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Innovation at DSM:Nanostructured Functional Coatings
Kornelia Matloka/Pascal BuskensMRS Spring 2011
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
Introducing DSM
Royal 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
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DSM -100 Years Of SuccessfulTransformations
Life Science Products
Coal
Fertilizers
Petrochemicals
Performance Materials
Bioterials / Biologics
Chemical engineering
Polymer technology
Fine chemicals
Material science
Mechanical engineering
Biotechnology
Technological competences1902 1930 19701950 1990 2000 2010
Profile and strategy
classical modern
Evolution
Page 4
NutritionNutrition PharmaPharma Industrial ChemicalsIndustrial ChemicalsPerformance MaterialsPerformance Materials
DSM Company Profile
Corporate StaffCorporate Staff
DSM Nutritional Products
DSM Food Specialties
Company details 2009 :Turnover 7,9 Billion €EBIT 443 Million €Employees 23.000
DSM Pharmaceutical Products
DSM Anti-Infectives
DSM Fibre IntermediatesDSM Resins
DSM Engineering Plastics
DSM Managing BoardDSM Managing Board
DSM Dyneema
DSM Innovation CenterDSM Innovation Center
Page 5
DSM Innovation CenterAccelerating and Supporting Innovation
EBA Biomedical
EBA Advanced Surfaces
EBA Bio-basedProducts & Services
CTO Office
Business Incubator Venturing
DSM Innovation CenterDSM Innovation Center
New Business DevelopmentNew Business Development
Excellence in Innovation
Licensing
Shared ServicesShared Services
Nanostructured Functional Coatings
Functional 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-level
DSM examples:Anti-reflective on glass and plasticsAnti-staticAnti-foulingAnti-foggingSelf-cleaningAnti-microbial (BMM)Lubricious (BMM)
Product Portfolio & Pipeline
Commercialized antireflective coatings:
claryl: picture framing/art displaysKhepriCoatTM: outdoor durable coating for lighting cover glass
Future 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
Page 8
Light Reflection and Transmission
Light is reflected at the boundary of two media with different refractiveindices (n1 and n2).
•In standard glass, 8% of the incident light is reflected ( i = 90°)•The total transmission depends also on the absorption and scattering of light
glass (n2 = 1.5)
air (n1 = 1.0)
air (n1 = 1.0)
Antireflective Coatings
Reflections 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– Expensive
2.Single layer nanoporous silica-based systems– Refractive index and thickness tuned to minimize the total reflection
Page 10
Single Layer Antireflective Coatings:“Moulton Relationship”
Mec
hani
csCl
eana
bilit
y
Optics
Moulton US2432484 (1943)Moulton US2432484 (1943)
DSM’s coating
Page 11
Single Layer Antireflective Coatings:Traditional vs.Core-shell AR Coatings
Binder
Solid silica particles
~100nm
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)
Page 13
Applications
Value proposition:improved light transmissionfor better visibility
•Picture framing
•Decorative glass
•Cabinets, shop furniture
•Architectural glass
•Refrigerator and freezer doors
•Displays
Value proposition:improved light transmissionfor higher yield/ energy saving
•Photovoltaic cells
•Solar thermal collectors
•Horticulture
•Lighting
•Lenses
Page 14
Commercial Applications:
Page 15
®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 / opticalrequirements
• Mechanically durable– Steel wool resistance: 250 g load,
10 rubs, no visible scratches
• Good cleaning properties
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300 350 400 450 500 550 600 650 700 750 800Wavelength (nm)
Tran
smitt
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(%)
ClarylClaryl uncoated
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First License Agreement For Khepricoattm
With Berliner Glas For Lighting Cover Applications
Page 17
Commercial Application: Solar Cover Glass
Page 18
Khepricoat™: DSM’s AR Coating for Solar Cover Glass
2-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
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Wavelength (nm)
Tran
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KhepricoatKhepricoat uncoated
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Wavelength (nm)
Tran
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KhepricoatKhepricoat uncoated
Page 19
By varying the coating layer thickness by adjusting the coating speed,the reflection minimum and optical properties can be tuned
Transmission
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300 500 700 900 1100 1300 1500 1700 1900 2100 2300 2500
wavelength [nm]
tran
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[%]
glass2mm3mm4mm5mm6mm7mm8mm9mm
Dipping speed(mm/sec):
Tunable Optical Performance
Page 20
Khepricoat™: DSM’s AR Coating for SolarCover 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
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Wavelength [nm]
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ain
[red
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Uncoated
With 1-side Kherpicoat(TM)
% gain
% gain (2nd Y-axis)
Transmission single side Khepricoat(TM) on 4mm SG Albarino-T
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Wavelength [nm]
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ain
[red
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Uncoated
With 1-side Kherpicoat(TM)
% gain
% gain (2nd Y-axis)
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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
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Angle of incidence [deg]
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[%]
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uncoated glassAR-coated glass
Transmission gain
Page 22
KhepriCoat™ Performance and Durability
•passed all test according to IEC 61215 (damp-heat, humidity-freeze, thermalcycling)
•TüV certification for commercial modules withKhepriCoat™ 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 deg
Performance of KhepriCoat™ coatedPV-modules
Module tests performed at Photovoltaik Institut Berlin (www.pi-berlin.com)
Page 24
KhepriCoatTM was used for the world record17% efficiency for multi-crystalline Si solar panels
Page 25
Application Process Development
Two sided coatings:• A commercial dip coating plant is operational at DSM (®claryl)• DSM provides technological support to customers
Single 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 DSM
One-Side Coating Processes
Choice of process depends on desired production speed and opticalrequirements of final product
• Spray coating: high production speeds possible (up to 20 meters perminute); low to medium level of optical homogeneity
• Roll coating: medium production speeds possible (up to 5 meters perminute); medium to high level of optical homogeneity
• DSM’s slot-die process: high production speeds and high level of opticalhomogeneity
Page 27
What is roll coating?
The principle of operation:
Doctor rollerDoctor roller Applying rollerApplying roller
Counter-pressingrollerCounter-pressingroller
Direction of feed
Page 28
DSM’s Slot-Die Process
• Slot-die is known e.g. from the photographic industry to coat plastic foils withmicron thick, non-optical coatings
• DSM adapted the technology to make it suitable for high speed deposition ofoptical coatings on rigid (glass) substrates (thickness = 100 – 150 nm; thicknesstolerance = 2 nm)
• DSM patented the adapted process
• Pilot-line available at DSM
DSM Strategy
Flexible 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
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 Kockelkoren
Business development:Hugo Schott,Chantal Jorissen
DSM Contact Persons
Mr. Hugo SchootBusiness Development Manager
Dr. Kornelia MatlokaR&D Scientist
