U.S. patent application number 09/877098 was filed with the patent office on 2001-10-11 for coated article including a dlc inclusive layer(s) and a layer(s) deposited using siloxane gas, and corresponding method.
This patent application is currently assigned to Guardian Industries Corporation. Invention is credited to Petrmichl, Rudolph Hugo, Thomsen, Scott V., Veerasamy, Vijayen S..
Application Number | 20010028956 09/877098 |
Document ID | / |
Family ID | 24635949 |
Filed Date | 2001-10-11 |
United States Patent
Application |
20010028956 |
Kind Code |
A1 |
Veerasamy, Vijayen S. ; et
al. |
October 11, 2001 |
Coated article including a DLC inclusive layer(s) and a layer(s)
deposited using siloxane gas, and corresponding method
Abstract
A substrate is coated with a coating system including at least
one diamond-like carbon (DLC) inclusive layer. In certain
embodiments, the coating system includes an anti-reflective layer,
a DLC inclusive layer provided for hardness/durability purposes, a
primer layer, and an FAS inclusive hydrophobic layer provided over
the primer layer. The anti-reflective layer is provided in order to
reduce visible light reflections off of the resulting coated
article and thus to improve visible transmission of the article. In
certain embodiments, the primer layer may be provided in order to
enable improved adhesion between the FAS inclusive layer and the
DLC inclusive layer that is provided for hardness/durability. In
certain embodiments, each of the anti-reflective layer, the DLC
inclusive layer, and/or the primer layer may include DLC for
purposes described herein. In certain alternative embodiments, the
primer and FAS layers need not be provided.
Inventors: |
Veerasamy, Vijayen S.;
(Farmington Hills, MI) ; Petrmichl, Rudolph Hugo;
(Ann Arbor, MI) ; Thomsen, Scott V.; (Milford,
MI) |
Correspondence
Address: |
NIXON & VANDERHYE P.C.
1100 North Glebe Road, 8th Floor
Airlington
VA
22201-4714
US
|
Assignee: |
Guardian Industries
Corporation
|
Family ID: |
24635949 |
Appl. No.: |
09/877098 |
Filed: |
June 11, 2001 |
Related U.S. Patent Documents
|
|
|
|
|
|
Application
Number |
Filing Date |
Patent Number |
|
|
09877098 |
Jun 11, 2001 |
|
|
|
09657132 |
Sep 7, 2000 |
|
|
|
09657132 |
Sep 7, 2000 |
|
|
|
09627441 |
Jul 28, 2000 |
|
|
|
09657132 |
Sep 7, 2000 |
|
|
|
09617815 |
Jul 17, 2000 |
|
|
|
09657132 |
Sep 7, 2000 |
|
|
|
09303548 |
May 3, 1999 |
|
|
|
6261693 |
|
|
|
|
09657132 |
Sep 7, 2000 |
|
|
|
09442805 |
Nov 18, 1999 |
|
|
|
09657132 |
Sep 7, 2000 |
|
|
|
09583862 |
Jun 1, 2000 |
|
|
|
Current U.S.
Class: |
428/408 |
Current CPC
Class: |
C03C 19/00 20130101;
C03C 15/02 20130101; C03C 17/3441 20130101; C03C 17/3652 20130101;
C03C 17/3634 20130101; B05D 5/083 20130101; C03C 17/36 20130101;
C23C 16/26 20130101; C03C 17/22 20130101; C03C 2217/77 20130101;
C03C 3/076 20130101; Y10T 428/24942 20150115; B08B 17/06 20130101;
C03C 23/006 20130101; B08B 17/065 20130101; C03C 23/0075 20130101;
B32B 17/1033 20130101; B60S 1/58 20130101; C03C 17/3644 20130101;
C03C 17/3482 20130101; C03C 2218/31 20130101; C03C 2217/76
20130101; C23C 16/0272 20130101; Y10T 428/31663 20150401; C03C
17/42 20130101; C03C 15/00 20130101; C03C 2217/78 20130101; Y10T
428/30 20150115; C03C 2217/282 20130101; B60S 1/54 20130101; G02B
5/208 20130101; C03C 2218/151 20130101; Y10T 428/24983
20150115 |
Class at
Publication: |
428/408 |
International
Class: |
B32B 009/00 |
Claims
What is claimed is:
1. A coated article comprising: a substrate; a hydrophobic coating
system provided on said substrate, said hydrophobic coating system
including an anti-reflective layer, a diamond-like carbon (DLC)
inclusive layer, a primer layer, and at least one fluoro-alkyl
silane (FAS) compound inclusive layer provided over said primer
layer; and wherein said hydrophobic coating system has an initial
contact angle .theta. of at least about 80 degrees, and an average
hardness of at least about 10 GPa.
2. The coated article of claim 1, wherein said DLC inclusive layer
includes sp.sup.3 carbon-carbon bonds.
3. The coated article of claim 1, wherein: said anti-reflective
layer has an index of refraction "n" of from about 1.5 to 1.8 and
includes silicon (Si) and sp.sup.3 carbon-carbon bonds; wherein
said anti-reflective layer is deposited in a manner so that at
least a portion of said DLC inclusive layer has a greater hardness
and higher density than said antireflective layer; and wherein said
anti-reflective layer is located between said DLC inclusive layer
and said substrate.
4. The coated article of claim 3, wherein said DLC inclusive layer
is provided between said primer layer and said anti-reflective
layer, and wherein said primer layer is provided directly between
said DLC inclusive layer and said FAS inclusive layer.
5. The coated article of claim 1, wherein said initial contact
angle is at least about 100 degrees.
6. The coated article of claim 5, wherein said initial contact
angle is at least about 110 degrees.
7. The coated article of claim 6, wherein said initial contact
angle is at least about 125 degrees.
8. The coated article of claim 1, wherein said coating system has a
surface energy .gamma..sub.C of less than or equal to about 20.2
mN/m.
9. The coated article of claim 1, wherein said coating system has a
surface energy .gamma..sub.C of less than or equal to about 19.5
mN/m.
10. The coated article of claim 1, wherein said coating system has
a surface energy .gamma..sub.C of less than or equal to about 18.0
mN/m.
11. The coated article of claim 1, wherein said FAS compound
includes at least one of:
CF.sub.3(CH.sub.2).sub.2Si(OCH.sub.3).sub.3;
CF.sub.3(CF.sub.2).sub.5(CH.sub.2).sub.2Si(OCH.sub.2CH.sub.3).sub.3;
CF.sub.3(CH.sub.2).sub.2SiCl.sub.3;
CF.sub.3(CF.sub.2).sub.5(CH.sub.2).su- b.2SiCl.sub.3;
CF.sub.3(CF.sub.2).sub.7(CH.sub.2).sub.2Si(OCH.sub.3).sub.3- ;
CF.sub.3(CF.sub.2).sub.5(CH.sub.2).sub.2Si(OCH.sub.3).sub.3;
CF.sub.3(CF.sub.2).sub.7(CH.sub.2).sub.2SiCl.sub.3;
CF.sub.3(CF.sub.2).sub.7(CH.sub.2).sub.2SiCH.sub.3Cl.sub.2; and
CF.sub.3(CF.sub.2).sub.7(CH.sub.2).sub.2SiCH.sub.3(OCH.sub.3).sub.2.
12. The coated article of claim 1, further comprising at least one
intermediate layer disposed between said coating system and said
substrate, and wherein said substrate comprises one of glass,
plastic and ceramic.
13. The coated article of claim 1, wherein each of said
anti-reflective layer and said primer layer include DLC and
sp.sup.3 carbon-carbon bonds.
14. The coated article of claim 13, wherein said DLC inclusive
layer has a greater hardness than each of said anti-reflective
layer and said primer layer, and wherein said DLC inclusive layer
has a greater ratio or percentage of sp.sup.3 carbon-carbon bonds
than each of said anti-reflective layer and said primer layer.
15. The coated article of claim 1, wherein said hydrophobic coating
system has an average hardness of at least about 20 GPa.
16. The coated article of claim 1, wherein said anti-reflective
layer includes DLC and is ion beam deposited using at least a first
gas including silicon (Si), and said DLC inclusive layer is ion
beam deposited using at least a second gas different than said
first gas.
17. The coated article of claim 16, wherein said anti-reflective
layer comprises more silicon (Si) than said DLC inclusive
layer.
18. The coated article of claim 16, wherein said first gas
comprises at least one siloxane gas and said second gas comprises
at least one hydrocarbon gas.
19. The coated article of claim 18, wherein said first gas
comprises HMDSO and said second gas comprises acetylene
(C.sub.2H.sub.2).
20. The coated article of claim 1, wherein at least about 50% of
carbon-carbon bonds in said DLC inclusive layer are sp.sup.3
carbon-carbon bonds, and where said antireflective layer is located
between said substrate and said DLC inclusive layer.
21. A coated article comprising: a substrate; a coating system on
said substrate, said coating system including an antireflective
layer, a diamond-like carbon (DLC) inclusive layer, a primer layer,
and an overlying layer for increasing initial contact angle .theta.
of the coated article, and wherein said primer layer is located
between said DLC inclusive layer and said overlying layer.
22. Th e article of claim 21, wherein said coating system has an
average hardness of at least about 10 GPa, and wherein said coating
system has an initial contact angle .theta. with a drop of water of
at least about 80 degrees.
23. The article of claim 21, wherein said overlying layer includes
at least one fluoro-alkyl silane (FAS) compound.
24. The article of claim 21, wherein each of said anti-reflective
layer and said primer layer include DLC and sp.sup.3 carbon-carbon
bonds, and wherein said DLC inclusive layer is located between said
primer layer and said anti-reflective layer and said DLC inclusive
layer has a greater ratio or percentage of sp.sup.3 carbon-carbon
bonds than each of said anti-reflective layer and said primer
layer.
25. The article of claim 24, wherein each of said primer layer and
said antireflective layer include DLC, Si and O.
26. The article of claim 21, wherein said substrate comprises at
least one of glass, ceramic, and plastic; and wherein said
overlying layer includes at least one FAS compound including at
least one of: CF.sub.3(CH.sub.2).sub.2Si(OCH.sub.3).sub.3;
CF.sub.3(CF.sub.2).sub.5(CH.-
sub.2).sub.2Si(OCH.sub.2CH.sub.3).sub.3;
CF.sub.3(CH.sub.2).sub.2SiCl.sub.- 3;
CF.sub.3(CF.sub.2).sub.5(CH.sub.2).sub.2SiCl.sub.3;
CF.sub.3(CF.sub.2).sub.7(CH.sub.2).sub.2Si(OCH.sub.3).sub.3;
CF.sub.3(CF.sub.2).sub.5(CH.sub.2).sub.2Si(OCH.sub.3).sub.3;
CF.sub.3(CF.sub.2).sub.7(CH.sub.2).sub.2SiCl.sub.3;
CF.sub.3(CF.sub.2).sub.7(CH.sub.2).sub.2SiCH.sub.3Cl.sub.2; and
CF.sub.3(CF.sub.2).sub.7(CH.sub.2).sub.2SiCH.sub.3(OCH.sub.3).sub.2.
27. The article of claim 21, wherein said coating system has an
average hardness of from about 20-80 GPa.
28. A method of making a coated article, the method comprising the
steps of: providing a substrate; depositing a first DLC inclusive
layer on the substrate using a first gas including silicon (Si) in
a manner such that the first DLC inclusive layer has an index of
refraction "n" of from about 1.4 to 2.0; depositing a second DLC
inclusive layer on the substrate over the first DLC inclusive layer
using a second gas different than the first gas in a manner such
that the second DLC inclusive layer has an index of refraction
greater than the index of refraction of the first DLC inclusive
layer, and wherein the second DLC inclusive layer has greater
hardness and a greater ratio or percentage of sp.sup.3
carbon-carbon bonds than the first DLC inclusive layer; and
depositing a third DLC inclusive layer on the substrate over the
second DLC inclusive layer using a gas including silicon (Si) in a
manner such that the second DLC inclusive layer includes a greater
percentage or ratio of sp.sup.3 carbon-carbon bonds than the third
DLC inclusive layer.
29. The method of claim 28, further comprising applying an FAS
inclusive layer over the second and third DLC inclusive layers, the
third DLC inclusive layer being a primer layer and further
comprising at least one oxide.
30. The method of claim 28, wherein the first DLC inclusive layer
is deposited on the substrate in a manner such that the first DLC
inclusive layer has an index of refraction "n" with a value between
respective indices of refraction "n" of the substrate and the
second DLC inclusive layer.
31. The method of claim 28, wherein the first gas includes at least
one of a siloxane compound and an oxygen inclusive organosilicon
compound, and wherein the second gas includes a hydrocarbon.
32. The method of claim 30, wherein the first gas comprises at
least one of tetramethyldisiloxane (TMDSO), tetraethoxylsilane
(TEOS), hexamethyldisiloxane (HMDSO), octamethylcyclotetrasiloxane
(OMCTSO), an ethoxy substituted silane, and an alkoxy substituted
silane.
33. The method of claim 30, wherein the second gas comprises at
least C.sub.2H.sub.2.
34. A method of making a coated article, the method comprising the
steps of: providing a substrate; depositing a first DLC inclusive
layer on the substrate using at least a first gas, the first gas
including at least one of a siloxane and an oxygen inclusive
organosilicon compound; and depositing a second DLC inclusive layer
on the substrate over the first DLC inclusive layer using a second
gas different than the first gas, in a manner such that the second
DLC inclusive layer includes more sp.sup.3 carbon-carbon bonds than
the first DLC inclusive layer.
35. The method of claim 34, wherein the first DLC inclusive layer
includes silicon (Si) and oxygen (O) in amounts such that the first
DLC inclusive layer has an index of refraction "n" of from about
1.4 to 2.0, and wherein the second gas comprises a hydrocarbon.
36. The method of claim 34, wherein the steps of depositing the
first and second DLC inclusive layers are performed in manners such
that the first DLC inclusive layer includes more silicon (Si) and
more oxygen (O) than the second DLC inclusive layer.
37. The method of claim 34, wherein the second gas comprises at
least C.sub.2H.sub.2.
38. The method of claim 34, wherein the first gas comprises at
least one of: tetramethyldisiloxane (TMDSO), tetraethoxylsilane
(TEOS), hexamethyldisiloxane (HMDSO), octamethylcyclotetrasiloxane
(OMCTSO), an ethoxy substituted silane, and an alkoxy substituted
silane.
39. The method of claim 34, further comprising: depositing a primer
layer including an oxide on the substrate in a location such that
the first and second DLC inclusive layers are located between the
primer layer and the substrate; and depositing an overlying layer
on the substrate over the primer for increasing contact angle of
the resulting coated article.
40. The method of claim 39, wherein the overlying layer comprises
at least one fluoro-alkyl silane (FAS) compound.
41. The method of claim 40, wherein the FAS compound includes at
least one of: CF.sub.3(CH.sub.2).sub.2Si(OCH.sub.3).sub.3;
CF.sub.3(CF.sub.2).sub.5-
(CH.sub.2).sub.2Si(OCH.sub.2CH.sub.3).sub.3;
CF.sub.3(CH.sub.2).sub.2SiCl.- sub.3;
CF.sub.3(CF.sub.2).sub.5(CH.sub.2).sub.2SiCl.sub.3;
CF.sub.3(CF.sub.2).sub.7(CH.sub.2).sub.2Si(OCH.sub.3).sub.3;
CF.sub.3(CF.sub.2).sub.5(CH.sub.2).sub.2Si(OCH.sub.3).sub.3;
CF.sub.3(CF.sub.2).sub.7(CH.sub.2).sub.2SiCl.sub.3;
CF.sub.3(CF.sub.2).sub.7(CH.sub.2).sub.2SiCH.sub.3Cl.sub.2; and
CF.sub.3(CF.sub.2).sub.7(CH.sub.2).sub.2SiCH.sub.3(OCH.sub.3).sub.2.
42. A method of making a coated article, the method comprising the
steps of: providing a substrate; ion beam depositing a DLC
inclusive layer on the substrate using at least a first gas
including a hydrocarbon, wherein the DLC inclusive layer includes
sp.sup.3 carbon-carbon bonds; and ion beam depositing a primer
layer on the substrate using at least a second gas, the second gas
being different than the first gas, the second gas including at
least one of a siloxane and an oxygen inclusive organosilicon
compound.
43. The method of claim 42, further comprising the step of
depositing a hydrophobic layer on the substrate over the primer
layer.
44. The method of claim 43, wherein the hydrophobic layer includes
at least one FAS compound and is in direct contact with the primer
layer.
45. The method of claim 42, further comprising ion beam depositing
an antireflection layer including DLC on the substrate at a
location such that the anti-reflection layer in between the
substrate and the DLC inclusive layer.
46. A coated article comprising: a substrate; a first layer
including Si, C and O provided on said substrate; and a second
layer including DLC provided on said substrate, said second layer
further including sp.sup.3 carbon-carbon bonds; and wherein said
first layer is located between said substrate and said second
layer.
47. The coated article of claim 46, wherein said first layer
includes DLC and sp.sup.3 carbon-carbon bonds, and wherein said
second layer is harder than said first layer and includes a greater
percentage or ratio of sp.sup.3 carbon-carbon bonds than said first
layer.
48. The coated article of claim 46, wherein said first layer is in
direct contact with said substrate, and wherein said first and
second layers are in direct contact with one another.
49. The coated article of claim 46, wherein said first layer is ion
beam deposited on the substrate using at least a siloxane gas, and
said second layer is ion beam deposited on the substrate using at
least a hydrocarbon gas.
50. The coated article of claim 49, wherein the coated article has
an initial contact angle .theta. of at least about 80 degrees, and
an average hardness of at least about 10 GPa.
51. The coated article of claim 50, further including a third layer
and a fourth layer, said third layer being located between said
fourth layer and said second layer, and wherein said third layer is
a primer layer comprising at least an oxide and said fourth layer
is a hydrophobic layer.
52. The coated article of claim 51, wherein each of said first,
second and third layers include DLC and sp.sup.3 carbon-carbon
bonds, and wherein said second layer has an average hardness
greater than respective average hardness(es) of said first and
third layers and wherein said second layer has a greater percentage
or ratio of sp.sup.3 carbon-carbon bonds than either of said first
and third layers.
53. A coated article comprising: a substrate; a DLC inclusive layer
provided on said substrate, said DLC inclusive layer including
sp.sup.3 carbon-carbon bonds; an oxide inclusive layer provided on
said substrate; a hydrophobic layer provided on said substrate; and
wherein said oxide inclusive layer is located between said DLC
inclusive layer and said hydrophobic layer.
54. The coated article of claim 53, wherein said oxide inclusive
layer is a primer layer and further includes DLC and sp.sup.3
carbon-carbon bonds, and wherein said DLC inclusive layer is harder
than said primer layer and includes a greater percentage or ratio
of sp.sup.3 carbon-carbon bonds than said primer layer.
55. The coated article of claim 54, wherein said primer layer is in
direct contact with each of hydrophobic layer and said DLC
inclusive layer.
56. The coated article of claim 54, wherein said primer layer is
ion beam deposited on the substrate using at least a siloxane gas,
and said DLC inclusive layer is ion beam deposited on the substrate
using at least a hydrocarbon gas.
57. The coated article of claim 54, wherein the coated article has
an initial contact angle .theta. of at least about 80 degrees, and
an average hardness of at least about 10 GPa.
58. The coated article of claim 53, further including an
anti-reflective layer provided between said DLC inclusive layer and
said substrate, wherein said antireflective layer includes C, Si,
and O and has an index of refraction "n" of from about 1.4 to
2.0.
59. The coated article of claim 58, wherein each of said
anti-reflective layer, said DLC inclusive layer, and said oxide
inclusive layer include DLC and sp.sup.3 carbon-carbon bonds, and
wherein said DLC inclusive layer has an average hardness greater
than respective average hardness(es) of said anti-reflective and
oxide inclusive layers and wherein said DLC inclusive layer has a
greater percentage or ratio of sp.sup.3 carbon-carbon bonds than
either of said anti-reflective layer or said oxide inclusive
layer.
60. The coated article of claim 53, wherein said hydrophobic layer
includes at least one FAS compound.
61. The coated article of claim 60, wherein said FAS compound
includes at least one of:
CF.sub.3(CH.sub.2).sub.2Si(OCH.sub.3).sub.3;
CF.sub.3(CF.sub.2).sub.5(CH.sub.2).sub.2Si(OCH.sub.2CH.sub.3).sub.3;
CF.sub.3(CH.sub.2).sub.2SiCl.sub.3;
CF.sub.3(CF.sub.2).sub.5(CH.sub.2).su- b.2SiCl.sub.3;
CF.sub.3(CF.sub.2).sub.7(CH.sub.2).sub.2Si(OCH.sub.3).sub.3- ;
CF.sub.3(CF.sub.2).sub.5(CH.sub.2).sub.2Si(OCH.sub.3).sub.3;
CF.sub.3(CF.sub.2).sub.7(CH.sub.2).sub.2SiCl.sub.3;
CF.sub.3(CF.sub.2).sub.7(CH.sub.2).sub.2SiCH.sub.3Cl.sub.2; and
CF.sub.3(CF.sub.2).sub.7(CH.sub.2).sub.2SiCH.sub.3(OCH.sub.3).sub.2.
62. A coated article comprising: a substrate including at least one
of plastic, glass and ceramic; a first DLC inclusive layer provided
on said substrate, said first DLC inclusive layer being deposited
on the substrate using at least a first gas, the first gas
including at least one of first gas comprises at least one of:
tetramethyldisiloxane (TMDSO), tetraethoxylsilane (TEOS),
hexamethyldisiloxane (HMDSO), octamethylcyclotetrasiloxane
(OMCTSO), an ethoxy substituted silane, TMS, and an alkoxy
substituted silane; and a second DLC inclusive layer provided on
said substrate, the second DLC inclusive layer being deposited
using at least a second gas different than the first gas, and
wherein at least a portion of said first DLC inclusive layer is
located between said substrate and said second DLC inclusive
layer.
63. The article of claim 62, wherein the second gas comprises a
hydrocarbon.
64. The article of claim 62, wherein the first gas comprises HMDSO
and the second gas comprises C.sub.2H.sub.2.
65. The article of claim 62, wherein the second DLC inclusive layer
has a greater average hardness than the first DLC inclusive
layer.
66. The article of claim 62, wherein the coated article has an
initial contact angle greater than about 80 degrees.
67. The article of claim 62, further comprises an FAS inclusive
layer provided on said first and second DLC inclusive layers,
wherein said first and second DLC inclusive layers are each located
at least partially between the FAS inclusive layer and the
substrate.
Description
[0001] This is a continuation-in-part (CIP) of each of U.S. patent
application Ser. No. 09/627,441, filed Jul. 28, 2000, Ser. No.
09/617,815 filed Jul. 17, 2000, Ser. No. 09/303,548, filed May 3,
1999, Ser. No. 09/442,805, filed Nov. 18, 1999, and Ser. No.
09/583,862 filed Jun. 1, 2000, the disclosures of which are all
hereby incorporated herein by reference.
[0002] This invention relates to a coated article including at
least one diamond-like carbon (DLC) inclusive layer and at least
one layer deposited using a siloxane and/or oxygen (O) inclusive
organosilicon compound gas (e.g., hexamethyldisiloxane gas which
may be abbreviated herein as HMDSO) provided on (directly or
indirectly) a substrate of glass, plastic, ceramic, or the like,
and a corresponding method of making the same.
BACKGROUND OF THE INVENTION
[0003] It is known to deposit diamond-like carbon (DLC) coatings on
a substrate. Unfortunately, DLC becomes dark in color and absorbs
visible light rays at high thicknesses. DLC may even absorb some
visible light at small thicknesses.
[0004] There exists a need in the art to coat articles such as
vehicle windows/windshields, architectural glass, etc. with DLC in
order to make such articles more scratch resistant and durable.
However, such articles may often be used in environments (e.g.,
vehicle windshields, vehicle windows, etc.) where high visible
light transmission (i.e., low visible light reflection and/or
absorption) is desirable. Thus, there exists a need in the art to
provide a coated article including at least one DLC inclusive
layer(s) thereon for durability purposes which at the same time can
experience sufficiently high visible light transmittance and/or low
visible light reflectance if same is desired.
[0005] Certain of the aforesaid parent applications discuss the use
of a TMS gas to form a DLC inclusive layer disposed between a glass
substrate and another DLC inclusive layer deposited via at least
acetylene gas. While such articles have many desirable
characteristics and function very well, the use of TMS gas to form
the layer between the other DLC inclusive layer and a glass
substrate has been found to lead to a resulting article
experiencing more visible light reflection than would otherwise be
desired. The refractive index "n" of glass is about 1.57, while the
refractive index "n" of DLC deposited via acetylene gas is about
2.0 in the visible range. A layer deposited using TMS gas typically
has a refractive index "n" of about 1.9 to 2.0. As a result of the
rather high refractive index "n" of such a TMS layer, the resulting
article tends to experience more visible light reflection than
would otherwise be desired in certain circumstances.
[0006] In view of the above, it is apparent that there exists a
need in the art for a coated article including at least one DLC
inclusive layer that has good visible transmission characteristics,
and a corresponding method of making the same. There also exists a
need in the art for a layer which can be deposited directly between
a glass substrate and a DLC inclusive layer that more closely
matches or couples the respective refractive indices of the glass
and DLC in order to reduce visible reflection(s) off of the
resulting coated article. Thus, there further exists a need in the
art for a layer having a refractive index "n" of from about 1.4 to
2.0 (more preferably from about 1.5 to 1.8) that is compatible with
DLC and glass which may be disposed between a DLC inclusive layer
and a glass substrate, which can limit visible light reflection off
of a resulting coated article and simultaneously can provide a good
bond between the DLC and glass.
[0007] It has also been found that under certain circumstances
hydrophobic layers such as fluoro-alkyl silane (FAS) inclusive
layers have trouble bonding directly to hard DLC inclusive layers
deposited using acetylene gas. Thus, there also exists a need in
the art for a DLC inclusive hydrophobic coating system including a
primer layer for improving bonding between an overlying hydrophobic
layer and an underlying DLC inclusive layer.
[0008] It is a purpose of different embodiments of this invention
to fulfill any and/or all of the above described needs in the art,
and/or other needs which will become apparent to the skilled
artisan once given the following disclosure.
SUMMARY OF THE INVENTION
[0009] In certain embodiments of this invention, a coated article
includes an oxygen (O) and/or silicon (Si) inclusive
anti-reflection layer disposed between a glass substrate and a
diamond-like carbon (DLC) inclusive layer. The presence of oxygen
and/or silicon in the anti-reflective layer tends to lower the
refractive index "n" (visible) so as to be within the range of from
about 1.4 to 2.0 (more preferably from about 1.5 to 1.9, and most
preferably from about 1.5 to 1.8), and also enables good bonding
with both the DLC inclusive layer(s) and the glass substrate. The
anti-reflective index "n" (visible) matching/coupling layer enables
visible reflection off of the resulting coated article to be
reduced. In certain exemplary embodiments, the anti-reflective
and/or index matching/coupling layer may include at least some DLC
to improve bonding and/or durability characteristics of the
resulting coated article.
[0010] According to an exemplary method of making such a coated
article, at least a siloxane gas (e.g., HMDSO, OMCTSO, TMDSO, TEOS,
etc.) is utilized in order to deposit the anti-reflective layer(s).
According to certain embodiments, at least an oxygen (O) inclusive
organosilicon (this phrase including siloxanes and other oxygen
inclusive organosilicon compounds) compound inclusive gas may be
used to deposit the antireflective layer(s).
[0011] In certain embodiments, an oxide inclusive primer layer(s)
may be provided over the DLC inclusive layer(s) and a hydrophobic
layer (e.g., FAS inclusive layer) may be provided over the primer
layer(s). The primer layer(s) may include or be of, for example,
any of the aforesaid materials that may be used for the index
matching layer and thus may be DLC inclusive in certain
embodiments. Alternatively, the primer layer(s) may instead be of
or include an oxide such as titanium oxide (TiO.sub.x), silicon
oxide (SiO.sub.x), HfO.sub.x, VO.sub.x, any combination thereof, or
any other suitable oxide material having any desired
stoichiometry.
[0012] Coated articles made according to certain embodiments of
this invention may be hydrophobic (e.g., shed water), while coated
articles made according to other embodiments of this invention need
not be hydrophobic. In hydrophobic embodiments, an object of this
invention is to provide a durable coated article that can shed or
repel water (e.g. automotive windshield, automotive backlite,
automotive side window, architectural window, bathroom shower
glass, residential window, bathroom shower door, coated ceramic
article/tile, etc.). In one exemplary hydrophobic embodiment, a
coating system includes each of DLC and FAS, the DLC being provided
for at least durability purposes and the FAS for increasing the
contact angle of the coating system.
[0013] In certain embodiments of this invention, an object of this
invention is to provide a coated substrate having a coating system
including sp.sup.3 carbon-carbon bonds and an adhesion energy (or
wettability) W with regard to water of less than or equal to about
23 mN/m, more preferably less than or equal to about 21 mN/m, even
more preferably less than or equal to about 20 mN/m, and in most
preferred embodiments less than or equal to about 19 mN/meter in
order to provide hydrophobicity. This can also be explained or
measured in energy per unit area (mJ/m.sup.2). Another exemplary
object is to provide a coating system having a surface energy
.gamma..sub.c (on the surface of the coated article) of less than
or equal to about 20.2 mN/m, more preferably less than or equal to
about 19.5 mN/m, and most preferably less than or equal to about 18
mN/m in order to provide hydrophobicity.
[0014] In hydrophobic embodiments, an object of this invention is
to provide a coated substrate, wherein a DLC inclusive coating
system has an initial (i.e. prior to being exposed to environmental
tests, rubbing tests, acid tests, UV tests, or the like) water
contact angle .theta. of at least about 80 degrees, more preferably
of at least about 100 degrees, even more preferably of at least
about 110 degrees, and most preferably of at least about 125
degrees.
[0015] Another object of this invention is to manufacture a coated
article wherein the temperature of an underlying glass substrate
may be less than about 200.degree. C., preferably less than about
150.degree. C., most preferably less than about 80.degree. C.,
during the deposition of a DLC inclusive coating system. This
reduces graphitization during the deposition process, as well as
reduces detempering and/or damage to low-E and/or IR-reflective
coatings already on the substrate in certain embodiments.
[0016] Yet another object of this invention is to fulfill any
and/or all of the aforesaid objects and/or needs.
[0017] This invention will now be described with respect to certain
embodiments thereof, along with reference to the accompanying
illustrations.
IN THE DRAWINGS
[0018] FIG. 1(a) is a schematic side cross sectional view
illustrating exemplary gases used in depositing a plurality of
layers on a substrate in accordance with an embodiment of this
invention.
[0019] FIG. 1(b) is a side cross sectional view of a coated article
resulting from the use of the gases of FIG. 1(a) during the article
manufacturing process.
[0020] FIG. 1c) is a side cross sectional view of a coated article
according to another embodiment of this invention, that is similar
to the embodiment of FIGS. 1(a)-(b) except that layers 4 and 6 are
not included in this embodiment.
[0021] FIG. 2 is a side cross sectional view of a coated article
according to another embodiment of this invention, wherein the DLC
and FAS inclusive coating(s) or coating system of FIG. 1(b) is
provided over an intermediate layer(s).
[0022] FIG. 3 is a side cross sectional view of a coated article
according to another embodiment of this invention.
[0023] FIG. 4(a) is a side cross sectional partially schematic view
illustrating a low contact angle .theta. of a water drop on a glass
substrate.
[0024] FIG. 4(b) is a side cross sectional partially schematic view
illustrating the coated article of any of the FIGS. 1-3 embodiments
of this invention and the contact angle .theta. of a water drop
thereon (when hydrophobicity is desired).
[0025] FIG. 5 is a perspective view of a linear ion beam source
which may be used in any embodiment of this invention for
depositing DLC inclusive layer(s) and siloxane gas-deposited
layer(s).
[0026] FIG. 6 is a cross sectional view of the linear ion beam
source of FIG. 5.
[0027] FIG. 7 is a diagram illustrating tilt angle as discussed
herein in accordance with certain embodiments of this
invention.
[0028] FIG. 8 is a flowchart illustrating certain steps taken
according to an exemplary embodiment of this invention, in
exemplary embodiments where the optional FAS inclusive hydrophobic
layer is thermally cured after being deposited on the
substrate.
[0029] FIG. 9 illustrates a chemical structure of exemplary
HMDSO.
[0030] FIG. 10 illustrates a chemical structure of exemplary
DMS.
[0031] FIG. 11 illustrates a chemical structure of exemplary
TMS.
[0032] FIG. 12 illustrates a chemical structure of exemplary
3MS.
[0033] FIG. 13 illustrates a chemical structure of exemplary
OMCTSO.
[0034] FIG. 14 illustrates a chemical structure of exemplary
TMDSO.
[0035] FIG. 15 illustrates a chemical structure of exemplary
TEOS.
DETAILED DESCRIPTION OF CERTAIN EMBODIMENTS OF THIS INVENTION
[0036] Referring now more particularly to the accompanying drawings
in which like reference numerals indicate like elements throughout
the accompanying views.
[0037] An object of this invention is to provide a method of making
a coated article having a durable light transmissive (e.g.,
transmissive to at least about 60% of visible light rays, more
preferably at least about 70%) coating system thereon. An
anti-reflective refractive index "n" matching/coupling layer is
provided between (either directly or indirectly) the substrate and
a hard DLC inclusive layer in order to reduce visible light
reflections off of the coated article thereby improving
transmission characteristics of the coated article. The
anti-reflective layer also provides good bonding of the DLC
inclusive layer to the substrate so as to enable the resulting
coated article to have good mechanical and/or chemical durability.
In order to manufacture such a coated article with a suitable
anti-reflective layer and bonding characteristics, a siloxane
and/or oxygen inclusive organosilicon gas may be used during the
deposition process of the anti-reflective index matching/coupling
layer. Thus, in certain preferred embodiments, the anti-reflective
index matching layer includes DLC, although it need not be as hard
as the DLC inclusive layer over top of it.
[0038] FIGS. 1(a) and 1(b) are side cross sectional views of a
coated article according to an embodiment of this invention,
wherein a diamond-like carbon (DLC) and fluoro-alkyl silane (FAS)
inclusive coating system 5 including layers 2, 3, 4 and 6 is
provided on substrate 1. Substrate 1 may be of glass, plastic,
ceramic, or the like. FIG. 1(a) illustrates exemplary gases (e.g.,
HMDSO and C.sub.2H.sub.2 (acetylene)) which may be used in the
deposition of layers 2-4, while FIG. 1(b) illustrates the resulting
coated article including the final resulting layers 2-4, 6 provided
on substrate 1.
[0039] DLC inclusive layer 3 (e.g., having an index of refraction
"n" of approximately 1.9 to 2.2, most preferably about 2.0) is
provided on the substrate 1 for scratch resistance and/or
durability (e.g., mechanical and/or chemical durability) purposes
in order to protect the underlying substrate 1 from scratches,
corrosion, and the like. Anti-reflective index matching layer 2 is
located between substrate 1 and DLC inclusive layer 3 in order to
couple or approximately match the respective indices of refraction
of DLC inclusive layer 3 and substrate 1. Anit-reflective layer 2
serves the purposes of enabling visible light reflectance off of
the article to be reduced, thereby improving transmittance of the
coated article. Layer 2 may be located directly between DLC
inclusive layer 3 and substrate 1 so as to contact both of them in
certain embodiments, or alternatively other layer(s) may be located
between index matching layer 2 and one/both of substrate 1 and
layer 3. Anti-reflective layer 2 may be referred to herein as an
"index matching" layer when it has an index of refraction "n" of a
value between the respective indices "n" of substrate 1 and layer
3.
[0040] Thus, the term "between" as used herein simply means that a
primary layer being referred to is located at some position between
two other layers regardless of whether they are in direct contact
(i.e., other layer(s) may also be located between the other layers,
in addition to the primary layer). For example, if a first layer is
referred to herein as being located "between" second and third
layers, then the first layer may or may not be in direct contact
with the second and third layers (e.g., fourth and fifth layers may
be located between the first and third layers). Likewise, the term
"on" herein means both directly on and indirectly on. For example,
if a first layer is "on" a substrate herein, the first layer may be
directly on (contacting) the substrate or alternatively additional
layer(s) may be located between the first layer and the
substrate.
[0041] Layers 4 and 6 are optional and need not be provided in all
embodiments of this invention. When provided, primer layer 4 serves
to improve bonding between FAS inclusive hydrophobic layer 6 and
DLC inclusive layer 3. FAS inclusive layer is provided for
hydrophobic purposes, although hydrophobicity may be achieved
absent FAS inclusive layer 6 in certain embodiments of this
invention. As layers 4 and 6 are optional, coating system 5 may be
made up of, for example, (i) layers 2, 3 only, (ii) layers 2-4
only, (iii) layers 2, 3 and 6 only, (iv) layers 2, 3, 4 and 6 only,
(v) layers 2, 3, 4 and 6 with other non-illustrated layer(s)
overlying the same, underlying the same, or intermingled within or
between any of layers 2, 3, 4 and/or 6, (vi) layers 2 and 3 along
with other non-illustrated layers, (vii) layers 2-4 along with
other non-illustrated layers, and so on. The point here is that
other layers may be provided on substrate 1 (other than those
illustrated in FIGS. 1(a) and 1(b)) according to different
embodiments of this invention.
[0042] Starting from the substrate moving outwardly,
anti-reflective layer 2 is first deposited on substrate 1. Layer 2
may be deposited directly on substrate 1 so as to contact same, or
instead other layer(s) may be located between layer 2 and substrate
1. In any event, layer 2 may be referred to herein as an "index
matching" layer. This phrase "index matching" (or "index coupling")
means that layer 2 has an index of refraction "n" having a value
that is between the respective indices of refraction "n" values of
substrate 1 and DLC inclusive layer 3, in order to reduce visible
light reflections off of the resulting coated article.
[0043] Anti-reflective layer 2 is preferably deposited on substrate
1 utilizing at least a siloxane gas, such as hexamethyldisiloxane
(HMDSO) gas, via an ion beam deposition process. It is noted that
oxygen (O), argon (Ar) and/or other gas(es) may also be used in
combination with the siloxane (e.g., HMDSO) in forming layer 2.
When HMDSO [see FIG. 9] is used during the deposition process for
layer 2, either alone or in combination with other gas(es), the
resulting layer 2 includes DLC and may be referred to as a DLC
inclusive layer that is a hybrid amorphous mixture of DLC and
SiO.sub.x that includes sp.sup.3 carbon-carbon (C--C) bonds,
silicon-oxygen (Si--O) bonds, etc. In certain other embodiments of
this invention, this type of anti-reflective layer 2 may instead be
formed where the HMDSO [see FIG. 9] is replaced in the ion beam
deposition process with another siloxane gas or oxygen inclusive
organosilicon compound gas such as but not limited to
tetramethyldisiloxane (TMDSO) [see FIG. 14],
octamethylcyclotetrasiloxane (OMCTSO) [see FIG. 13],
tetraethoxylsilane (TEOS) [see FIG. 15], any other suitable
siloxane, any other suitable ethoxy substituted silane, any other
alkoxy substituted silane, any other oxygen inclusive organosilicon
compound inclusive gas, or any combination or mixture thereof, etc.
Again, these other gas(es) may be used either alone or in
combination with other gas(es) such as oxygen (O) and/or argon (Ar)
to form layer 2 via an ion beam deposition or any other suitable
process. Other than the O and Ar gases mentioned above, each of
these gases is considered one or both of a siloxane gas or an
oxygen inclusive organosilicon compound gas, as will be appreciated
by those skilled in the art.
[0044] By using the aforesaid gas(es) during the formation of
anti-reflective index coupling layer 2, the resulting layer 2 even
when including DLC is not as hard as DLC inclusive layer 3 because
layer 2 preferably has a lesser amount/percentage of sp.sup.3
carbon-carbon (C--C) bonds than does layer 3. Moreover, the
aforesaid gases enable a DLC inclusive layer 2 to be formed that
has an index of refraction "n" that is from about 1.4 to 2.0, more
preferably from about 1.5 to 1.8, thereby enabling layer 2 to
function in an index coupling manner so as to reduce visible
reflections. It is also noted that layer 2 also functions as a
primer layer to improve bonding between a glass substrate 1 and DLC
inclusive layer 3. Because there is more Si in layer 2 than in
layer 3, layer 2 tends to bond better to substrate 1 than would
layer 3 and layer 3 tends to bond better to layer 2 than it would
to the substrate 1 (see discussion of TMS layer in parent
application(s), incorporated herein by reference). In still further
embodiments of this invention, TMS gas (see FIG. 11), 3MS gas (see
FIG. 12), DMS gas (see FIG. 10), and/or any other suitable gas may
be used instead of or in combination with HMDSO in the ion beam
deposition of layer 2 on substrate 1.
[0045] DLC inclusive layer 3 preferably includes at least some
amount of DLC in the form of highly tetrahedral amorphous carbon
(ta-C) (i.e., including sp.sup.3 carbon-carbon (C--C) bonds), in
order to enhance the durability and/or scratch resistance of the
coated article. In certain embodiments, one or both of layers 2 and
4 may also include at least some amount of highly tetrahedral
amorphous carbon (ta-C), although typically not as much as is
present in layer 3 so that layer 3 is harder than layers 2 and 4.
Thus, DLC inclusive layer 3 preferably has a greater percentage per
unit area of highly tetrahedral amorphous carbon (ta-C) than do
either of layers 2 and 4. Highly tetrahedral amorphous carbon
(ta-C) forms sp carbon-carbon (C--C) bonds, and is a special form
of diamond-like carbon (DLC).
[0046] DLC inclusive layer 3 may be formed and deposited on
substrate 1 in any manner described for depositing a DLC inclusive
layer described in any of the parent applications Ser. Nos.
09/617,815, 09/303,548, 09/442,805, or 09/583,862, all of which are
incorporated herein by reference. Preferably DLC inclusive layer 3
is deposited on substrate 1 and layer 2 via an ion beam deposition
process using at least a hydrocarbon gas such as C.sub.2H.sub.2
(acetylene). Other gas(es) such as oxygen and/or argon may be used
in combination with acetylene during this deposition process. In
other embodiments of this invention, acetylene gas may be replaced
or complimented with e.g., any other suitable hydrocarbon gas for
use in or adjacent the ion beam source during the deposition of DLC
inclusive layer 3. The use of, for example, acetylene gas results
in a DLC inclusive layer 3 that has more sp.sup.3 carbon-carbon
(C--C) bonds than do either of layers 2 and 4. Thus, layer 3 is
harder than layers 2 and 4 and functions to improve the durability
(e.g., scratch resistance and/or chemical resistance) of the
resulting coated article.
[0047] In embodiments where primer layer 4 is desired, layer 4 is
deposited on (either directly or indirectly) DLC inclusive layer 3.
Oxide inclusive primer layer 4 preferably is deposited on layer 3
utilizing at least a siloxane gas such as hexamethyldisiloxane
(HMDSO) gas via an ion beam deposition process. It is noted that
oxygen (O), argon (Ar) and/or other gas(es) may also be used in
combination with the HMDSO [see FIG. 9] in forming layer 4. When
HMDSO is used during the deposition process for primer layer 4,
either alone or in combination with other gas(es), the resulting
primer layer 4 includes DLC, and may be referred to as a DLC
inclusive layer that is a hybrid amorphous mixture of DLC and
SiO.sub.x that includes sp carbon-carbon (C--C) bonds,
silicon-oxygen (Si--O) bonds, etc. In certain other embodiments of
this invention, this type of primer layer 4 may instead be formed
where the HMDSO is replaced in the deposition process with another
siloxane gas or an oxygen inclusive organosilicon compound gas such
as but not limited to tetramethyldisiloxane (TMDSO) [see FIG. 14],
octamethylcyclotetrasiloxane (OMCTSO) [see FIG. 13],
tetraethoxylsilane (TEOS) [see FIG. 15], any other suitable
siloxane, any other suitable ethoxy substituted silane, any other
alkoxy substituted silane, any other oxygen inclusive organosilicon
compound inclusive gas, any combination or mixture thereof, etc.
Again, these other gas(es) may be used either alone or in
combination with other gas(es) such as oxygen and/or argon to form
primer layer 4 via an ion beam deposition process. Each of these
gases (other than O and Ar) is considered one or both of a siloxane
gas or an oxygen inclusive organosilicon compound gas, as will be
appreciated by those skilled in the art.
[0048] By using these gases during the formation of primer layer 4,
the resulting layer 4 even when including DLC is not as hard as DLC
inclusive layer 3 because layer 4 preferably has a lesser
amount/percentage of sp.sup.3 carbon-carbon (C--C) bonds than does
layer 3. Purposes of primer layer 4 include improving bonding
between FAS inclusive layer 6 and DLC inclusive layer 3, and
improving durability of the overall coating system. As for
improving the bonding characteristics of FAS inclusive layer 6 to
DLC inclusive layer 3, it is believed that FAS will not bond
extremely well to carbon itself in layer 3, but will bond to
materials such as silicon oxide which is in primer layer 4. Thus,
the Si, C, and/or O in primer layer 4 enables layer 4 to be both
durable (due to the DLC in layer 4) as well as improve bonding
between layers 6 and 3 (due to the C, Si and/or O in layer 4). For
example, DLC inclusive layer 3 bonds well to the C and/or Si in
primer layer 4, while the FAS inclusive layer 6 bonds well to the
Si and/or O in primer layer 4.
[0049] In other embodiments of this invention, primer layer 4 need
not include DLC and instead may be made of or include any of
titanium oxide (TiO.sub.x), silicon oxide (SiO.sub.x), VO.sub.x,
HfO.sub.x, any mixture thereof, or any other suitable material such
as another oxide layer. In still further embodiments of this
invention, any of the aforesaid oxides may be mixed with a DLC
inclusive material (e.g., deposited via HMDSO or any of the other
gases discussed above) to form primer layer 4.
[0050] When a hydrophobic coating is desired, this may be achieved
in any manner described in any of the parent application(s), all
incorporated herein by reference. Layer 6 may or may not be needed
in hydrophobic embodiments depending upon the manner in which
hydrophobicity is achieved. Where fluoro-alkyl silane (FAS)
compound inclusive layer 6 is desired, it may be applied on
substrate 1 over layers 2, 3 and 4 as shown in FIGS. 1(a) and 1(b).
Due at least to hydrophobic layer 6, the resulting coating system 5
can function in a hydrophobic manner (i.e., it is characterized by
high water contact angles O and/or low surface energies as
described below), and optionally may be characterized by low tilt
angle(s) .beta. in certain embodiments. In general, the DLC
inclusive layer(s) 2, 3 and/or 4 provide durability, hydrophobicity
and priming, while FAS inclusive layer 6 functions to even further
increase the contact angle .theta. of the coating system 5.
[0051] It is surmised that the surface of DLC inclusive primer
layer 4 (or layer 3 when primer layer 4 is not present in certain
embodiments) includes highly reactive dangling bonds immediately
after its formation/deposition, and that the application of FAS
inclusive layer 6 onto the surface of primer layer 4 shortly after
layer 4's formation enables tight binding and/or anchoring of FAS
inclusive layer 6 to the surface of layer 4. This results in
increased contact angle .theta. (improved hydrophobicity) and a
durable coating system 5. In certain embodiments of this invention,
it has been found that FAS inclusive layer 6 bonds more completely
to DLC inclusive primer layer 4 when FAS layer 6 is applied on the
upper surface of layer 4 within one hour or so after layer 4 is
formed, more preferably within thirty minutes after layer 4 is
formed, and most preferably within twenty minutes after layer 4 is
formed. As discussed in more detail below (see FIG. 8), at least
FAS inclusive layer 6 may be heated (thermally cured) after it has
been deposited on the substrate 1 in order to improve its
durability in certain embodiments.
[0052] Overlying layer 6 may be substantially all FAS, or only
partially FAS in different embodiments of this invention. Layer 6
preferably includes at least one compound having an FAS group.
Generally speaking, FAS compounds generally comprise silicon atoms
bonded to four chemical groups. One or more of these groups
contains fluorine and carbon atoms, and the remaining group(s)
attached to the silicon atoms are typically alkyl (hydrocarbon),
alkoxy (hydrocarbon attached to oxygen), or halide (e.g., chlorine)
group(s). Exemplary types of FAS for use in layer 6 include
CF.sub.3(CH.sub.2).sub.2Si(OCH.sub.3).sub.3 [i.e., 3,3,3
trifluoropropyl)trimethoxysilane];
CF.sub.3(CF.sub.2).sub.5(CH.sub.2).sub-
.2Si(OCH.sub.2CH.sub.3).sub.3 [i.e.,
tridecafluoro-1,1,2,2-tetrahydrooctyl- -1-triethoxysilane];
CF.sub.3(CH.sub.2).sub.2SiCl.sub.3;
CF.sub.3(CF.sub.2).sub.5(CH.sub.2).sub.2SiCl.sub.3;
CF.sub.3(CF.sub.2).sub.7(CH.sub.2).sub.2Si(OCH.sub.3).sub.3;
CF.sub.3(CF.sub.2).sub.5(CH.sub.2).sub.2Si(OCH.sub.3).sub.3;
CF.sub.3(CF.sub.2).sub.7(CH.sub.2).sub.2SiCl.sub.3;
CF.sub.3(CF.sub.2).sub.7(CH.sub.2).sub.2SiCH.sub.3Cl.sub.2; and/or
CF.sub.3(CF.sub.2).sub.7(CH.sub.2).sub.2SiCH.sub.3(OCH.sub.3).sub.2.
These FAS material may be used either alone or in any suitable
combination for layer 6. At least partial hydrolysate (hydrolysed)
versions of any of these compounds may also be used. Moreover, it
is noted that this list of exemplary FAS materials is not intended
to be limiting, as other FAS type materials may also be used in
layer 6. While FAS inclusive layer 6 is applied over layers 2-4
physical rubbing (or buffing) in certain preferred embodiments of
this invention, layer 6 could instead be applied in any other
suitable manner in other embodiments of this invention. Moreover,
according to alternative embodiments of this invention, a
hydrophobic type layer 6 for increasing contact angle and thus
hydrophobicity need not include FAS. Other hydrophobic layers 6
could instead be used.
[0053] According to certain embodiments of this invention, while
layers 2-4 may each include DLC, at least two of these three layers
is/are preferably deposited using different precursor or feedstock
gases (e.g., a siloxane gas such as HMDSO or the like for layer(s)
2, 4 vs. a hydrocarbon gas such as C.sub.2H.sub.2 or the like for
layer 3) so that layer 3 has different characteristics (e.g.,
different hardnesses and/or densities) than layer(s) 2 and/or 4.
Layers 2 and 4 may have approximately the same characteristics in
certain embodiments of this invention. Alternatively, layers 2 and
4 may also have different characteristics and be deposited with
different gases or gas combinations in other embodiments of this
invention.
[0054] In an exemplary embodiment, anti-reflective index matching
DLC inclusive layer 2 may be deposited using a plasma ion beam
deposition technique utilizing HMDSO gas and oxygen (O) gas (e.g.,
the oxygen gas may flow through the ion beam source itself while
the HMDSO gas may be introduced into the ion beam outside of the
source itself between the slit and the substrate and/or in the
source itself). Meanwhile, DLC inclusive layer 3 may be deposited
using an ion beam deposition technique utilizing a C.sub.2H.sub.2
(acetylene) inclusive precursor or feedstock gas either alone or in
combination with oxygen and/or argon. Still further, primer DLC
inclusive layer 4 may be deposited using an ion beam deposition
technique utilizing HMDSO gas and both argon (Ar) and oxygen (O)
gas (e.g., the oxygen/argon gases may flow through the ion beam
source itself while the HMDSO gas may be introduced into the ion
beam outside of the source itself between the slit and the
substrate and/or in the source itself). The addition of the Ar gas
for use in depositing primer layer 4 (Ar may not be used for layer
2) may cause layer 4 to have a greater hardness than layer 2,
although layer 4 may still not be as hard as layer 3.
[0055] Additionally, it is believed that the underlying layer 2
(including DLC, Si and O) deposited using e.g., HMDSO functions as
a barrier layer to prevent certain impurities from getting into or
out of the substrate 1. Moreover, when HMDSO (see FIG. 9) is used
in the deposition process of layer 2, the Si in layer 2 helps to
enable overlying DLC inclusive layer 3 to better bond and/or adhere
to a glass substrate 1 via layer 2.
[0056] Surprisingly, it has also been found that the use of layer 2
(e.g., deposited via HMDSO or other siloxane gas) provides a more
continuous/contiguous coating on a glass surface at very thin
thicknesses as compared to a DLC inclusive layer 3 deposited using
C.sub.2H.sub.2 (acetylene) gas directly on glass. As a result,
layer 2 can be deposited first directly on glass I at a relatively
thin thickness, and the overlying layer 3 need not be as thick as
would otherwise be required. In general, the thinner the layer 3,
the higher the transmission of the overall coating system.
Moreover, the provision of layer 2 may enable improved yields to be
achieved, as the occurrence of pinholes in the coating system is
less likely.
[0057] In embodiments such as where DLC inclusive layer 3 is formed
on the substrate using a C.sub.2H.sub.2 (acetylene) inclusive
precursor or feedstock gas and DLC inclusive layers 2 and/or 4
is/are formed on the substrate using at least a HMDSO (or other
siloxane or oxygen inclusive organosilicon gas) inclusive precursor
or feedstock gas, then layer(s) 2 and/or 4 tend to intermix with
layer 3 during the deposition process. Thus, there may not be a
clear line(s) delineating or separating layers 2, 3 and 4 in the
final product due to this intermixing (i.e., ion mixing) of the
material from the different layers. However, for purposes of
simplicity, the layers 2-4 are referred to and illustrated herein
as separate layers due to the different deposition processes (e.g.,
gases and/or energies) used in respective formations of adjacent
layers.
[0058] It has been found that the DLC inclusive layer 3 formed
using a hydrocarbon gas, such as C.sub.2H.sub.2 (acetylene)
inclusive precursor or feedstock, tends to have a greater hardness
and density than do layers 2 and 4 formed e.g., using at least a
siloxane such as HMDSO inclusive precursor or feedstock gas. For
example, in certain exemplary embodiments of this invention, layer
3 may have an average hardness (measured via a nano-indentation
hardness measuring technique) of from about 45-85 GPa, more
preferably from about 50-70 GPa, and most preferably from about
55-60 GPa. Meanwhile, when formed via HMDSO or some other siloxane,
layer(s) 2 and 4 may have an average hardness(es) of from about
1-35 GPa, and more preferably from about 10-30 GPa. Using a
nano-indentation hardness measuring technique, the final coating
system 5, including e.g., layers 2-4 and 6, may have an average
hardness of at least about 10 GPa, more preferably from about 25-60
GPa, and even more preferably from about 30-45 GPa.
[0059] Thus, coating system 5 includes silicon (Si) and oxygen (O)
and DLC inclusive layer 2 which functions as both an index
matching/coupling layer and to improve the bonding characteristics
of harder DLC inclusive layer 3 to the substrate. While the Si in
layer 2 improves the bonding of layer 3 to substrate 1, it is
preferred that less Si be provided in layer 3 than in layer 2
because the provision of Si in a DLC inclusive layer may result in
decreased scratch resistance and/or decreased hardness. Layer 3 may
or may not include Si in different embodiments of this invention.
While layer 2 allows for improved bonding to the substrate and
reduced visible light reflections, the provision of DLC and some
sp.sup.3 carbon-carbon bonds therein allows this layer 2 to have
rather high hardness values so as to render the resulting product
more durable and thus resistant to scratching, abrasions, and the
like. Because primer layer 4 may include DLC, Si and O in certain
embodiments as well, many of these same attributes apply to layer 4
as well.
[0060] In embodiments where substrate 1 is of or includes glass
(e.g., soda-lime-silica glass), anti-reflective layer 2 may be from
about 10 to 250 angstroms (A) thick, more preferably from about 10
to 150 angstroms thick, and most preferably from about 30-50
angstroms thick; DLC inclusive layer 3 may be from about 10 to 250
angstroms thick, more preferably from about 10 to 150 angstroms
thick, and most preferably about 30-60 angstroms (.ANG.) thick, and
primer layer 4 may be from about 10 to 250 .ANG. thick, more
preferably from about 10 to 150 .ANG. thick. FAS inclusive layer 6
may be from about 5-80 angstroms (.ANG.) thick, more preferably
from about 20-50 .ANG. thick. However, these thicknesses are not
limiting and the layers may be of other appropriate thicknesses in
certain embodiments of this invention. Moreover, in embodiments
where substrate 1 is of or includes plastic, layers 2, 3 and/or 6
may be of greater thickness(es) than those described above.
[0061] In certain embodiments, DLC inclusive layer 3 may have an
approximately uniform distribution of sp.sup.3 carbon-carbon bonds
throughout a large portion of its thickness, so that much of the
layer has approximately the same density. In such embodiments,
layers 2 and/or 4 may include a lesser percentage(s) of sp.sup.3
carbon-carbon bonds. As with layer 3, the distribution of sp.sup.3
carbon-carbon bonds in layers 2 and 4 may be approximately uniform
through their respective thicknesses, or alternatively may vary. In
layer 2 for example, the percentage or ratio of sp.sup.3
carbon-carbon bonds may increase throughout the thickness of the
layer 2 toward layer 3. Likewise, in layer 3 the percentage or
ratio of sp.sup.3 carbon-carbon bonds may be approximately uniform
through the layer's thickness or instead may gradually increase
throughout the thickness of the layer 3 toward layer 4. It is noted
that in DLC inclusive layer 3, at least about 40% (more preferably
at least about 60%, and most preferably at least about 80%) of the
carbon-carbon bonds in that layer 3 are of the sp.sup.3
carbon-carbon type. In each of layers 2 and 4, at least about 5%
(more preferably at least about 10%, and most preferably at least
about 20%) of the carbon-carbon bonds are of the sp.sup.3
carbon-carbon type. However, in layers 2 and 4 a lesser percentage
of the total bonds in the entire layer(s) are sp.sup.3
carbon-carbon type bonds due to the presence of, e.g., Si and O in
these layers.
[0062] It is believed that the presence of sp.sup.3 carbon-carbon
bonds in layers 2-4 increases the density and hardness of the
coating system, thereby enabling it to satisfactorily function in
automotive environments. Layers 2-4 may or may not include sp.sup.2
carbon-carbon bonds in different embodiments, although formation of
sp.sup.2 carbon-carbon bonds is likely in all of these layers and
even preferred to some extent especially in layers 2 and 4.
[0063] When hydrophobicity is desired, in order to improve the
hydrophobic nature of coating system 5 atoms in addition to carbon
(C) may be provided in at least layer 3 when layers 4 and 6 are not
provided. For example, in certain embodiments of this invention
when layer 3 is the outermost layer, that layer 3 (taking the
entire layer thickness, or only a thin 10 A thick layer portion
thereof into consideration) may include in addition to the carbon
atoms of the sp.sup.3 carbon-carbon bonds, by atomic percentage,
from about 0-20% Si (more preferably from about 0-10%), from about
0-20% oxygen (O) (more preferably from about 0-15%), and from about
5-60% hydrogen (H) (more preferably from about 535% H). Optionally,
in such embodiments layer 3 may include from about 0-10% (atomic
percentage) fluorine (F) (more preferably from about 0-5% F) in
order to further enhance hydrophobic characteristics of the
coating. This is discussed in more detail in one or more of the
parent cases, incorporated herein by reference. In general, the
provision of H in layer 3 reduces the number of polar bonds at the
coating's surface, thereby improving the coating system's
hydrophobic properties. These material(s) may or may not be
provided in layer 3 when a hydrophobic coating system is not
desired, or when layers 4 and 6 are provided in the system.
[0064] FIG. 1(c) is a side cross sectional view of a coated article
according to another embodiment of this invention, the coated
article including substrate 1 and layers 2 and 3 thereon. This FIG.
1(c) embodiment is similar to the FIGS. 1(a)-1(b) embodiment,
except that layers 4 and 6 are not provided in this embodiment.
Thus, for example, the coated article may include substrate 1
(e.g., glass) on which layer 2 (e.g., formed using a HMDSO, or
other siloxane or oxygen inclusive organosilicon gas) and DLC
inclusive layer 3 (e.g., formed using C.sub.2H.sub.2 gas) are
formed. This coated article may or may not be hydrophobic in
different embodiments of this invention. Optionally, this coated
article may even be hydrophillic in certain embodiments of this
invention.
[0065] FIG. 2 is a side cross sectional view of a coated article
according to another embodiment of this invention, including
substrate 1 (e.g. glass), DLC inclusive coating system 5 including
layers 2, 3, 4 and 6 as described above with regard to the FIG. 1
embodiment, and intermediate layer(s) 7 provided between layer 2
and substrate 1. Intermediate layer 7 may be of or include, for
example, any of silicon nitride, silicon oxide, an infrared (IR)
reflecting layer or layer system, an ultraviolet (UV) reflecting
layer or layer system, another DLC inclusive layer(s), or any other
type of desired layer(s). In this embodiment, it is noted that
coating system 5 is still "on" substrate 1. The term "on" herein
means that substrate 1 supports DLC coating system 5, regardless of
whether or not other layer(s) (e.g. 7) are provided therebetween
(this also applies to the term "over" herein). Thus, coating system
5 may be provided directly on substrate 1 as shown in FIG. 1, or
may be provided on substrate I with another coating system or layer
7 therebetween as shown in FIG. 2. Exemplar coatings/layers that
may be used as low-E or other coating(s)/layer(s) 7 are shown
and/or described in any of U.S. Pat. Nos. 5,837,108, 5,800,933,
5,770,321, 5,557,462, 5,514,476, 5,425,861, 5,344,718, 5,376,455,
5,298,048, 5,242,560, 5,229,194, 5,188,887 and 4,960,645, which are
all hereby incorporated herein by reference.
[0066] FIG. 3 illustrates another embodiment of this invention that
is the same as the FIG. 1 embodiment, except that primer layer 4 is
not provided. It has been found that primer layer 4 need not be
provided in all embodiments of this invention. Likewise, in other
embodiments of this invention (not shown), FAS inclusive layer 6
need not be provided. In still further embodiments (not shown), one
or more intermediate layer(s) 7 may be provided between layer 2 and
substrate 1 in the FIG. 3 embodiment.
[0067] Referring to the different embodiments of FIGS. 1-3, coating
system 5 is at least about 60% transparent to or transmissive of
visible light rays, more preferably at least about 70%
transmissive, even more preferably at least about 85% transmissive,
and most preferably at least about 95% transmissive of visible
light rays.
[0068] When substrate 1 is of glass, it may be from about 1.0 to
5.0 mm thick, preferably from about 2.3 to 4.8 mm thick, and most
preferably from about 3.7 to 4.8 mm thick. In certain embodiments,
another advantage of coating system 5 is that the ta-C (e.g., in
layers 2-4) therein may reduce the amount of soda (e.g., from a
soda-lime-silica glass substrate 1) that can reach the surface of
the coated article and cause stains/corrosion. In such embodiments,
substrate 1 may be soda-lime-silica glass and include, on a weight
basis, from about 60-80% SiO.sub.2, from about 10-20% Na.sub.2O,
from about 0-16% CaO, from about 0-10% K.sub.2O, from about 0-10%
MgO, and from about 0-5% Al.sub.2O.sub.3. Iron and/or other
additives may also be provided in the glass composition of the
substrate 1. In certain other embodiments, substrate 1 may be soda
lime silica glass including, on a weight basis, from about 66-75%
SiO.sub.2, from about 10-20% Na.sub.2O, from about 5-15% CaO, from
about 0-5% MgO, from about 0-5% Al.sub.2O.sub.3, and from about
0-5% K.sub.2O. Most preferably, substrate 1 is soda lime silica
glass including, by weight, from about 70-74% SiO.sub.2, from about
12-16% Na.sub.2O, from about 7-12% CaO, from about 3.5 to 4.5% MgO,
from about 0 to 2.0% Al.sub.2O.sub.3, from about 0-5% K.sub.2O, and
from about 0.08 to 0.15% iron oxide. Soda lime silica glass
according to any of the above embodiments may have a density of
from about 150 to 160 pounds per cubic foot (preferably about 156),
an average short term bending strength of from about 6,500 to 7,500
psi (preferably about 7,000 psi), a specific heat (0-100 degrees C)
of about 0.20 Btu/lbF, a softening point of from about 1330 to 1345
degrees F, a thermal conductivity of from about 0.52 to 0.57
Btu/hrftF, and a coefficient of linear expansion (room temperature
to 350 degrees C) of from about 4.7 to 5.0.times.10.sup.-6 degrees
F. Also, soda lime silica float glass available from Guardian
Industries Corp., Auburn Hills, Mich., may be used as substrate 1.
Any such aforesaid glass substrate 1 may be, for example, green,
blue or grey in color when appropriate colorant(s) are provided in
the glass in certain embodiments.
[0069] In certain other embodiments of this invention, substrate 1
may be of borosilicate glass, or of substantially transparent
plastic, or alternatively of ceramic. In certain borosilicate
embodiments, the substrate 1 may include from about 75-85%
SiO.sub.2, from about 0-5% Na.sub.2O, from about 0 to 4%
Al.sub.2O.sub.3, from about 0-5% K.sub.2O, from about 8-15%
B.sub.2O.sub.3, and from about 0-5% Li.sub.2O.
[0070] In still further embodiments, an automotive window (e.g.
windshield or side window) including any of the above glass
substrates laminated to a plastic substrate may combine to make up
substrate 1, with the coating system(s) of any of the FIGS. 1-3
embodiments or any other embodiment herein provided on the outside
or inside surface(s) of such a window. In other embodiments,
substrate 1 may include first and second glass sheets of any of the
above mentioned glass materials laminated to one another, for use
in window (e.g. automotive windshield, residential window,
commercial architectural window, automotive side window, vacuum IG
window, automotive backlight or back window, etc.) and other
similar environments.
[0071] In hydrophobic embodiments of this invention, hydrophobic
performance of the coating system of any of the FIGS. 1-3
embodiments is a function of contact angle .theta., surface energy
.gamma., tilt angle .beta., and/or wettability or adhesion energy
W.
[0072] The surface energy .gamma. of a coating system may be
calculated by measuring its contact angle .theta. (contact angle
.theta. is illustrated in FIGS. 4(a) and 4(b)). FIG. 4(a) shows the
contact angle of a drop on a substrate absent this invention, while
FIG. 4(b) shows the contact angle of a drop on a substrate having a
coating system thereon according to a hydrophobic embodiment of
this invention. A sessile drop 31 of a liquid such as water is
placed on the coating as shown in FIG. 4(b). A contact angle
.theta. between the drop 31 and underlying coating system 5
appears, defining an angle depending upon the interface tension
between the three phases in the point of contact. Generally, the
surface energy .gamma..sub.c of a coating system can be determined
by the addition of a polar and a dispersive component, as follows:
.gamma..sub.c=.gamma..sub.C- P+.gamma..sub.CD, where .gamma..sub.CP
is the coating's polar component and .gamma..sub.CD the coating's
dispersive component. The polar component of the surface energy
represents the interactions of the surface which is mainly based on
dipoles, while the dispersive component represents, for example,
van der Waals forces, based upon electronic interactions. Generally
speaking, the lower the surface energy .gamma..sub.C of coating
system 5, the more hydrophobic the coating and the higher the
contact angle .theta..
[0073] Adhesion energy (or wettability) W can be understood as an
interaction between polar with polar, and dispersive with
dispersive forces, between the coating system and a liquid thereon
such as water. .gamma..sup.P is the product of the polar aspects of
liquid tension and coating/substrate tension; while .gamma..sup.D
is the product of the dispersive forces of liquid tension and
coating/substrate tension. In other words,
.gamma..sup.P=.gamma..sub.LP*.gamma..sub.CPA; and
.gamma..sup.D=.gamma..sub.LD*.gamma..sub.CD; where .gamma..sub.LP
is the polar aspect of the liquid (e.g. water), .gamma..sub.CP is
the polar aspect of coating system (e.g., coating system 5);
.gamma..sub.LD is the dispersive aspect of liquid (e.g. water), and
.gamma..sub.CD is the dispersive aspect of the coating system. It
is noted that adhesion energy (or effective interactive energy) W,
using the extended Fowkes equation, may be determined by:
[0074] W=[.gamma..sub.LP*.gamma..sub.CP]{fraction
(1/2)}+[.gamma..sub.LD*.- gamma..sub.CD]{fraction
(1/2)}=.gamma..sub.1(1+cos .theta.), where .gamma..sub.1 is liquid
tension and .theta. is the contact angle. W of two materials is a
measure of wettability indicative of how hydrophobic the coating
system is.
[0075] When analyzing the degree of hydrophobicity of outermost
layer/portion of the coating system 5 with regard to water, it is
noted that for water .gamma..sub.LP is 51 mN/m and .gamma..sub.LD
is 22 mN/m. In certain embodiments of this inention, the polar
aspect .gamma..sub.CP of surface energy of layers 3, 4 and/or 6 is
from about 0 to 0.2 (more preferably variable or tunable between 0
and 0.1) and the dispersive aspect .gamma..sub.CD of the surface
energy of layers 3, 4 and/or 6 is from about 16-22 mN/m (more
preferably from about 16-20 mN/m). Using the above-listed numbers,
according to certain embodiments of this invention, the surface
energy .gamma..sub.C of layer 6 (or 3 in certain embodiments) (and
thus coating system 5) is less than or equal to about 20.2 mN/m,
more preferably less than or equal to about 19.5 mN/m, and most
preferably less than or equal to about 18.0 mN/m; and the adhesion
energy W between water and the coating system is less than about 25
mN/m, more preferably less than about 23 mN/m, even more preferably
less than about 20 mN/m, and most preferably less than about 19
mN/m. These low values of adhesion energy W and the coating
system's surface energy yc, and the high initial contact angles
.theta. achievable, illustrate the improved hydrophobic nature of
the coating systems 5 according to different embodiments of this
invention. While layers 3, 4 and/or 6 functions to provide much of
the hydrophobic nature of the coating system 5, optional underlying
DLC inclusive layer 2 improves the bonding characteristics of the
coating system 5 to the substrate 1 (e.g., glass substrate) and yet
still provides adequate hardness characteristics regarding the
coating system 5 as a whole.
[0076] The initial contact angle 0 of a conventional glass
substrate 1 with sessile water drop 31 thereon is typically from
about 22-24 degrees, although it may dip as low as 17 or so degrees
in some circumstances, as illustrated in FIG. 4(a). Thus,
conventional glass substrates are not particularly hydrophobic in
nature. In hydrophobic embodiments of this invention, the provision
of coating system 5 on substrate 1 causes the contact angle .theta.
to increase to the angles discussed herein, as shown in FIG. 4(b)
for example, thereby improving the hydrophobic nature of the
article. As discussed in Table 1 of Ser. No. 09/303,548, the
contact angle .theta. of a ta-C DLC layer is typically less than 50
degrees, although it may be higher than that in certain
circumstances as a function of ion energy. However, the makeup of
DLC-inclusive coating system 5 described herein (with or without
FAS inclusive layer 6) enables the initial contact angle .theta. of
the system relative to a water drop (i.e. sessile drop 31 of water)
to be increased in certain embodiments to at least about 80
degrees, more preferably to at least about 100 degrees, even more
preferably at least about 110 degrees, and most preferably at least
about 125 degrees, thereby improving the hydrophobic
characteristics of the DLC-inclusive coating system. An "initial"
contact angle .theta. means prior to exposure to environmental
conditions such as sun, rain, abrasions, humidity, etc.
[0077] FIGS. 5-6 illustrate an exemplary linear or direct ion beam
source 25 which may be used to deposit layers 2, 3 and 4 of coating
system 5, clean a substrate, or surface plasma treat a DLC
inclusive coating with H and/or F according to different
embodiments of this invention. Ion beam source 25 includes
gas/power inlet 26, anode 27, grounded cathode magnet portion 28,
magnet poles 29, and insulators 30. A 3 kV DC power supply may be
used for source 25 in some embodiments. Linear source ion
deposition allows for substantially uniform deposition of layers 24
as to thickness and stoichiometry. As mentioned above, FAS
inclusive layer 6 is preferably not applied using ion beam
technology (rubbing/buffing is a preferred deposition technique for
layer 6), although it may be formed in such a manner in certain
embodiments of this invention.
[0078] Ion beam source 25 is based upon a known gridless ion source
design. The linear source is composed of a linear shell (which is
the cathode and grounded) inside of which lies a concentric anode
(which is at a positive potential). This geometry of cathode-anode
and magnetic field 33 gives rise to a close drift condition. The
anode layer ion source can also work in a reactive mode (e.g. with
oxygen and nitrogen). The source includes a metal housing with a
slit in a shape of a race track as shown in FIGS. 5-6. The hollow
housing is at ground potential. The anode electrode is situated
within the cathode body (though electrically insulated) and is
positioned just below the slit. The anode can be connected to a
positive potential as high was 3,000 or more volts (V). Both
electrodes may be water cooled in certain embodiments.
Feedstock/precursor gases, described herein, are fed through the
cavity between the anode and cathode. The gas(es) used determines
the make-up of the resulting layer deposited on an adjacent
substrate 1.
[0079] The linear ion source also contains a labyrinth system that
distributes the precursor gas (e.g., TMS (i.e., (CH.sub.3).sub.4Si
or tetramethylsilane); acetylene (i.e., C.sub.2H.sub.2); 3MS (i.e.,
trimethyldisilane); DMS (i.e., dichloro-dimethylsilane); HMDSO
(i.e., hexamethyldisiloxane); TEOS (i.e., tetraethoxysilane), etc.)
fairly evenly along its length and which allows it to
supersonically expand between the anode-cathode space internally.
The electrical energy then cracks the gas to produce a plasma
within the source. The ions are expelled out at energies in the
order of eVc-a/2 when the voltage is Vc-a. The ion beam emanating
from the slit is approximately uniform in the longitudinal
direction and has a Gaussian profile in the transverse direction.
Exemplary ions 34 are shown in FIG. 6. A source as long as one
meter may be made, although sources of different lengths are
anticipated in different embodiments of this invention. Finally,
electron layer 35 is shown in FIG. 6 completes the circuit thereby
enabling the ion beam source to function properly.
[0080] In certain embodiments of this invention, gases discussed
herein (e.g., HMDSO, TEOS, acetylene, etc.) may be fed through the
ion beam source via cavity 42 until they reach the area near slit
44 where they are ionized. However, in other embodiments of this
invention described above, a gas such as HMDSO (e.g., for layers 2
and 4) may be injected into the ion beam at location 39 between the
slit and the substrate 1, while gas such as oxygen and/or argon is
caused to flow through cavity 42 in the source itself adjacent the
ion emitting slit 44. Alternatively, gases such as HMDSO, TEOS,
etc. may be injected into the ion beam both at 39 and via cavity
42.
[0081] In alternative embodiments of this invention, an ion beam
source device or apparatus as described and shown in FIGS. 1-3 of
U.S. Pat. No. 6,002,208 (hereby incorporated herein by reference in
its entirety) may be used to deposit/form DLC inclusive layers 2-4
on substrate 1 in accordance with any of the FIGS. 1-3 embodiments
of this invention. One or multiple such ion beam source devices may
be used (e.g., one source may deposit all layers 2-4, or
alternatively a different source may be used for each of layers
2-4). In certain embodiments, another ion beam source may be
provided for initially cleaning the surface of substrate 1 prior to
deposition of layers 2-4. After layers 2-4 are deposited, FAS
inclusive layer 6 is preferably applied or deposited thereon.
[0082] Referring to FIG. 7, tilt angle .beta. characteristics
associated with certain embodiments of this invention will be
explained. In a hydrophobic coating, it is often desirable in
certain embodiments to have a high contact angle .theta. (see FIG.
4(b)) in combination with a low tilt angle .beta.. As shown in FIG.
7, tilt angle .beta. is the angle relative to the horizontal 43
that the coated article must be tilted before a 30 .mu.L (volume)
drop 41 (e.g., of water) thereon begins to flow down the slant at
room temperature without significant trail. A low tilt angle means
that water and/or other liquids may be easily removed from the
coated article upon tilting the same or even in high wind
conditions. In certain embodiments of this invention, coated
articles herein have an initial tilt angle .beta. of no greater
than about 30 degrees, more preferably no greater than about 20
degrees, and even more preferably no greater than about 10 degrees.
In certain embodiments, the tilt angle does not significantly
increase over time upon exposure to the environment and the like,
while in other embodiments it may increase to some degree over
time.
[0083] Referring to FIGS. 1 and 5-6, an exemplary method of
depositing a coating system 5 on substrate 1 will now be described.
This method is for purposes of example only, and is not intended to
be limiting.
[0084] Prior to coating system 5 being formed on glass substrate 1,
the top surface of substrate 1 may be cleaned by way of a first
linear or direct ion beam source. For example, a glow discharge in
argon (Ar) gas or mixtures of Ar/O.sub.2 (alternatively CF.sub.4
plasma) may be used to remove any impurities on the substrate
surface. Such interactions are physio-chemical in nature. This
cleaning creates free radicals on the substrate surface that
subsequently can be reacted with other monomers yielding substrate
surfaces with specialized properties. The power used may be from
about 100-300 Watts. Substrate 1 may also be cleaned by, for
example, sputter cleaning the substrate prior to actual deposition
of coating system 5; using oxygen and/or carbon atoms at an ion
energy of from about 800 to 1200 eV, most preferably about 1,000
eV.
[0085] After cleaning, the deposition process begins using a linear
ion beam deposition technique via second ion beam source as shown
in FIGS. 5-6, or in FIGS. 1-3 of the '208 patent; with a conveyor
having moved the cleaned substrate 1 from the first or cleaning
source to a position under the second source. The second ion beam
source functions to deposit a DLC inclusive index matching layer 2
on substrate 1, with at least HMDSO and oxygen being used as
gas(es) fed through the source or inserted at 39. Because of the Si
in the HMDSO gas used in the source, the resulting layer 2 formed
on substrate includes at least Si and O as well as DLC. The Si
portion of DLC inclusive layer 2 enables good bonding of layer 2 to
substrate 1 (substrate 1 is glass in this example), and thus will
also improve the bonding characteristics of layer 3 to the
substrate via layer 2. The O portion of layer 2 increases
transmission and enables the refractive index "n" of layer 2 to be
lowered so as to reduce visible light reflections off of the final
coated article.
[0086] After layer 2 has been formed, either the same or another
ion beam source is used to deposit layer 3 over (directly on in
preferred embodiments) layer 2. To deposit overlying DLC inclusive
layer 3, another gas such as at least C.sub.2H.sub.2 is fed through
the source (or inserted at location 39) so that the source expels
the ions necessary to form layer 3 overlying layer 2 on substrate
1. The C.sub.2H.sub.2 gas may be used alone, or in exemplary
alternative embodiments the gas may be produced by bubbling a
carrier gas (e.g. C.sub.2H.sub.2) through a precursor monomer (e.g.
TMS or 3MS) held at about 70 degrees C (well below the flashing
point). Acetylene feedstock gas (C.sub.2H.sub.2) is used in certain
embodiments for depositing layer 3 to prevent or minimize/reduce
polymerization (layer 2 may or may not be polymerized in certain
embodiments) and to obtain an appropriate energy to allow the ions
to penetrate the surface on the substrate/layer 2 and subimplant
therein, thereby causing layer 3 to intermix with layer 2 in at
least an interface portion between the layers. The actual gas flow
may be controlled by a mass flow controller (MFC) which may be
heated to about 70 degrees C. In certain optional embodiments,
oxygen (O.sub.2) gas may be independently flowed through an MFC.
The temperature of substrate 1 may be room temperature; an arc
power of about 1000 W may be used; precursor gas flow may be about
25 sccm; the base pressure may be about 10.sup.-6 Torr. The optimal
ion energy window for the majority of layers 2, 3 is from about
100-1,000 eV (preferably from about 100-400 eV) per carbon ion. At
these energies, the carbon in the resulting layers 2, 3 emulates
diamond, and sp.sup.3 C--C bonds form. However, compressive
stresses can develop in ta-C when being deposited at 100-150 eV.
Such stress can reach as high as 10 GPa and can potentially cause
delamination from many substrates. It has been found that these
stresses can be controlled and decreased by using an ion energy
during the deposition process in a range of from about 200-1,000
eV. As stated above, layers 2 and 3 intermix with one another at
the interface between the two layers, thereby improving the bonding
between the layers. At particle energies (carbon energies) of
several hundred eV, a considerable material transport can take
place over several atomic distances. This is caused by the
penetration of fast ions and neutrals as well as by the recoil
displacement of struck atoms. At sufficiently high particle
energies and impact rates, there is an enhanced diffusion of the
thermally agitated atoms near the film surface that occurs via the
continuously produced vacancies. In the formation of ta-C:H, these
effects can help improve film adhesion by broadening the interface
(i.e., making it thicker, or making an interfacial layer between
the two layers 2 and 3 (or between layer 2 and glass 1) due to atom
mixing). After layer 2 is deposited, the carbon from layer 3
implants into layer 2 (i.e., subimplantation) so as to make the
bond better of layer 3 to the substrate. Thus, layers 2 and 3 are
contiguous due to this intermixing, and this "smearing" between the
layers enhances the adhesion of layer 3 to both layer 2 and thus
the substrate 1.
[0087] High stress is undesirable in the thin interfacing portion
of layer 2 that directly contacts the surface of a glass substrate
1 in the FIG. 1 embodiment. Thus, for example, the first 1-40%
thickness (preferably the first 1-20% and most preferably the first
5-10% thickness) of layer 2 may optionally be deposited on
substrate 1 using high anti-stress energy levels of from about
200-1,000 eV, preferably from about 400-500 eV. Then, after this
initial interfacing layer portion of layer 2 has been grown, the
ion energy in the ion deposition process may be decreased (either
quickly or gradually while deposition continues) to about 100-200
eV, preferably from about 100-150 eV, to grow the remainder of
layer(s) 2 and/or layer(s) 3-4. Thus, in certain embodiments,
because of the adjustment in ion energy and/or gases during the
deposition process, DLC inclusive layers 2-4 may optionally have
different densities and different percentages of sp.sup.3 C--C
bonds at different layer portions thereof (the lower the ion
energy, the more sp.sup.3 C--C bonds and the higher the
density).
[0088] While direct ion beam deposition techniques are preferred in
certain embodiments, other methods of deposition may also be used
in different embodiments. For example, filtered cathodic vacuum arc
ion beam techniques may be used to deposit layers 2-4. Also, in
certain embodiments, CH.sub.4 may be used as a feedstock gas during
the deposition process instead of or in combination with the
aforesaid C.sub.2H.sub.2 gas.
[0089] After layers 2-3 have been deposited, primer layer 4 is
deposited in a manner similar to that described above for layer 2.
However, in one particular example, the gases used in forming layer
4 may include in addition to the HMDSO and oxygen described above,
argon (Ar) mixed with the oxygen gas in order to enable more
sp.sup.3 C--C bonds to be formed in layer 4 than in layer 2 so that
layer 4 is harder than layer 2 (for durability purposes). The Ar/O
mixture is preferably fed through the source via cavity 42 while
the HMDSO gas is preferably inserted into the ion beam at 39, or
alternatively may in addition or instead be caused to flow through
the source at 42 along with the Ar/O gas mixture.
[0090] After DLC inclusive layers 2-4 have been formed on substrate
1, FAS inclusive layer 6 is deposited thereon or applied thereto as
shown in FIG. 1 (e.g., by rubbing or otherwise applying/depositing
this layer 6 in any other suitable manner). After FAS inclusive
layer 6 has been formed on the substrate 1, the coated article is
heated (e.g., at about 70-120 degrees C, or any other temperature
mentioned above). Surprisingly, as mentioned previously, it has
been found that heating the coated article in such a manner
improves the durability of FAS inclusive layer 6, and thus of the
overall coating system. It is thought that such hearing may "cure"
layer 6 or otherwise cause it to more completely bond to itself
and/or layer 4.
[0091] FIG. 8 is a flowchart illustrating certain steps taken in
the manufacture of a hydrophobic coated article according to an
embodiment of this invention. A substrate 1 (e.g., glass, plastic,
or ceranic substrate) is provided at step 10. At least one DLC
inclusive layer 2-4 is deposited on the substrate at step 11.
Following formation of the DLC inclusive layer(s), an FAS compound
inclusive layer is deposited on the substrate in step 12. The FAS
inclusive layer is preferably deposited directly on the upper
surface of a DLC inclusive layer or a primer layer in certain
embodiments of this invention. After the DLC and FAS inclusive
layers have been deposited on the substrate, the entire coated
article (or alternatively only the FAS inclusive layer) is
subjected to heating for curing purposes in step 13. The heating
may take place in any suitable oven or furnace, or alternatively
may be implemented by an IR or any other type of localized heating
device. This heating may be at a temperature of from about 50 to
300 degrees C, more preferably at a temperature of from about 70 to
200 degrees C, and even more preferably at a temperature of from
about 70-100 degrees C. However, it is noted that as the heating
time goes up, the required temperature goes down. Thus, for
purposes of example only, the heating may be conducted at about 80
degrees C for about 60 minutes (1 hour). Alternatively, the heating
may be conducted at about 250 degrees C for about 5 minutes, or at
about 150 degrees C for about 20 minutes. The time which the coated
article is subjected to heating may range from about 20 seconds to
2 hours in certain embodiments of this invention, more preferably
from about one (1) minute to one (1) hour, depending on the
temperature used. In preferred embodiments of this invention, at
least the FAS inclusive layer (and preferably the entire coated
article) is heated at a temperature and for a period of time
sufficient to achieve one or more of the durability and/or
hydrophobic properties discussed above.
[0092] As will be appreciated by those skilled in the art, coated
articles according to different embodiments of this invention may
be utilized in the context of automotive windshields, automotive
side windows, automotive backlites (i.e., rear windows),
architectural windows, residential windows, ceramic tiles, shower
doors, and the like.
[0093] Once given the above disclosure, many other features,
modifications, and improvements will become apparent to the skilled
artisan. Such other features, modifications, and improvements are,
therefore, considered to be a part of this invention, the scope of
which is to be determined by the following claims. For example and
without limitation, certain coated articles according to this
invention may be hydrophobic, other coated articles according to
this invention may be hydrophilic, and still other coated articles
according to this invention may be neither hydrophobic nor
hydrophilic.
* * * * *