U.S. patent application number 13/137044 was filed with the patent office on 2011-11-10 for method of making window unit including diamond-like carbon (dlc) coating.
This patent application is currently assigned to Guardian Industries Corp.. Invention is credited to Vijayen S. Veerasamy.
Application Number | 20110274854 13/137044 |
Document ID | / |
Family ID | 27787711 |
Filed Date | 2011-11-10 |
United States Patent
Application |
20110274854 |
Kind Code |
A1 |
Veerasamy; Vijayen S. |
November 10, 2011 |
Method of making window unit including diamond-like carbon (DLC)
coating
Abstract
A method of making a coated article (e.g., window unit), and
corresponding coated article are provided. A layer of or including
diamond-like carbon (DLC) is formed on a glass substrate. Then, a
protective layer is formed on the substrate over the DLC inclusive
layer. During heat treatment (HT), the protective layer prevents
the DLC inclusive layer from significantly burning off. Thereafter,
the resulting coated glass substrate may be used as desired, it
having been HT and including the protective DLC inclusive
layer.
Inventors: |
Veerasamy; Vijayen S.;
(Farmington Hills, MI) |
Assignee: |
Guardian Industries Corp.
Auburn Hills
MI
|
Family ID: |
27787711 |
Appl. No.: |
13/137044 |
Filed: |
July 18, 2011 |
Related U.S. Patent Documents
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Application
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Filing Date |
Patent Number |
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12588342 |
Oct 13, 2009 |
7988836 |
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13137044 |
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10891187 |
Jul 15, 2004 |
7622161 |
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12588342 |
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10091589 |
Mar 7, 2002 |
6827977 |
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10891187 |
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Current U.S.
Class: |
427/595 ;
427/383.5; 427/404; 432/9 |
Current CPC
Class: |
Y10T 428/24628 20150115;
C23C 16/56 20130101; C03C 2217/78 20130101; Y10T 428/30 20150115;
C03C 17/366 20130101; C03C 17/3441 20130101; C03C 17/3626 20130101;
Y10T 428/265 20150115; B32B 17/10981 20130101; C03C 17/3636
20130101; C03C 2218/365 20130101; C03C 17/3634 20130101; B60J 1/002
20130101; Y10S 427/105 20130101; C03C 17/3482 20130101; C23C 16/26
20130101; B32B 17/10009 20130101; C03C 17/36 20130101; C03C 17/3435
20130101; B32B 17/10174 20130101; Y10S 427/103 20130101; B32B
17/1055 20130101 |
Class at
Publication: |
427/595 ;
427/404; 427/383.5; 432/9 |
International
Class: |
B05D 5/00 20060101
B05D005/00; C23C 16/26 20060101 C23C016/26; C23C 16/40 20060101
C23C016/40; F27D 99/00 20100101 F27D099/00; B05D 3/02 20060101
B05D003/02; C23C 14/34 20060101 C23C014/34; C23C 16/48 20060101
C23C016/48; B05D 1/36 20060101 B05D001/36; C23C 16/34 20060101
C23C016/34 |
Claims
1-54. (canceled)
55. A method of making a coated article, the method comprising:
forming a layer comprising diamond-like carbon (DLC) so as to be
supported by at least a glass substrate, forming a layer comprising
a nitride and/or metal oxide on the glass substrate over at least
the layer comprising DLC, forming a solar control multi-layer
coating including at least one layer comprising silver (Ag) and/or
nickel chrome (NiCr) and at least one dielectric layer so as to be
supported by the glass substrate, so that the solar control
multi-layer coating and the layer comprising DLC are formed on
opposite sides of the glass substrate, wherein the glass substrate
supporting each of the solar control multi-layer coating, the layer
comprising DLC, and the layer comprising the nitride and/or metal
oxide is adapted to be heat treated.
56. The method of claim 55, wherein the layer comprising DLC is
formed via an ion beam, and wherein carbon atoms thereof are
subimplanted into the glass substrate via said ion beam.
57. The method of claim 55, wherein the layer comprising the
nitride and/or metal oxide is at least partially formed via
sputtering.
58. The method of claim 55, wherein the layer comprising DLC
comprises amorphous DLC and has more sp.sup.3 carbon-carbon bonds
than sp.sup.2 carbon-carbon bonds.
59. The method of claim 55, wherein the layer comprising DLC has an
average hardness of at least 10 GPa.
60. The method of claim 55, wherein the layer comprising the
nitride and/or metal oxide comprises silicon nitride.
61. The method of claim 55, wherein the dielectric layer comprises
zinc oxide.
62. The method of claim 55, wherein said solar control multi-layer
coating includes at least one layer comprising silver.
63. The method of claim 55, further comprising heat treating the
glass substrate supporting each of the solar control multi-layer
coating, the layer comprising DLC, and the layer comprising the
nitride and/or metal oxide.
64. The method of claim 55, wherein the layer comprising the
nitride and/or metal oxide comprises NiCrO.sub.x.
65. The method of claim 55, wherein the layer comprising the
nitride and/or metal oxide comprises TiO.sub.x.
66. The method of claim 55, wherein the layer comprising the
nitride and/or metal oxide comprises magnesium oxide.
67. A method of making a coated article, the method comprising:
having a glass substrate that supports at least a layer comprising
diamond-like carbon (DLC) and a protective film, the layer
comprising DLC being located between at least the glass substrate
and the protective film; wherein the protective film comprises
nitride and/or metal oxide; heat treating the glass substrate with
each of the layer comprising DLC and the protective film thereon,
wherein the heat treating comprises heating the glass substrate
using at least temperature(s) of at least 580 degrees C. in an
atmosphere including oxygen, for a time period sufficient for at
least one of bending and thermally tempering the glass
substrate.
68. The method of claim 67, wherein the protective film comprises
NiCrO.sub.x.
69. The method of claim 67, wherein the protective film comprises
TiO.sub.x,
70. The method of claim 67, wherein the protective film comprises
the nitride and the metal oxide.
71. The method of claim 67, wherein the layer comprising DLC is
formed directly on and contacting the glass substrate via an ion
beam, and wherein carbon atoms thereof are subimplanted into the
glass substrate.
72. The method of claim 67, further comprising removing at least
part of the protective film after the heat treating.
73. The method of claim 67, wherein the layer comprising DLC
comprises amorphous DLC and has more sp.sup.3 carbon-carbon bonds
than sp.sup.2 carbon-carbon bonds.
Description
[0001] This invention relates to a method of making a coated
article to be used in a window unit or any other suitable
application. For example, in certain embodiments this invention
relates to a method of making a window unit (e.g., vehicle window
such as vehicle windshield, backlite, sunroof, or sidelite, or IG
window unit) including a step of heat treating a glass substrate
coated with at least a layer comprising diamond-like carbon
(DLC).
BACKGROUND OF THE INVENTION
[0002] Vehicle windows (e.g., windshields, backlites, sunroofs, and
sidelites) are known in the art. For purposes of example, vehicle
windshields typically include a pair of bent glass substrates
laminated together via a polymer interlayer such as polyvinyl
butyral (PVB). It is known that one of the two glass substrates may
have a coating (e.g., low-E coating) thereon for solar control
purposes such as reflecting IR and/or UV radiation, so that the
vehicle interior can be more comfortable in certain weather
conditions. Conventional vehicle windshields are made as follows.
First and second flat glass substrates are provided, one of them
optionally having a low-E coating sputtered thereon. The pair of
glass substrates are washed and booked together (i.e., stacked on
one another), and then while booked are heat bent together into the
desired windshield shape at a high temperature(s) (e.g., 8 minutes
at about 600-625 degrees C.). The two bent glass substrates are
then laminated together via the polymer interlayer to form the
vehicle windshield.
[0003] Insulating glass (IG) window units are also known in the
art. Conventional IG window units include at least first and second
glass substrates (one of which may have a solar control coating on
an interior surface thereof) that are coupled to one another via at
least one seal(s) or spacer(s). The resulting space or gap between
the glass substrates may or may not be filled with gas and/or
evacuated to a low pressure in different instances. However, many
IG units are required to be tempered. Thermal tempering of the
glass substrates for such IG units typically requires heating the
glass substrates to temperature(s) of at least about 600 degrees C.
for a sufficient period of time to enable thermal tempering.
[0004] Other types of coated articles also require heat treatment
(HT) (e.g., tempering, heat bending, and/or heat strengthening) in
certain applications. For example and without limitation, glass
shower doors, glass table tops, and the like require HT in certain
instances.
[0005] Diamond-like carbon (DLC) is sometimes known for its scratch
resistant properties. For example, different types of DLC are
discussed in the following U.S. Pat. Nos. 6,303,226; 6,303,225;
6,261,693; 6,338,901; 6,312,808; 6,280,834; 6,284,377; 6,335,086;
5,858,477; 5,635;245; 5,888,593; 5,135,808; 5,900,342; and
5,470,661, all of which are hereby incorporated herein by
reference.
[0006] It would sometimes be desirable to provide a window unit
with a protective coating including DLC in order to protect the
window from scratches and the like. Unfortunately, DLC tends to bum
off at temperatures of from approximately 380 to 400 degrees C., as
the heat treatment is typically conducted in an atmosphere
including oxygen. Thus, it will be appreciated that DLC as a
protective overcoat cannot withstand the heat treatments (HT) at
the extremely high temperatures described above which are often
required in the manufacture of vehicle windows, IC window units,
and/or the like.
[0007] Accordingly, those skilled in the art will appreciate that a
need in the art exists for a method of providing heat treated (HT)
windows with a protective coating (one or more layers) comprising
DLC. A need for corresponding windows also exists.
BRIEF SUMMARY OF THE INVENTION
[0008] An object of this invention is to provide a method of making
a coated article (e.g., window unit), including heat treatment
(HT), wherein the coated article includes a coating (one or more
layers) comprising diamond-like carbon (DLC).
[0009] Another object of certain example embodiments of this
invention is to provide a method of making a coated article by (a)
coating a glass substrate with a layer comprising DLC, then (b)
forming a protective layer on the glass substrate over the DLC, and
(c) heat treating the coated article with the DLC and the
protective layer thereon with the protective layer preventing the
DLC from burning off (in part or entirely) during the heat
treatment. The resulting coated article may be used in the context
of, for example and without limitation, vehicle windows,
architectural windows, insulating glass (IG) window units, shower
doors, glass table tops, and/or the like.
[0010] Another object of certain example embodiments of this
invention is to provide a coated article (e.g., window unit) made
in accordance with the above technique.
[0011] Another object of certain example embodiments of this
invention is to fulfill one or more of the above-listed objects
and/or needs.
[0012] In certain example embodiments of this invention, one or
more of the above-listed objects and/or needs is/are fulfilled by
providing a method of making an insulating glass (IG) window unit,
the method comprising: providing a glass substrate; forming a layer
comprising diamond-like carbon (DLC) on the glass substrate;
forming a protective layer on the glass substrate over the layer
comprising DLC; heat treating the glass substrate with the layer
comprising DLC and the protective layer thereon so that during the
heat treating the protective layer prevents significant burnoff of
the layer comprising DLC, wherein the heat treating comprises
heating the glass substrate to temperature(s) sufficient for
thermal tempering; and after the heat treating, coupling the glass
substrate with at least the layer comprising DLC thereon to another
substrate in making the IG window unit.
[0013] In certain other example embodiments of this invention, one
or more of the above-listed objects and/or needs is/are fulfilled
by providing a method of making a vehicle windshield, the method
comprising: providing a glass substrate; forming a layer comprising
diamond-like carbon (DLC) on the glass substrate; forming a
protective layer on the glass substrate over the layer comprising
DLC; heat treating the glass substrate with the layer comprising
DLC and the protective layer thereon, wherein the heat treating
comprises heating the glass substrate to temperature(s) sufficient
for bending the glass substrate; and after the heat treating,
laminating the glass substrate with at least the layer comprising
DLC thereon to another substrate via at least a polymer inclusive
interlayer in making the vehicle windshield.
[0014] In still further example embodiments of this invention, one
or more of the above-listed objects and/or needs may be fulfilled
by providing method of making a coated article, the method
comprising: providing a glass substrate; forming a layer comprising
diamond-like carbon (DLC) on the glass substrate; forming a
protective layer on the glass substrate over the layer comprising
DLC; heat treating the glass substrate with the layer comprising
DLC and the protective layer thereon, and wherein the heat treating
comprises heating the glass substrate using at least temperature(s)
of at least 580 degrees C. for at least one of bending and
thermally tempering the glass substrate.
[0015] In yet other example embodiments of this invention, one or
more of the above-listed objects and/or needs may be fulfilled by
providing a coated article comprising: a glass substrate that is
thermally tempered and/or bent; a layer comprising diamond-like
carbon (DLC) supported by the glass substrate; and a protective
layer comprising a carbide provided on the glass substrate over the
layer comprising DLC. In certain example instances, the carbide may
comprise at least one of: boron carbide, titanium carbide, hafnium
carbide, titanium hafnium carbide, tantalum carbide, and zirconium
carbide.
BRIEF DESCRIPTION OF THE DRAWINGS
[0016] FIG. 1 is a cross sectional view of part of an insulating
glass (IG) window unit according to an example embodiment of this
invention.
[0017] FIG. 2 is a cross sectional view of part of a laminated
vehicle windshield according to another example embodiment of this
invention.
[0018] FIGS. 3(a)-3(d) illustrate steps taken according to an
example embodiment of this invention in making either of the window
units of FIGS. 1-2, or any other type of suitable coated
article.
[0019] FIG. 4 is a flowchart illustrating steps taken according to
an example embodiment of this invention in making either of the
window units of FIGS. 1-2, or any other type of suitable coated
article.
DETAILED DESCRIPTION OF THE INVENTION
[0020] Referring now more particularly to the accompanying drawings
in which like reference numerals indicate like parts throughout the
several views.
[0021] Certain example embodiments of this invention relate to
methods of making coated articles that require heat treatment (HT),
so as to include a protective coating (one or more layers)
including diamond-like carbon (DLC). In certain instances, the HT
may require heating a supporting glass substrate, with the DLC
thereon, to temperature(s) of from 550 to 800 degrees C., more
preferably from 580 to 800 degrees C. (which is well above the
burn-off temperature of DLC). In particular, certain example
embodiments of this invention relate to a technique for enabling
the DLC to withstand such HT without significantly burning off
during the same. In certain embodiments, a protective layer is
formed on the glass substrate over the DLC so as to reduce the
likelihood of the DLC burning off during HT. Thus, much if not all
of the DLC remains on the glass substrate, and does not burn off,
during the HT. Following HT, the protective layer may or may not be
removed (e.g., via etching or any other suitable technique) in
different embodiments of this invention.
[0022] FIG. 1 is a cross sectional view of part of an insulating
glass (IG) window unit according to an example embodiment of this
invention. The IG window unit includes first glass substrate 1 and
second glass substrate 3 which are sealed together and/or spaced
from one another via one or more spacers/seals 5. The gap or space
7 defined between the opposing substrates 1 and 3 may or may not be
filled with gas (e.g., Ar) and may or may not be evacuated to a
pressure lower than atmospheric in different embodiments of this
invention. Glass substrate(s) 1 and/or 3 may be soda-lime-silica
glass (e.g., made via the known float process), or any other
suitable type of glass (e.g., borosilicate glass) in different
embodiments of this invention. Each substrate 1, 3 may be from
about 1 to 10 mm thick, more preferably from 2 to 5 mm thick, and
most preferably from about 2.5 to 3.6 mm thick in certain example
embodiments of this invention.
[0023] Still referring to FIG. 1, optionally, substrate 1 and/or 3
may have a solar control coating (e.g., multi-layer low-E coating)
9 provided on an interior surface thereof facing the other
substrate. For example and without limitation, the solar control
coating may include any of the coatings in any of U.S. Pat. Nos.
5,688,585, 5,557,462, 4,898,790, 5,514,476, 3,682,528, 5,376,455,
5,377,045, 5,514,476, 5,770,321, 5,902,505, 5,942,338, 6,059,909,
6,060,178, 6,132,881, or 6,159,607, or U.S. Ser. No. 09,794,224
(see WO 02/04375), all of which are hereby incorporated herein by
reference. Many of these solar control coatings include at least
one (and sometimes multiple) IR reflecting layer (e.g., including
or of Ag and/or NiCr) sandwiched between a pair of dielectric
layers; where the dielectric layers may or may not contact the Ag
or NiCr. However, the instant invention is not so limited, and any
other type of solar control coating 9 may instead be used in
different instances. In certain example embodiments, coating 9
includes at least one layer for reflecting infrared (IR) radiation
(e.g., a layer comprising one or more of Ag, Au, Ni, NiCr, or the
like).
[0024] The IG window unit of FIG. 1, even after heat treatment (HT)
such as thermal tempering of at least coated glass substrate 1,
further includes a coating (including one or more layers) including
at least one layer 11 of or including diamond-like carbon (DLC)
provided on the exterior surface of glass substrate 1. The layer 11
of or including DLC may or may not be doped in certain example
embodiments of this invention (e.g., may or may not be doped with
one or more of H, N, B, Si, and/or any other suitable dopant). For
example and without limitation, the layer 11 of or including DLC
may be any of the DLC inclusive layers of any of U.S. Pat. Nos.
6,303,226; 6,303,225; 6,261,693; 6,338,901; 6,312,808; 6,280,834;
6,284,377; 6,335,086; 5,858,477; 5,635,245; 5,888,593; 5,135,808;
5,900,342; or 5,470,661, or alternatively may be any other suitable
type of DLC inclusive layer. DLC inclusive layer 11 may be
hydrophobic (high contact angle), hydrophilic (low contact angle),
or neither, in different embodiments of this invention.
[0025] DLC inclusive layer 11 may be from about 5 to 1,000
angstroms (.ANG.) thick in certain example embodiments of this
invention, more preferably from 10-300 .ANG. thick. In certain
example embodiments of this invention, layer 11 including DLC may
have an average hardness of at least about 10 GPa, more preferably
at least about 20 GPa, and most preferably from about 20-90 GPa.
Such hardness renders layer (s) 11 resistant to scratching, certain
solvents, and/or the like. Layer 11 may, in certain example
embodiments, be of or include a special type of DLC known as highly
tetrahedral amorphous carbon (t-aC), and may be hydrogenated
(t-aC:H) in certain embodiments. This type of DLC includes more
sp.sup.3 carbon-carbon (C--C) bonds than sp.sup.2 carbon-carbon
(C--C) bonds. In certain example embodiments, at least about 50% of
the carbon-carbon bonds in the layer 11 may be sp.sup.3
carbon-carbon (C--C) bonds, more preferably at least about 60% of
the carbon-carbon bonds in the layer 11 may be sp.sup.3
carbon-carbon (C--C) bonds, and most preferably at least about 70%
of the carbon-carbon bonds in the layer 11 may be sp.sup.3
carbon-carbon (C--C) bonds. In certain example embodiments of this
invention, the DLC may have a density of at least about 2.4
gm/cm.sup.3, more preferably of at least about 2.7 gm/cm.sup.3.
Example linear ion beam sources that may be used to deposit DLC
inclusive layer 11 on substrate 1 include any of those in any of
U.S. Pat. Nos. 6,261,693, 6,002,208, 6,335,086, or 6,303,225 (all
incorporated herein by reference). When using an ion beam source to
deposit layer(s) 11, hydrocarbon feedstock gas(es) (e.g.,
C.sub.2H.sub.2), HMDSO, or any other suitable gas, may be used in
the ion beam source in order to cause the source to emit an ion
beam toward substrate 1 for forming layer(s) 11. It is noted that
the hardness and/or density of layer(s) 11 may be adjusted by
varying the ion energy of the depositing apparatus.
[0026] Coating 11 enables the IG unit of FIG. 1 to be more scratch
resistant than if the coating 11 were not provided. It is noted
that while coating 11 is on glass substrate 1 in certain
embodiments of this invention, additional layer(s) may or may not
be under coating 11 between the substrate 1 and coating 11 in
certain example embodiments of this invention. Thus, the phrase "on
the substrate" as used herein is not limited to being in direct
contact with the substrate as other layer(s) may still be provided
therebetween. However, in certain embodiments of this invention,
carbon atoms and/or bonds of DLC inclusive layer 11 are
subimplanted into the glass substrate 1 as discussed in U.S. Pat.
Nos. 6,303,226 and/or 6,261,693. Moreover, as explained below, it
is possible for additional layer(s) to be provided on the substrate
1 over DLC inclusive layer 11 in certain embodiments of this
invention. As will be seen from the discussion below, protective
layer 17 on the final window product is optional, although it is
used in the manufacturing process.
[0027] In certain example embodiments of this invention, the IG
window unit of FIG. 1 has a visible transmission of at least 50%,
more preferably of at least 60%, and in some cases at least
70%.
[0028] FIG. 2 is a cross sectional view of an example vehicle
windshield according to another embodiment of this invention. In
the FIG. 2 embodiment, the glass substrates 1 and 3, solar control
coating 9, DLC inclusive layer 11, and protective layer 17 are as
described above with respect to the FIG. 1 embodiment. In
windshield embodiments, glass substrates 1 and 3 are preferably
heat bent to a desired curved shape(s) in a know manner via HT.
After bending, the glass substrates are laminated to one another
via a polymer inclusive interlayer 15. Polymer inclusive interlayer
15, provided for lamination purposes, may include PVB,
polyurethane, ethylene-vinyl acetate (EVA), polyvinyl chloride
(PVC), a polyester, polycarbonate, polypropylene, polyethylene,
and/or polyurethacrylate, or the like in different embodiments of
this invention. In certain windshield embodiments, the resulting
windshield may have a visible transmission of at least 70%, an in
some instances at least 75%.
[0029] Referring to FIGS. 3-4, it will now be explained how various
coated articles according to different embodiments of this
invention (e.g., the coated articles of FIGS. 1 and/or 2, or other
types of coated articles) may be made.
[0030] Initially, glass substrate 1 is provided. Optionally, one or
both surfaces of the glass substrate 1 may be ion beam milled to
remove at least 2 .ANG. of glass thickness therefrom. Optionally, a
multi-layer solar control coating 9 may be deposited (e.g., via
sputtering) on one side of the substrate 1. As shown in FIG. 3(a),
one or more layer(s) 11 of or including DLC may then be deposited
(e.g., via ion beam deposition) on the other side of the glass
substrate 1 (see step A in FIG. 4). The DLC inclusive layer(s) 11
may be deposited either directly on glass substrate 1 so as to
enable subimplantation into the glass, or alternatively may be
deposited on the substrate 1 over one or more other layer(s) not
shown.
[0031] Then, as shown in FIG. 3(b), a protective layer 17 is
deposited on the substrate 1 over the DLC inclusive layer 11 (see
step B in FIG. 4). Protective layer 17 may be deposited via
sputtering, CVD, ion beam deposition, or any other suitable
technique. In one example embodiment of this invention, protective
layer 17 may be of or include amorphous silicon (a-Si). Optionally,
when comprising a-Si, layer 17 may be deposited via DC sputtering
using Ar gas and a Si target doped (e.g., with one or more of P, B,
and/or Al, or any other suitable dopant) so as to be conductive.
Thus, a-Si protective layer 17 may be doped in certain example
embodiments of this invention, although it need not be doped in all
embodiments of this invention. While layer 17 may comprise a-Si in
certain embodiments (doped or intrinsic), this invention is not so
limited. Alternatively, instead of a-Si, layer 17 may be of or
include one or more of: silicon nitride, silicon oxide, silicon
oxynitride, BC.sub.x (boron carbide where x is from 0.75 to 1.5),
TiC.sub.x (titanium carbide, where x is from 0.47 to 0.99--this may
be oxidation resistant), HfC.sub.x (hafnium carbide, where x is
from 0.47 to 0.99), Ti.sub.xHf.sub.yC (titanium hafnium carbide,
where in certain non-limiting examples x may be about 0.6 and y may
be about 0.4), TaC.sub.x (tantalum carbide, where x is from 0.47 to
0.99), ZrC.sub.x (zirconium carbide, where x is from 0.47 to 0.99),
Cr, NiCr, NiCrO.sub.x, Ti, a removable slurry of magnesium oxide,
and/or TiO.sub.x.
[0032] When protective layer 17 includes a carbide, it may be
formed in one of many different ways. For example and without
limitation, carbide layers 17 herein may be formed by depositing a
carbide directly on the DLC inclusive layer 11. Alternatively,
carbide layers 17 may be formed by depositing the metal (e.g,. B,
Ti, Hf, Ta, and/or Zr) via sputtering directly onto DLC inclusive
layer 11 and then heating the same to form the carbide. The heating
used in forming the carbide may be part of the heat treating for
tempering, bending, or the like (i.e., during the ramp-up phase of
HT when the temperature of the coated substrate is rising to
tempering/bending levels); or alternatively the heating used to
form the carbide may be a separate and distinct HT performed prior
to the HT for tempering, or the like. Thus, protective layer 17 may
be formed before and/or during the HT for tempering or the like in
different embodiments of this invention. The carbides may also be
formed by any other suitable technique. Other suitable materials
may also be used for layer 17 in different embodiments of this
invention. In certain embodiments of this invention, protective
layer 17 may be from about 5 to 500 .ANG. thick, more preferably
from about 5 to 100 .ANG. thick, even more preferably from about 5
to 50 .ANG. thick, and most preferably from about 5 to 20 .ANG.
thick. Layer 17 is preferably continuous, but need not be.
[0033] As shown in FIG. 3(c), the glass substrate 1 with at least
layers 11 and 17 thereon, is then heat treated (HT) for purposes of
thermal tempering, heat bending, heat strengthening, and/or the
like (see step C in FIG. 4). At least part of this HT may be
conducted, for example, in an atmosphere including oxygen at
temperature(s) of from 550 to 800 degrees C., more preferably from
580 to 800 degrees C. (i.e., temperature(s) above the burn-off
temperature of DLC). The HT may last for at least one minute, more
preferably from 1-10 minutes, in certain example non-limiting
embodiments of this invention. During HT, the presence of
protective layer 17 protects DLC inclusive layer 11 from the HT and
prevents layer 11 from burning off. While in some instances, some
of layer 11 may still burn off during HT, most if not all of DLC
inclusive layer 11 remains on the substrate 1 even after the HT due
to the presence of protective layer 17. In example embodiments
where layer 17 includes a-Si, the HT causes oxidation of at least
some of the a-Si turning it to silicon oxide.
[0034] In certain embodiments, following the HT, the protective
layer 17 may be removed (e.g., via known etching techniques and/or
via ion beam milling using an ion beam source using a gas such as
Ar) as shown in FIG. 3(d) (see step D in FIG. 4). However, this
step is optional, as in other embodiments of this invention
protective layer 17 is not removed and remains on the glass
substrate 1 over the DLC inclusive layer 11 in the final
product.
[0035] The scratch resistant heat treated glass substrate 1 (e.g.,
tempered and/or bent), with DLC inclusive layer 11 and optionally
layer(s) 9 and/or 17 thereon, in accordance with the FIG. 1 or FIG.
2 embodiments of this invention, is then coupled to another
substrate 3 in order to form a window product (see step E in FIG.
4). In the FIG. 1 embodiment, the substrate 1 with DLC inclusive
layer 11 and optionally layer(s) 9 and/or 17 thereon is coupled to
another substrate 3 via at least one seal and/or spacer 5 to form
an IG unit. In the FIG. 2 embodiment, the substrate 1 with DLC
inclusive layer 11 and optionally layer(s) 9 and/or 17 thereon is
laminated to another substrate 3 via polymer inclusive interlayer
15 to form a vehicle windshield or the like. Alternatively, the FIT
substrate 1 with at least DLC inclusive layer 11 thereon need not
be coupled to another substrate, and may be used in applications
such as shower doors, glass table tops, vehicle windows, and/or the
like.
[0036] As can be seen from the above, the instant inventions
enables DLC to withstand FIT, thereby enabling it to be used in HT
applications where it previously could not be used.
[0037] While the invention has been described in connection with
what is presently considered to be the most practical and preferred
embodiments, it is to be understood that the invention is not to be
limited to the disclosed embodiments, but on the contrary, is
intended to cover various modifications and equivalent arrangements
included within the spirit and scope of the appended claims.
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