment layer 60 may be a multi-layer structure. For example, the second phase adjustment layer 60 may include a first layer 80, a second layer 82, and a third layer 84.

[0091] The second phase adjustment layer 60 may have a thickness in the range of 500 to 1,000 angstroms, such as 600 to 825 angstroms, or such as 619 to 817 angstroms.

[0092] The first film 80 may comprise a metal oxide layer, for example, a zinc oxide layer. The second film 82 may comprise a metal alloy oxide material, for example, zinc stannate. The third film 84 may comprise a metal oxide layer, for example, a zinc oxide layer. 5. Top coat layer

[0093] The topcoat layer 56 may include one or more materials and / or layers such as those described above for the first or second phase adjusting layers 50 or 60 .

[0094] The topcoat layer 56 may have a thickness in the range of 300 to 450 angstroms. The topcoat layer 56 may have a thickness in the range of 300 to 400 angstroms, or 340 to 375 angstroms. The topcoat layer 56 may have a thickness in the range of 275 to 450 angstroms, 300 to 415 angstroms, 311 to 411 angstroms, or 346 to 368 angstroms.

[0095] The topcoat layer 56 may include a first film 76 and a second film 78. The first film 76 may include a metal oxide layer, such as a zinc oxide layer, and the second film 78 may include a metal alloy oxide layer, such as a zinc stannate layer. 6. Overcoat

[0096] The improved P-polarized reflective coating 36 may include an overcoat 58 positioned on the topcoat layer 56. The overcoat 58 may be deposited on the topcoat layer 56 to help protect the underlying layers from mechanical and chemical attack during processing. The overcoat 58 may be an oxygen barrier coating layer to prevent or reduce the passage of atmospheric oxygen into the underlying layers of the improved P-polarized reflective coating 36, for example, during heating or bending. The overcoat 58 may include any desired material or mixture of materials. In one exemplary embodiment, the overcoat 58 may include a layer having one or more metal oxide materials, such as, but not limited to, oxides of aluminum, silicon, or mixtures thereof (e.g., a silica-alumina coating). For example, the overcoat 58 may be 0 wt.% to 100 wt.% alumina and / or 100 wt.% to 0 wt.% silica, for example, 5 wt.% to 95 wt.% alumina and 95 wt.% to 5 wt.% silica, for example, 10 wt.% to 90 wt.% alumina and 90 wt.% to 10 wt.% silica, for example, 15 wt.% to 90 wt.% alumina and 85 wt.% to 10 wt.% silica, for example, 50 wt.% to 75 wt.% alumina and 50 wt.% to 25 wt.% silica, for example, 50 wt.% to 70 wt.% alumina and 50 wt.% to 30 wt.% silica, for example, 35 wt.% to 100 wt.% alumina and 65 wt.% to 0 wt.% silica, for example, 70 wt.% to 90 wt.% alumina and 30 wt.% to 10 wt.% silica, for example, 75 wt.% to 85 wt.% alumina and 25 wt.% to 15 wt.% silica, for example, 88 wt.% alumina and 12 wt.% silica, for example, 65 wt.% to 75 wt.% alumina and 35 wt.% to 25 wt.% silica, for example, 70 wt.% alumina and 30 wt.% silica, for example, 60 wt.% to less than 75 wt.% alumina and greater than 25 wt.% to 40 wt.% silica, or a single coating layer containing these ranges. The overcoat 58 may be a single coating layer containing 85 wt.% silica and 15 wt.% alumina.Other materials, such as aluminum, chromium, hafnium, yttrium, nickel, boron, phosphorus, titanium, zirconium and / or their oxides may also be present to adjust the refractive index of overcoat 58. In one non-limiting example, the refractive index of overcoat 58 may be in the range of 1 to 3, such as 1 to 2, or such as 1.4 to 2, such as 1.4 to 1.8.

[0097] The overcoat 58 may be a silica-alumina combination coating. The overcoat 58 may be sputtered from two cathodes (e.g., one silicon and one aluminum) or from a single cathode containing both silicon and aluminum. This silicon oxide / aluminum overcoat 58 may be a Si (Si) oxide / aluminum oxide coating, where "x" varies from greater than 0 to less than 1. x Al 1-x O 1.5+x / 2 may also be written as

[0098] Alternatively, the overcoat 58 may be a multi-layer coating formed by separately formed layers of metal oxide material, such as, but not limited to, a bi-layer formed by forming one metal oxide-containing layer (e.g., a silica and / or alumina-containing first layer) over another metal oxide-containing layer (e.g., a silica and / or alumina-containing second layer). The individual layers of the multi-layer protective coating may have any desired thickness.

[0099] The overcoat 58 may have any desired thickness. In one non-limiting example, the overcoat 58 is a silicon oxide / aluminum coating (SiO / Aluminum) having a thickness in the range of 100-1,000 Angstroms, such as 600-800 Angstroms, or such as 700 Angstroms. x Al 1-x O 1.5+x / 2 ) may also be used. Intermediate Layer

[0100] 5A and 5B, the laminate 12 may include an intermediate layer 34. The intermediate layer 34 may include a material suitable for holding the layers 22 and 28 together. The intermediate layer 34 may be made of a polymer such as polyvinyl butyral (PVB). The intermediate layer 34 may be positioned on the second surface 26 and / or the third surface 30. The intermediate layer 34 may be in contact with the modified P-polarized reflective coating 36. The intermediate layer 34 may have any thickness suitable for holding the layers 22 and 28 together. The intermediate layer 34 may be a 0.76 mm thick PVB intermediate layer 34.

[0101] 5A, the first layer 22 may be non-parallel to the second layer 28. The intermediate layer 34 may be positioned between the first layer 22 and the second layer 28 and may be wedge-shaped. The wedge shape of the intermediate layer 34 is configured to reflect radiation 16 off the stack 12 at an appropriate angle to avoid ghosting (e.g., to avoid seeing multiple images based on the direction of light reflecting off the stack 12, which are focused at different points).

[0102] Referring to FIG. 5B, the intermediate layer 34 may be a uniform thickness layer in other structures of the laminate 12, and the intermediate layer 34 does not need to be wedge-shaped to avoid ghosting issues, as other design aspects of the laminate 12 counteract ghosting. Additional Coating Layer

[0103] As described above, the stack 12 may include additional layers in addition to the modified P-polarized reflective coating 36. The stack 12 may also include an antireflective coating 38. The antireflective coating 38 may be positioned on the first surface 24 and / or the fourth surface 32. The antireflective coating may comprise alternating layers of relatively high and low refractive index materials. A "high" refractive index material is any material having a higher refractive index than a "low" refractive index material. A low refractive index material may be a material having a refractive index of 1.75 or less. Non-limiting examples of such materials include silica, alumina, and mixtures or combinations thereof. A high refractive index material may be a material having a refractive index greater than 1.75. Non-limiting examples of such materials include zirconia and zinc stannate. The antireflective coating may be a multilayer coating having, for example, a first metal alloy oxide layer (first layer), a second metal oxide layer (second layer), a third metal alloy oxide layer (third layer), and a metal oxide top layer (fourth layer). In one non-limiting example, the fourth layer (upper low refractive index layer) comprises silica, alumina, or a mixture or combination thereof, the third layer (upper high refractive index layer) comprises zinc stannate, zirconia, or a mixture or combination thereof, the second layer (lower low refractive index layer) comprises silica, alumina, or a mixture or combination thereof, and the first layer (lower high refractive index layer) comprises zinc stannate, zirconia, or a mixture or combination thereof. Other suitable antireflective coatings are disclosed in column 2, line 53 to column 3, line 38 and Examples 1 to 3 of Patent Document 1. Further suitable antireflection coatings are disclosed in column 2, line 64 to column 5, line 22, column 8, lines 12-30, column 10, line 65 to column 11, line 11, column 13, line 7 to column 14, line 46, column 16, lines 35-48, column 19, line 62 to column 21, line 4, Examples 1-13, and Tables 1-8 of Patent Document 2.

[0104] The antireflective coating 38 reduces the overall visible light reflectance and / or improves the visible light transmittance of the modified P-polarized reflective coating 36. Materials having an index of refraction of about 2 are particularly useful for the antireflective coating 38. It will be appreciated that providing the antireflective coating 38 on the first surface 24 or the fourth surface 32 can modify the Brewster angle from that of the air-glass or glass-air interface to that of the air-antireflective coating material interface or the antireflective coating material-air interface. This modifies the amount of P-polarized radiation that is reflected and refracted by the inclusion of the antireflective coating 38 compared to that at the air-glass or glass-air interface.

[0105] The display system of the substrate may have only two metal functional layers or only three metal functional layers. In embodiments including only two metal functional layers, the improved P-polarized reflective coating may have the following thickness ranges for each layer: JPEG2025131769000002.jpg95167

[0106] In an embodiment including only two metallic functional layers, the improved P-polarized reflective coating may have the following thickness ranges for each layer: JPEG2025131769000003.jpg103167 Brewster's Angle

[0107] The Brewster angle is defined as the angle of incidence of P-polarized radiation at which it is completely transmitted through the surface of stack 12 it contacts. In other words, the Brewster angle is the angle of incidence at which all P-polarized radiation is refracted / transmitted so that no P-polarized radiation is reflected.

[0108] The Brewster angle at an air-glass interface (e.g., if laminate 12 is glass) is approximately 57°. The Brewster angle at a glass-air interface (e.g., if laminate 12 is glass) is approximately 33°. Thus, if the angle of incidence of radiation 16 from radiation source 14 striking fourth surface 32 of laminate 12 inside the air-glass interface is 57°, all of the P-polarized radiation will be refracted and none will be reflected from fourth surface 32 to the user's eye 20.

[0109] 6, the Brewster angle of the fourth surface 32 of the system 10 may be changed by positioning an improved P-polarization reflective coating 36 on the first surface 24 or the fourth surface 32. In FIG. 6, the improved P-polarization reflective coating 36 is positioned on the fourth surface 32. In this case, the Brewster angle of the fourth surface 32 becomes the Brewster angle of the air-improved P-polarization reflective coating 36 interface.

[0110] Continuing with reference to Figure 6, ghosting may be eliminated by positioning the modified P-polarization reflective coating 36 on the first surface 24 or the fourth surface 32 by adjusting the angle at which radiation 16 strikes the modified P-polarization reflective coating 36. As shown in Figure 6, an example will be described that includes the modified P-polarization reflective coating 36 positioned on the fourth surface 32. Radiation 16 strikes the modified P-polarization reflective coating 36 at a coating incidence angle θ c The coating incident angle θ c is the incident angle θ with respect to the first surface 24 b may be chosen to be the Brewster angle of the glass-air interface. In other words, the coating incidence angle θ c is the incident angle θ bmay be selected to be 33°. In this case, P-polarized radiation will reflect from the modified P-polarizing reflective coating 36 at the fourth surface 32 to the user's eye 20, but will not reflect from the first surface 24 to the user's eye 20 because all P-polarized radiation will be refracted at the Brewster's angle. If a polarizing filter 18 is used to filter out substantially all S-polarized radiation before it reaches the stack 12, only P-polarized radiation that is reflected from the modified P-polarizing reflective coating 36 at the fourth surface 32 will reach the user's eye 20 (as shown in FIG. 6), thereby reducing or eliminating ghosting. It will be appreciated that the modified P-polarizing reflective coating 36 may be positioned on the first surface 24, and radiation 16 may be directed toward the stack 12, such that radiation 16 contacts the fourth surface 32 at the Brewster's angle (57°) of the air-glass interface and contacts the first surface 24 at an angle other than the Brewster's angle of the glass-modified P-polarizing reflective coating 36 interface. Test Configuration

[0111] 7 , a test fixture 86 is shown in which radiation 16 from a radiation source 14 contacts the stack 12 at an angle of 60° relative to the normal to the stack 12. In the test fixture 86, the radiation source 14 is positioned so that the radiation 16 emitted therefrom contacts the stack 12 at an angle of incidence of 60° relative to the normal to the stack 12. Properties of the stack 12 and the reflected radiation 16 (reference stack values) may be measured from the test fixture 86.

[0112] Using test fixture 86, laminate 12 including first layer 22, second layer 28, intermediate layer 34, and modified P-polarized reflective coating 36 may exhibit a luminous transmittance (LTA) of at least 70% using Standard Illuminant A, measured according to automotive industry standards. Using test fixture 86, laminate 12 including first layer 22, second layer 28, intermediate layer 34, and modified P-polarized reflective coating 36 may exhibit a reflectance of P-polarized radiation of at least 10% using a D65 illuminant and a 10° detector. Using test fixture 86, laminate 12 including first layer 22, second layer 28, intermediate layer 34, and modified P-polarized reflective coating 36 may have a total reflectance of up to 60%, for example, up to 55% or up to 52%. example

[0113] The following examples are presented to demonstrate the general principles of the present invention, and the invention should not be understood as being limited to the specific examples shown.

[0114] The following examples demonstrate the improved P-polarized reflective coating of the present invention, along with several comparative examples. The examples and comparative examples are computer-modeled samples that can be reproduced using commercially available software, such as OPTICS (v.6.0) and WINDOW (v7.3.4.0) software, available from Lawrence Berkeley National Laboratory, or WVASE software, available from J.A. Woollam. The improved P-polarized reflective coating was modeled, and values ​​were calculated with the coating applied to the surfaces of the laminate. The laminate was modeled to include two layers of 2 mm clear glass with a 0.76 mm polyvinyl butyral (PVB) interlayer. The coating was applied over at least a portion of the third surface of the laminate, as described above.

[0115] Table 1 shows the thicknesses (in Angstroms) of the various layers in the modeled coating. Table 1 does not show the thicknesses of the sacrificial metal layers that were modeled directly on top of the corresponding corner metal functional layers. The thickness of each sacrificial metal layer ranged from 10 to 50 Angstroms, although any suitable thickness could be selected.

[0116] [Table 1]

[0117] Comparative Example 1 is an uncoated laminate. Comparative Examples 2 and 3 are commercially available coatings. Examples 1-7 are triple metal functional layer modified P-polarized reflective coatings of the present invention applied to laminates and optimized for improved P-polarized radiation reflectivity. Examples 8-13 are dual metal functional layer modified P-polarized reflective coatings of the present invention applied to laminates and optimized for improved P-polarized radiation reflectivity.

[0118] According to Table 1, for the triple metal functional layer enhanced P-polarized reflective coating, the base layer was deposited directly on the substrate and included a first film deposited directly on the substrate and a second film deposited directly on the first film. The first film included a zinc stannate (Zn2SnO4) layer. The second film included a zinc oxide (containing up to 10 wt.% tin oxide) layer. The first metal functional layer was a metallic silver layer deposited directly on the base layer. The first sacrificial metal layer was a titanium (TiO x) layer. As described above, the sacrificial metal layer was deposited as metallic titanium, and then all or part of the layer was oxidized in a subsequent processing step. The first phase adjustment layer was deposited directly on the first sacrificial metal layer and included a first film, a second film, and a third film. The first film was deposited directly on the first sacrificial metal layer and included a zinc oxide layer (containing up to 10 wt.% tin oxide). The second film was deposited directly on the first film and included a zinc stannate layer. The third film was deposited directly on the second film and included a zinc oxide layer (containing up to 10 wt.% tin oxide). The second metal functional layer was a metallic silver layer deposited directly on the first phase adjustment layer. The second sacrificial metal layer was deposited directly on the second metal functional layer. x ) layer (similar to the first sacrificial metal layer). The second phase adjustment layer was deposited directly on the second sacrificial metal layer and included a first film, a second film, and a third film. The first film was deposited directly on the second sacrificial metal layer and included a zinc oxide layer (containing up to 10 wt.% tin oxide). The second film was deposited directly on the first film and included a zinc stannate layer. The third film was deposited directly on the second film and included a zinc oxide layer (containing up to 10 wt.% tin oxide). The third metal functional layer was a metallic silver layer deposited directly on the second phase adjustment layer. The third sacrificial metal layer was deposited directly on the third metal functional layer and included a titanium (TiO x ) layer (similar to the first and second sacrificial metal layers). The topcoat layer was deposited directly on the third sacrificial metal layer and included a first film and a second film. The first film was deposited directly on the third sacrificial metal layer and included a zinc oxide layer (containing up to 10 wt.% tin oxide). The second film was deposited directly on the first film and included a zinc stannate layer. The overcoat was deposited directly on the topcoat layer and included a silica-alumina combination coating with 85% SiO2 and 15% Al2O3.

[0119] According to Table 1, for the dual metal functional layer modified P-polarized reflective coating, the base layer was deposited directly on the substrate and included a first film deposited directly on the substrate and a second film deposited directly on the first film. The first film included a zinc stannate (Zn2SnO4) layer. The second film included a zinc oxide (containing up to 10 wt.% tin oxide) layer. The first metal functional layer was a metallic silver layer deposited directly on the base layer. The first sacrificial metal layer was a titanium (TiO x ) layer. As described above, the sacrificial metal layer was deposited as metallic titanium, and then all or part of the layer was oxidized in a subsequent processing step. The first phase adjustment layer was deposited directly on the first sacrificial metal layer and included a first film, a second film, and a third film. The first film was deposited directly on the first sacrificial metal layer and included a zinc oxide layer (containing up to 10 wt.% tin oxide). The second film was deposited directly on the first film and included a zinc stannate layer. The third film was deposited directly on the second film and included a zinc oxide layer (containing up to 10 wt.% tin oxide). The second metal functional layer was a metallic silver layer deposited directly on the first phase adjustment layer. The second sacrificial metal layer was deposited directly on the second metal functional layer. x ) layer (similar to the first sacrificial metal layer). The topcoat layer was deposited directly on the second sacrificial metal layer and included a first film and a second film. The first film was deposited directly on the second sacrificial metal layer and included a zinc oxide layer (containing up to 10 wt.% tin oxide). The second film was deposited directly on the first film and included a zinc stannate layer. The overcoat was deposited directly on the topcoat layer and included a silica-alumina combination coating with 85% SiO2 and 15% Al2O3.

[0120] Table 2 shows the results of calculations of relevant properties that can be reproduced using the software mentioned above.

[0121] In Table 2, "P-Rf60-Y" refers to the reflectance of P-polarized radiation from the film side (outside) using a D65 illuminant and a 10° detector according to the CIE 1964 10° Supplementary Standard Observer. "P-Rg60-Y" refers to the reflectance of P-polarized radiation from the glass side (inside) using a D65 illuminant and a 10° detector according to the CIE 1964 10° Supplementary Standard Observer. "LTA" refers to the luminous transmittance (LTA) using Standard Illuminant A. "RfL*," "Rfa*," and "Rfa*" are the reflectance from the film side for the L*, a*, and b* lightness values. L*, a*, and b* are based on the 1976 CIELAB color system as specified by the International Commission on Illumination. The L*, a*, and b* values ​​indicate color center point values. "Tsol" refers to the solar transmittance of the laminate. "RfSol" refers to the solar reflectance of the laminate from the film side.

[0122] [Table 2]

[0123] The invented laminate exhibits improved reflectivity of P-polarized radiation such that the reflectivity of P-polarized radiation is at least 10% while maintaining an LTA of at least 70%.

[0124] The invention is further described in the following numbered sections.

[0125] Item 1: A laminate having improved reflectivity of P-polarized radiation, comprising: a first layer having a first side that comprises an outer surface of the laminate and a second side opposite the first side; a second layer having a third side adjacent the second side and a fourth side that opposes the third side and comprises an inner surface of the laminate; an intermediate layer positioned between the first layer and the second layer; and an improved P-polarized reflective coating positioned on at least a portion of at least one of the sides of the first layer and / or the second layer, wherein the laminate exhibits a luminous transmittance (LTA) of at least 70% using Standard Illuminant A and a reflectance of P-polarized radiation of at least 10% when contacted with radiation from a radiation source comprising P-polarized radiation at an angle of 60° relative to the normal to the laminate.

[0126] Item 2: The stack of item 1, wherein the improved P-polarized reflective coating comprises multiple layers.

[0127] Item 3: The laminate of items 1 or 2, wherein an improved P-polarized reflective coating is positioned on at least a portion of the second surface or the third surface.

[0128] Item 4: A stack described in items 2 or 3, wherein the improved P-polarized reflective coating comprises a base layer positioned on at least a portion of one of the surfaces, a first metal functional layer positioned on at least a portion of the base layer, an optional first sacrificial metal layer positioned on at least a portion of the first metal functional layer, a first phase adjustment layer positioned on at least a portion of the first sacrificial metal layer, a second metal functional layer positioned on at least a portion of the first phase adjustment layer, a second sacrificial metal layer positioned on at least a portion of the second metal functional layer, a topcoat layer positioned on at least a portion of the second sacrificial metal layer, and an overcoat positioned on at least a portion of the topcoat layer.

[0129] Item 5: The stack described in item 4, wherein the improved P-polarized reflective coating further comprises a second phase adjustment layer positioned on at least a portion of the second sacrificial metal layer, a third metal functional layer positioned on at least a portion of the second phase adjustment layer, a third sacrificial metal layer positioned on at least a portion of the third metal functional layer, a topcoat layer positioned on at least a portion of the third sacrificial metal layer, and an overcoat positioned on at least a portion of the topcoat layer.

[0130] Item 6: A stack described in item 4 or 5, wherein the base layer comprises a first film comprising a metal alloy oxide film and a second film of the base layer positioned on the first film of the base layer and comprising an oxide mixture film.

[0131] Clause 7: The laminate of clause 6, wherein the first film of the base layer comprises a zinc oxide / tin alloy, preferably zinc stannate.

[0132] Clause 8: The stack of clause 6 or clause 7, wherein the second film of the base layer comprises a metal oxide film, preferably zinc oxide.

[0133] Item 9: A stack described in any one of items 4 to 8, wherein the first phase adjustment layer and / or the second phase adjustment layer comprises a first film comprising a metal oxide film, a second film positioned on the first film of the first phase adjustment layer and / or the second phase adjustment layer, the second film of the first phase adjustment layer and / or the second phase adjustment layer comprising a metal alloy oxide film, and a third film positioned on the second film of the first phase adjustment layer and / or the second phase adjustment layer, the third film of the first phase adjustment layer and / or the second phase adjustment layer comprising a metal oxide film.

[0134] Item 10: A stack as described in item 9, wherein the first film of the first phase adjustment layer and / or the second phase adjustment layer and / or the third film of the first phase adjustment layer and / or the second phase adjustment layer comprises a metal oxide film, preferably zinc oxide.

[0135] Clause 11: A stack according to clause 9 or clause 10, wherein the second film of the first phase adjustment layer and / or the second phase adjustment layer comprises a zinc oxide / tin alloy, preferably zinc stannate.

[0136] Item 12: A laminate according to any one of items 4 to 11, wherein the first, second and / or third metal functional layer comprises at least one noble or semi-noble metal, in particular selected from silver, gold, platinum, palladium, osmium, iridium, rhodium, ruthenium, copper, mercury, rhenium, aluminum and combinations thereof, more preferably metallic silver.

[0137] Item 13: The laminate of any one of items 4 to 12, wherein the first metal functional layer, the second metal functional layer and / or the third metal functional layer comprises metallic silver.

[0138] Item 14: The stack of any one of items 4 to 13, wherein the first sacrificial metal layer, the second sacrificial metal layer and / or the third sacrificial metal layer comprises at least one of titanium, niobium, tungsten, nickel, chromium, iron, tantalum, zirconium, aluminum, silicon, indium, tin, zinc, molybdenum, hafnium, bismuth, vanadium, manganese and combinations thereof, preferably titanium.

[0139] Item 15: A stack described in any one of items 4 to 14, wherein the first sacrificial metal layer, the second sacrificial metal layer and / or the third sacrificial metal layer have a thickness in the range of 10 to 50 angstroms, preferably 20 to 40 angstroms, more preferably 25 to 35 angstroms.

[0140] Item 16: A laminate described in any one of items 4 to 15, wherein the top coat layer comprises a first film comprising a metal oxide film and a second film positioned on the first film of the top coat layer, the second film of the top coat layer comprising a metal alloy oxide film.

[0141] Item 17: The laminate of item 16, wherein the second film of the topcoat layer comprises a zinc oxide / tin alloy, preferably zinc stannate.

[0142] Item 18: The laminate of items 16 or 17, wherein the first film of the topcoat layer comprises a metal oxide film, preferably zinc oxide.

[0143] Item 19: The laminate of any one of items 4 to 18, wherein the overcoat comprises a silica-alumina combination coating.

[0144] Item 20: The laminate of any one of items 2 to 19, further comprising an anti-reflective coating positioned on at least a portion of the first surface or the fourth surface.

[0145] Item 21: The stack of item 20, wherein the antireflective coating comprises a multilayer coating having a first metal alloy oxide layer (first layer), a second metal oxide layer (second layer), a third metal alloy oxide layer (third layer), and a metal oxide top layer (fourth layer).

[0146] Item 22: The laminate of any one of items 1 to 21, wherein an improved P-polarized reflective coating is positioned on at least a portion of the first surface or the fourth surface.

[0147] Item 23: The laminate of any one of items 1 to 22, wherein the first layer and the second layer are non-parallel to each other.

[0148] Item 24: The laminate of any one of items 1 to 23, wherein the intermediate layer comprises a wedge-shaped intermediate layer.

[0149] Item 25: The laminate of any one of items 1 to 24, wherein the intermediate layer comprises a coating layer of uniform thickness.

[0150] Item 26: The laminate of any one of items 1 to 25, wherein the intermediate layer comprises polyvinyl butyral (PVB).

[0151] Item 27: A laminate according to any one of items 1 to 26, wherein the laminate exhibits a total reflectance of up to 60%, preferably up to 55%, more preferably up to 52%, when contacted with radiation from a radiation source at an angle of 60° relative to the normal to the laminate.

[0152] Item 28: The laminate according to any one of items 1 to 27, wherein the laminate comprises a laminate for an automobile.

[0153] Clause 29: A display system for projecting an image, comprising: a laminate having improved reflectivity of P-polarized radiation, the laminate comprising: a first layer having a first side comprising an outer surface of the laminate and a second side opposite the first side; a second layer having a third side adjacent to the second side and a fourth side opposite the third side and comprising an inner surface of the laminate; an intermediate layer positioned between the first layer and the second layer; and an improved P-polarized reflective coating positioned on at least a portion of at least one of the sides of the first layer and / or the second layer, wherein the laminate exhibits a luminous transmittance (LTA) of at least 70% using Standard Illuminant A and a reflectance of P-polarized radiation of at least 10% when contacted with radiation from a radiation source comprising P-polarized radiation at an angle of 60° relative to the normal to the laminate; and a radiation source directed at the laminate, the radiation source emitting radiation comprising P-polarized radiation.

[0154] Clause 30: The system of clause 29, further comprising a polarizing filter positioned between the light source and the stack and configured to pass at least a portion of the P-polarized radiation.

[0155] Clause 31: The system of clause 30, wherein the polarizing filter filters at least a portion of the S-polarized radiation emitted from the radiation source.

[0156] Clause 32: The system of clause 31, wherein the polarizing filter filters substantially all of the S-polarized radiation emitted from the radiation source.

[0157] Clause 33: A system described in any one of clauses 29 to 32, wherein when the radiation source emits radiation directed at the stack, an image is projected onto an area inside the stack.

[0158] Clause 34: The system of clause 33, wherein the image is at least one of a static image or a dynamic image.

[0159] Clause 35: The system of clause 33 or clause 34, wherein the image comprises color.

[0160] Clause 36: The system of any one of clauses 29 to 35, wherein the image comprises an image in a head-up display.

[0161] Item 37: The system of any one of items 29 to 36, wherein the laminate comprises an automotive laminate.

[0162] Clause 38: A system described in any one of clauses 29 to 37, wherein an improved P-polarized reflective coating is positioned on at least a portion of the second surface or the third surface.

[0163] Clause 39: The system of clause 38, wherein an improved P-polarized reflective coating is positioned on at least a portion of the first surface or the fourth surface.

[0164] Clause 40: The system of clause 39, wherein a modified P-polarized reflective coating is positioned on at least a portion of the fourth surface such that radiation contacts the first surface at an angle approximately equal to the Brewster angle of the first surface-air interface, and a radiation source directed at the stack is positioned at an angle relative to the stack; or wherein a modified P-polarized reflective coating is positioned on at least a portion of the first surface such that radiation contacts the fourth surface at an angle approximately equal to the Brewster angle of the air-fourth surface interface, and a radiation source directed at the stack is positioned at an angle relative to the stack.

[0165] Clause 41: A system described in any one of clauses 29 to 40, wherein the improved P-polarized reflective coating comprises a base layer positioned on at least a portion of a surface, a first metal functional layer positioned on at least a portion of the base layer, an optional first sacrificial metal layer positioned on at least a portion of the first metal functional layer, a first phase adjustment layer positioned on at least a portion of the first sacrificial metal layer, a second metal functional layer positioned on at least a portion of the first phase adjustment layer, a second sacrificial metal layer positioned on at least a portion of the second metal functional layer, a topcoat layer positioned on at least a portion of the second sacrificial metal layer, and an overcoat positioned on at least a portion of the topcoat layer.

[0166] Clause 42: The system described in clause 41, wherein the improved P-polarized reflective coating further comprises a second phase adjustment layer positioned on at least a portion of the second sacrificial metal layer, a third metal functional layer positioned on at least a portion of the second phase adjustment layer, a third sacrificial metal layer positioned on at least a portion of the third metal functional layer, a topcoat layer positioned on at least a portion of the third sacrificial metal layer, and an overcoat positioned on at least a portion of the topcoat layer.

[0167] Clause 43: The system described in clause 41 or clause 42, wherein the base layer comprises a first film comprising a metal alloy oxide film and a second film of the base layer positioned on the first film of the base layer and comprising an oxide mixed film.

[0168] Clause 44: The system of clause 43, wherein the first film of the base layer comprises a zinc oxide / tin alloy, preferably zinc stannate.

[0169] Clause 45: The laminate of clause 43 or 44, wherein the second film of the base layer comprises a metal oxide film, preferably zinc oxide.

[0170] Clause 46: A system described in any one of clauses 41 to 45, wherein the first phase adjustment layer and / or the second phase adjustment layer comprises a first film comprising a metal oxide film, a second film positioned on the first film of the first phase adjustment layer and / or the second phase adjustment layer, the second film of the first phase adjustment layer and / or the second phase adjustment layer comprising a metal alloy oxide film, and a third film positioned on the second film of the first phase adjustment layer and / or the second phase adjustment layer, the third film of the first phase adjustment layer and / or the second phase adjustment layer comprising a metal oxide film.

[0171] Clause 47: The system described in clause 46, wherein the first film of the first phase adjustment layer and / or the second phase adjustment layer and / or the third film of the first phase adjustment layer and / or the second phase adjustment layer comprises a metal oxide film, preferably zinc oxide.

[0172] Clause 48: The system of clause 46 or 47, wherein the second film of the first phase adjustment layer and / or the second phase adjustment layer comprises a zinc oxide / tin alloy, preferably zinc stannate.

[0173] Clause 49: The system of any one of clauses 41 to 48, wherein the first metal functional layer, the second metal functional layer, and / or the third metal functional layer comprises at least one noble or semi-noble metal, in particular selected from silver, gold, platinum, palladium, osmium, iridium, rhodium, ruthenium, copper, mercury, rhenium, aluminum, and combinations thereof, more preferably metallic silver.

[0174] Clause 50: The system of any one of clauses 41 to 49, wherein the first metal functional layer, the second metal functional layer and / or the third metal functional layer comprises metallic silver.

[0175] Clause 51: The system of any one of clauses 41 to 50, wherein the first sacrificial metal layer, the second sacrificial metal layer and / or the third sacrificial metal layer comprises at least one of titanium, niobium, tungsten, nickel, chromium, iron, tantalum, zirconium, aluminum, silicon, indium, tin, zinc, molybdenum, hafnium, bismuth, vanadium, manganese and combinations thereof, preferably titanium.

[0176] Item 52: A system described in any one of items 41 to 51, wherein the first sacrificial metal layer, the second sacrificial metal layer and / or the third sacrificial metal layer have a thickness in the range of 10 to 50 angstroms, preferably 20 to 40 angstroms, more preferably 25 to 35 angstroms.

[0177] Item 53: A system described in any one of items 41 to 52, wherein the topcoat layer comprises a first film comprising a metal oxide film and a second film positioned on the first film of the topcoat layer, the second film of the topcoat layer comprising a metal alloy oxide film.

[0178] Item 54: The system of item 53, wherein the second film of the topcoat layer comprises a zinc oxide / tin alloy, preferably zinc stannate.

[0179] Item 55: The system of item 53 or 54, wherein the first film of the topcoat layer comprises a metal oxide film, preferably zinc oxide.

[0180] Item 56: A system described in any one of items 41 to 55, wherein the overcoat comprises a silica-alumina combination coating.

[0181] Item 57: The system described in any one of items 29 to 56, further comprising an anti-reflective coating positioned on at least a portion of the first surface or the fourth surface.

[0182] Item 58: The system described in Item 57, wherein the antireflective coating comprises a multi-layer coating having a first metal alloy oxide layer (first layer), a second metal oxide layer (second layer), a third metal alloy oxide layer (third layer), and a metal oxide top layer (fourth layer).

[0183] Clause 59: A system described in any one of clauses 29 to 58, wherein an improved P-polarized reflective coating is positioned on at least a portion of the first surface or the fourth surface.

[0184] Item 60: A system described in any one of items 29 to 59, wherein the first layer and the second layer are non-parallel to each other.

[0185] Clause 61: The system of any one of clauses 29 to 60, wherein the intermediate layer comprises a wedge-shaped intermediate layer.

[0186] Item 62: A system described in any one of items 29 to 61, wherein the intermediate layer comprises a coating layer of uniform thickness.

[0187] Item 63: The system of any one of items 29 to 62, wherein the intermediate layer comprises polyvinyl butyral (PVB).

[0188] Item 64: A system described in any one of items 29 to 63, wherein the laminate exhibits a total reflectance of up to 60%, preferably up to 55%, more preferably up to 52%, when contacted with radiation from a radiation source at an angle of 60° relative to the normal of the laminate.

[0189] Item 65: The system of any one of items 29 to 64, wherein the laminate comprises an automotive laminate.

[0190] Clause 66: A method for projecting an image in a head-up display, comprising: providing a laminate having improved reflectivity of P-polarized radiation, the laminate comprising: a first layer having a first side comprising an outer surface of the laminate and a second side opposite the first side; a second layer having a third side adjacent the second side and a fourth side opposite the third side and comprising an inner surface of the laminate; an intermediate layer positioned between the first layer and the second layer; and an improved P-polarized reflective coating positioned on at least a portion of at least one of the sides of the first layer and / or the second layer, wherein the laminate exhibits a luminous transmittance (LTA) of at least 70% using Standard Illuminant A and a reflectance of P-polarized radiation of at least 10% when contacted with radiation from a radiation source comprising P-polarized radiation at an angle of 60° relative to a normal to the laminate; and directing a radiation source emitting radiation comprising P-polarized radiation at the laminate so that an image is projected onto a region inside the laminate.

[0191] Item 67: A laminate having improved reflectivity for P-polarized radiation, comprising: a first layer having a first surface comprising an outer surface of the laminate and a second surface opposite the first surface; a second layer having a third surface adjacent the second surface and a fourth surface opposite the third surface and comprising an inner surface of the laminate; an intermediate layer positioned between the first layer and the second layer; and an improved P-polarized reflective coating positioned on at least a portion of at least one of the surfaces of the first layer and / or the second layer, wherein the laminate exhibits a luminous transmittance (LTA) of at least 70% using Standard Illuminant A and a reflectance of P-polarized radiation of at least 5% when contacted with radiation from a radiation source comprising P-polarized radiation at an angle of 60° to the normal to the laminate.

[0192] Clause 68: A laminate having improved reflectivity of P-polarized radiation, comprising: a first layer having a first surface comprising an outer surface of the laminate and a second surface opposite the first surface; a second layer having a third surface adjacent the second surface and a fourth surface opposite the third surface and comprising an inner surface of the laminate; an intermediate layer positioned between the first layer and the second layer; and an improved P-polarized reflective coating positioned on at least a portion of at least one of the surfaces of the first layer and / or the second layer, wherein the laminate exhibits a luminous transmittance (LTA) of at least 70% using Standard Illuminant A and a reflectance of P-polarized radiation of at least 5%, when contacted with radiation from a radiation source comprising P-polarized radiation at an angle of 60° to the normal to the laminate, and has an Rfa* in the range of -2 to 2 and an Rfb* in the range of -2 to 2.

[0193] Item 69: A laminate having improved reflectivity of P-polarized radiation, comprising: a first layer having a first surface comprising an outer surface of the laminate and a second surface opposite the first surface; a second layer having a third surface adjacent the second surface and a fourth surface opposite the third surface and comprising an inner surface of the laminate; an intermediate layer positioned between the first layer and the second layer; and an improved P-polarized reflective coating positioned on at least a portion of at least one of the surfaces of the first layer and / or the second layer, wherein the laminate exhibits a luminous transmittance (LTA) of at least 70% using Standard Illuminant A and a reflectance of P-polarized radiation of at least 5% when contacted with radiation from a radiation source comprising P-polarized radiation at an angle of 60° to the normal to the laminate.

[0194] Clause 70: A laminate having improved reflectivity of P-polarized radiation, comprising: a first layer having a first surface comprising an outer surface of the laminate and a second surface opposite the first surface; a second layer having a third surface adjacent the second surface and a fourth surface opposite the third surface and comprising an inner surface of the laminate; an intermediate layer positioned between the first layer and the second layer; and an improved P-polarized reflective coating positioned on at least a portion of at least one of the surfaces of the first layer and / or the second layer, wherein the laminate exhibits a luminous transmittance (LTA) of at least 70% using Standard Illuminant A and a reflectance of P-polarized radiation of at least 5% when contacted with radiation from a radiation source comprising P-polarized radiation at an angle of 60° to the normal to the laminate, and has an Rfb* in the range of -2 to 2.

[0195] Item 71: A laminate having improved reflectivity for P-polarized radiation, comprising: a first layer having a first surface comprising an outer surface of the laminate and a second surface opposite the first surface; a second layer having a third surface adjacent the second surface and a fourth surface opposite the third surface and comprising an inner surface of the laminate; an intermediate layer positioned between the first layer and the second layer; and an improved P-polarized reflective coating positioned on at least a portion of at least one of the surfaces of the first layer and / or the second layer, wherein the laminate exhibits a luminous transmittance (LTA) of at least 70% using Standard Illuminant A and a reflectance of P-polarized radiation of at least 5%, and has an external reflectance of 15% or less, when contacted with radiation from a radiation source comprising P-polarized radiation at an angle of 60° to the normal to the laminate.

[0196] While the present invention has been described in detail for purposes of illustration based on what are presently considered to be the most practical and preferred embodiments, it is to be understood that such details are for this purpose only and that the invention is not limited to the disclosed embodiments, but is intended to cover modifications and equivalent arrangements that do not depart from the spirit and scope of the appended claims. For example, it will be understood that the present invention contemplates, to the extent possible, that one or more features of any embodiment can be combined with one or more features of any other embodiment.

Claims

1. 1. A display system for projecting an image, comprising:

1. A laminate having improved reflectivity of P-polarized radiation, comprising: a first layer having a first surface comprising an outer surface of the laminate and a second surface opposite the first surface; a second layer having a third surface adjacent the second surface and a fourth surface opposite the third surface and comprising an inner surface of the laminate; an intermediate layer positioned between the first layer and the second layer; and an improved P-polarized reflective coating positioned on at least a portion of at least one of the surfaces of the first layer and / or the second layer, comprising: a base layer positioned on at least a portion of one of said surfaces; a first metal functional layer positioned on at least a portion of the base layer; a first phase adjustment layer positioned on at least a portion of the first metal functional layer; a second metal functional layer positioned on at least a portion of the first phase adjustment layer; a topcoat layer positioned over at least a portion of the second metal functional layer; and an improved P-polarized reflective coating comprising an overcoat positioned over at least a portion of the topcoat layer; a laminate that exhibits a luminous transmittance (LTA) of at least 70% using Standard Illuminant A and a reflectance of at least 10% of P-polarized radiation when contacted with radiation from a radiation source comprising P-polarized radiation at an angle of 60° relative to the normal to the laminate; a radiation source directed at said stack, said radiation source emitting radiation comprising P-polarized radiation.

2. 10. The display system of claim 1, further comprising a polarizing filter positioned between the light source and the stack and configured to pass at least a portion of P-polarized radiation.

3. 3. The display system of claim 1, wherein the modified P-polarized reflective coating is positioned on at least a portion of the fourth surface such that radiation contacts the first surface at an angle approximately equal to the Brewster angle of the first surface-air interface, and the radiation source directed at the stack is positioned at an angle relative to the stack; or wherein the modified P-polarized reflective coating is positioned on at least a portion of the first surface such that radiation contacts the fourth surface at an angle approximately equal to the Brewster angle of the air-fourth surface interface, and the radiation source directed at the stack is positioned at an angle relative to the stack.

4. The improved P-polarized reflective coating comprises: a second phase adjustment layer positioned on at least a portion of the second sacrificial metal layer; a third metal functional layer positioned on at least a portion of the second phase adjustment layer; a topcoat layer positioned over at least a portion of the third sacrificial metal layer; and The display system of any one of claims 1 to 3, further comprising an overcoat positioned over at least a portion of the topcoat layer.

5. The first phase adjustment layer or the second phase adjustment layer, a first film comprising a metal oxide film; a second film positioned on the first film of the first phase adjustment layer and / or the second phase adjustment layer, the second film of the first phase adjustment layer and / or the second phase adjustment layer comprising a metal alloy oxide film; The system of any one of claims 1 to 4, further comprising a third film positioned on the second film of the first phase adjustment layer and / or the second phase adjustment layer, the third film of the first phase adjustment layer and / or the second phase adjustment layer comprising a metal oxide film.

6. the base layer has a thickness of 350 to 500 angstroms; the first phase adjustment layer has a thickness in the range of 675 to 1,050 angstroms; the second phase adjustment layer has a thickness in the range of 600 to 850 angstroms; the first metal functional layer has a thickness in the range of 50 to 150 angstroms; The system of any one of claims 1 to 5, wherein the second metal functional layer has a thickness in the range of 50 to 125 Angstroms.

7. The system of any one of claims 1 to 6, wherein the first metal function layer and the second metal function layer have a combined thickness in the range of 50 to 150 Angstroms.

8. The system of any one of claims 1 to 7, wherein the first metal functional layer or the second metal functional layer comprises silver, and the system does not include any other metal functional layers.

9. The system of any one of claims 1 to 8, wherein the first metal function layer, the second metal function layer, and the third metal function layer have a combined thickness in the range of 250 to 275 Angstroms.

10. The system of any one of claims 1 to 9, wherein the base layer, the first phase adjustment layer, and the top coat have a combined thickness in the range of 1600 to 1850 Angstroms.

11. 11. The system of claim 1, wherein the modified P-polarized reflective coating further comprises a first sacrificial layer positioned between the first metallic functional layer and the first phase adjustment layer.

12. The system of any one of claims 1 to 11, wherein the modified P-polarized reflective coating further comprises a second sacrificial layer positioned between the second metal functional layer and the topcoat layer.

13. The system of any one of claims 1 to 12, wherein the first phase adjustment layer and the second phase adjustment layer have a combined thickness in the range of 1450 to 1575.

14. The system of any one of claims 1 to 13, wherein the modified P-polarized reflective coating further comprises a third sacrificial metal layer positioned over at least a portion of the third metal functional layer.

15. a first sacrificial contact layer positioned on at least a portion of the first metal functional layer between the first metal functional layer and the first phase adjustment layer; The system of any one of claims 1 to 14, further comprising a second metal functional layer positioned on the second metal functional layer between the second metal functional layer and the topcoat layer.

Images