Coated article with sputter-deposited transparent conductive coating capable of surviving harsh environments, and method of making the same

Abstract

Certain example embodiments relate to sputter-deposited transparent conductive coatings (TCCs) that are capable of surviving the harsh environments of ovens so that they can be included, for example, in oven door applications. In certain example embodiments, zirconium oxide (e.g., ZrO 2 or other suitable stoichiometry) may be used as a protective overcoat to protect an underlying Ag layer from corrosion in the atmosphere. In certain three lite oven door example embodiments, surfaces 2 and 4 each have an Ag-based TCC sputter-deposited thereon. The Ag-based TCC may have a sheet resistance of about either 4 or 5 ohms/square in certain example embodiments.

1 . A method of making a door for an oven, the method comprising:
 providing first, second, and third substantially parallel and spaced apart glass substrates, the first substrate being provided for an interior side of the door and the third substrate being provided for an exterior side of the door;   sputter-depositing a first transparent conductive coating (TCC) on a first major surface of the first substrate, the first major surface of the first substrate being closest to the third substrate;   sputter-depositing a second TCC on a first major surface of the second substrate, the first major surface of the second substrate being closest to the third substrate; and   thermally tempering at least the first and second substrates,   wherein each said TCC is silver-based and includes a zirconium oxide protective overcoat.   
     
     
         2 . The method of  claim 1 , wherein:
 each said TCC comprises:
 a first barrier layer of silicon nitride provided on the second substrate, 
 a first nickel chromium inclusive contact layer provided on the first barrier layer, 
 a silver-inclusive conductive layer provided on the first contact layer, 
 a second nickel chromium inclusive contact layer provided on the conductive layer, and 
 a second barrier layer of silicon nitride provided on the second contact layer, and the protective overcoat is provided on the second contact layer. 
   
     
     
         3 . The method of  claim 2 , wherein each said TCC has a sheet resistance of about 4 ohms/square. 
     
     
         4 . The method of  claim 2 , wherein each said TCC has a sheet resistance of about 5 ohms/square. 
     
     
         5 . The method of  claim 2 , wherein the first and/or second barrier layer(s) is/are doped with aluminum. 
     
     
         6 . The method of  claim 1 , wherein the third substrate is a decorative glass substrate. 
     
     
         7 . The method of  claim 1 , wherein the first, second, and third substrates have a visible transmission of at least 50%. 
     
     
         8 . The method of  claim 1 , wherein the first, second, and third substrates have a visible transmission of at least 60%. 
     
     
         9 . The method of  claim 1 , wherein a surface of the third substrate corresponding to the exterior side of the door does not exceed 178 degrees F. when an oven to which the door is connected reaches an interior temperature of about 850 degrees F. 
     
     
         10 . The method of  claim 1 , wherein a surface of the third substrate corresponding to the exterior side of the door does not exceed 163 degrees F. when an oven to which the door is connected reaches an interior temperature of about 850 degrees F. 
     
     
         11 . The method of  claim 2 , wherein each said contact layer is about 15-20 angstroms thick. 
     
     
         12 . The method of  claim 11 , wherein the silver-inclusive conductive layer is about 3-15 nm thick. 
     
     
         13 . The method of  claim 1 , further comprising building at least the first, second, and third substrates into an assembly in making the oven door. 
     
     
         14 . A method of making an oven, the method comprising:
 making an oven door according to the method of  claim 1 ; and   connecting the oven door to the oven.   
     
     
         15 - 20 . (canceled)