DSM KhepriCoat presentation GPD Finland 2011

Anti-Reflective Hybrid Coatings
for Glass Application
N. Arfsten, P. Buskens, R. Habets, T. Kockelkoren, H. Langermans,
A. Overbeek, R. Rijk, M. Rooijmans, J. Scheerder,
Kornelia Matloka

GPD Finland 2011

Outline

• DSM and DSM EBA Advanced Surfaces

• Introduction to anti-reflective (AR) coatings

• DSM AR coating technology and applications

• DSM ‘s AR coating performance for solar cell cover glass

• AR coating application technologies

Glass Performance Days, Finland 2011

DSM -100 Years Of Successful
Transformations
Royal DSM N.V. uses its competences in life sciences and materials sciences
to create solutions that nourish, protect and improve performance

Evolution 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 Biotechnology


DSM Innovation Center
Accelerating 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 Venturing


Nanostructured Functional Coatings

Functional coating:
A functional coating is a coating which achieves any additional function beyond that of the
usual protective and decorative.

Nanostructured hybrids
hybrid materials prepared through hydrolysis and condensation of metal oxide precursors
in the presence of organic molecules, polymers or biocomponents;
controlled/structured on nano-level

DSM examples:
Anti-reflective on glass and plastics
Anti-static
Anti-fouling
Anti-fogging
Self-cleaning
Anti-microbial (BMM)
Lubricious (BMM)


Product Portfolio & Pipeline

Available antireflective products:

claryl: picture framing/art displays
KhepriCoatTM: 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


Antireflective Coatings

Reflection can be reduced and transmission can be increased by using
antireflective 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


Single Layer Antireflective Coatings:
“Moulton Relationship”

Moulton US2432484 (1943)
Cleanability
Mechanics

DSM’s coating
(Picture courtesy of Corning)

Optics

Single Layer Antireflective Coatings:
Traditional vs.Core-shell AR Coatings
Solid silica particles

Binder

~100nm


Coating’s Surface Analysis

There is a certain surface roughness, but not
on such scale as in the traditional AR

White Light Optical Profiler

AFM image


Coating’s Surface Analysis: SEM

Preparation Core-Shell Particles

Coating application method
depends on the product application

Silica precursor
aqueous polymer
dispersion

-
alcohol
+ +
+
+ +
+
+ +
+ + +


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)


Applications

Value proposition: Value proposition:
improved light transmission improved light transmission
for better visibility for higher yield/ energy saving
•Picture framing •Photovoltaic cells
•Refrigerator and freezer doors •Solar thermal collectors
•Cabinets, shop furniture •Horticulture
•Architectural glass •Lighting
•Decorative glass •Lenses
•Displays


DSM’s AR Coating Performance


Optical Performance on 4.0 mm Float 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 SG Albarino-T
96 4,5

4
95
3,5

94
3
% gain (2nd Y-axis)

93 2,5

% gain [red line]
% Transmission
Transmission Single side Khepricoat(TM) on 4mm Pilkington Optiwhite
96 4.5 2
92
4 1,5
95
91 1
3.5
94
0,5
90
3 Uncoated

93 With 1-side Kherpicoat(TM) 0
% gain [red line]
% Transmission

% gain (2nd Y-axis) % gain
2.5 89
-0,5
92
2 88 -1
350 400 450 500 550 600 650 700 750 800 850
91
1.5 Wavelength [nm]

90
Uncoated 1
With 1-side Kherpicoat(TM)

89 % gain
0.5

88 0
350 400 450 500 550 600 650 700 750 800 850
Wavelength [nm]


Tunable optical performance

By varying coating thickness optical properties can be tuned
100

98 Dipping speed
(mm/sec):

96 glass
2mm
transmission [%]

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]


Optical Performance:
Angle-Dependent Transmission
• The gain in transmission increases at higher angles of incidence to almost
10% (green line)
• The biggest gain in transmission is obtained at angles above 30 degrees

100 10

95 9
Average 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]


Performance of KhepriCoat™ coated
PV-modules

• Passed all tests 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 deg

Module tests performed at Photovoltaik Institut Berlin (www.pi-berlin.com)

KhepriCoat™ Performance and Durability


Coating Application Methods


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
2. Spray coating – 2012
3. Slot die coating – pilot coating line at DSM


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

One-Side Coating Processes

Choice 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


Acknowledgements :

R&D AR development & customer support:
Nanning Arfsten, Jens Thies, Pascal Buskens, Roberto Habets, Patrick
Vrijaldenhoven, Harm Langermans, Ad Overbeek, Jurgen Scheerder, Ron de
Rijk, Marnix Rooijmans, Tessa Kockelkoren

Business development:
Hugo Schoot,
Chantal Jorissen

DSM Contact Persons

Mr. Hugo Schoot Dr. Kornelia Matloka
Business Development Manager R&D Scientist


Thank you for your attention
Contact us via www.khepricoat.com

DSM KhepriCoat presentation GPD Finland 2011

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