Method of making coated article including diamond-like carbon (DLC) and FAS

#This invention relates to a method of thermally curing a hydrophobic coating system including diamond-like carbon (DLC) and at least one fluoro-alkyl silane (FAS) compound provided on (directly or indirectly) a substrate of glass, plastic, ceramic, or the like, and a resulting coated article. The coating system may include one or more layers, and the DLC portion of the coating may be deposited on the substrate utilizing plasma ion beam deposition in certain embodiments.

#Conventional substrates (e.g., glass) are susceptible to retaining water on their surfaces in many different environments, e.g., when used as automotive windows (e.g. backlites, side windows, and/or windshields) or as architectural/residential windows. When water is retained or collects on automotive windows, the water may freeze (i.e. forming ice). Additionally, the more water retained on a windshield, the higher power wiper motor(s) and/or wiper blade(s) required.

#Thus, there exists a need in the art for a coated article (e.g. coated glass, ceramic or plastic substrate) that can repel water and/or dirt, and a method of making the same.

#FIG. 1(a) is a flowchart illustrating certain steps taken according to an exemplary embodiment of this invention.

#FIG. 1(b) is a side cross sectional view of a coated article according to an embodiment of this invention, wherein a substrate is provided with a DLC and FAS inclusive coating system thereon having hydrophobic qualities.

#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 or coating system of FIG. 1(b) is provided over an intermediate layer(s).

#Referring now more particularly to the accompanying drawings in which like reference numerals indicate like elements throughout the accompanying views.

#An object of this invention is to provide a method of making an article having a durable hydrophobic coating thereon. As will be explained in more detail below, the higher the contact angle θ the more hydrophobic a particular coating or coated article. Thus, it is desirable to have a high contact angle θ if a hydrophobic type product is wanted.

#The parent application filed Jul. 17, 2000 discloses a hydrophobic coating on an article, the coating including among other things at least one diamond-like carbon (DLC) inclusive layer as well as at least one fluoro-alkyl silane (FAS) compound inclusive layer. Surprisingly, it has been found that by heating at least the FAS compound inclusive layer (the FAS inclusive layer may be heated primarily by itself after its deposition, or alternatively the entire coated article including the FAS inclusive layer may be heated) applied on (directly or indirectly) a diamond-like carbon (DLC) inclusive layer, the bond between the two layers may be strengthened and/or contact angle characteristics of the resulting coated article may be improved.