DSM KhepriCoat presentation GPD Finland 2011

Anti-Reflective Hybrid Coatingsfor Glass ApplicationN. 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 SuccessfulTransformations

Life Science Products

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Technological competences1902 1930 19701950 1990 2000 2010

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Nanostructured Functional Coatings

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

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

DSM examples:Anti-reflective on glass and plasticsAnti-staticAnti-foulingAnti-foggingSelf-cleaningAnti-microbial (BMM)Lubricious (BMM)


Product Portfolio & Pipeline

Available antireflective products:

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


Antireflective Coatings

Reflection can be reduced and 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


Single Layer Antireflective Coatings:“Moulton Relationship”

Mec

hani

csCl

eana

bilit

y

Optics

Moulton US2432484 (1943)Moulton US2432484 (1943)

DSM’s coating(Picture courtesy of Corning)


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

Binder

Solid silica particles

~100nm


Coating’s Surface Analysis

White Light Optical Profiler

AFM image

There is a certain surface roughness, but noton such scale as in the traditional AR


Coating’s Surface Analysis: SEM

+

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Silica precursor

alcohol

Preparation Core-Shell Particles

aqueous polymerdispersion

Coating application methoddepends on the product application


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:improved light transmissionfor higher yield/ energy saving

•Photovoltaic cells

•Solar thermal collectors

•Horticulture

•Lighting

•Lenses


Value proposition:improved light transmissionfor better visibility

•Picture framing

•Refrigerator and freezer doors

•Cabinets, shop furniture

•Architectural glass

•Decorative glass

•Displays

DSM’s AR Coating Performance


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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With 1-side Kherpicoat(TM)

% gain

% gain (2nd Y-axis)

Transmission single side Khepricoat(TM) on 4mm SG Albarino-T

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% gain (2nd Y-axis)

Optical Performance on 4.0 mm Float Glass


By varying coating thickness optical properties can be tuned

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300 500 700 900 1100 1300 1500 1700 1900 2100 2300 2500

wavelength [nm]

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glass2mm3mm4mm5mm6mm7mm8mm9mm

Dipping speed(mm/sec):

Tunable optical performance


Optical Performance:Angle-Dependent Transmission

• The gain in transmission increases at higher angles of incidence to almost10% (green line)

• The biggest gain in transmission is obtained at angles above 30 degrees

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Angle of incidence [deg]

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uncoated glassAR-coated glass

Transmission gain


• Passed all tests according to IEC 61215 (damp-heat, humidity-freeze,thermal cycling)

• 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)

http://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/min2. Spray coating – 20123. 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 ofoptical coatings on rigid (glass) substrates (thickness = 100 – 150 nm; thicknesstolerance = 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 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


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 Schoot,Chantal Jorissen

DSM Contact Persons

Mr. Hugo SchootBusiness Development Manager

Dr. Kornelia MatlokaR&D Scientist


Thank you for your attentionContact us via www.khepricoat.com

http://www.khepricoat.com/

DSM KhepriCoat presentation GPD Finland 2011

Technology

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