Head-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 and the full benefit of U.S. Patent Application No. 16 / 111,496, filed on August 24, 2018, and U.S. Provisional Patent Application No. 62 / 552,467, filed on August 31, 2017, the disclosures of which are incorporated herein by reference.

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

Background Art

[0003] Conventional automotive head - up displays (HUDs) use an electromagnetic radiation source within the dashboard to project light reflected off the driver's eyes onto the windshield to create 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 the electromagnetic radiation that is typically reflected at an angle to the windshield and typical non - polarized light sources such as light - emitting diodes (LEDs) found in conventional vehicles, the reflected light is primarily S - polarized light, which has a much lower component than light that is P - polarized. In an extreme case, when the angle of incidence of the electromagnetic radiation on the windshield is the Brewster angle (about 57°) of the air - glass interface, the P - polarized reflectivity is zero percent.

[0004] Light from the radiation source (mainly S-polarized light) is reflected on both the innermost surface and the outermost surface of the front glass due to the refractive index mismatch between air and glass. As a result, two reflected images are formed, one on each surface. The multiple images formed within the HUD are a phenomenon called "ghosting", and it is the goal of HUD technology to remove or minimize the presence of "ghosts". The conventional method to eliminate ghosting is to use a wedge-shaped vinyl layer between the inner and outer glass laminates of the front glass and adjust the arrangement of the two glass laminates to align with the two reflected images. This wedge-shaped vinyl increases the cost of the front glass and also increases the complexity of manufacturing the front glass.

[0005] Also, it is desirable to provide the front glass with solar control, heat generation, and / or antenna functions by applying a coating to at least one of the glass laminates. This additional coating causes a third reflectance mismatch within the front glass and a third reflected image on the HUD system that causes a third reflection, and it is difficult to cancel this out with a wedge-shaped vinyl layer.

[0006] Conventional HUD systems have other problems due to the fact that many drivers wear polarized sunglasses to reduce glare from the road or other sources during driving. Typical polarized sunglasses function by blocking S-polarized radiation. P-polarized radiation can pass through polarized sunglasses. However, as described above, in conventional HUD systems, the front glass reflects mainly S-polarized radiation to form the HUD image, and the P-polarized radiation reflected on the front glass surface is extremely small. This is especially true when the front glass is typically positioned at an angle close to the Brewster angle of the air-glass interface. Thus, a driver wearing conventional polarized sunglasses may not be able to see the HUD image formed mainly by S-polarized radiation.

[0007] Accordingly, in this technical field, it is required that one or more of these problems be reduced or eliminated by a system and / or a component. For example, it can be said that it is desirable to provide a HUD system that projects an image visible to a driver wearing polarized sunglasses and / or reduces or eliminates ghosting.

Prior Art Documents

Patent Documents

[0008]

Patent Document 1

Patent Document 2

Summary of the Invention

[0009] The present invention targets a laminate such as a windshield having improved P-polarized radiation reflectivity. The laminate includes a first layer having a first surface (No. 1 surface) that is the outer surface of the laminate and a second surface (No. 2 surface) facing the first surface, and a second layer having a third surface (No. 3 surface) facing the second surface and a fourth surface (No. 4 surface) facing the third surface and being the inner surface of the laminate. An intermediate layer is disposed between the first layer and the second layer. The improved P-polarized reflective coating of the present invention is disposed on at least a part of at least one of the first layer and / or the second layer. When the laminate contacts radiation from a radiation source having P-polarized radiation at an angle of 60° with respect to the normal of the laminate, the laminate exhibits a luminous transmittance (LTA) of at least 70% based on the value using a standard light source A and a reflectivity of at least 5%, for example at least 10%, of the P-polarized radiation.

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

[0011] The base layer may include a first film including a metal alloy oxide film and a second film of the base layer positioned on the first film of the base layer and including an oxide film. The first film of the base layer may include zinc oxide / tin alloy, particularly zinc stannate. The second film of the base layer may include a metal oxide film, 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 phase adjustment layer and / or the second phase adjustment layer may include a first film containing an oxide film, a second film positioned on the first film of the first phase adjustment layer and / or the second phase adjustment layer and containing a metal alloy oxide film, which is the second film of the first phase adjustment layer and / or the second phase adjustment layer, and a third film positioned on the second film of the first phase adjustment layer and / or the second phase adjustment layer and containing an oxide film, which is the third film of the first phase adjustment layer and / or the second phase adjustment layer. 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 may contain a metal oxide film, particularly zinc oxide. The second film of the first phase adjustment layer and / or the second phase adjustment layer may contain 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. The second phase adjustment layer may have a thickness in the range of 500 to 1,000 angstroms, preferably 600 to 850 angstroms.

[0013] The first metal functional layer, the second metal functional layer, and / or the third metal functional layer may include at least one noble metal or noble-like metal, particularly those selected from silver, gold, platinum, palladium, osmium, iridium, rhodium, ruthenium, copper, mercury, rhenium, aluminum, and combinations thereof, more preferably including 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 sacrificial metal layer, the second sacrificial metal layer, and / or the third sacrificial metal layer may include 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 including titanium. The first sacrificial metal layer, the second sacrificial metal layer, and / or the 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 top coat layer may include a first film containing an oxide film and a second film positioned on the first film of the top coat layer and containing a metal alloy oxide film. The first film of the top coat layer may include a metal oxide film, particularly zinc oxide. The second film of the top coat layer may include a zinc oxide / tin alloy, particularly zinc stannate. The top coat layer may have a thickness in the range of 300 to 400 angstroms, preferably in the range of 340 to 375 angstroms. The top coat layer may have a thickness in the range of 275 to 450 angstroms, preferably in the range of 300 to 415 angstroms.

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

[0017] The laminate 12 may further include an anti-reflection coating positioned on at least a part of the first surface or the fourth surface. The anti-reflection coating may be positioned on at least a part 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%, more preferably up to 52% when in contact with radiation from a radiation source at an angle of 60° with respect to the normal of the laminate. The laminate may be a laminate for automobiles.

[0018] Furthermore, the present invention is also directed to a display system for projecting an image, including a laminate having improved P-polarized radiation reflectivity. The laminate includes a first layer having a first surface which is the outer surface of the laminate and a second surface facing the first surface, a second layer having a third surface facing the second surface and a fourth surface facing the third surface and being the inner surface of the laminate, an intermediate layer positioned between the first layer and the second layer, and an improved P-polarized reflection coating positioned on at least a part of at least one of the surfaces of the first layer and / or the second layer. When the laminate is in contact with radiation from a radiation source having P-polarized radiation at an angle of 60° with respect to the normal of the laminate, the laminate exhibits a luminous transmittance (LTA) of at least 70% based on the value using standard light source A and a reflectivity of at least 10% of the P-polarized radiation. The display system also includes a radiation source directed towards the laminate that emits radiation having P-polarized radiation.

[0019] The system may further include a polarizing filter positioned between the radiation source and the laminate and configured to allow at least a part of the P-polarized radiation to pass through. The polarizing filter may filter at least a part 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 towards 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 within a head-up display. The laminate may be an automotive laminate such as an automotive front windshield. The improved P-polarized reflection coating may be positioned on at least a part of the second surface or the third surface. The improved P-polarized reflection coating may be positioned on at least a part of the first surface or the fourth surface. The improved P-polarized reflection coating is positioned on at least a part of the fourth surface such that the radiation contacts the first surface at an angle substantially equal to the Brewster angle of the first surface-air interface, and the radiation source directed towards the laminate may be positioned at an angle with respect to the laminate.

[0020] Furthermore, the present invention is also directed to a method of projecting an image in a head-up display, which includes providing a laminate having improved P-polarized radiation reflectivity. The laminate includes a first layer having a first surface that is the outer surface of the laminate and a second surface facing the first surface, a second layer having a third surface facing the second surface and a fourth surface facing the third surface and being the inner surface of the laminate, an intermediate layer disposed between the first layer and the second layer, and an improved P-polarized reflection coating positioned on at least a portion of at least one of the surfaces of the first layer and / or the second layer. When the laminate contacts radiation from a radiation source having P-polarized radiation at an angle of 60° with respect to the normal of the laminate, the laminate exhibits a luminous transmittance (LTA) of at least 70% with respect to the value using a standard light source A and a reflectivity of at least 10% of the P-polarized radiation. Also included is directing a radiation source emitting radiation having P-polarized radiation toward the laminate such that an image is projected onto an inner region of the laminate.

[0021] The above or other features and characteristics of the present invention, and the functions of the related elements of the method of operation and structure, as well as the combinations of components and the economics of manufacture, will become more apparent by considering the following description and the accompanying claims, which refer to all of the attached drawings forming a part of this specification, such as designating corresponding parts by reference numerals in different drawings. However, it should be clearly understood that the drawings are for illustration and description only and are not intended to limit the present 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 Description of the Drawings

[0022]

Figure 1

Figure 2A

Figure 2B

Figure 2C

Figure 2D

Figure 2E

Figure 2F

Figure 3A

Figure 3B

Figure 4A

Figure 4B

Figure 5A

Figure 5B

Figure 6

Figure 7

DETAILED DESCRIPTION OF THE INVENTION

[0023] For the following description, terms such as "end", "upper", "lower", "right", "left", "vertical", "horizontal", "upper part", "lower part", "lateral direction", "longitudinal direction" and their derivatives are to be considered in relation to the present invention as oriented within the drawings. However, it will be understood that the present invention can contemplate various alternative changes and process steps unless the contrary designation is clearly made. It will also be understood that the specific devices and processes shown in the accompanying drawings or described in the following specification are merely exemplary embodiments or aspects of the present invention. As a result, specific dimensions and other physical characteristics relating to the embodiments or aspects disclosed herein are not to be construed as limitations.

[0024] For the following detailed description, it will be understood that the present invention can contemplate various alternative changes and process steps unless the contrary designation is made. Also, except for all operating examples or unless otherwise specifically stated, all numbers used in the specification and claims are to be understood as being modified in all instances by the term "about". Accordingly, unless the contrary is stated, the numerical parameters set forth in the following specification and the appended claims are approximations that can vary depending upon the desired properties obtainable 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 be construed in light of the reported significant digits and by applying ordinary rounding techniques.

[0025] It should be understood that all numerical ranges described in this specification are such that they include all sub-ranges subsumed therein. For example, the range of "1 to 10" is such that it includes all sub-ranges (and including those) between the minimum value of 1 described and the maximum value of 10 described, that is, having a minimum value of 1 or more and a maximum value of 10 or less.

[0026] Regarding the coating layer described in this specification, the term "above" means being farther away from the substrate on which the coating layer is positioned. For example, the second layer positioned "above" the first layer means that the second layer is positioned farther away from the substrate compared to 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 layer and the second layer.

[0027] The term "film" means a region having a configuration different from others. 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, for example, two or more types of monomers or polymers.

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

[0030] The terms "metal" and "metal oxide" include silicon and silica respectively, and also include the originally recognized metals and metal oxides, even though silicon has not been conventionally regarded as a metal.

[0031] "At least" means "above". "Below" means "below".

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

[0033] The "reference laminate" is defined as a laminate having two 2-mm clear float glasses separated by a 0.76-mm layer of PVB with an improved P-polarized light reflectivity coating on the No. 3 surface. The "reference laminate value" means the reported value measured for the laminate, such as LTA or reflectivity, using the test apparatus shown in FIG. 7.

[0034] The discussion of the present invention may describe a given feature as "particularly" or "preferably" within a given range of limitations (for example, within a given range of limitations, "preferably", "more preferably", or "even more preferably"). It will be understood that the present invention is not limited to these specific or preferred limitations, but rather encompasses the entire scope of the present disclosure.

Examples

[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 an aircraft. However, the display system 10 is not limited to a head-up display in a vehicle and may be any type of display that projects an image. Non-limiting examples of displays that may be considered as "display systems" include displays for advertisements, promotions, or information. The display system 10 may project an image visible to humans (e.g., within the visible spectrum). Alternatively, the display system 10 may project an image within the non-visible region of the electromagnetic spectrum.

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

[0037] Continuing to refer to FIG. 1, the display system 10 may further include a polarizing filter 18. The polarizing filter 18 may be positioned between the radiation source 14 and the laminate 12. The polarizing filter 18 may pass at least a portion of the P-polarized and / or S-polarized radiation. The polarizing filter 18 may pass only the P-polarized radiation. The polarizing filter 18 may filter at least a portion of the S-polarized radiation so that the filtered portion cannot pass through. The polarizing filter 18 may filter substantially the entire S-polarized radiation so that substantially the entire S-polarized radiation cannot pass through. By substantially the entire in this context, it means that the polarizing filter 18 filters at least 95%, for example at least 97%, at least 99%, or 100% of the S-polarized radiation.

[0038] Continuing to refer to FIG. 1, the radiation source 14 may emit the radiation 16 so that at least a portion of the radiation 16 is reflected from the laminate 12 and directed towards the user's eye 20. A portion of the radiation that is not reflected by the laminate 12 may be refracted, absorbed, or otherwise transmitted by the laminate 12. The user may be wearing polarized sunglasses 21, and the radiation 16 directed towards the user's eye 20 may be directed towards the polarized sunglasses 21. The polarized sunglasses 21 may filter the S-polarized radiation so that at least a portion of the S-polarized radiation cannot pass through.

[0039] Continuing to refer to FIG. 1, when the radiation source 14 emits radiation 16 directed towards the laminate 12, an image is projected onto the area inside the laminate 12, and the image may be visible to the user's eyes 20. The image of the display system 10 may be static or dynamic. The image may include color, or may be a single-color image or a multi-color image. The image may be an image within the HUD. The HUD may be a HUD within an automobile or other vehicle. In this example, the laminate 12 may be a windshield or other laminate 12 within the vehicle, and the radiation source 14 may be directed towards the laminate 12 so that the driver (or other user) can view the image during vehicle operation, and the image may be displayed. Laminate

[0040] Referring to FIGS. 1 and 2A - 2F, various examples of the laminate 12 of the present invention are shown. The laminate 12 may include a first layer 22 having a first surface 24 (No. 1 surface) and an opposing second surface 26 (No. 2 surface). Further, the laminate 12 may include a second layer 28 having a third surface 30 (No. 3 surface) and an opposing fourth surface 32 (No. 4 surface). This surface numbering follows the convention 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. When the laminate 12 is the windshield of a vehicle, the first surface 24 may be the surface closest to the sun, and the fourth surface 32 may be the surface closest to the vehicle interior. Thus, the fourth surface 32 may be the surface of the laminate 12 that is positioned inside the vehicle and closest to the radiation source 14 directed towards the laminate 12.

[0041] The first layer 22 and / or the second layer 28 may be transparent or translucent to visible light radiation. "Transparent" means having a transmittance of visible light radiation from a value greater than 0% to 100%. Alternatively, the layer may be translucent. "Translucent" means diffusing visible light radiation so that an object on the opposite side of the viewer cannot be clearly visually recognized. Examples of suitable materials include, but are not limited to, plastic substrates (such as acrylic polymers like polyacrylate, 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, or copolymers of any of these monomers, or mixtures of all of these), ceramic substrates, glass substrates, or mixtures or combinations of any of the above. For example, layers 22 and 28 may include conventional soda-lime silicate glass, borosilicate glass, or lead glass. The glass may be clear glass. "Clear glass" means unstained or uncolored glass. Alternatively, the glass may be stained or otherwise colored glass. The glass may be annealed or heat-treated glass. As used herein, the term "heat-treated" means forged or at least partially forged. The glass may be of any type, such as conventional float glass, and may have any optical properties, such as any value of visible light radiation transmittance, ultraviolet radiation transmittance, infrared radiation transmittance, and / or total solar energy transmittance, and may be of any configuration. "Float glass" means glass formed by a conventional float process in which molten glass is deposited on a molten metal bath and controllably cooled to form a float glass ribbon.

[0042] The first layer and / or the second layers 22 and / or 28 may be, for example, clear float glass or dyed or colored glass. Layers 22 and 28 may be of any desired dimensions, for example, in terms of length, width, shape, or thickness. Non-limiting examples of glass that can be used in the practice of the present invention include clear glass, Starphire(R), Solargreen(R), Solextra(R), GL-20(R), GL-35(TM), Solarbronze(R), Solargray(R) glass, Pacifica(R) glass, SolarBlue(R) glass, and Optiblue(R) 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 aforementioned materials 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 each other. The first and second layers 22 and 28 may each be, for example, clear float glass or dyed or colored glass, or one of the layers 22 or 28 may be clear glass and the other layer 22 or 28 may be colored glass.

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

[0045] Continuing to refer to FIGS. 2E and 2F, laminate 12 may include additional coating layers in addition to improved P-polarization reflective coating 36. Laminate 12 may 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 be positioned on the fourth surface 32 when the improved P-polarization reflective coating 36 is positioned on the second surface 26 (FIG. 2E) or the third surface 30 (FIG. 2F). Improved P-polarization reflective coating

[0046] Referring to FIGS. 3A and 3B, the improved P-polarization reflective coating 36 may be a dual-metal functional layer improved P-polarization reflective coating 36. In the dual-metal functional layer improved P-polarization reflective coating 36, a base layer 44 may be positioned on a substrate 42 (substrate 42 which is 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 top coat layer 56 may be positioned on the second sacrificial metal layer 54. An overcoat 58 may be positioned on the top coat layer 56.

[0047] Referring to FIG. 3B, at least one of the layers of the improved P-polarization reflective coating 36 in the dual-metal functional layer improved P-polarization reflective coating 36 may include a plurality of 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 top coat 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] Referring to FIGS. 4A and 4B, the improved P-polarization reflective coating 36 is a triple-metal functional improved reflective coating 36 that includes several additional layers as compared to the dual-metal functional layer improved P-polarization reflective coating 36 of FIGS. 3A and 3B. The triple-metal functional improved P-polarization reflective coating 36 may further include a second phase adjustment layer 60 positioned on the second sacrificial metal layer 54 (as compared to the dual-metal functional layer improved P-polarization 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 top coat layer 56 and the 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 improved P-polarization reflective coating 36 in the triple metal functional layer may include a plurality of layers. The second phase adjustment layer 60 in the triple metal functional layer improved P-polarization reflective coating 36 may have a plurality of layers in addition to those described for the double metal functional layer improved P-polarization 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 top coat layer 56 of the plurality of layers described above, the first film 76 may be positioned on the third sacrificial metal layer 64.

[0050] Based on this disclosure, it will be understood that further repeating coating portions are within the scope of the present invention. For example, according to this disclosure, additional phase adjustment layers, metal functional layers, and / or sacrificial metal layers may be added (e.g., to form an improved P-polarization reflective coating 36 with a quadruple or quintuple metal functional layer, etc.).

[0051] The improved P-polarization reflective coating 36 may be a low-emissivity conductive coating that transmits the coating for visible wavelength energy but reflects longer wavelength solar infrared energy. "Low emissivity" means an emissivity of less than 0.4, for example less than 0.3, for example less than 0.2, for example less than 0.1, for example 0.05 or less.

[0052] When the improved P-polarization reflective coating 36 is applied to the substrate 42, the substrate 42 may be made an intermediate color such that the reflectance of lightness a* and / or b* is between -2 and 2 according to the 1976 CIELAB color system defined by the International Commission on Illumination. The substrate 42 may have a low external reflectance such that the reflectance is 30% or less, for example 15% or less, when viewed from an angle perpendicular to the substrate 42.

[0053] The improved P-polarization 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 and vacuum sputtering (such as magnetron sputter deposition (MSVD)). Other coating methods, such as sol-gel deposition, can also be used, although not limited thereto. In one non-limiting example, the improved P-polarization reflective coating 36 may be deposited by MSVD.

[0054] The improved P-polarization reflective coating 36 may be deposited on a part or the entire surface of the substrate 42. In some examples, the improved P-polarization reflective coating 36 may be deposited on a first broad area of the substrate 42, and then a part of the first broad area is "removed" so that the improved P-polarization reflective coating 36 is positioned on a second narrow area, which is a small area of the first broad 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, nitride, oxynitride, and / or a mixture thereof. Examples of materials suitable for the base layer 44 may include oxides, nitrides, or oxynitrides of titanium, hafnium, zirconium, niobium, zinc, bismuth, lead, indium, tin, and mixtures thereof. These may have small amounts of other materials such as manganese in bismuth oxide or tin in indium tin oxide. Also, oxides of metal alloys or metal mixtures such as zinc- and tin-containing oxides (e.g., zinc stannate), oxides of indium tin alloys, silicon nitride, aluminum silicon nitride, or aluminum nitride may be used. Also, doped metal oxides such as antimony- or indium-doped tin oxide or nickel- or boron-doped silicon oxide may 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. The base layer 44 may include a single material. Alternatively, the base layer 44 may include multiple materials and / or multiple layers.

[0056] The base layer 44 may allow for the 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 the improved P-polarization reflective coating 36. Also, the base layer 44 may provide chemical and / or mechanical protection against other layers of the improved P-polarization reflective coating 36, such as the metal functional layers 46, 52, and 62.

[0057] When a high transmittance of visible light is desired, the base layer 44 functions as an antireflection layer to prevent reflection of the metal functional layers 46, 52, and 62, reducing the overall visible light reflectance and / or improving the visible light transmittance of the improved P-polarization reflective coating 36. Materials having a refractive index of about 2 are particularly useful for preventing reflection of the metal functional layers 46, 52, and 62.

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

[0059] As described above, the base layer 44 may include metal oxides, mixtures of metal oxides, and / or metal alloy oxides. For example, the base layer 44 may include oxides of zinc and tin.

[0060] The base layer 44 may have a thickness in the range of 300 to 550 angstroms. For example, the base layer 44 may have a thickness in the 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 in the 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 an oxide mixed 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" means both a true alloy and a mixture of oxides. The zinc / tin alloy oxide may be obtained from magnetron sputtering vacuum deposition from cathodes of zinc and tin. The cathodes may contain zinc and tin in a ratio of 5 wt.% to 95 wt.% of zinc and 95 wt.% to 5 wt.% of tin, for example 10 wt.% to 90 wt.% of zinc and 90 wt.% to 10 wt.% of tin. However, other ratios of zinc to tin can also be used. An exemplary metal alloy oxide for the first film 42 is Zn X Sn 1-X O 2-X (which may be written as formula 1). For example, "x" may be greater than 0 and may be any fraction or decimal between greater than 0 and less than 1. The stoichiometric form of formula 1 is "Zn2SnO4", which is generally called zinc stannate. The zinc stannate layer may be sputter-deposited from a cathode having 52 wt.% of zinc and 48 wt.% of tin in the presence of oxygen. For example, the first film 66 may contain 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 so as to improve the sputtering characteristics of the cathode. For example, the tin cathode may contain a small amount (for example, up to 10 wt.%, for example, up to 5 wt.%) of tin so as to improve sputtering. Thus, the resulting zinc oxide film may contain a small proportion of tin oxide, for example, up to 10 wt.% of tin oxide, for example, up to 5 wt.% of tin oxide. A coating layer deposited from a zinc cathode having up to 10 wt.% of tin is referred to herein as a "zinc oxide film" even when a small amount (for example, up to 10 wt.%) of tin oxide is present. The tin in the cathode is believed to mainly form tin oxide in the second zinc oxide film 68. 2. Metal 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 a layer without breaks or separations, such as a homogeneous layer.

[0065] The metal functional layers 46, 52, and 62 provide reflectivity of electromagnetic radiation in at least a part of the infrared radiation region of the electromagnetic spectrum, such as within the solar infrared radiation region and / or the thermal infrared radiation region of the electromagnetic spectrum.

[0066] Examples of materials useful for the metal functional layers 46, 52, and 62 include noble metals 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 metal functional layers 46, 52, and 62 may include metallic silver.

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

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

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

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

[0071] The third metal functional layer 62 may include any of the materials described above with respect to the first or second metal functional layer 46 or 52. For example, the third metal functional layer 70 may include silver. The third metal functional layer 70 may be a continuous layer positioned on the second phase adjustment layer 60.

[0072] For example, the third metal functional layer 62 may be a continuous layer having a thickness within the range of 50 to 200 angstroms, 75 to 150 angstroms, or 60 to 140.

[0073] This metal functional layer 46, the second metal functional layer 52, and any third metal functional layer 62 have a combined thickness. The combined thickness may be within the range of 100 to 350 angstroms, 150 to 300 angstroms, or 175 to 275 angstroms. In an embodiment including only the first and second metal functional layers 46 and 52, the combined thickness may be within the range of 150 to 250 angstroms, 175 to 225 angstroms, 175 to 215 angstroms, or 178 - 211 angstroms. For an embodiment including the first, second, and third metal functional layers 46, 52, and 62, the combined thickness may be within the range of 225 to 325 angstroms, 240 to 300 angstroms, 250 to 280 angstroms, or 253 to 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, 62. The sacrificial metal layers 48, 54, and 64 may protect the corresponding metal functional layers 46, 52, and 62 during coating processes such as thermal annealing and / or subsequent processing. 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 and / or thermal annealing such as the deposition of the upper phase adjustment layers 50 and 60 or the top coat layer 56. If an oxide or nitride material is used for the upper phase adjustment layers 50 and 60 or the top coat layer 56, the sacrificial metal layers 48, 54, and 64 may each contain a material that is oxophilic or nitrophilic. 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] The 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 a plurality of film layers. The first sacrificial metal layer 48 may contain any of the materials described above. For example, the first sacrificial metal layer 48 may contain titanium.

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

[0078] The 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 with respect to 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 thickness or different thicknesses within a range of 10 to 50 angstroms, for example, 20 to 40 angstroms or 25 to 35 angstroms. The thickness of the sacrificial metal layer may be selected to provide sufficient protection to the underlying functional metal layer (e.g., preferably, the sacrificial metal or the like oxidizes to protect the underlying metal functional layer during the deposition of the overlying layer). 4. Phase adjustment layer

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

[0082] The phase adjustment layers 50 and 60 may enable 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 improved P-polarization 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 improved P-polarization reflective coating 36 can be changed, and the sunlight control performance, thermal infrared insulation performance, color and / or beauty of the improved P-polarization reflective coating 36 can be changed. Also, the phase adjustment layers 50 and 60 may provide chemical and / or mechanical protection for other layers of the improved P-polarization reflective coating 36, such as the metal functional layers 46, 52 and 62.

[0083] When a high transmittance of visible light is desired, the phase adjustment layers 50 and 60 function as an antireflection layer, preventing the reflection of the metal functional layers 46, 52 and 62, reducing the overall visible light reflectivity and / or improving the visible light transmittance of the improved P-polarization reflective coating 36. Materials having a refractive index of about 2 are particularly useful for preventing the reflection of the metal functional layers 46, 52 and 62.

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

[0085] The first phase adjustment layer 50 may have a thickness within the range of 600 to 1,100 angstroms. For example, the first phase adjustment layer 50 may have a thickness within the range of 700 to 1,100 angstroms, such as within the range of 850 to 1,050 angstroms, such as within the range of 675 to 1050 angstroms or such as within the range of 689 to 1048 angstroms. For example, the first phase adjustment layer 50 may have a thickness within the range of 600 to 1,000 angstroms, such as within the range of 675 to 875 angstroms or such as within the range of 689 to 866 angstroms. For example, the first phase adjustment layer 50 may have a thickness within the range of 825 to 1100 angstroms, such as within the range of 850 to 1075 angstroms, such as within the range of 875 to 1050 angstroms, such as within the range of 879 to 1048 angstroms.

[0086] The first phase adjustment layer 50 may be a single layer or may have a structure of multiple layers. 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. For example, the first film 70 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] Any 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 as described above with respect to the first phase adjustment layer 50. For example, the second phase adjustment layer 60 has a multi-film structure. For example, the second phase adjustment layer 60 may include a first film 80, a second film 82, and a third film 84.

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

[0092] The first film 80 may include a metal oxide film such as a zinc oxide film. The second film 82 may include a metal alloy oxide material such as zinc stannate. The third film 84 may include a metal oxide film such as a zinc oxide film. 5. Top coat layer

[0093] The top coat layer 56 may include one or more materials and / or layers as described above with respect to the first or second phase adjustment layer 50 or 60.

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

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

[0096] The improved P-polarization 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 assist in protecting the underlying layer from mechanical and chemical attacks during processing. The overcoat 58 may be an oxygen barrier coating layer to prevent or reduce the passage of ambient oxygen into the underlying layer of the improved P-polarization reflectivity 36, for example, during heating or bending. The overcoat 58 may include any desired material or mixture of materials. In an 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 include 0 wt.% to 100 wt.% alumina and / or 100 wt.% to 0 wt.% silica, such as 5 wt.% to 95 wt.% alumina and 95 wt.% to 5 wt.% silica, such as 10 wt.% to 90 wt.% alumina and 90 wt.% to 10 wt.% silica, such as 15 wt.% to 90 wt.% alumina and 85 wt.% to 10 wt.% silica, such as 50 wt.% to 75 wt.% alumina and 50 wt.% to 25 wt.% silica, such as 50 wt.% to 70 wt.% alumina and 50 wt.% to 30 wt.% silica, such as 35 wt.% to 100 wt.% alumina and 65 wt.% to 0 wt.% silica, such as 70 wt.% to 90 wt.% alumina and 30 wt.% to 10 wt.% silica, such as 75 wt.% to 85 wt.% alumina and 25 wt.% to 15 wt.% silica, such as 88 wt.% alumina and 12 wt.% silica, such as 65 wt.% to 75 wt.% alumina and 35 wt.% to 25 wt.% silica, such as 70 wt.% alumina and 30 wt.% silica, such as an alumina content of less than 60 wt.% to 75 wt.% and a silica content greater than 25 wt.% to 40 wt.%, and may be a single coating layer within these ranges. The overcoat 58 may also 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, for example, to adjust the refractive index of the overcoat 58. In a non-limiting example, the refractive index of the overcoat 58 may be in the range of 1 to 3, such as 1 to 2, or for example 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 (for example, one silicon and one aluminum), or from a single cathode containing both silicon and aluminum. This silicon oxide / aluminum overcoat 58 may be written as Si x Al 1-x O 1.5+x / 2 where "x" varies from a value greater than 0 to a value less than 1.

[0098] Alternatively, the overcoat 58 may be a multi-layer coating formed by layers of separately formed metal oxide materials, such as, but not limited to, a two-layer coating formed by forming one metal oxide-containing layer (for example, a first layer containing silica and / or alumina) on top of the other metal oxide-containing layer (for example, a second layer containing silica and / or alumina). The individual layers of the multi-layer protective coating may have any desired thickness.

[0099] The overcoat 58 may have any desired thickness. In a non-limiting example, the overcoat 58 is a silicon oxide / aluminum coating (Si x Al 1-x O 1.5+x / 2 ) having a thickness in the range of 100 to 1,000 angstroms, such as 600 to 800 angstroms or for example 700 angstroms. Intermediate layer

[0100] Referring to FIGS. 5A and 5B, the laminate 12 may include an intermediate layer 34. The intermediate layer 34 may include a material suitable for holding both layers 22 and 28 together. The intermediate layer 34 may be made from 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 an improved P-polarized light reflection coating 36. The intermediate layer 34 may have any thickness suitable for holding both layers 22 and 28 together. The intermediate layer 34 may be a PVB intermediate layer 34 having a thickness of 0.76 mm.

[0101] Referring to FIG. 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 such that radiation 16 is reflected off the laminate 12 at an appropriate angle so as to avoid ghosting (e.g., to avoid multiple images being visible based on the direction of light reflected off the laminate 12 that converges at different points).

[0102] Referring to FIG. 5B, the intermediate layer 34 may be a layer of uniform thickness in other configurations of the laminate 12, and since other design aspects of the laminate 12 counter ghosting, the intermediate layer 34 need not be wedge-shaped to avoid the problem of ghosting. Additional coating layer

[0103] As described above, laminate 12 may include additional layers in addition to the improved P-polarization reflective coating 36. Laminate 12 may include an anti-reflective coating 38. The anti-reflective coating 38 may be positioned on the first surface 24 and / or the fourth surface 32. The anti-reflective coating may comprise alternating layers of a material with a relatively high refractive index and a material with a low refractive index. The material with a "high" refractive index is any material having a higher refractive index than the material with a "low" refractive index. The material with a low refractive index 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. The material with a high refractive index may be a material having a refractive index greater than 1.75. Non-limiting examples of such materials include zirconia and zinc stannate. The anti-reflective coating may be, for example, 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). 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 anti-reflective coatings are disclosed in Patent Document 1, lines 53 to 38 of the second column and Examples 1 to 3. Further suitable anti-reflective coatings are disclosed in Patent Document 2, lines 64 to 22 of the second column, lines 12 to 30 of the eighth column, lines 65 to 11 of the tenth column, lines 7 to 46 of the thirteenth column, lines 35 to 48 of the sixteenth column, lines 62 to 4 of the nineteenth column, Examples 1 to 13, and Tables 1 to 8.

[0104] The anti-reflection coating 38 reduces the overall visible light reflectance and / or improves the visible light transmittance of the improved P-polarization reflective coating 36. Materials having a refractive index of about 2 are particularly useful for the anti-reflection coating 38. By providing the anti-reflection coating 38 on the first surface 24 or the fourth surface 32, it will be understood that the Brewster angle can be changed from the Brewster angle of the air-glass interface or the glass-air interface to the Brewster angle of the air-anti-reflection coating material interface or the anti-reflection coating material-air interface. Thereby, the amount of P-polarized radiation that is reflected and refracted can be changed by including the anti-reflection coating 38 as compared to the case of the air-glass interface or the glass-air interface.

[0105] The display system of the substrate may have only two metal functional layers or only three metal functional layers. In an embodiment including only two metal functional layers, the improved P-polarization reflective coating can have the following thickness ranges for each layer. JPEG0007695286000001.jpg95167

[0106] In an embodiment including only two metal functional layers, the improved P-polarization reflective coating can have the following thickness ranges for each layer. JPEG0007695286000002.jpg103167 Brewster angle

[0107] The Brewster angle is defined as the angle of incidence of P-polarized radiation that completely transmits through the surface of the laminate 12 with which the P-polarized radiation 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 of the air - glass interface (for example, when the laminate 12 is glass) is approximately 57°. The Brewster angle of the glass - air interface (for example, when the laminate 12 is glass) is approximately 33°. Thus, when the incident angle of the radiation 16 from the radiation source 14 hitting the fourth surface 32 of the laminate 12 inside the laminate 12 having an air - glass interface is 57°, all the P - polarized radiation is refracted and nothing is reflected from the fourth surface 32 to the user's eye 20.

[0109] Referring to FIG. 6, the Brewster angle of the fourth surface 32 of the system 10 may be changed by positioning the improved P - polarized reflective coating 36 on the first surface 24 or the fourth surface 32. In FIG. 6, the improved P - polarized 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 - polarized reflective coating 36 interface.

[0110] Continuing to refer to FIG. 6, ghosting may be removed by adjusting the angle at which the radiation 16 hits the improved P - polarized reflective coating 36 and by positioning the improved P - polarized reflective coating 36 on the first surface 24 or the fourth surface 32. As shown in FIG. 6, an example including the improved P - polarized reflective coating 36 positioned on the fourth surface 32 will be described. The radiation 16 contacts the improved P - polarized reflective coating 36 at a coating incident angle θ c This coating incident angle θ c may be selected such that the incident angle θ b with respect to the first surface 24 is the Brewster angle of the glass - air interface. In other words, the coating incident angle θ c is the incident angle θ bIt may be selected to be 33°. In this case, the P-polarized radiation is reflected from the improved P-polarized reflective coating 36 to the user's eye 20 at the fourth surface 32. Since all the P-polarized radiation is refracted at the Brewster angle, it is not reflected from the first surface 24 to the user's eye 20. When the polarization filter 18 is used to filter substantially all the S-polarized radiation before it reaches the laminate 12, only the P-polarized radiation reflected from the improved P-polarized reflective coating 36 at the fourth surface 32 (as shown in FIG. 6) reaches the user's eye 20, so ghosting is reduced or eliminated. The improved P-polarized reflective coating 36 may be positioned on the first surface 24 such that the radiation 16 contacts the fourth surface 32 at the Brewster angle (57°) of the air-glass interface and contacts the first surface 24 at an angle that is not the Brewster angle of the glass-improved P-polarized reflective coating 36 interface, and it will be understood that the radiation 16 may be directed towards the laminate 12. Test configuration

[0111] Referring to FIG. 7, a test apparatus 86 is shown in which radiation 16 from a radiation source 14 contacts the laminate 12 at an angle of 60° with respect to the normal of the laminate 12. In the test apparatus 86, the radiation source 14 is positioned such that the radiation 16 emitted therefrom contacts the laminate 12 at an incident angle of 60° with respect to the normal of the laminate 12. The characteristics (reference laminate values) of the laminate 12 and the reflected radiation 16 may be measured from the test apparatus 86.

[0112] By using test apparatus 86, laminate 12, which includes the above-described first layer 22, second layer 28, intermediate layer 34, and improved P-polarization reflective coating 36, may exhibit a visual transmittance (LTA) of at least 70% using standard light source A, measured according to automotive industry standards. By using test apparatus 86, laminate 12, which includes the above-described first layer 22, second layer 28, intermediate layer 34, and improved P-polarization reflective coating 36, may exhibit a reflectance of at least 10% of P-polarized radiation using a D65 light source and a 10° detector. By using test apparatus 86, laminate 12, which includes the above-described first layer 22, second layer 28, intermediate layer 34, and improved P-polarization reflective coating 36, may have a total reflectance of up to 60%, for example up to 55% or up to 52%. Example

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

[0114] In the following examples, an improved P-polarization reflective coating according to the present invention is shown in parallel with a plurality of comparative examples. The examples and comparative examples are reproducible computer model samples using commercially available software such as OPTICS (v.6.0) software and WINDOW (v7.3.4.0) software commercially available from Lawrence Berkeley National Laboratory or WVASE software commercially available from J. A. Woollam. The improved P-polarization reflective coating was modeled and the values were calculated with the coating applied on the surface of the laminate. The laminate was modeled to include two layers of 2 mm clear glass separated by a 0.76 mm thick polyvinyl butyral (PVB) intermediate layer. The coating was applied on at least a portion of the third surface of the laminate as described above.

[0115] Table 1 shows the thicknesses of various layers in the modeled coating (in angstroms). Table 1 does not show the thickness of the sacrificial metal layer directly modeled on top of the corresponding corner metal functional layer. The thickness range of each sacrificial metal layer was 10 - 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 improved P-polarized radiation reflective coatings of the present invention, optimized to have improved P-polarized radiation reflectivity when applied to a laminate. Examples 8 - 13 are dual-metal functional layer improved P-polarized reflectivity coatings of the present invention, optimized to have improved P-polarized radiation reflectivity when applied to a laminate.

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

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

[0120] Table 2 shows the calculation results of related properties reproducible using the above software.

[0121] In Table 2, "P-Rf60-Y" means the reflectance of P-polarized radiation using a D65 light source and a 10° detector from the film side (outer side) according to the CIE1964 10° supplementary standard observer. "P-Rg60-Y" means the reflectance of P-polarized radiation using a D65 light source and a 10° detector from the glass side (inner side) according to the CIE1964 10° supplementary standard observer. "LTA" means the visual transmittance (LTA) using a standard light source A. "RfL*", "Rfa*", and "Rfa*" are the reflectances from the film side for the lightness of L*, a*, and b*. L*, a*, and b* based on the 1976 CIELAB color system are defined by the International Commission on Illumination. The values of L*, a*, and b* indicate the color center point values. "Tsol" means the solar transmittance of the laminate. "RfSol" means the solar reflectance of the laminate from the film side.

[0122]

Table 2

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

[0124] The present invention will be further described in the following numbered paragraphs.

[0125] Item 1: A laminate having improved P-polarized radiation reflectivity, comprising: a first layer having a first surface that forms the outer surface of the laminate and a second surface that faces the first surface; a second layer having a third surface adjacent to the second surface and a fourth surface that faces the third surface and forms the inner surface of the laminate; an intermediate layer positioned between the first layer and the second layer; and an improved P-polarized radiation reflecting 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% and a reflectivity of at least 10% of P-polarized radiation, as measured using a standard light source A, when in contact with radiation from a radiation source that includes P-polarized radiation at an angle of 60° with respect to the normal of the laminate.

[0126] Item 2: The laminate according to Item 1, wherein the improved P-polarized radiation reflecting coating comprises a plurality of layers.

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

[0128] Item 4: The laminate according to Item 2 or 3, wherein the improved P-polarized radiation reflecting coating comprises a base layer positioned on at least a portion of at least one 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 top coat layer positioned on at least a portion of the second sacrificial metal layer, and an overcoat positioned on at least a portion of the top coat layer.

[0129] Item 5: The improved P-polarization reflective coating further comprises a second phase adjustment layer positioned on at least a part of the second sacrificial metal layer, a third metal functional layer positioned on at least a part of the second phase adjustment layer, a third sacrificial metal layer positioned on at least a part of the third metal functional layer, a top coat layer positioned on at least a part of the third sacrificial metal layer, and an overcoat positioned on at least a part of the top coat layer; the laminate according to Item 4.

[0130] Item 6: 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; the laminate according to Item 4 or Item 5.

[0131] Item 7: The first film of the base layer comprises zinc oxide / tin alloy, preferably zinc stannate; the laminate according to Item 6.

[0132] Item 8: The second film of the base layer comprises a metal oxide film, preferably zinc oxide; the laminate according to Item 6 or Item 7.

[0133] Item 9: The first phase adjustment layer and / or the second phase adjustment layer comprises a first film comprising a metal oxide film, a second film of the first phase adjustment layer and / or the second phase adjustment layer positioned on the first film of the first phase adjustment layer and / or the second phase adjustment layer and comprising a metal alloy oxide film, and a third film of the first phase adjustment layer and / or the second phase adjustment layer positioned on the second film of the first phase adjustment layer and / or the second phase adjustment layer and comprising a metal oxide film; the laminate according to any one of Items 4 to 8.

[0134] Item 10: 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; the laminate according to Item 9.

[0135] Item 11: The laminate according to Item 9 or 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: The laminate according to any one of Items 4 to 11, wherein the first metal functional layer, the second metal functional layer, and / or the third metal functional layer is selected from at least one noble metal or noble metal-like element, in particular, silver, gold, platinum, palladium, osmium, iridium, rhodium, ruthenium, copper, mercury, rhenium, aluminum, and combinations thereof, more preferably comprising metallic silver.

[0137] Item 13: The laminate according to 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 laminate according to 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 comprising titanium.

[0139] Item 15: The laminate according to 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 has a thickness in the range of 10 to 50 angstroms, preferably 20 to 40 angstroms, more preferably 25 to 35 angstroms.

[0140] Item 16: The laminate according to 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 according to Item 16, wherein the second film of the top coat layer comprises a zinc oxide / tin alloy, preferably zinc stannate.

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

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

[0144] Item 20: The laminate according to any one of Items 2 to 19, further comprising an antireflection coating positioned on at least a part of the first surface or the fourth surface.

[0145] Item 21: The laminate according to Item 20, wherein the antireflection 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).

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

[0147] Item 23: The laminate according to 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 according to any one of Items 1 to 23, wherein the intermediate layer comprises a wedge-shaped intermediate layer.

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

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

[0151] Item 27: The laminate according to any one of Items 1 to 26, which exhibits a total reflectance of up to 60%, preferably up to 55%, more preferably up to 52% when in contact with radiation from a radiation source at an angle of 60° with respect to the normal of the laminate.

[0152] Item 28: The laminate according to any one of Items 1 to 27, which comprises a laminate for automobiles.

[0153] Item 29: A display system for projecting an image, comprising a laminate having improved P-polarized radiation reflectivity, a first layer comprising a first surface on the outer surface of the laminate and a second surface facing the first surface, a second layer comprising a third surface adjacent to the second surface and a fourth surface facing the third surface and comprising the inner surface of the laminate, an intermediate layer positioned between the first layer and the second layer, and an improved P-polarized reflection coating positioned on at least a part of at least one of the surfaces of the first layer and / or the second layer, the laminate having a visual transmittance (LTA) of at least 70% and a reflectance of at least 10% of P-polarized radiation, as measured using a standard light source A, when in contact with radiation from a radiation source comprising P-polarized radiation at an angle of 60° with respect to the normal of the laminate, and a radiation source directed towards the laminate that emits radiation comprising P-polarized radiation.

[0154] Item 30: The system according to Item 29, further comprising a polarizing filter positioned between the light source and the laminate and configured to allow at least a part of the P-polarized radiation to pass through.

[0155] Item 31: The system according to Item 30, wherein the polarizing filter filters at least a part of the S-polarized radiation emitted from the radiation source.

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

[0157] Claim 33: The system according to any one of claims 29 to 32, wherein when the radiation source emits radiation directed at the laminate, an image is projected onto an area inside the laminate.

[0158] Claim 34: The system according to claim 33, wherein the image is at least one of a still image or a moving image.

[0159] Claim 35: The system according to claim 33 or 34, wherein the image has a color.

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

[0161] Claim 37: The system according to any one of claims 29 to 36, wherein the laminate comprises a laminate for an automobile.

[0162] Claim 38: The system according to any one of claims 29 to 37, wherein the improved P-polarization reflective coating is positioned on at least a part of the second surface or the third surface.

[0163] Claim 39: The system according to claim 38, wherein the improved P-polarization reflective coating is positioned on at least a part of the first surface or the fourth surface.

[0164] Item 40: The improved P-polarization reflective coating is positioned on at least a portion of the fourth surface such that radiation contacts the first surface at an angle substantially equal to the Brewster angle of the first surface-air interface, and the radiation source directed towards the laminate is positioned at an angle with respect to the laminate, or the improved P-polarization reflective coating is positioned on at least a portion of the first surface such that radiation contacts the fourth surface at an angle substantially equal to the Brewster angle of the air-fourth surface interface, and the radiation source directed towards the laminate is positioned at an angle with respect to the laminate, the system according to Item 39.

[0165] Item 41: The improved P-polarization reflective coating includes a base layer positioned on at least a portion of at least one 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 top coat layer positioned on at least a portion of the second sacrificial metal layer, and an overcoat positioned on at least a portion of the top coat layer, the system according to any one of Items 29 to 40.

[0166] Item 42: The improved P-polarization reflective coating further includes 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 top coat layer positioned on at least a portion of the third sacrificial metal layer, and an overcoat positioned on at least a portion of the top coat layer, the system according to Item 41.

[0167] Item 43: The system according to Item 41 or 42, wherein the base layer includes a first film having a metal alloy oxide film and a second film of the base layer positioned on the first film of the base layer and having an oxide mixed film.

[0168] Item 44: The system according to Item 43, wherein the first film of the base layer includes a zinc oxide / tin alloy, preferably zinc stannate.

[0169] Item 45: The laminate according to Item 43 or 44, wherein the second film of the base layer includes a metal oxide film, preferably zinc oxide.

[0170] Item 46: The system according to any one of Items 41 to 45, wherein the first phase adjustment layer and / or the second phase adjustment layer includes a first film having a metal oxide film, a second film of the first phase adjustment layer and / or the second phase adjustment layer positioned on the first film of the first phase adjustment layer and / or the second phase adjustment layer and having a metal alloy oxide film, and a third film of the first phase adjustment layer and / or the second phase adjustment layer positioned on the second film of the first phase adjustment layer and / or the second phase adjustment layer and having a metal oxide film.

[0171] Item 47: The system according to Item 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 includes a metal oxide film, preferably zinc oxide.

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

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

[0174] Item 50: The system according to any one of Items 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] Item 51: The system according to any one of Items 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 comprising titanium.

[0176] Item 52: The system according to 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 has a thickness in the range of 10 to 50 angstroms, preferably 20 to 40 angstroms, more preferably 25 to 35 angstroms.

[0177] Item 53: The system according to any one of Items 41 to 52, 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.

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

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

[0180] Item 56: The system according to any one of Items 41 to 55, wherein the overcoat comprises a silica-alumina combination coating.

[0181] Item 57: The system according to any one of Items 29 to 56, further comprising an antireflection coating positioned on at least a part of the first surface or the fourth surface.

[0182] Item 58: The system according to Item 57, wherein the antireflection 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] Item 59: The system according to any one of Items 29 to 58, wherein an improved P-polarization reflective coating is positioned on at least a part of the first surface or the fourth surface.

[0184] Item 60: The system according to any one of Items 29 to 59, wherein the first layer and the second layer are non-parallel to each other.

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

[0186] Item 62: The system according to any one of Items 29 to 61, wherein the intermediate layer comprises a coating layer of uniform thickness.

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

[0188] Item 64: The system according to any one of Items 29 to 63, wherein when the laminate contacts the radiation from the radiation source at an angle of 60° with respect to the normal of the laminate, it exhibits a total reflectance of up to 60%, preferably up to 55%, more preferably up to 52%.

[0189] Item 65: The system according to any one of Items 29 to 64, wherein the laminate comprises a laminate for an automobile.

[0190] Item 66: A method of projecting an image in a head-up display, comprising a laminate having improved P-polarized radiation reflectivity, the laminate comprising a first layer having a first surface comprising an outer surface of the laminate and a second surface facing the first surface, a second layer having a third surface adjacent to the second surface and a fourth surface facing 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, the laminate providing a laminate that exhibits a luminous transmittance (LTA) of at least 70% and a reflectance of at least 10% of P-polarized radiation with a value using a standard light source A when the laminate contacts the radiation from a radiation source comprising P-polarized radiation at an angle of 60° with respect to the normal of the laminate, and directing a radiation source that emits radiation comprising P-polarized radiation towards the laminate such that an image is projected onto an inner region of the laminate.

[0191] Item 67: A laminate having improved P-polarized radiation reflectivity, comprising: a first layer having a first surface that is the outer surface of the laminate and a second surface that faces the first surface; a second layer having a third surface adjacent to the second surface and a fourth surface that faces the third surface and is the inner surface of the laminate; an intermediate layer positioned between the first layer and the second layer; and an improved P-polarized radiation reflective coating positioned on at least a part 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% and a reflectivity of at least 5% of P-polarized radiation, as measured using a standard light source A, when in contact with radiation from a radiation source comprising P-polarized radiation at an angle of 60° with respect to the normal of the laminate.

[0192] Item 68: A laminate having improved P-polarized radiation reflectivity, comprising: a first layer having a first surface that is the outer surface of the laminate and a second surface that faces the first surface; a second layer having a third surface adjacent to the second surface and a fourth surface that faces the third surface and is the inner surface of the laminate; an intermediate layer positioned between the first layer and the second layer; and an improved P-polarized radiation reflective coating positioned on at least a part 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% and a reflectivity of at least 5% of P-polarized radiation, as measured using a standard light source A, when in contact with radiation from a radiation source comprising P-polarized radiation at an angle of 60° with respect to the normal of the laminate, and has Rfa* within the range of -2 to 2 and Rfb* within the range of -2 to 2.

[0193] Item 69: A laminate having improved P-polarized radiation reflectivity, comprising: a first layer having a first surface that is the outer surface of the laminate and a second surface that faces the first surface; a second layer having a third surface adjacent to the second surface and a fourth surface that faces the third surface and is the inner surface of the laminate; an intermediate layer positioned between the first layer and the second layer; and an improved P-polarized radiation 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 at least 70% luminous transmittance (LTA) and at least 5% reflectivity of P-polarized radiation, with a value using standard light source A, and has an Rfa* within the range of -2 to 2 when the laminate is in contact with radiation from a radiation source having P-polarized radiation at an angle of 60° with respect to the normal of the laminate.

[0194] Item 70: A laminate having improved P-polarized radiation reflectivity, comprising: a first layer having a first surface that is the outer surface of the laminate and a second surface that faces the first surface; a second layer having a third surface adjacent to the second surface and a fourth surface that faces the third surface and is the inner surface of the laminate; an intermediate layer positioned between the first layer and the second layer; and an improved P-polarized radiation 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 at least 70% luminous transmittance (LTA) and at least 5% reflectivity of P-polarized radiation, with a value using standard light source A, and has an Rfb* within the range of -2 to 2 when the laminate is in contact with radiation from a radiation source having P-polarized radiation at an angle of 60° with respect to the normal of the laminate.

[0195] Item 71: A laminate having improved P-polarized radiation reflectivity, comprising: a first layer having a first surface that forms the outer surface of the laminate and a second surface that faces the first surface; a second layer having a third surface adjacent to the second surface and a fourth surface that faces the third surface and forms the inner surface of the laminate; an intermediate layer positioned between the first layer and the second layer; and an improved P-polarized radiation coating positioned on at least a part of at least one of the surfaces of the first layer and / or the second layer, wherein when the laminate is in contact with radiation from a radiation source comprising P-polarized radiation at an angle of 60° with respect to the normal of the laminate, the laminate exhibits a luminous transmittance (LTA) of at least 70% and a reflectivity of at least 5% of the P-polarized radiation, with an external reflectivity of 15% or less, as measured using a standard light source A.

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

Claims

1. A laminate (12) having improved P-polarized radiation reflectivity, comprising: A first layer (22) having a first surface that forms the outer surface of the laminate and a second surface that faces the first surface; A second layer (28) having a third surface adjacent to the second surface and a fourth surface that faces the third surface and forms the inner surface of the laminate; An intermediate layer (34) positioned between the first layer (22) and the second layer (28); and An improved P-polarized radiation reflective coating (36) positioned on at least a portion of at least one surface of the first layer (22) and / or the second layer (28), the improved P-polarized radiation reflective coating (36) comprising a base layer (44) positioned on at least a portion of at least one surface, the base layer (44) having a thickness in the range of 350 to 500 angstroms; A first metal functional layer (46) positioned on at least a portion of the base layer (44); A first phase adjustment layer (50) positioned on at least a portion of the first metal functional layer (46), the first phase adjustment layer (50) having a thickness in the range of 600 to 1,100 angstroms; A second metal functional layer (52) positioned on at least a portion of the first phase adjustment layer (50); A top coat layer (56) positioned on at least a portion of the second metal functional layer (52), the top coat layer (56) having a thickness in the range of 300 to 450 angstroms; and An overcoat (58) positioned on at least a portion of the top coat layer (56), the overcoat (58) having a thickness in the range of 100 to 1,000 angstroms, the improved P-polarized radiation reflective coating (36) comprising the overcoat (58); The first metal functional layer (46) and the second metal functional layer (52) have a combined thickness in the range of 175 to 225 angstroms; When the laminate (12) is in contact with radiation from a radiation source that is P-polarized radiation at an angle of 60° with respect to the normal of the laminate (12), the laminate (12) exhibits a visual transmittance (LTA) of at least 70% based on the value using the standard light source A and a reflectance of at least 10% of the P-polarized radiation using the D65 light source and a 10° detector.

2. The laminate (12) according to claim 1, wherein the improved P-polarization reflective coating (36) is positioned on at least a part of the second surface or the third surface.

3. The laminate (12) according to claim 1 or 2, wherein the overcoat (58) comprises a silica-alumina combination coating.

4. The laminate (12) according to any one of claims 1 to 3, wherein the base layer (44) comprises a first film comprising a metal alloy oxide film and a second film positioned on the first film of the base layer, and the second film of the base layer comprises an oxide mixed film.

5. The laminate (12) according to any one of claims 1 to 4, wherein the improved P-polarization reflective coating (36) further comprises a first sacrificial metal layer (48) positioned on at least a part of the first metal functional layer (46).

6. The laminate (12) according to claim 5, wherein the improved P-polarization reflective coating (36) further comprises a second sacrificial metal layer (54) positioned on at least a part of the second metal functional layer (52).

7. The improved P-polarization reflective coating (36) a second phase adjustment layer (60) positioned on at least a part of the second sacrificial metal layer (54); a third metal functional layer (62) positioned on at least a part of the second phase adjustment layer (60); and further comprises a third sacrificial metal layer (64) positioned on at least a part of the third metal functional layer (62). The top coat layer (56) is positioned on at least a part of the third sacrificial metal layer (64), and the overcoat (58) is positioned on at least a part of the top coat layer (56). Instead of the first metal functional layer (46) and the second metal functional layer (52) having a combined thickness in the range of 175 to 225 angstroms, the first metal functional layer (46), the second metal functional layer (52), and the third metal functional layer (62) have a combined thickness in the range of 175 to 275 angstroms. The laminate (12) according to claim 6.

8. The laminate (12) according to claim 7, wherein the first metal functional layer (46), the second metal functional layer (52), and / or the third metal functional layer (62) comprises metallic silver.

9. Further comprising an antireflection coating (38) positioned on at least a part of the first surface or the fourth surface, and the improved P-polarized light reflective coating (36) is positioned on a surface different from the surface on which the antireflection coating (38) is positioned. The laminate (12) according to any one of claims 1 to 8.

10. The laminate (12) according to claim 9, wherein the antireflection coating (38) comprises a multi-layer coating having a first metal alloy oxide layer, a second metal oxide layer, a third metal alloy oxide layer, and a metal oxide top layer.

11. The laminate (12) according to any one of claims 1 to 10, wherein the intermediate layer (34) comprises polyvinyl butyral (PVB).

12. The laminate (12) according to any one of claims 1 to 11, wherein when the laminate contacts radiation from the radiation source at an angle of 60° with respect to the normal of the laminate, it exhibits a total reflectance of up to 60%.

13. The laminate (12) according to any one of claims 1 to 12, wherein the laminate (12) is an automotive laminate.

14. A method of projecting an image onto a head-up display, comprising: providing a laminate (12) having improved P-polarized radiation reflectivity, comprising: a first layer (22) having a first surface comprising an outer surface of the laminate (13) and a second surface facing the first surface; a second layer (28) having a third surface adjacent to the second surface and a fourth surface facing the third surface and comprising an inner surface of the laminate (13); an intermediate layer (34) positioned between the first layer (22) and the second layer (28); and an improved P-polarized reflective coating (36) positioned on at least a portion of at least one surface of the first layer (22) and / or the second layer (28), the improved P-polarized reflective coating (36) comprising a base layer (44) positioned on at least a portion of at least one surface, the base layer (44) having a thickness in the range of 350 to 500 angstroms; a first metal functional layer (46) positioned on at least a portion of the base layer (44); a first phase adjustment layer (50) positioned on at least a portion of the first metal functional layer (46), the first phase adjustment layer (50) having a thickness in the range of 600 to 1,100 angstroms; a second metal functional layer (52) positioned on at least a portion of the first phase adjustment layer (50); a top coat layer (56) positioned on at least a portion of the second metal functional layer (52), the top coat layer (56) having a thickness in the range of 300 to 450 angstroms; and an overcoat (58) positioned on at least a portion of the top coat layer (56), the overcoat (58) having a thickness in the range of 100 to 1,000 angstroms, the improved P-polarized reflective coating (36) comprising the overcoat (58); the first metal functional layer (46) and the second metal functional layer (52) having a combined thickness in the range of 175 to 225 angstroms; When the laminate (12) is in contact with radiation from a radiation source that is P-polarized radiation at an angle of 60° with respect to the normal of the laminate (12), showing a visual transmittance (LTA) of at least 70% with respect to the value using a standard light source A and a reflectance of at least 10% of the P-polarized radiation using a D65 light source and a 10° detector; Directing the radiation source that emits radiation having P-polarized radiation toward the laminate (12) so that an image is projected onto an inner region of the laminate (12); A method comprising.

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