Superhydrophobic Coatings- The Road Ahead

Superhydrophobic Coatings- The Road Ahead

Prospects for Technology and Application Potential

Aravind Chander V, Industry Manager

Chemicals and Materials, Technical Insights

March 20, 2013March 20, 2013

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Today’s Presenter

•Experience base covering a broad range of sectors in

• Chemicals - coatings, catalysis, specialty chemicals, and oil and gas

Aravind Chander V, Industry Manager

Frost & Sullivan

2

• High tech materials & technologies- smart materials, composites

• Food and biotechnology - nutrition and health

• Nanotechnology - electronics, chemicals and energy

•Over five years of research and consulting expertise, leading and assisting

projects that involve various types of industry analysis.

•Chemical Engineer with MBA in Technology Management.

Agenda

Today’s presentation will cover:

� A Brief Snapshot

� Application Landscape

� Impact Mapping of Drivers & Challenges

3

� Key Developments

� Highlights of Regulatory Scenario

� Insights – The Road Ahead

� Conclusions

A Brief Snapshot

Superhydrophobic surfaces and coatings have been inspired biomimetically from the water-repelling and

self-cleaning properties of lotus leaf. The surface is characterized by a high water contact angle of more

than 150°and a small sliding angle of less than 15°.

Superhydrophobic surfaces and coatings have been inspired biomimetically from the water-repelling and

self-cleaning properties of lotus leaf. The surface is characterized by a high water contact angle of more

than 150°and a small sliding angle of less than 15°.

Sneak Preview

• Low cost and ease of manufacturing enables to explore

a wide range of solutions across application such as anti-

corrosion in marine vessels, aircraft parts; self-cleaning in

• Low cost and ease of manufacturing enables to explore

a wide range of solutions across application such as anti-


• The presence of moisture on surface which is supposed to

remain dry has led to a number of problems such as corrosion,

bio-fouling, buildup of dust particles, loss of equipment

• The presence of moisture on surface which is supposed to

remain dry has led to a number of problems such as corrosion,


Contextual Importance Key Strengths

4


building exteriors, architectural & automotive glass, and

textiles.

• Availability of non-toxic, anticorrosive and antifouling

hydrophobic materials with the chemistry know-how of

formulation and research studies conducted on various

substrates allow the development and testing of newer

products across different application segments.

•The potential of superhydrophobic coatings has been

effectively commercialized only in some applications

currently. However, more promising applications will be

explored soon.


building exteriors, architectural & automotive glass, and

textiles.

• Availability of non-toxic, anticorrosive and antifouling

hydrophobic materials with the chemistry know-how of

formulation and research studies conducted on various

substrates allow the development and testing of newer

products across different application segments.

•The potential of superhydrophobic coatings has been

effectively commercialized only in some applications

currently. However, more promising applications will be

explored soon.


efficiency and many more.

•The shortcomings of hydrophobic coatings such as irreparable

wetting of the surfaces due to dust formation leading to

punctiform soiling has given rise to the development of

superhydrophobic coatings that possess extreme anti-wetting

properties and other properties, such as anti-fouling, anti-

corrosion, anti-condensation, anti-ice and anti-snow, self-

cleaning, anti-condensation, anti-friction, and anti-clotting.

Incorporation of these properties in products has opened up

newer opportunities in sectors including aerospace, automotive,

optics, and healthcare.


efficiency and many more.

•The shortcomings of hydrophobic coatings such as irreparable

wetting of the surfaces due to dust formation leading to

punctiform soiling has given rise to the development of

superhydrophobic coatings that possess extreme anti-wetting

properties and other properties, such as anti-fouling, anti-

corrosion, anti-condensation, anti-ice and anti-snow, self-

cleaning, anti-condensation, anti-friction, and anti-clotting.

Incorporation of these properties in products has opened up

newer opportunities in sectors including aerospace, automotive,

optics, and healthcare.

Application Landscape-- Introduction

Materials and Substrates

Coating and Deposition Technologies

Chemical Vapor Deposition

Layer-by-layer Deposition

Sol-Gel Techniques

Electrodeposition

AutomotiveAutomotiveAutomotive

TextilesTextilesTextiles

AerospaceAerospaceAerospace

Ap

pli

cati

on

s a

cro

ss S

ecto

rs

Galvanic Cell Reaction

NanosphereLithography

Polymers

Glass

5

Plasma Treatment

Solvent Casting

Templating

OptometricsOptometricsOptometrics

Medical DevicesMedical DevicesMedical Devices

MarineMarineMarine

MicrofluidicsMicrofluidicsMicrofluidics

Ap

pli

cati

on

s a

cro

ss S

ecto

rs

Plastic Transformation

Polyelectrolyte Multilayers

Self-assembly

Anodization Thermal/Electron Beam Evaporation

Metal

Nanoparticles

Diatomaceous Earth

Composites

Application Landscape--Industrial Significance and Prospects

De-IcingAnti-fogging

• Safer and better functional products

• Higher capacity of heat exchangers

• New product and processes (IPR-protected, implemented and commercialized

Industrial SignificanceCoating PropertiesApplication Sectors

• Increase life span of the substrates

• Reduce labour cost involved in cleaning

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Self-cleaning• Reduce labour cost involved in cleaning

• Improve the usability and functionality of substrates

Anti-wetting

• Increase transmission of light, esp. in solar panels

• Increase life span of the substrates

• Prevent contamination

• Improve the usability and functionality of substrates

Anti-corrosion

• Prevent growth of mould and mildew and

• water seepage.

• Improve wettability characteristics

• Help in phase separation (oil and water phases) in oil and gas industry.

Industrial SignificanceCoating PropertiesApplication Sectors

Anti-fouling

• Prevent adherence of microorganisms and barnacles, especially to ship hulls in marine vessels

Application Landscape--Industrial Significance and Prospects (contd.)

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• Promote self cleaning effect, thereby, reducing labour costs.

• Speed enhancement of boats and marine vessels

Anti-microbial

• Reduces growth and survival of microbes in substrates, thereby, limiting chances of infection and the spread of contagious diseases

• Improved odor protection, especially in garments

• Increases lifespan of the products

Impact Mapping of Drivers and Challenges

Very Certain

Demand for anti-fouling properties

Adoption of self-cleaning surfaces

Large-scale production is complex

Environmental concerns

Process compatibility on a diverse array of substrates

Wider application markets

8

Source: Frost & SullivanBusiness Drivers Business Challenges Technology Drivers Technology Challenges

Unimportant Critical

Very Uncertain

Requirement of specialized knowledge and skilled resources

Coating is sensitive to mechanical wear

Lack of Technologies to enhance performance

Key Developments--Recent Innovations

Anti- icing Coatings: Aerospace Research and Development Directorate, JapanAerospace Exploration Agency (JAXA), has developed an innovative super hydrophobiccoating that has the ability to prevent icing of the aircraft parts. The researchersdeveloped the anti-icing coating using polytetrafluoroethylene (PTFE) material.

Anti-Fouling Coatings: International Yacht Paint, a unit of AzkoNobel CoatingsLtd., has developed a premium range antifouling coatings under the name of"Micron WA." The coatings are based on the Water Activated Matrix (WAM)technology that has the ability to allow the minimal use of copper and also helpsin efficient biocide delivery, thereby, leading to reduced patina formation andbarnacle adherence on the ships’ hull. Source: : International Yacht Paint

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Water Repellant Coatings: Hydrobead has developed a water repellent coatinghas been designed to mimic the lotus leaf. The coating can be applied to anysurface that requires extreme water repellency, such as rain gear, outdoorequipment (tents, tarps), fencing, roofs, or other surfaces subject to waterdegradation or corrosion.

Anti-Corrosion Coatings– Ross Nanotechnology, has developed a nanotechnology-based super hydrophobic coating that completely repels water and heavy oils. TheNeverWet™ coating can be used onto any surface and offers complete protectionagainst corrosion and liquid penetration without touching the underlying surface. NokiaResearch Centre is also prominent in this space.

Source: Ross Nanotechnology

Self Cleaning Artificial Skin: UT-BATTELLE, LLC has developed a self-cleaning skin likeprosthetic polymer surfaces that is super hydrophobic in nature. The developed surfaces canbe used on the surfaces of the artificial organs to obtain a skin-like look and haptic feel.

Key Developments—New Products

0

Zschimmer & Schwarz Mohsdorf GmbH & Co. KG has developed a superhydrophobicfinish in emulsion form that has both water- and oil-repellant properties. It can be applied on textiles or fabrics at low temperatures. Also the finishes are resistant to washing and dry cleaning.

HIREC

NeroShield

Anthydrin NK

NeroShields Inc., has formulated a superhydrophobic nanotechnology-based coating sealer product. It is based on the natural process of electrostatic self-assembly (ESA) which not only imparts hydrophobic properties but also self-cleaning and anti-fungal features. It creates a breathable water-repellent membrane using polymers as building blocks. The product is available in four different types for different surfaces, including concrete, glass, wood, and metal (car).

NTT Advanced Technology Corporation has developed a series of superhydrophobiccoating for different surfaces and applications. It also repels ice and snow besides water.

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HIREC Series

Water-resistant

nanocoating

NeverWet

coating for different surfaces and applications. It also repels ice and snow besides water.

It has been developed in both spray and coating forms. The primary application of theproduct is in the communication equipment field for radars, antennas, andcommunication towers.

Xeromax Sciences (P2i) has developed a superhydrophobic technology which when applied on textiles results in a durable water repellent material. The nano-coating also has the ability to repel the stains on a fabric while being abrasion-resistant. It can serve textile applications, such as weatherproof clothing, water- and stain-resistant apparel, protective work clothing as well as other accessories including bags and wallets. Other potential uses could be in fuel cells and air filters.

Ross Nanotechnologies has developed NeverWet, a superhydrophobic coating product for multiple applications. Neverwet coatings provide a surface contact angle of about 160 degrees to 175 degrees with water, making the water droplet an almost perfect sphere. It possesses features such as anti-wetting, anti-icing, anti-corrosion, anti-bacterial, and

self-cleaning.

Highlights of Regulatory Scenario

Environmental AspectEnvironmental Aspect

• Registration, Evaluation, and Authorization of Chemicals

(REACH) has been effective in the EU since 1981. This

regulation requires the registration of all chemicals that are

being used by companies for product manufacture. Such

registration processes gives additional cost burden to

companies while also may cause the removal of toxic

chemicals that might also be the most efficient ones from the

market. The coating manufacturers need to either find

alternatives or come up with eco-friendly credentials for their

chemicals.

• Other countries also have regulations governing chemicals

that are likely to be used in coatings. For instance, China

• Registration, Evaluation, and Authorization of Chemicals

(REACH) has been effective in the EU since 1981. This

regulation requires the registration of all chemicals that are

being used by companies for product manufacture. Such

registration processes gives additional cost burden to

companies while also may cause the removal of toxic

chemicals that might also be the most efficient ones from the

market. The coating manufacturers need to either find

alternatives or come up with eco-friendly credentials for their

chemicals.

• Other countries also have regulations governing chemicals


Product AspectProduct Aspect

• Volatile Organic compound (VOC) containing coatings creates

tropospheric ozone that is harmful. The European VOC Directive

sets emission levels for VOC precursors and recommends

installation of equipment for reduced emission. Coating

manufacturers have significantly reduced solid content so as to

comply with this regulation. This has driven new efforts for

process development.

• Fluoropolymers, such as polytetra fluoroethylene (PTFE) are

used in this industry. Even though the Restriction of Hazardous

Substances (RoHS) directive had not included PTFE, its safety is

still debated. In fact, some manufacturers have resorted to

developing eco-friendly alternatives.

• Volatile Organic compound (VOC) containing coatings creates

tropospheric ozone that is harmful. The European VOC Directive

sets emission levels for VOC precursors and recommends

installation of equipment for reduced emission. Coating

manufacturers have significantly reduced solid content so as to

comply with this regulation. This has driven new efforts for

process development.

• Fluoropolymers, such as polytetra fluoroethylene (PTFE) are

used in this industry. Even though the Restriction of Hazardous

Substances (RoHS) directive had not included PTFE, its safety is

still debated. In fact, some manufacturers have resorted to

developing eco-friendly alternatives.

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REACH, Korea’s Toxic Chemicals Control Act, and Japan’s

Chemical Substances Control Law are some notable

regulations.


REACH, Korea’s Toxic Chemicals Control Act, and Japan’s

Chemical Substances Control Law are some notable

regulations.

developing eco-friendly alternatives.developing eco-friendly alternatives.

Application Aspect

• Laws governing textiles are Textile Products (Indication of Fibre Content) Regulation 1986 and Textile Products (Determination of

composition) Regulations 2008. These also include nanomaterials, fluorinated polymers, and other toxic substances used in their

development. Textile companies need to comply with these while getting coating products from SH coating manufacturers.

• General Product (Safety) Regulations in UK control safety aspects of several products, including sports, leisure goods, and textiles.

• The Restriction of the Use of certain Hazardous Substances in Electrical and Electronic Equipment Regulations 2006 governs the use

of permitted levels of hazardous substances including lead, mercury, nanomaterials, and certain bromine compounds.

• The Food and Drug Administration’s (FDA) Center for Devices and Radiological Health (CDRH) have set regulations that also govern

coatings used on medical devices. The device needs to be verified using the standards, the recent risk analysis standard being ISO

14971:2000.

• Laws governing textiles are Textile Products (Indication of Fibre Content) Regulation 1986 and Textile Products (Determination of

composition) Regulations 2008. These also include nanomaterials, fluorinated polymers, and other toxic substances used in their

development. Textile companies need to comply with these while getting coating products from SH coating manufacturers.

• General Product (Safety) Regulations in UK control safety aspects of several products, including sports, leisure goods, and textiles.

• The Restriction of the Use of certain Hazardous Substances in Electrical and Electronic Equipment Regulations 2006 governs the use

of permitted levels of hazardous substances including lead, mercury, nanomaterials, and certain bromine compounds.

• The Food and Drug Administration’s (FDA) Center for Devices and Radiological Health (CDRH) have set regulations that also govern

coatings used on medical devices. The device needs to be verified using the standards, the recent risk analysis standard being ISO

14971:2000.

Insights – The Road Ahead 2020

Widespread commercialization activities in textiles especially for sportswear and military applications is due to the requirement of hydrophobic textiles by consumers. Increased commercialization is expected in aerospace applications in the next two years.

Basic research focusing on the development of Antireflective coatings, especially for solar cells and Biocidal coatings as secondary functional attributes.

Biocidal

The need for alternate corrosion protection technology is driving the research for anti-corrosive super hydrophobic coatings. However, the availability of existing corrosion protection technologies and specialty anti-corrosion coatings makes the entry of in this space a challenging one

Antireflective

Coatings for

Alternate Energy

Sector

Hydrophobic Anti Fog/

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2013 2015 2017-18 2020

Biocidal

Coatings for

Healthcare

Self

Cleaning

Coatings

Scratch

Resistant

Coatings

Anti Fouling

Coatings

Coatings for

textiles

Anti

Corrosion

Coatings

Anti Fog/

Anti-Icing

Coatings

Conclusions

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Superhydrophobic coatings are in the development and applied R&D stage. Certain functionalities of the coatings, suchas robust nature and resistance to wear are to be enhanced for complete realization of their commercial potential.Several industry and academic research projects are striving to address this need.

Superhydrophobic coatings are in the development and applied R&D stage. Certain functionalities of the coatings, suchas robust nature and resistance to wear are to be enhanced for complete realization of their commercial potential.Several industry and academic research projects are striving to address this need.

Key market requirements for superhydrophobic coatings include development of both colored and transparent coatingsfor desired applications; improved performance in comparison to competing products (hydrophilic self-cleaningKey market requirements for superhydrophobic coatings include development of both colored and transparent coatingsfor desired applications; improved performance in comparison to competing products (hydrophilic self-cleaning

Superhydrophobic coatings were commercially introduced in the mid-1990s and ever since, they have been used in awide variety of sectors, such as aerospace, automotive, healthcare, optics, microfluidics, electronics, filtration, to namea few. Superhydrophobic paints, self-cleaning glasses, and water-repellant clothing are some of the commerciallyavailable products while some areas of intense research include coatings on marine vessels, automotive and aircraftparts, electronics, medical devices, bio-consumables, and architectural components.

Superhydrophobic coatings were commercially introduced in the mid-1990s and ever since, they have been used in awide variety of sectors, such as aerospace, automotive, healthcare, optics, microfluidics, electronics, filtration, to namea few. Superhydrophobic paints, self-cleaning glasses, and water-repellant clothing are some of the commerciallyavailable products while some areas of intense research include coatings on marine vessels, automotive and aircraftparts, electronics, medical devices, bio-consumables, and architectural components.

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33

44

55

66

for desired applications; improved performance in comparison to competing products (hydrophilic self-cleaningmaterials); and utilization of safer raw materials and processes.for desired applications; improved performance in comparison to competing products (hydrophilic self-cleaningmaterials); and utilization of safer raw materials and processes.

USA, Germany, and UK are the leaders in the development and production of superhydrophobic coatings. Most of theresearch projects are supported through funds from the government.USA, Germany, and UK are the leaders in the development and production of superhydrophobic coatings. Most of theresearch projects are supported through funds from the government.

The different research networks and regular funding activities from government, industry, and venture capitalists in thisdomain are likely to facilitate faster and increased commercial product development. In addition, the intellectual propertyprotection and expansion strategies taken up by companies will help in broadening the research database and spurcreative developments.

The different research networks and regular funding activities from government, industry, and venture capitalists in thisdomain are likely to facilitate faster and increased commercial product development. In addition, the intellectual propertyprotection and expansion strategies taken up by companies will help in broadening the research database and spurcreative developments.

Differentiating the product applications, revamping the innovation portfolio, and investing special capital are strategiesfollowed by companies to manage R&D activities, and in turn, improve product development. Also, with higher revenuegeneration, the organization’s market share and position will improve.

Differentiating the product applications, revamping the innovation portfolio, and investing special capital are strategiesfollowed by companies to manage R&D activities, and in turn, improve product development. Also, with higher revenuegeneration, the organization’s market share and position will improve.

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Superhydrophobic Coatings- The Road Ahead