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Innovation at DSM: Nanostructured Functional Coatings

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Innovation at DSM: Nanostructured Functional Coatings
Presentation of Kornelia Matloka at the MRS 2011

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Innovation at DSM: Nanostructured Functional Coatings

  1. 1. Innovation at DSM:Nanostructured Functional CoatingsKornelia Matloka/Pascal BuskensMRS Spring 2011
  2. 2. Outline• Introduction to DSM and DSM EBA Advanced Surfaces• Introduction to anti-reflective (AR) coatings• DSM AR coating technology and applications• KhepriCoatTM: anti-reflective coating technology for solar cell cover glass Page 1
  3. 3. Introducing DSMRoyal DSM N.V. uses its competences in life sciences and materialssciences to create solutions that nourish, protect and improveperformance•Annual net sales of € ~8 billion•Locations in five continents•~ 24,000 employees•Top leader in the Dow Jones Sustainability World Index Page 2
  4. 4. DSM -100 Years Of SuccessfulTransformationsEvolution Bioterials / Biologics Life Science Products Performance Materials Petrochemicals Fertilizers Coal 1902 1930 1950 1970 1990 2000 2010 Technological competences Mechanical engineering Chemical engineering Polymer technology Material science Fine chemicals classical modern BiotechnologyProfile and strategyPage 3
  5. 5. DSM Company Profile DSM Managing Board Company details 2009 : Turnover 7,9 Billion € DSM Innovation Center EBIT 443 Million € Employees 23.000 Corporate Staff Nutrition Nutrition Pharma Pharma Performance Materials Performance Materials Industrial Chemicals Industrial Chemicals DSM Nutritional Products DSM Pharmaceutical Products DSM Resins DSM Fibre Intermediates DSM Food Specialties DSM Anti-Infectives DSM Engineering Plastics DSM DyneemaPage 4
  6. 6. DSM Innovation CenterAccelerating and Supporting Innovation DSM Innovation Center New Business Development Shared Services EBA Biomedical Excellence in Innovation EBA Bio-based CTO Office Products & Services EBA Advanced Surfaces Licensing Business Incubator VenturingPage 5
  7. 7. Nanostructured Functional CoatingsFunctional coating:A functional coating is a coating which achieves any additional function beyondthat of the usual protective and decorative.Nanostructured hybridshybrid materials are prepared through hydrolysis and condensation of metaloxide precursors in the presence of organic molecules, polymers orbiocomponents; controlled/structured on nano-levelDSM examples:Anti-reflective on glass and plasticsAnti-staticAnti-foulingAnti-foggingSelf-cleaningAnti-microbial (BMM)Lubricious (BMM)
  8. 8. Product Portfolio & PipelineCommercialized antireflective coatings: claryl: picture framing/art displaysKhepriCoatTM: outdoor durable coating for lighting cover glassFuture product pipeline (combination of functionalities):For electronic display and thin film solar markets:• Easy-to-clean + antireflective coating• Anti reflective coatings (one side) and conductive coatings (other side) for glass and plastic substrates• Functional materials
  9. 9. Light Reflection and TransmissionLight is reflected at the boundary of two media with different refractiveindices (n1 and n2). air (n1 = 1.0)glass (n2 = 1.5) air (n1 = 1.0)•In standard glass, 8% of the incident light is reflected ( i = 90°)•The total transmission depends also on the absorption and scattering of lightPage 8
  10. 10. Antireflective CoatingsReflections can be reduced/transmission can be increased by usingantireflective coatings.In general there are 2 different anti-reflective coating technologies:1.Interference-type multilayer systems – Expensive2.Single layer nanoporous silica-based systems – Refractive index and thickness tuned to minimize the total reflection
  11. 11. Single Layer Antireflective Coatings: “Moulton Relationship” Moulton US2432484 (1943)CleanabilityMechanics DSM’s coating Optics Page 10
  12. 12. Single Layer Antireflective Coatings:Traditional vs.Core-shell AR Coatings Solid silica particles Binder ~100nmPage 11
  13. 13. DSM’s Antireflective Coating Technology• DSM’s AR coating can be applied by various coating technologies: – 2-sided: dip coating – 1-sided: roll, spray or slot-die coating• DSM’s AR coating can be applied on different types of glass: – Float glass – Patterned glass – Borosilicate glass• Flexible curing conditions: – Batch ovens (450 C) – Temper ovens (700 C)
  14. 14. Applications Value proposition: Value proposition: improved light transmission improved light transmission for better visibility for higher yield/ energy saving •Picture framing •Photovoltaic cells •Decorative glass •Solar thermal collectors •Cabinets, shop furniture •Horticulture •Architectural glass •Lighting •Refrigerator and freezer doors •Lenses •DisplaysPage 13
  15. 15. Commercial Applications: Page 14
  16. 16. ®Claryl: DSM’s AR Coated Picture Framing Glass• Excellent optical properties – 1.2 +/-0,1% average reflection – 0.5% reflection after human eye correction – excellent color fastness – improved viewing angle performance – Reflection minimum (color) can be tuned to technical / optical requirements 100• Mechanically durable 98 – Steel wool resistance: 250 g load, 96 10 rubs, no visible scratches 94 92 Transmittance (%) 90• Good cleaning properties 88 86 Claryl Claryl uncoated 84 82 80 Page 15 300 350 400 450 500 550 600 650 700 750 800 Wavelength (nm)
  17. 17. First License Agreement For KhepricoattmWith Berliner Glas For Lighting Cover Applications Page 16
  18. 18. Commercial Application: Solar Cover Glass Page 17
  19. 19. Khepricoat™: DSM’s AR Coating for Solar Cover Glass2-sided coated 4 mm ultrawhite float glass• Maximum gain/peak in transmission up to 8%• Average gain in transmission up to 6% (depending on the wavelength range) at perpendicular angle 100 100 98 98 96 96 94 94Transmittance (%) Transmittance (%) 92 92 90 90 88 88 86 86 84 Khepricoat 84 Khepricoat Khepricoat uncoated Khepricoat uncoated 82 82 80 80 350 450 550 650 750 850 950 300 800 1300 1800 2300 Wavelength (nm) Wavelength (nm) Page 18
  20. 20. Tunable Optical Performance By varying the coating layer thickness by adjusting the coating speed, the reflection minimum and optical properties can be tuned Transmission 100 98 Dipping speed (mm/sec): 96 glass 2mmtransmission [%] 3mm 94 4mm 5mm 92 6mm 7mm 8mm 90 9mm 88 86 300 500 700 900 1100 1300 1500 1700 1900 2100 2300 2500 wavelength [nm] Page 19
  21. 21. Khepricoat™: DSM’s AR Coating for Solar Cover Glass 1-sided coated 4 mm ultrawhite float glass • KhepriCoat™ has an excellent performance on float and on rolled glass • Maximum gain/peak in transmission (perpendicular) up to 4% • Average gain in transmission up to 3% (depending on wavelength range) Transmission Single side Khepricoat(TM) on 4mm Pilkington Optiwhite Transmission single side Khepricoat(TM) on 4mm SG Albarino-T 96 4,5 96 4,5 4 4 95 95 3,5 3,5 94 94 3 % gain (2nd Y-axis) 3 93 2,5 % gain [red line] 93% Transmission % gain [red line] % Transmission % gain (2nd Y-axis) 2,5 2 92 92 2 1,5 91 91 1 1,5 0,5 90 90 Uncoated 1 Uncoated With 1-side Kherpicoat(TM) With 1-side Kherpicoat(TM) 0 89 % gain % gain 0,5 89 -0,5 88 0 88 -1 350 400 450 500 550 600 650 700 750 800 850 350 400 450 500 550 600 650 700 750 800 850 Wavelength [nm] Wavelength [nm] Page 20
  22. 22. Optical Performance:Angle-Dependent Transmission • The gain in transmission increases at higher angles of incidence to almost 10% (green line)! • The highest gain in transmission is obtained at angles above 30 degrees 100 10 95 9Average transmission 370-800 nm [%] Transmission gain (%) uncoated glass 90 8 AR-coated glass Transm is sion gain 85 7 80 6 0 10 20 30 40 50 60 70 Angle of incidence [deg] Page 21
  23. 23. KhepriCoat™ Performance and DurabilityPage 22
  24. 24. Performance of KhepriCoat™ coated PV-modules •passed all test according to IEC 61215 (damp-heat, humidity-freeze, thermal cycling) •TüV certification for commercial modules with KhepriCoat™ AR coating obtained •no degradation during damp-heat test for 2000 hours (twice the IEC test norm) •up to 3% performance increase at normal angle •up to 5% performance increase at 60 degModule tests performed at Photovoltaik Institut Berlin (www.pi-berlin.com)
  25. 25. KhepriCoatTM was used for the world record17% efficiency for multi-crystalline Si solar panelsPage 24
  26. 26. Application Process DevelopmentTwo sided coatings:• A commercial dip coating plant is operational at DSM (®claryl)• DSM provides technological support to customersSingle sided coatings:DSM is commercializing three technologies:1.Roll coating >3 m/min - Q1 20112.Spray coating – 20123.Slot die coating – pilot coating line at DSMPage 25
  27. 27. One-Side Coating ProcessesChoice of process depends on desired production speed and optical requirements of final product• Spray coating: high production speeds possible (up to 20 meters per minute); low to medium level of optical homogeneity• Roll coating: medium production speeds possible (up to 5 meters per minute); medium to high level of optical homogeneity• DSM’s slot-die process: high production speeds and high level of optical homogeneity
  28. 28. What is roll coating? The principle of operation: Doctor roller Applying rollerDirection of feed Counter-pressing roller Page 27
  29. 29. DSM’s Slot-Die Process• Slot-die is known e.g. from the photographic industry to coat plastic foils with micron thick, non-optical coatings• DSM adapted the technology to make it suitable for high speed deposition of optical coatings on rigid (glass) substrates (thickness = 100 – 150 nm; thickness tolerance = 2 nm)• DSM patented the adapted process• Pilot-line available at DSM Page 28
  30. 30. DSM StrategyFlexible business models depending on the application / value chain:•Supply of ®claryl AR-coated picture framing glass produced in our own plant•Licensing of KhepriCoat™ AR-coating technology for large-volume applications•Active application development•Strategic partnerships in the value chain
  31. 31. Acknowledgements :R&D AR development & customer support:Nanning Arfsten, Jens Thies, Pascal Buskens, Roberto Habets, PatrickVrijaldenhoven, Harm Langermans, Ad Overbeek, Jurgen Scheerder, Ron deRijk, Marnix Rooijmans, Tessa KockelkorenBusiness development:Hugo Schott,Chantal Jorissen
  32. 32. DSM Contact PersonsMr. Hugo Schoot Dr. Kornelia MatlokaBusiness Development Manager R&D Scientist
  33. 33. Thank you for your attentionContact us via www.khepricoat.com

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