a novel aerosol based wet coating technology called nfog™and...

A novel aerosol based wet coating technology called nFOG™ and its applications

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Beneq launches nFOG™ wet coating technologyBeneq is pleased to announce the launch of its new atmosphericwet coating technology called nFOG™ for use in applicationssuch as anti-reflective coatings for large-sized glass. This newtechnology combines the advantages of the speed of spraycoating, the quality of dip coating and the high material yield ofroller coating.

September 3, 2014 Espoo, Finlandhttp://www.beneq.com/sites/default/files/140903%20Beneq%20News.pdf


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)

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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!

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• Wide range of coating materials and substrates, e.g.• Mesoporous SiO2 coatings on glass and Si-wafer• CeO2 coatings on glass and metal• Crystalline nanocellulosa (CNC) coatings on glass• PVB (polyvinyl butyral) coatings on glass• KhepriCoat® glass coatings with pilot-scale nFOG

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Mesoporous SiO2 coatings on glass and Si-waferM. 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

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*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, 309.

Mesoporous SiO2 coatings on glass and Si-waferM. Järn and M. Tuominen

• Glass slides were coated with excellent transparency

• Similar structure as for dip coated films!

• The applications range from catalysis, chromatography, gas separation, water purification, chemical sensing, uptake and release of active components, and low dielectrical and optical coatings. *

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*D. Grosso, A. R. Balkenende, P. A. Albouy, A. Ayral,| H. Amenitsch, F. Babonneau, Chem. Mater. 2001, 13, 1848.

Dip coated nFOG coated

uncoatednFOG coated

CeO2 coatings on glass and metalA. Ahniyaz and M. Tuominen

• CeO2 (1%) in hexane-dispersion

• Curing in room temperature

• nFOG-parameters:– Precursor feed rate– Gas feed rate– Treatment time

• Coating parameters:– Concentration– Viscosity

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0.5 % of CeO2 4.4 % of CeO2

8.4 % of CeO2

1.4 % of CeO2

6.6 % of CeO2

CeO2 coatings on glass and metalA. Ahniyaz and M. Tuominen

• Uniformity of nFOG-coated samples is better than dip coated samples

• Uniformity is at least at the same level or better when CeO2dispersed in water

• CeO2 coatings have several potential application, e.g. UV-protection, fire resistance, corrosion protection, etc.

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1.8 % of CeO2 (nFOG) 2.1 % of CeO2 (dip)

0.7 % of CeO2 (nFOG) 2.3 % of CeO2 (dip)

1.4 % of CeO2 in water (nFOG)

CNC (crystallinenanocellulose) coatingsA. 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 CNC-coatings include reinforcement of glass laminates, fire retardant coatings, etc.

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PVB (polyvinyl butyral) coatings on glassA. 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

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KhepriCoat® glass coatings with pilot-scale nFOGS. 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!

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*Tammela, S., Combination of nFOGTM and KhepriCoat ® technologies to deliver superior quality of anti-fogging coating on solar cover glass. Glass Performance Days, June 24‒26, 2015 Tampere.


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Pilot scale (Beneq)- Batch/continuous process- Sample size 600×1300 mm


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

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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 %

0.6 m

*Tammela, S., Combination of nFOGTM and KhepriCoat ® technologies to deliver superior quality of anti-fogging coating on solar cover glass. Glass Performance Days, June 24‒26, 2015 Tampere.

Science behind the nFOG coating techniquePostdoc-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.

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Conclusions

• nFOG™ is a versatile technique for various applications, for example:– Coatings: Latex, SiO2, TiO2, CeO2, 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 SiO2-film

prepared by dip coating– Better uniformity of CeO2-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™

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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

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SP, your innovation partner in nFOG-research

• SP is a leading international group of institutes that specialise in research and innovation. www.sp.se

• 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

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Thank you for your attention!Acknowledgements• M. Järn, A. Oko, A. Sugunan, M. Sterley, A. Ahniyaz, A. Larsson, J Harra, J.

Rissler.

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