A novel aerosol based wet coating technology called nfog and its applications

Transcription

1 A novel aerosol based wet coating technology called nfog and its applications Beneq launches nfog wet coating technology Beneq is pleased to announce the launch of its new atmospheric wet coating technology called nfog for use in applications such as anti-reflective coatings for large-sized glass. This new technology combines the advantages of the speed of spray coating, the quality of dip coating and the high material yield of roller coating. September 3, 2014 Espoo, Finland 1

2 A novel aerosol based wet coating technology called nfog and its applications Background Beneq is an equipment manufacturer SP is an innovation partner New coatings and applications Testing and characterisation Collaboration (joint projects, contract work, etc.) Approaches Replace current coating techniques + Coating and end applications already exist Higher performance (quality, production rate, cost, etc.) New coatings and applications In house With partners (universities, RTOs and industry) 2

3 nfog coating process Thin uniform liquid film is formed because of small droplets FOG Not sensitive to the shape or to the size of the substrate Two or more materials can be mixed efficiently in aerosol form All un-used material is collected in liquid form and re-cycled high yield >95% The process atmosphere is controlled Nitrogen atmosphere safety! Easy up-scalability! 3

4 A novel aerosol based wet coating technology called nfog and its applications Wide range of coating materials and substrates, e.g. Mesoporous SiO 2 coatings on glass and Si-wafer CeO 2 coatings on glass and metal Crystalline nanocellulosa (CNC) coatings on glass PVB (polyvinyl butyral) coatings on glass KhepriCoat glass coatings with pilot-scale nfog 4

5 Mesoporous SiO 2 coatings on glass and Si-wafer M. Järn and M. Tuominen 1. Dip coating of the substrate in solution containing metal precursor and structure directing agent 2. Ordered structure formed through evaporation induced self-assembly (EISA)* 3. Removal of the template through calcination *D. Grosso, F. Cagnol, G. J. de A. A. Soler- Illia, E. L. Crepaldi, H. Amenitsch, A. Brunet-Bruneau, A. Bourgeois, C. Sanchez, Adv. Funct. Mater. 2004, 14,

6 Mesoporous SiO 2 coatings on glass and Si-wafer M. Järn and M. Tuominen Glass slides were coated with excellent transparency Similar structure as for dip coated films! Dip coated nfog coated The applications range from catalysis, chromatography, gas separation, water purification, chemical sensing, uptake and release of active components, and low dielectrical and optical coatings. * nfog coated uncoated *D. Grosso, A. R. Balkenende, P. A. Albouy, A. Ayral, H. Amenitsch, F. Babonneau, Chem. Mater. 2001, 13,

7 CeO 2 coatings on glass and metal A. Ahniyaz and M. Tuominen CeO 2 (1%) in hexanedispersion Curing in room temperature nfog-parameters: Precursor feed rate Gas feed rate Treatment time Coating parameters: Concentration Viscosity 0.5 % of CeO % of CeO % of CeO % of CeO % of CeO 2 7

8 CeO 2 coatings on glass and metal A. Ahniyaz and M. Tuominen 1.8 % of CeO 2 (nfog) 2.1 % of CeO 2 (dip) Uniformity of nfog-coated samples is better than dip coated samples Uniformity is at least at the same level or better when CeO 2 dispersed in water CeO 2 coatings have several potential application, e.g. UVprotection, fire resistance, corrosion protection, etc. 0.7 % of CeO 2 (nfog) 2.3 % of CeO 2 (dip) 1.4 % of CeO 2 in water (nfog) 8

9 CNC (crystallinenanocellulose) coatings A. Oko, M. Järn and M. Tuominen Commercial CNC was diluted in water A glass was coated with an uniform CNC-layer Next, the stiffness measurements and visual analysis, i.e. transparency, reflection, diffuse scattering of light and haze will be performed. The potential applications for CNCcoatings include reinforcement of glass laminates, fire retardant coatings, etc. 9

10 PVB (polyvinyl butyral) coatings on glass A. Oko, M. Sterley and M. Tuominen Commercial PVB-powder (~4%) was diluted in ethanol and coated on glass The coated glass samples were laminated with PVB-film using lab-scale laminating equipment The adhesion/shear strength of laminated samples was measured Next steps: stiffness measurements visual analysis, i.e. transparency, reflection, diffuse scattering of light and haze 10

11 KhepriCoat glass coatings with pilot-scale nfog S. Tammela, J. Boonen, K. Asikkala, T. Määttä, R. Rijk-de, M. Mennig, P. Meriläinen Hollow silica nanoparticles synthesized from a charged latex polymer template and a binder material The latex polymer template vaporizes out during the curing Smooth closed surface Reduces the risk of degradation Prevent dirt and residue of all kinds Cleanable and contaminant free AR-coating! *Tammela, S., Combination of nfog TM and KhepriCoat technologies to deliver superior quality of anti-fogging coating on solar cover glass. Glass Performance Days, June 24 26, 2015 Tampere. 11

12 KhepriCoat glass coatings with pilot-scale nfog S. Tammela, J. Boonen, K. Asikkala, T. Määttä, R. Rijk-de, M. Mennig, P. Meriläinen Pilot scale (Beneq) - Batch/continuous process - Sample size mm 12

13 KhepriCoat glass coatings with pilot-scale nfog S. Tammela, J. Boonen, K. Asikkala, T. Määttä, R. Rijk-de, M. Mennig, P. Meriläinen Uniformity (reflection measurement) The standard deviation of the coating thickness of these samples is below 1 %. Edge quality (visual evaluation) Coffee stain effect Drying air flow control is critical Edge effect < 3 mm 0.6 m 0.85 m 0.4 % 1.0 % 0.7 % 0.4 % 1.0 % 4.0 % 0.5 % 0.3 % 0.2 % 0.2 % 2.3 % 2.0 % 0.5 % 0.7 % 0.5 % 1.1 % 1.3 % 0.0 % 0.3 % 0.5 % 0.7 % 0.8 % 0.2 % 2.0 % 1.1 % 0.2 % 0.3 % 1.2 % 0.1 % 4.0 % 0.0 % 0.3 % 0.3 % 0.1 % 0.1 % 4.0 % 0.0 % 0.1 % 0.2 % 0.1 % 1.2 % 2.0 % 0.8 % 0.3 % 0.6 % 1.2 % 0.8 % 0.0 % 0.5 % 0.1 % 0.5 % 0.2 % 0.8 % 2.0 % 0.6 % 0.7 % 0.3 % 0.2 % 0.3 % 4.0 % 0.8 % 1.4 % 1.0 % 1.7 % 2.3 % 4.0 % 0.2 % 0.1 % 0.3 % 1.3 % 2.3 % 2.0 % 1.0 % 0.9 % 0.7 % 0.3 % 0.7 % 0.0 % 1.2 % 1.9 % 1.7 % 1.0 % 0.5 % 2.0 % 0.2 % 0.9 % 0.1 % 0.2 % 0.7 % 4.0 % *Tammela, S., Combination of nfog TM and KhepriCoat technologies to deliver superior quality of anti-fogging coating on solar cover glass. Glass Performance Days, June 24 26, 2015 Tampere. 13

14 Science behind the nfog coating technique Postdoc-project: J. Harra, J. Rissler and M. Tuominen In order to obtain fundamental understanding of the nfog coating technique, it is important to characterize the aerosol produced by the nfog equipment. This can be accomplished with experimental setups utilizing on-line aerosol measurement instruments, such as, a scanning mobility particles sizer, an electrical low pressure impactor and an optical particle sizer. These measurements will give new information on the size and number concentrations of the droplets produced by the atomizer of nfog, as well as, on the effect of the different operational parameters, such as, the precursor feed rate and the gas flow rate. Furthermore, the measurements will help to understand the aerosol processes, including the gravitational settling, coagulation and losses of the generated droplets, inside the deposition chamber of nfog. The results obtained from the aerosol measurements can be utilized in the optimization of the coatings. 14

15 Conclusions nfog is a versatile technique for various applications, for example: Coatings: Latex, SiO 2, TiO 2, CeO 2, graphene, CNC, PVB, etc. Substrates: Glass, Si-wafer, metal, wood, polymers, paper, etc. nfog-coatings have an excellent uniformity A well-ordered pore structure was achieved, comparable to the SiO 2 -film prepared by dip coating Better uniformity of CeO 2 -coating than by dip coating, especially on rough surface STDV of AR-coating was as low as ~1% with low visual edge effect (< 3 mm) Easy control of coating thickness from 10 nm up-to several microns Easy up-scalability and high yield (>95%) From lab-scale nfog (SP/Stockholm) pilot-scale nfog (Beneq/Finland) industrial-scale nfog 15

16 Next steps Continue the nfog-research in the collaboration with industry and research partners Replacement of the current coating techniques in already existing applications Development of new coatings (in-house, with partners) and search of totally new applications Obtain fundamental understanding of the nfog coating technique by characterizing the aerosol produced by the nfog equipment Next generation nfog-equipment at SP (2016/Q1-2) From curvature/textured surfaces to 3D-configurations Mixing of materials and breaking of agglomerates in aerosol form Possibility to heated chamber 16

17 SP, your innovation partner in nfog-research SP is a leading international group of institutes that specialise in research and innovation. We create, use and provide world class expertise for innovation and the creation of added value both for the corporate sector and for a sustainable society. SP s facilities and competence in the nfog-research: Lab-scale nfog equipment and nfog equipment for 3D parts (-2016/Q1-2 ) Surface modification/cleaning: chemical, (atmospheric) plasma, corona, etc. Curing/drying of coatings: UV, IR, heat, etc. Formulation and functionalization of coatings Evaluation and characterisation of coatings 17

18 A novel aerosol based wet coating technology called nfog and its applications Thank you for your attention! Acknowledgements M. Järn, A. Oko, A. Sugunan, M. Sterley, A. Ahniyaz, A. Larsson, J Harra, J. Rissler. TIME - TRANSPARENT INTELLIGENT MATERIALS FOR EXCELLENCE 18