Non-contact coated glass and related coating system and method

Patent metadata

Field	Value
Publication number	US-2017210666-A1
Application number	US-201715410320-A
Country	US
Kind code	A1
Filing date	Jan 19, 2017
Priority date	Jan 26, 2016
Publication date	Jul 27, 2017
Grant date	—

Abstract

A coated glass article and of a system and method for forming a coated glass article are provided. The process includes applying a first coating precursor material to the first surface of the glass article and supporting the glass article via a gas bearing. The process includes heating the glass article and the coating precursor material to above a glass transition temperature of the glass article while the glass article is supported by the gas bearing such that during heating, a property of the first coating precursor material changes forming a coating layer on the first surface of the glass article from the first precursor material. The high temperature and/or non-contact coating formation may form a coating layer with one or more new physical properties, such as a deep diffusion layer within the glass, and may form highly consistent coatings on multiple sides of the glass.

First claim

What is claimed is:

1 . A process for applying a coating layer to glass, comprising:
providing a glass article having a first surface and a second surface opposing the first surface; applying a first coating precursor material to the first surface of the glass article; supporting the glass article via a gas bearing; and heating the glass article and the coating precursor material to above a glass transition temperature of the glass article while the glass article is supported by the gas bearing; wherein during heating, a property of the first coating precursor material changes, such that a first coating layer is formed on the first surface of the glass article from the first precursor material.

2 . The process of claim 1 , wherein the first coating precursor is applied to the first surface of the glass article when the temperature of the glass article is above the glass transition temperature and while the glass article is supported by the gas bearing.

3 . The process of claim 1 , wherein the property of the first coating precursor that changes during heating to form the first coating layer is at least one of a chemical composition, an oxidation state, a shape, a diffusion depth and diffusion profile.

4 . The process of claim 1 , wherein the first coating precursor is applied to the first surface via gas delivered by the gas bearing during heating of the glass article.

5 . The process of claim 1 , wherein the first coating layer includes a diffusion zone located within the material of the glass article extending from an interface between the first coating layer and the glass article toward the center of the glass article, wherein, within the diffusion zone, a concentration of a component of the coating layer decreases as the depth into the glass article increases.

6 . The process of claim 5 , wherein the depth of the diffusion zone is greater than 50 nm.

7 . The process of claim 6 , further comprising applying a second coating precursor material to the second surface of the glass article, wherein during heating, a property of the second coating precursor material changes, such that a second coating layer is formed on the second surface of the glass article from the second precursor material.

8 . The process of claim 7 , wherein the first coating precursor material is the same as the second coating precursor material, wherein the second coating layer includes a second diffusion zone located within the material of the glass article extending from an interface between the second coating layer and the glass article toward the center of the glass article, wherein within the second diffusion zone a concentration of a component of the second coating layer decreases as the depth into the glass article increases.

9 . The process of claim 8 , wherein the depth of the second diffusion zone is greater than 50 nm, wherein the depth of the diffusion zone of the first coating layer and the depth of the second diffusion zone of the second coating layer are within 10% of each other.

10 . The process of claim 8 , wherein a measured property of the first coating layer is within 10% of a measured physical property of the second coating layer, wherein the measured properties of the first and second coating layers are at least one of electrical resistance, refractive index, optical transmission, reflectance, hardness and modulus of elasticity.

11 . The process of claim 1 , further comprising cooling the glass article and the first coating layer to below the glass transition temperature of the glass article while the glass article is supported by the gas bearing.

12 . The process of claim 11 , wherein during the heating step the article is heated to a temperature above the glass transition temperature and below a softening point of the glass material, wherein, during cooling, a heat transfer rate from the article during cooling is greater than 450 kW/m 2 for an area of the first surface.

13 . The process of claim 12 , wherein cooling occurs in a cooling station comprising a heat sink, wherein the glass article is supported by gas from the gas bearing and spaced from the heat sink such that a gap is located between the first surface of the glass article and an opposing heat sink surface, wherein the gap is less than 200 μm, wherein the glass article is cooled by transferring thermal energy from the heated glass article to the heat sink by conduction across the gap such that more than 20% of the thermal energy leaving the heated article crosses the gap and is received by the heat sink.

14 . The process of claim 13 , wherein during cooling, surface compressive stresses and central tensile stresses are created within the glass article, wherein the surface compressive stress is greater than 150 MPa.

15 . The process of claim 1 , wherein the first coating precursor material is different from a glass material of the glass article, wherein the first coating precursor material comprises at least one of SiO 2 , an Ag salt, a Cu salt, an Na salt, BN, TiO 2 , ZnO, MgF 2 , aluminum-doped ZnO, lithium salt, Cu, Au, Ag, Al, Sn, C, an oxide, a nitride, a carbide, a sulfide, a selenide, fluoride, aluminum oxynitride, TiN, TiSi 2 , an organometallic material, amorphous silicon, polycrystalline silicon and fluorine doped SnO 2 , wherein the glass article is at least 50% silicon dioxide by weight, wherein the first coating layer is at least one of a continuous, contiguous coating covering the first surface of a glass article and a patterned coating layer covering less than all of the first surface of the glass article.

16 . A coated glass article comprising:
a glass article comprising:
a first major surface;
a second major surface opposite the first major surface; and
glass material of at least 50% silicon dioxide by weight; and
a first coating layer located on the first major surface, the first coating layer formed from a material different than the glass material of the glass article, the first coating layer including a first diffusion zone located within the material of the glass article extending from an interface between the first coating layer and the glass article toward the center of the glass article, wherein within the first diffusion zone a concentration of a material of the first coating layer decreases as the depth into the glass article increases; wherein the diffusion zone has a depth greater than 50 nm.

17 . The coated glass article of claim 16 , further comprising a second coating layer located on the second major surface, the second coating layer formed from a material different than the glass material of the glass article, the second coating layer including a second diffusion zone located within the material of the glass article extending from the interface between the second coating layer and the glass article toward the center of the glass article, wherein within the second diffusion zone a concentration of a material of the second coating layer decreases as the depth into the glass article increases.

18 . The coated glass article of claim 17 , wherein the first and second coating layers each have a thickness that is between 0.001% and 10% of an average thickness of the glass article measured between the first and second major surfaces.

19 . The coated glass article of claim 17 , wherein second diffusion zone has a depth greater than 50 nm, wherein the depth of the second diffusion zone is within 1% of the depth of the first diffusion zone.

20 . The coated glass article of claim 16 , wherein the first

Assignees

• Corning Inc

Inventors

• Chang Theresa
• Huang Ming-Huang
• Gaskill Linda
• Lezzi Peter Joseph
• Wasson Kevin Lee

Classifications

• C03C17/002 Primary

  for flat glass, e.g. float glass · CPC title

• C03C17/256

  Coating containing TiO2 · CPC title

• C03C17/25

  by deposition from the liquid phase · CPC title

• C03C17/22

  with other inorganic material (C03C17/34, C03C17/44 take precedence) · CPC title

• C03C17/3417

  all coatings being oxide coatings · CPC title