Systems with infrared rejection coatings

Abstract

A transparent structure may have structural layers such as an inner layer and an outer layer. The transparent structure may be curved. At least one of the inner layer and the outer layer may be coated with an infrared rejection coating. The infrared rejection coating may extend to an edge of the transparent structure. To prevent corrosion of the infrared rejection coating, an infrared reflective coating may include a corrosion-reduction material, an overcoat layer may be incorporated to the top of the infrared rejection coating, a bead of varnish may be provided around the periphery of the infrared rejection coating, and / or an edge of the infrared rejection coating may be laser-etched. An opaque masking layer may be incorporated in the transparent structure. To increase the uniformity of the appearance of the transparent layer, the infrared rejection coating may be interposed between the opaque masking layer and an exterior.

Description

Systems With Infrared Rejection CoatingsThis application claims priority to U.S. provisional patent application No. 63 / 611,418, filed December 18, 2023, which is hereby incorporated by reference herein in its entirety.Field

[0001] This relates generally to structures that pass light, and, more particularly, to transparent structures.Background

[0002] Transparent structures, such as windows, generally include transparent layers, such as glass layers. The transparent structure may include one or more coatings.Summary

[0003] A system such as a vehicle, a building, or an electronic device may have transparent structures, such as windows. A transparent structure may separate an interior region from an exterior region, such as the interior and exterior regions of a vehicle. A transparent structure may have structural layers such as an inner glass layer and an outer glass layer. The inner and outer glass layers may be separated by an air gap, or the space between the inner and outer glass layers may be filled with interlayers. The outer glass layer may be transparent, while the inner glass layer may be tinted, such as using active tinting.

[0004] One or more infrared rejection coatings may be applied to the inner and / or outer glass layers. The infrared rejection coating may be formed from multiple metal / di electric layers that block infrared light. At least one of these metal layers may be textured to diffusively reflect at least some of the visible light that is incident on the coating.Alternatively, the infrared rejection coating may be formed from dielectrics, such as dielectric layers with alternating high and low indexes of refraction. The dielectrics may be textured.

[0005] The infrared rejection coating may extend to an edge of the transparent structure.To prevent corrosion of the infrared rejection coating, an infrared reflective coating may include a corrosion-reduction material, an overcoat layer may be incorporated to the top of the infrared rejection coating, a bead of varnish may be provided around the periphery of the infrared rejection coating, and / or an edge of the infrared rejection coating may be laser-etched.

[0006] An opaque masking layer may be incorporated in the transparent structure. To increase the uniformity of the appearance of the transparent layer, the infrared rejection coating may be interposed between the opaque masking layer and an exterior.

[0007] The transparent structure may form a part of a vehicle, such as canopy that extends over the windshield, roof glass, and / or backlite, or may be a clear pre-formed polymer two- dimensional or three-dimensional substrate, such as polycarbonate. A vehicle canopy may extend from a front of the vehicle to a rear of the vehicle, and between sides of the vehicle. The vehicle may include a vehicle body that has a first reflectivity profile, and the coating (on the transparent structure) may have a second reflectivity profile that matches the first reflectivity profile. In this way, the transparent structure may have a similar appearance to the vehicle body.Brief Description of the Drawings

[0008] FIG. l is a schematic diagram of an illustrative system in accordance with some embodiments.

[0009] FIG. 2 is a cross-sectional side view of an illustrative transparent structure having an infrared rejection coating in accordance with some embodiments.

[0010] FIG. 3 is a side view of an illustrative transparent structure having an infrared rejection coating that extends to an edge of the transparent structure in accordance with some embodiments.

[0011] FIG. 4 is a front view of an illustrative transparent having an infrared rejection coating that extends to an edge of the transparent structure in accordance with some embodiments.

[0012] FIG. 5 is a side view of an illustrative infrared rejection coating in accordance with some embodiments.

[0013] FIG. 6 is a side view of an illustrative transparent structure with a bead of varnish that extends around a peripheral edge of an infrared rejection coating in accordance with some embodiments.

[0014] FIG. 7 is a side view of an illustrative transparent structure with an infrared rejection coating that is separated by an edge by a gap in accordance with some embodiments.

[0015] FIG. 8 is a side view of an illustrative transparent structure with a transparent layerthat forms a ledge for varnish in accordance with some embodiments.

[0016] FIG. 9 is a side view of an illustrative curved transparent structure having an infrared rejection coating and an ultraviolet filter in accordance with some embodiments.

[0017] FIG. 10A is a side view of an illustrative system that may include a transparent structure in accordance with some embodiments.

[0018] FIG. 10B is a front view of an illustrative system that may include a transparent structure in accordance with some embodiments.Detailed Description

[0019] A system may have transparent structures, such as windows. The transparent structures may include structures for blocking infrared light. Optionally, additional coatings, such as active tint layers, antireflection layers, or electro-optically adjustable components may also be incorporated into the transparent structures. The system may be an electronic device, a building, a vehicle, or other suitable system. Illustrative configurations in which the system with the transparent structures is a vehicle may sometimes be described herein as an example. This is merely illustrative. Transparent structures may be formed in any suitable system.

[0020] The electrically adjustable components of the transparent structures may be used to adjust the optical properties of the windows. For example, electrically adjustable transparent structures may be adjusted to change the absorption (and / or reflection) of light and therefore the light transmission of the transparent structures. An adjustable light modulator layer (e.g., an active tint layer) may, for example, serve as an electrically adjustable sunroof for a rooftop window or may be used to implement an electrically adjustable shade for a side, front, or rear window. In an illustrative configuration, the transparency of the transparent structure may be modulated using a liquid crystal light modulator such as a guest-host liquid crystal light modulator. Adjustable optical component layers may also be used to display images, to provide illumination, and / or to otherwise adjust the appearance and behavior of a window.

[0021] A transparent structure for the system may include multiple glass layers. For example, a window may include an inner transparent structural layer (sometimes referred to as an inner glass layer) and an outer transparent structural layer (sometimes referred to as an outer glass layer). The inner and outer layers of the window may be separated by a gap. The gap may be filled with air or may be filled with a polymer, liquid, or other functionaldielectric. Alternatively, the gap may be a vacuum (e.g., the transparent structure may be an evacuated sealed glazing with support micro pillars). Illustrative configurations in which the inner and outer glass layers are separated by polymer, such as a polymer adhesive, are sometimes described herein as an example.

[0022] The glass layers of a window may be single-layer glass layers (e.g., single layers of heat strengthened or tempered glass) or, in some configurations, may be multi-layer structures formed, for example, from first and second glass layers that are laminated together. A laminated glass layer may have a polymer such as polyvinyl butyral (PVB) that joins first and second glass layers to form a sheet of laminated glass. Multi-layer glass structures (laminated glass layers formed from two or more laminated glass layers with interposed PVB) and single-layer glass layers may include optional tinting (e.g., dye, pigment, etc.). Polymer layers in laminated glass layers (e.g., PVB layers) may also optionally be passively tinted.

[0023] As an alternative to glass, polymer layers may be used in forming windows. For example, windows may include one or more polymer layers, such as polycarbonate or acrylic layers. Laminated window structures may be formed from multiple polymer layers with an interlayer, such as a thermoplastic urethane (TPU) interlayer. In general, any desired interlayer may be used.

[0024] In some cases, it may be desirable to reduce an amount of infrared light that passes through a transparent structure. For example, reducing the amount of infrared light passing through a window may reduce the amount of heat that enters a system, such as an electronic device, vehicle, or building. To reduce the amount of infrared light passing through the window, an infrared light rejection (IRR) coating may be incorporated on one or more layers, such as glass or polymer layers, in the window. Examples in which an IRR coating is coupled to glass window layers are sometimes described herein, but the infrared light rejection coating may be applied on any desired window layers, such as polymer window layers.

[0025] Moreover, it may be desirable that the transparent structure have appearance characteristics that match surrounding portions of the system (e.g., the vehicle). For example, if the transparent structure is surrounded by plastic or metal, it may be desirable for the window to have diffuse reflectance, low haze, and an angle-independent color appearance. Additionally, it may be desirable for the transparent structure to have a matte (or less glossy)appearance.

[0026] The IRR coating may include one or more infrared reflective layers (such as a silver and dielectric stack and / or a stack of dielectric layers with alternating high and low refractive indexes) that reduce the amount of infrared light that passes through the transparent structure. In some embodiments, the infrared reflective layers may be textured and / or additional diffusive particles may be included in the coating to create a diffuse reflection. In other words, the IRR coating may be a diffuse infrared light rejection coating. At the same time, the transparent structure may have clear (e.g., non-diffuse) transmission. In this way, the appearance of the transparent window with the IRR coating may match the appearance of the surrounding metal or plastic portions of the system.

[0027] Alternatively, the IRR coating may be non-diffuse. In other words, the infrared IRR coating may reflect light specularly, or the infrared IRR coating may be a mixture of specular and diffuse.

[0028] An opaque masking layer, such as a black mask, may be applied to the transparent structure, such as along one or more edges of the transparent structure. To improve the uniformity of the appearance of the transparent structure between the portion with the opaque masking layer and the portion without the opaque masking layer, the IRR coating may be interposed between the opaque masking layer and an outer glass layer. In other words, the IRR coating may be between a viewer of the transparent structure and the opaque masking layer.

[0029] Additionally, the IRR coating may extend to the edge of the transparent structure, and therefore to the edge of the opaque masking layer. Corrosion-resistant material may be added to the IRR coating to prevent corrosion at the edges of the IRR coating. In this way, the IRR coating may extend to the edge of the transparent structure and the opaque masking layer, providing a uniform appearance across the transparent structure.

[0030] An illustrative system of the type that may include transparent structures with one or more IRR coatings is shown in FIG. 1. System 10 may be an electronic device, a vehicle, a building, or any other desired system. For example, system 10 may be an electronic device, such as a cell phone, a laptop computer, a desktop computer, a tablet computer, a television, or any other desired electronic device. The electronic device may include a device housing, a display on a front face of the device housing, and electronic components within the device housing. In other examples, system 10 may be a vehicle having a body with a chassis towhich wheels are mounted, propulsion and steering systems, and other vehicle systems. The vehicle body may include doors, trunk structures, a hood, side body panels, a roof, and / or other body structures. The vehicle body may be formed from plastic, metal, glass, and / or other suitable materials. Seats may be formed in the interior of the body. However, these examples are merely illustrative. In general, system 10 may be any desired system.

[0031] Regardless of the particular system, system 10 may include transparent structures such as transparent structure(s) 16 (also referred to as window(s) 16 herein). Transparent structures 16 may separate the interior of system 10 from the exterior environment that is surrounding system 10. For example, transparent structures 16 may include windows on the front and / or rear of an electronic device; on the front, rear, and sides of a vehicle; or on the sides of a building, as examples. In some illustrative embodiments, transparent structures 16 may include a windshield, a backlite, one or more side windows, a canopy (e.g., a single piece canopy that extends over the areas traditionally occupied by the windshield, backlite, and roof glass), and / or a roof glass. In some illustrative embodiments, a transparent structure, such as a windshield or canopy, may extend over headlights of the vehicle (e.g., the headlights may operate through the transparent structure). In general, however, windows 16 may be formed in any desired locations within any desired systems.

[0032] Input-output devices 21 may include sensors, audio components, displays, and other components. For example, input-output devices 21 may provide output to an occupant of a system, may make measurements of the environment surrounding the system, and may gather input from an occupant of the system. If desired, some of the input-output devices may operate through transparent structure(s) 16. In some examples, input-output devices 21 may include communication devices, such as radios, that receive and / or send radio waves through transparent structure(s) 16. In other examples, input-output devices 21 may include optical sensors, such as light detection and ranging (LIDAR) sensors, other infrared optical components, radar sensors, or other suitable sensors that operate through transparent structure(s) 16.

[0033] Controller 23 may include storage and processing circuitry such as volatile and nonvolatile memory, microprocessors, application-specific integrated circuits, digital signal processors, microcontroller, and other circuitry for controlling the operation of the system, such as the vehicle. During operation, controller 23 may control the components of the system based on input from input-output devices 21.

[0034] An illustrative configuration for a transparent structure such as one of transparent structures 16 of FIG. 1 is shown in FIG. 2. As shown in FIG. 2, transparent structures 16 may separate interior region 14 (e.g., a region inside system 10, such as a region inside a system) from exterior region 18 (e.g., a region on the outside of system 10, such as region outside the system). Transparent structure 16 may include inner layer 20 and outer layer 22. Layers 20 and 22 may be glass layers, ceramic layers, sapphire layers, polymer layers (such as polycarbonate or acrylic layers), or any other desired layers, and may be transparent or partially transparent (e.g., may be tinted to reduce the transmission of some visible light). Layers 20 and 22 may be also referred to as substrates herein (e.g., when coatings are applied to the layers).

[0035] Layers 20 and 22 may be formed from single-layer glass structures and / or multilayer glass structures. These layers may be strengthened (e.g., by annealing, tempering, and / or chemical strengthening). In general, inner layer 20 may be a single-layer glass structure (e.g., a single layer of tempered glass) or a laminated glass layer and outer layer 22 may be a single-layer glass structure (e.g., a single layer of tempered glass) or a laminated glass layer. In embodiments in which layer 20 and / or layer 22 are laminated glass layers, they may include multiple layers of glass that are laminated together using one or more polymer layers. In embodiments in which layer 20 and / or layer 22 are laminated polymer layers, they may include multiple layers of polymer that are laminated together using one or more additional polymer layers. The polymer layers may be a layer of polyvinyl butyral, thermoplastic polyurethane, or other suitable polymer for attaching the glass layers.

[0036] Layers 20 and 22 may be separated by gap 25. Gap 25 may be an air gap, or gap 25 may be filled with any desired substance. For example, gap 25 may be filled with a polymer, liquid, or other dielectric. In some cases, gap 25 may be omitted, if desired. For example, gap 25 may be filled by one or more other materials, such as optically clear adhesive (OCA). In some embodiments, electronic components, such as lights, displays, liquid crystal layers, and / or other components, may be incorporated in gap 25 to provide transparent structure 16 with an adjustable appearance. For example, transparent structure 16 may have an adjustable tint, adjustable haze, adjustable color, adjustable display, adjustable color, and / or other adjustable appearance.

[0037] Light, such as light 27, may be incident on transparent structure 16. As shown in FIG. 2, light 27 may be incident on outer layer 22, having reached transparent structure 16from exterior region 18. Light 27 may include visible, infrared, ultraviolet, and other wavelengths. To reduce the transmission of infrared light through transparent structure 16, inner layer 20 may be coated with infrared rejection coating 24, which may reflect infrared light (e.g., infrared wavelengths of light 27) from reaching interior region 14. Reducing the infrared light passing through transparent structure 16 may reduce the heat transferred to interior region 14 from exterior region 18.

[0038] Although light 27 is shown as being in exterior region 18, light with undesirable infrared components may be in interior region 14 and blocked by infrared rejection coating 24 on inner layer 20, as well.

[0039] Although infrared rejection coating 24 is shown in FIG. 2 as being on the outer surface of inner layer 20, this is merely illustrative. As shown in FIG. 2, infrared rejection coating 24 may be at location 24' on the inner surface of outer layer 22 instead of or in addition to being on inner layer 20. Alternatively or additionally, infrared rejection coating 24 may be formed on the outside of transparent structure 16 (i.e., on the outer surface of outer layer 22 or the inner surface of inner layer 20), or may be formed on an additional layer that is formed between inner layer 20 and outer layer 22. In general, infrared rejection coating 24 may be formed anywhere within window 16 to reduce the amount of infrared light that passes through transparent structure 16.

[0040] If infrared rejection coating 24 is formed on a polymer layer, such as a layer of polycarbonate, it may be desirable to include an additional coating layer between infrared rejection coating 24 and the polymer layer. For example, a coating layer may be applied (e.g., through chemical vapor deposition (CVD) on the polymer layer prior to applying infrared rejection coating 24. The coating layer may reduce the stress on the polymer when infrared rejection coating 24 is deposited and may be formed from any desired material. In some examples, the coating layer may be a hybrid coating layer such as SiOCH or any SiOxCy:H material. For example, the hybrid coating layer may be formed from hexamethyldisiloxane (HMDSO). However, these materials are merely illustrative. In general, the hybrid coating may be formed from any desired material, such as ZrOC:H or TiOC:H. The coating may also be an anti -reflection layer, as it may have a refractive index that is the same or slightly higher than the underlying polymer. The refractive index of the coating may be graded, if desired.

[0041] Regardless of where one or more infrared rejection coatings, such as infraredrejection coating 24, are formed, the infrared reflection coatings may extend to an edge of the transparent structure and / or to an edge of an opaque masking layer on the transparent structure. An illustrative example is shown in FIG. 3.

[0042] As shown in FIG. 3, transparent structure 16 may include transparent layer 22 at exterior region 18 and layer 20 at interior region 14. In some embodiments, transparent layer 22 may be formed from glass, sapphire, polycarbonate, or other transparent material, and layer 20 may be formed from tinted glass, tinted sapphire, tinted polycarbonate, or other tinted material. However, these materials are merely illustrative. In general, one or both of layers 20 or 22 may be tinted, or both layers 20 and 22 may be transparent.

[0043] Layer 30 may be a polyvinyl butyral (PVB) layer, or may be another suitable adhesive layer, such as an optically-clear adhesive (OCA). Layer 30 may bond the transparent layers to one another and to the other layers between the transparent layers. Layer 30 may be index-matched to transparent layer 20 (and / or to transparent layer 22). In other words, layer 30 may have a refractive index within 0.1, within 0.2, or within 0.3 of the refractive index of layers 20 (and / or layer 22), as examples. In some embodiments, layer 30 may also be index-matched to one another and / or to the layers in transparent structure 16.For example, intervening layers may have a gradient of refractive index values that gradually changes within transparent structure 16.

[0044] Opaque masking layer 28 may be formed at edge E of transparent structure 16 between transparent layers 20 and 22. Opaque masking layer 28 may be formed from black frit (or frit of another desired color), a sputterable mask material, a physical vapor deposition (PVD) layer, and / or any other suitable opaque material. If desired, opaque masking layer 28 may extend around a periphery of transparent structure 16 along one or more edges E. For example, opaque masking layer 28 may be used to mask underlying adhesive that is used to bond transparent structure 16 to system 10.

[0045] IRR coating 24 may be formed between outer transparent layer 22 and opaque masking layer 28. IRR coating 24 may be coupled to transparent layer 22, and may be aligned with edge E of transparent structure 16 (e.g., an edge of IRR coating 24 may be aligned with edge E). IRR coating 24 may be deposited on or otherwise bonded / attached to transparent layer 22, with or without one or more intervening layers between transparent layer 22 and coating 24.

[0046] IRR coating 24 may include one or more metal layers, such as a silver layer, and / ormay include multiple dielectric layers with alternating high and low indexes of refraction. The metal layer and / or dielectric layers may be colored or uncolored, to impart a desired appearance on structure 16. Alternatively or additionally, coating 24 may include one or more ceramic layers to increase the reflectivity of the coating and / or one or more layers with metal particles, such as silver particles, to modify the reflectivity profile of the coating.

[0047] If IRR coating 24 is a diffuse IRR coating, then at least one of the metal layers or dielectric layers used to block infrared light may have a textured surface. The textured surface may have random texture, pseudo-random texture, or other texture. For example, the textured surface may include textured features, such as protrusions, that are have a roughness (e.g., height) of at least 0.3 microns, of between 0.1 and 0.5 microns, of less than 0.5 microns, or other suitable roughness. The textured features may be separated laterally by at least 500 nm, by less than 1 micron, by at least 100 microns, by between 100 microns and 750 microns, by between 500 and 750 microns, or other suitable distance. The textured features may be micro-facetted surface structures.

[0048] Infrared light may be rejected by IRR coating 24. In particular, infrared light may be absorbed and / or reflected by IRR coating 24 to prevent the infrared light from passing through structure 16. The textured surface may include textured features that are spaced apart to prevent diffusion of infrared light. Therefore, any infrared light reflected by IRR coating 24 may be reflected specularly, rather than diffusely. In other words, by spacing the textured features apart at a distance that is less than infrared wavelengths (e.g., less than the maximum infrared wavelength, such as 2.5 microns), the textured surface may not diffuse infrared light and may act as a conventional IRR coating with respect to infrared light. For example, spacing textured features apart by approximately 500 nm, by less than 1 micron, between 250 nm and 750 nm, or other suitable distance, may prevent the textured surface from diffusing infrared light.

[0049] However, with respect to visible light, IRR coating 24 may allow some visible light to pass and may diffuse other portions of visible light as diffused light. In particular, due to the texture of IRR coating 24, at least some visible light may be diffusely reflected as diffuse light. For example, diffuse light may be diffused with a Lambertian reflectance profile. In this way, transparent structure 16 may have a matte appearance. However, this is merely illustrative. In general, light may be diffused with any suitable reflectance profile.

[0050] IRR coating 24 may pass at least 5% of incident visible light, at least 10% ofincident visible light, between 5% and 25% of incident visible light, or other suitable amount of incident visible light. In this way, transparent structure 16 may pass some incident light, allowing viewers to see through transparent structure 16, while diffusely reflecting a majority of incident visible light.

[0051] In general, by reflecting light with diffuse reflection, transparent structure 16 (with IRR coating 24) may match an appearance of other materials in system 10. For example, if transparent structure 16 is formed in a system and is surrounded by paint / plastic portions of a body of the system, transparent structure 16 may reflect diffuse light in a similar or the same fashion as the surrounding portions of the body.

[0052] In some embodiments, less than 10% of visible light reflected by coating 24 (such as 6% of reflected light) may be specular, while the rest of the reflected visible light is diffuse. However, this is merely illustrative. In general, coating 24 may reflect any suitable amounts of specular or diffuse light.

[0053] Alternatively, IRR coating 24 may be a non-diffuse IRR coating. In these embodiments, IRR coating 24 may be formed from metal layers and / or dielectric layers that reject infrared light, without having the texture that diffuses visible light. In this way, IRR coating 24 may diffuse light specularly, instead of diffusely.

[0054] Although not shown in FIG. 3, other layers, such as an active tint layer, may be included within structure 16. The active tint layer may be, for example, a cholesteric liquid crystal layer, other liquid crystal layer, or other light modulator that reduces the transmission of visible light through structure 16. The active tint layer may be adjusted, such as by a controller in a system, to adjust the tint level of transparent structure 16. For example, the active tint layer may be adjusted between a light transmission (e.g., a visible light transmission) of at least 70% and a light transmission (e.g., a visible light transmission) of at least 30%, as examples. In general, however, the active tint layer may be adjusted between any suitable transparencies. For example, the allowable transparencies of the active tint layer may be determined based on structure 16 (e.g., a windshield may require more transparency, while a canopy may be less transparent).

[0055] Alternatively or additionally, an adjustable haze layer, a light (or light guide), a display, and / or other adjustable components may be incorporated between layers 20 and 22 in transparent structure 16.

[0056] Because IRR coating 24 is between opaque masking layer 28 and exterior region 18,the appearance of opaque masking layer 28 and therefore transparent structure 16 will be more closely matched with the appearance of the surrounding system (e.g., system 10 of FIG. 1) in which transparent structure 16 is mounted. By extending IRR coating 24 entirely, or nearly entirely, to edge E, the appearance may be uniform across transparent structure 16. A front view of an illustrative transparent structure with an opaque masking layer at the edges is shown in FIG. 4.

[0057] As shown in FIG. 4, transparent structure 16 may include transparent portion 29 and an opaque portion formed from opaque masking layer 28. Opaque masking layer 28 may surround transparent portion 29 and may extend around the periphery of transparent structure 16 along edges E.

[0058] In the illustrative example of FIG. 4, opaque masking layer 28 may extend entirely around transparent structure 16. However, this is merely illustrative. In general, opaque masking layer 28 may extend around any desired portion of transparent structure 16, such as entirely between one or more edges of transparent structure 16 and / or partially between one or more edges of transparent structure 16.

[0059] As discussed, IRR coating 24 (FIG. 3) may extend entirely across transparent structure 16, covering both transparent portion 29 and the opaque portion formed by opaque masking layer 28. In this way, the appearance of transparent structure 16 may be uniform (e.g., light reflected by IRR coating 24 may be reflected across the entirety of transparent structure 16). Additionally, by forming IRR coating 24 between opaque masking layer 28 and the front of transparent structure 16, transparent structure 16 may have an appearance that more closely matches the appearance of the surrounding system. In particular, light may be reflected by IRR coating 24 in a diffuse manner that matches the reflectivity of the surrounding system.

[0060] However, by extending IRR coating 24 to one or more edges E of transparent structure 16, IRR coating 24 may be exposed to the environment surrounding transparent structure 16. To prevent corrosion, IRR coating 24 may be modified. An illustrative example of an IRR coating that may be used in transparent structure 16 is shown in FIG. 5.

[0061] Spacer layer 32 (also referred to as barrier layer 32 herein) may be formed on a substrate, such as one of transparent layers 20 or 22 (FIG. 3). Spacer layer 32 may be an amorphous layer and may be dense to protect the underlying transparent layer and the layers above spacer layer 32 while they are deposited. Spacer layer 32 may have a thickness of lessthan 50 nm, of greater than 20 nm, of between 20 nm and 30 nm, or other suitable thickness.

[0062] In general, spacer layer 32 may have an index of refraction close to that of the underlying transparent layer to reduce the reflection of light incident on the transparent layer. For example, spacer layer 32 may have an index of refraction between 1.2 and 1.7, between 1.2 and 1.5, between 1.5 and 1.7, between 1.7 and 2, or any other desired value. In this way, spacer layer 32 may form an antireflection coating on the transparent layer.

[0063] In some examples, spacer layer 32 may be a zinc oxide. For example, ZnSnOx may be used to form spacer layer 32. Alternatively, spacer layer 32 may include TiOx, bismuth oxide, SiN, SiZrOxNy, NbO, another binary oxide, or any other desired material.

[0064] If the underlying transparent layer is formed from a polymer, such as polycarbonate, it may be desirable to include an additional coating layer between the transparent layer and spacer layer 32. For example, a coating layer may be applied (e.g., through chemical vapor deposition (CVD)) on the transparent layer prior to applying spacer layer 32. The coating layer may reduce the stress on the polymer of the transparent layer when the rest of the stack up is deposited and may be formed from any desired material. In some examples, the coating layer may be a hybrid coating layer such as SiOCH, any SiOxCy:H material (such as HMDSO), ZrOC:H, TiOC:H, or other desired hybrid material. The coating may also be an anti-reflection layer, as it may have a refractive index that is the same or slightly higher than the underlying polymer. The refractive index of the coating may be graded, if desired.

[0065] Seed layer 34 may be formed on spacer layer 32. Seed layer 34 may be a doped zinc oxide layer, such as Al doped ZnOx, or may be any other desired layer which would promote the growth of highly textured Ag, such as NiO. In some examples, seed layer 34 may be a crystalline layer. However, any desired material may be used to form seed layer 34. In general, seed layer 34 may facilitate the deposition of a high quality (Real(n) < 0.1, preferably Real part (n) less than 0.07 at 550 nm) infrared reflective layer 36.

[0066] Seed layer 34 may have a thickness of less than 10 nm, less than 5 nm, between 2 nm and 7 nm, or other suitable thickness.

[0067] Infrared reflective layer 36 may be formed on seed layer 34. Infrared reflective layer 36 may be silver, or may be another desired infrared reflective material. In some examples, infrared reflective layer 36 may be a poly crystalline silver layer. Infrared reflective layer 36 may have any desired thickness, such as less than 30 nm, more than 8 nm, between 15-30 nm, between 10 nm and 20 nm, or other desired thickness. In one illustrativeembodiment, infrared reflective layer 36 may have a thickness equal to the grain size of the polycrystalline silver forming infrared reflective layer 36. For example, the grain size may be 15-30 nm and the thickness of infrared reflective layer 36 may be 15-30 nm. In other words, infrared reflective layer 36 may be a polycrystalline silver layer that is one grain thick.

[0068] If desired, infrared reflective layer 36 may be patterned. For example, material within infrared reflective layer 36, such as silver, may interfere with the transmission of waves, such as radio waves. If it is desirable to have radio waves pass through window 16 (e.g., if system 10 is a vehicle, a building, or an electronic device), infrared reflective layer 36 may be pattered to have openings. As a result, waves, such as radio waves, may pass through the openings unimpeded, while the remaining portions of infrared reflective layer 36 block infrared light from passing through window 16.

[0069] If infrared reflective layer 36 is exposed to an edge of transparent structure 16 (e.g., as shown in FIG. 3), infrared reflective layer 36 may be modified to prevent corrosion. For example, a corrosion-resistance material, such as zinc, gold, or other suitable material, may be added to the silver (or other metal) that provides infrared reflectivity. The specific corrosion-resistance material may be determined to ensure thermodynamic stability and a suitable lattice structure of infrared reflective layer 36.

[0070] In some embodiments, the corrosion-resistance material may form less than 3%, less than 5%, between 2% and 7%, or other suitable proportion of infrared reflective layer 36. The corrosion-resistance material may preferentially leach into the environment surrounding transparent structure 16, and may therefore prevent corrosion to infrared reflective layer 36.

[0071] Alternatively or additionally, IRR coating 24 may be etched very close to the edge of transparent structure 16. In other words, an edge of IRR coating 24 may be separated from the edge of transparent structure 16 by a gap, such as a gap of less than 8 mm from the edge of transparent structure 16. For example, the edge of IRR coating 24 may be separated from the edge of transparent structure 16 by a gap of less than 500 microns, 200 microns or less, less than 250 nm, between 100 microns and 200 and microns, between 250 nm (or approximately 250 nm) and 500 microns (or approximately 500 microns) or other suitable distance. To form the gap, laser etching may be used, as an example. In other words, the edge of IRR coating 24 may be laser-etched using a suitable laser, such as a femto-second laser, a pico-second laser, a micro-second laser, or a nano-second laser. The laser may be used to etch entirely through IRR coating 24, or at least through the metal (e.g., silver) layersof IRR coating 24. Such a gap from the edge may be smaller than traditional coatings, while infrared reflective layer(s) 36 may be protected from environmental corrosion by being spaced apart from the edge (such as by applying a laminate over IRR coating 24 and / or causing the metal of infrared reflective layer(s) 36 to become discontinuous / diffuse at the edge).

[0072] Alternatively or additionally, as another corrosion-reduction technique, a bead of varnish, such as a UV-curable urethane or other material, may be applied to an edge of IRR coating 24. An illustrative example is shown in FIG. 6.

[0073] As shown in FIG. 6, bead of varnish 42 (also referred to as wrap 42 herein) may extend around a periphery of IRR coating 24 to separate infrared reflective layer(s) 36 (FIG.5) from the exterior of transparent structure 16. Varnish 42 may be formed from UV-curable urethane or other suitable material. For example, varnish 42 may include one or more acrylates that cure in response to UV light. In this way, infrared reflective layer(s) 36 may be protected from environmental corrosion with the varnish.

[0074] In the example of FIG. 6, varnish 42 may extend from a portion of transparent layer 22 to a portion of opaque masking layer 28 to completely cover an edge surface of IRR coating 24. However, this arrangement is merely illustrative. In general, varnish 42 may extend over any one or more suitable portions of IRR coating 24 to cover one or more of the infrared reflective layers in IRR coating 24.

[0075] Additionally, FIG. 6 shows IRR coating 24 extending to edge E of transparent structure 16. However, IRR coating 24 may extend within less than 500 microns from the edge, 200 microns or less from the edge, less than 250 nm from the edge, between 250 nm (or approximately 250 nm) and 500 microns (or approximately 500 microns) or other suitable distance from the edge, and varnish 42 may extend from edge E toward IRR coating 24 to cover the edge of IRR coating 24. An illustrative example is shown in FIG. 7.

[0076] As shown in FIG. 7, IRR coating 24 may be separated from edge E of transparent structure 26 by distance 45. Distance 45 may be, for example, less than 8 mm, less than 500 microns, less than 200 microns, between 100 microns and 200 microns, less than 250 nm, between 250 nm (or approximately 250 nm) and 500 microns (or approximately 500 microns) or other suitable distance. As a result, opaque masking layer 28 may extend over an edge of IRR coating 24 and separate the edge of IRR coating 24 from edge E. Opaque masking layer 28 may provide additional protection from environmental corrosion to that provided byvarnish 42.

[0077] If desired, a second masking layer, such as masking layer 31, may be provided between IRR coating 24 and transparent layer 20. In some embodiments, masking layer 31 may be a PVD coating, while masking layer 28 is a ceramicized coating. However, this is merely illustrative. In general, one or both masking layers 28 and / or 31 may be incorporated into transparent structure 16.

[0078] In some embodiments, IRR coating 24 may be etched only partially through the coating, and / or transparent layer 22 may be extended to provide a ledge for varnish 42. An illustrative example is shown in FIG. 8.

[0079] As shown in FIG. 8, IRR coating 24 may have partially de-coated edge 47. For example, IRR coating 24 may be partially ablated at edge 47, such as by removing only some of the layers in IRR coating 24. In some embodiments, all of the metal layers (e.g., silver layers) in IRR coating 24 may be removed at edge 47 to prevent environmental corrosion of IRR coating 24.

[0080] Additionally or alternatively, transparent layer 22 may be extended by distance 49, which may be, for example, less than 500 microns, less than 200 microns, between 100 microns and 200 microns, less than 250 nm, between 250 nm (or approximately 250 nm) and 500 microns (or approximately 500 microns) or other suitable distance. In this way, transparent layer 22 may form a ledge on which varnish 42 may be formed.

[0081] Returning to FIG. 5, regardless of the corrosion-reduction technique(s) used, getter layer 37 may be formed on infrared reflective layer 36. Getter layer 37 may include lossy dielectric material. For example, getter layer 37 may include amorphous material, such as amorphous silicon or amorphous germanium, may include ink, and / or may include nanoparticles. The nanoparticles may be metal nanoparticles, such as silver nanoparticles. Alternatively or additionally, getter layer 37 may include a Zn layer, an Al layer, an AlZn layer, an Al -rich AIN layer, a Ti layer, a NiCr layer, and / or an alloy layer.

[0082] Getter layer 37 may have a thickness of 2 nm or less, 5 nm or less, between 1 nm and 2 nm, or any other desired thickness. Regardless of the thickness and material of getter layer 37, the getter layer may protect infrared reflective layer 36 (e.g., a silver layer) from oxidizing as other layers are deposited over infrared reflective layer 36. For example, oxygen gas may be used during the deposition of layers over infrared reflective layer 36, which would otherwise oxidize the silver (or other material) within infrared reflective layer 36. Inthis way, getter layer 37 may help prevent the oxygen gas from reaching infrared reflective layer 36 and oxidizing the material forming infrared reflective layer 36.

[0083] This stack of layers may be repeated any desired number of times (e.g., including spacer layer 38, which may be formed from the same material as spacer layer 32 or another material discussed in connection with spacer layer 32) to ensure sufficient infrared reflectivity. For example, an infrared reflection coating may include at least three infrared reflective layers, at least four infrared reflective layers, or any other desired number of infrared reflective layers.

[0084] Overcoat layer 40 may be formed on the top of the infrared reflection coating stack. Overcoat layer 40 may be formed from any desired material, such as a polymer material, a dielectric material, or an oxide material. In some examples, overcoat layer 40 may include an ZrSiOx, AlSiOx, SiOx, or SiON layer. By incorporating overcoat layer 40 on the infrared reflection coating stack, infrared reflective layer(s) 36 may be further protected from corrosion. In some embodiments, for example, overcoat layer 40 may wrap around an edge of infrared reflective layer(s) 36.

[0085] An infrared rejection coating, such as coating 24 may be formed on any desired transparent structure, such as transparent structure 16. In some examples, an infrared reflection coating may be formed on a curved transparent structure. An example of this arrangement is shown in FIG. 8.

[0086] As shown in FIG. 8, transparent structure 16 may include curved layer 58. Curved layer 58 may be an inner or outer window layer, such as layer 20 or layer 22 of FIG. 2. Curved layer 58 may be formed from glass, ceramic, sapphire, polycarbonate, acrylic, or any other desired material. Curved layer 58 may be formed from a single-layer glass structure and / or multi-layer glass structures. Curved layer 58 may be strengthened (e.g., by annealing, tempering, and / or chemical strengthening), if desired. In general, curved layer 58 may be a single-layer glass structure (e.g., a single layer of tempered glass) or a laminated glass layer. In embodiments in which curved layer 58 is a laminated glass layer, curved layer 58 may include multiple layers of glass that are laminated together using one or more polymer layers. IRR coating 24 may be formed on an outer surface of one of the multiple glass layers, or between the multiple glass layers. The polymer layers may be a layer of polyvinyl butyral or other suitable polymer for attaching the glass layers.

[0087] Although the side view of transparent structure 16 only shows curved layer 58curved in one direction, this is merely illustrative. If desired, curved layer 58 may be curved in two different directions or three different directions. In other words, curved layer 58 may exhibit compound curvature, if desired.

[0088] Curved layer 58 may be curved with a geometric strain of at least 0.5%, at least 0.8%, at least 1%, at least 2%, at least 3%, between 3.5% and 6.5%, between 2% and 6%, at least 5%, or other suitable strain. In this way, curved layer 58 may be a highly-curved transparent layer.

[0089] IRR coating 24 may be formed on curved layer 58. In particular, IRR coating 24 may have a curvature that matches the curvature of curved layer 58. In this way, an infrared rejection coating may be formed on a curved window.

[0090] In some illustrative embodiments, system 10 (FIG. 1) may be a vehicle, and transparent structure 16 may form a single-piece canopy structure that extends over the regions traditionally occupied by the windshield, roof glass, and backlite, or that covers separate structure that form the windshield, roof glass, and backlite. For example, transparent structure 16 may form a windshield for the vehicle, and may extend to the front of the vehicle and overlap headlights of the vehicle. An illustrative example of a transparent structure that forms a canopy for a system is shown in FIGS. 9A and 9B

[0091] As shown in FIG. 9 A, transparent structure 64 of system 10 may extend from a region at front F of body 62 to a region at rear R of body 62, and may be coupled to body 62 between front F and rear R. Transparent structure 64 may correspond to transparent structure 16 of FIGS. 1-6 (e.g., an infrared rejection coating may be formed on some or all of transparent structure 64, and transparent structure 64 may be formed of the same materials as discussed above in connection with transparent structure 16).

[0092] Structure 64 may have curvature 66 between front F and rear R (e.g., along an axis that extends between front F and rear R of system 10). Windows 68 (e.g., side windows of the vehicle) may be formed below structure 64 on the sides of system 10, if desired.

[0093] Although curvature 66 is shown as having a constant radius in FIG. 8 A, this is merely illustrative. In some embodiments, curvature 66 may have a non-constant radius, such as having a smaller radius at the front and the rear (e.g., the areas conventionally occupied by the windshield and backlite) and a larger radius at the top of system 10. In general, however, curvature 66 may be varied in any desired manner along the length of structure 64.

[0094] In addition to, or instead of, varying curvature 66 of structure 64 between the front and rear of the vehicle, a curvature of structure 64 between the sides of the vehicle may be varied. An illustrative rear view of a system having structure 64 is shown in FIG. 9B.

[0095] As shown in FIG. 9B, structure 64 may extend from a region at one side S of system 10 to a region at the other side S of system 10, and may be coupled to body 62 between the sides S. Windows 16 (e.g., side windows of the vehicle) may be formed beneath structure 64 at sides S of system 10, if desired.

[0096] Structure 64 may have curvature 70 between sides S of system 10. Curvature 70 may extend along an axis between sides S of system 10 and may be perpendicular to the axis along which curvature 66 extends. For example, curvature 70 may have a non-constant radius (e.g., the radius may change along the curvature 70 as it extends between sides S). In an illustrative embodiment, curvature 70 may have a smaller radius at the sides of the system and a larger radius at the top of system 10. However, this is merely illustrative. In general, curvature 70 may be varied in any desired manner between sides S. Alternatively, curvature 70 may have a constant radius between sides S, if desired.

[0097] Structure 64 may be formed from a large piece of curved glass. For example, structure 64 may have an area of at least 5 m2, at least 6 m2, at least 7 m2, or other suitable area to extend between the front and rear of a system and between the sides of the system.

[0098] Moreover, structure 64 may require complex curvature. In an illustrative example, structure 64 may have a first curvature in the area traditionally occupied by a windshield, a second curvature in the area traditionally occupied by a roof of the system, and a third curvature in the area traditionally occupied by a backlite. The first, second, and / or third curvatures may be the same, or may vary from one another. For example, the first, second, and / or third curvatures may have different radii of curvature from the other portions of structure 64. However, these differences in curvature are merely illustrative. In general, structure 64 may have any desired curvature.

[0099] Although not shown in FIGS. 9A and 9B, a transparent structure, such as transparent structure 64 (or transparent structure 16) may be curved to wrap around front F of system 10 laterally (e.g., perpendicular to the direction of travel of system 10). In other words, the transparent structure may extend to cover the A pillar on the driver and / or passenger side of system 10.

[0100] Alternatively or additionally, a transparent structure, such as transparent structure 64(or transparent structure 16) may form a windshield that extends along the vehicle in the direction of travel from a plane defining the front row of seats inside the system to a plane forward of the front lights (e.g., headlights) of the system. The windshield may cover the headlights, if desired. In some embodiments, the headlights may operate through the windshield.

[0101] However, these examples of a transparent structure in a vehicle are merely illustrative. In general, transparent structure 16 may be used to form any suitable transparent structure in a vehicle, such as a windshield, backlite, roof glass, canopy, side windows, and / or glass portions of the vehicle body, and an IRR coating (e.g., IRR coating 24 may be applied to any of the transparent structures). In some embodiments an IRR coating may be formed on all transparent structures of a system to ensure that the transparent structures appear homogenous. Alternatively, transparent structure 16 may be incorporated into any other desired system, such as a building, electronic device, or other system.

[0102] In accordance with an embodiment, a transparent structure configured to separate an interior from an exterior is provided that includes a first transparent layer having a first edge, the first transparent layer having a first surface facing the exterior and an opposing second surface; a second transparent layer having a second edge aligned with the first edge; an infrared rejection coating coupled to the second surface of the first transparent layer where the infrared rejection coating is aligned with the first edge; and an opaque masking layer interposed between the infrared rejection coating and the second transparent layer.

[0103] In accordance with another embodiment, the infrared rejection coating optionally includes infrared reflective layers that include silver.

[0104] In accordance with another embodiment, the infrared reflective layers optionally further include a corrosion-resistance material.

[0105] In accordance with another embodiment, the corrosion-resistance material optionally includes zinc or gold.

[0106] In accordance with another embodiment, the infrared rejection coating optionally further includes an overcoat layer.

[0107] In accordance with another embodiment, the overcoat layer optionally includes a material selected from the group consisting of: SiOx, SiON, and ZrSiOx.

[0108] In accordance with another embodiment, the infrared rejection coating optionally further includes a bead of varnish that extends around an edge of the infrared rejectioncoating, where the bead of varnish separates the infrared reflective layers from the exterior.

[0109] In accordance with another embodiment, the bead of varnish optionally includes UV-curable urethane.

[0110] In accordance with another embodiment, the opaque masking layer optionally includes a black frit material.

[0111] In accordance with an embodiment, a system having an interior and an exterior is provided that includes a body having a front, a rear, and sides that extend from the front to the rear, and a transparent structure coupled to the body where the transparent structure has an edge and includes first and second transparent layers, an infrared rejection coating coupled to the first transparent layer, where the infrared rejection coating extends to within 500 microns of the edge, and an opaque masking layer interposed between the first and second transparent layers, where the infrared rejection coating is interposed between the opaque masking layer and the exterior.

[0112] In accordance with another embodiment, the transparent structure optionally forms a canopy that extends from the front to the rear and between the sides of the body.

[0113] In accordance with another embodiment, the system optionally includes headlights, where the transparent structure forms a windshield that covers the headlights.

[0114] In accordance with another embodiment, the infrared rejection coating optionally has a laser-etched edge that is within 200 microns from the edge of the transparent structure.

[0115] In accordance with another embodiment, the infrared rejection coating optionally includes an infrared reflective layer that includes silver.

[0116] In accordance with another embodiment, the infrared rejection coating is optionally aligned with the edge of the transparent structure.

[0117] In accordance with another embodiment, the infrared rejection coating optionally further includes zinc.

[0118] In accordance with another embodiment, the infrared rejection coating optionally further includes a bead of varnish around a periphery of the infrared rejection coating that overlaps an edge of the infrared reflective layer.

[0119] In accordance with another embodiment, the first transparent layer optionally forms a ledge on which the bead of varnish is formed.

[0120] In accordance with an embodiment, a transparent structure having an edge and having an interior and an exterior is provided that includes a first transparent layer at theexterior, a second transparent layer at the interior, and an infrared rejection coating coupled to the first transparent layer, the infrared rejection coating is aligned with the edge, and the infrared rejection coating includes an infrared reflective layer that includes a corrosionresistance material.

[0121] In accordance with another embodiment, the transparent structure optionally further includes an opaque masking layer between the first transparent layer and the second transparent layer, where the infrared rejection coating is interposed between the opaque masking layer and the exterior.

[0122] The foregoing is merely illustrative and various modifications can be made to the described embodiments. The foregoing embodiments may be implemented individually or in any combination.

Claims

ClaimsWhat is Claimed is:

1. A transparent structure configured to separate an interior from an exterior, comprising: a first transparent layer having a first edge, wherein the first transparent layer has a first surface facing the exterior and an opposing second surface; a second transparent layer having a second edge aligned with the first edge; an infrared rejection coating coupled to the second surface of the first transparent layer, wherein the infrared rejection coating is aligned with the first edge; and an opaque masking layer interposed between the infrared rejection coating and the second transparent layer.

2. The transparent structure of claim 1, wherein the infrared rejection coating comprises infrared reflective layers that include silver.

3. The transparent structure of claim 2, wherein the infrared reflective layers further include a corrosion-resistance material.

4. The transparent structure of claim 3, wherein the corrosion-resistance material comprises zinc or gold.

5. The transparent structure of claim 3, wherein the infrared rejection coating further comprises an overcoat layer.

6. The transparent structure of claim 5, wherein the overcoat layer comprises a material selected from the group consisting of: SiOx, SiON, and ZrSiOx.

7. The transparent structure of claim 5, wherein the infrared rejection coating further comprises a bead of varnish that extends around an edge of the infrared rejection coating, wherein the bead of varnish separates the infrared reflective layers from the exterior.

8. The transparent structure of claim 7, wherein the bead of varnish comprises UV-curable urethane.

9. The transparent structure of claim 3, wherein the opaque masking layer comprises a black frit material.

10. A system having an interior and an exterior, comprising: a body having a front, a rear, and sides that extend from the front to the rear; and a transparent structure coupled to the body, wherein the transparent structure has an edge and comprises: first and second transparent layers, an infrared rejection coating coupled to the first transparent layer, wherein the infrared rejection coating extends to within 500 microns of the edge, and an opaque masking layer interposed between the first and second transparent layers, wherein the infrared rejection coating is interposed between the opaque masking layer and the exterior.

11. The system of claim 10, wherein the transparent structure forms a canopy that extends from the front to the rear and between the sides of the body.

12. The system of claim 10, further comprising: headlights, wherein the transparent structure forms a windshield that covers the headlights.

13. The system of claim 10, wherein the infrared rejection coating has a laser-etched edge that is within 200 microns from the edge of the transparent structure.

14. The system of claim 10, wherein the infrared rejection coating comprises an infrared reflective layer that includes silver.

15. The system of claim 14, wherein the infrared rejection coating is aligned with the edge of the transparent structure.

16. The system of claim 15, wherein the infrared rejection coating further includes zinc.

17. The system of claim 15, wherein the infrared rejection coating further includes a bead of varnish around a periphery of the infrared rejection coating that overlaps an edge of the infrared reflective layer.

18. The system of claim 17, wherein the first transparent layer forms a ledge on which the bead of varnish is formed.

19. A transparent structure having an edge and having an interior and an exterior, the transparent structure comprising: a first transparent layer at the exterior; a second transparent layer at the interior; and an infrared rejection coating coupled to the first transparent layer, wherein the infrared rejection coating is aligned with the edge, and wherein the infrared rejection coating comprises an infrared reflective layer that includes a corrosion-resistance material.

20. The transparent structure of claim 19, further comprising: an opaque masking layer between the first transparent layer and the second transparent layer, wherein the infrared rejection coating is interposed between the opaque masking layer and the exterior.

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