FABRICATION OF DEVICES

FABRICATION OF DEVICES

Avenue Nicolas Copernic, 1 / B-7000 Mons / T. : +32 (0)65 55 49 02 / www.materianova.be

Fabrication on new substrates (coated glasses and steel) towards innovative applications (Light emit-ting windows, Light emitting steel panels, Organic solar cells on soft Substrates..),

Nature and properties of the substrate (roughness, transparency, conductivity, reflectivity..)

Optimization of conductivity and transparency of electrodes (Evaporation vs Sputtering),

New active materials (in-house synthesis, supported by theoretical calculation and modelling),

Optimization of device architectures (stack definition and connections towards best efficiencies.

CHALLENGES

Devices based on Organic semiconductors for lighting and light harvesting,

Poor environmental impact (Green energy, low consumption, low costs of production),

Versatile applications (large scale, on soft/ rigid supports + transparent/ opaque surfaces),

Towards building integration (roofs, wall, windows..),

Research supported through many collab-orations with industrial key players and Universities Worldwide.

CONTEXT AND TOPICS OF OUR RESEARCH

Optical and Electrical characterization according to international standards,

Measurements of efficiencies of Oled’s and OPV’s,

High resolution imaging techniques (AFM, TEM, SEM...)

CHARACTERIZATION

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CORROSION PROTECTION

HIGH DURABILITY COATINGS FOR METALS

CORROSION PROTECTIONHIGH DURABILITY COATINGS FOR METALS


Selection and evaluation of non toxic inhibitors

Self-Healing for an active protection against corrosion

Coatings with increased barrier properties on any metallic substrate

Study of the corrosion and protection mechanisms

APPLICATIONS

Metal

Na+Na+

Na+

Men+

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Cl-

Cl-

Cl-

ALTERNATIVE TO CR (VI)Development of alternative passivation or conversion treatments based on hybrid organic/inorganic coatings

SELF-HEALING Synthesis of inhibitor nanocontainers as anti-corro-sion pigment for improved corrosion resistance and self-healing. Nanocontainers developed at Materia Nova are mainly based on nanoclay.

METAL PLATING Environmentally friendly protective metallic coatings by plasma PVD and electroplating processing

SHORT-TIME EVALUATION OF COATINGS PERFORMANCES AND DURABILITYDevelopment of specific evaluation methods based on electrochemical techniques

Evaluation of the compatibility of pretreatments with organic coatings in terms of adherence, edge protection, …

SKILLS/KNOW-HOW

Double layer hydroxide nanoclay

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POLYMERS AND (NANO)COMPOSITES

SPECIAL HIGH PERFORMANCE POLYMERS AND (NANO)COMPOSITES

POLYMERS AND (NANO)COMPOSITESSPECIAL HIGH PERFORMANCE POLYMERS AND (NANO)COMPOSITES

Meet growing industrial demand for materials with improved properties Acceptable economic costs Low environmental impact Understanding the structure-properties relationship


SKILLS / KNOW-HOW Synthesis and formulation of polymeric compositions

Synthesis of monomers, polymers and (nano)fillers derived from renewable resources

Polycondensation, polymer blending and compatibilization

Nanocomposites processing

Reactive extrusion and dry mixing technologies

Thermoset resins for composites, adhesives and coatings

Improving fire behavior of polymeric materials by devel-oping environmentally friendly flame retardant systems

Materials characterization (thermal, mechanical, electrical, fire reaction, anti-bacterial, barrier, …)

APPLICATIONS Fire proofing of polymeric materials for building

and transport

Highly conductive materials for electronics

Biobased polymers with improved anti-bacterial properties for food packaging

Polyurethane-based materials for insulation and painting

Self-healing materials for transport

Wood-Plastic-Composites with improved performances for building

Improving mechanical resistance of elastomers

Use of nanoparticles for efficient recycling of automotive parts

Nanocomposites lightweight materials

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GAS DETECTION BY CHEMICAL SENSORS

FOR A BETTER CONTROL OF OUR ENVIRONMENT

GAS DETECTION BY CHEMICAL SENSORSFOR A BETTER CONTROL OF OUR ENVIRONMENT


Materia Nova, in collaboration with the University of Mons (UMONS), also works on the sensors based on optical fibre.

The sensor consists in the deposit (on the fibre tip or on fibre Bragg grating structure) of an appropriate indicator reacting with the chemical and/or biological analyte bringing a change in its optical properties.

OPTICAL FIBRE CHEMICAL SENSORS

Sensors for H2, NO2, Fire detection, pH…

OPTICAL FIBRE SENSORS CURRENTLY DEVELOPED

Possibility of measurement distributed over long distances

Compact in size & very small volume

Immunity to electromagnetic interferences ‘noises’

Multisensors on the same fibre

Valid in liquid or gaseous phase

Advantages

Development of sensitive materials with a reversible change in electrical or optical properties in contact with species to detect.

Synthesis and microscopic design of the sensitive materials.

Integration of the sensitive layers on substrates for transduction by methods involving the wet chemical methods (Spin-coating, Dip-coating, Spray-coating, Screen-printing, Electrodeposition…) or via vacuum deposition process (sublimation or sputtering).

OUR EXPERTISE

This kind of sensors uses the electrical properties of semiconductor material sensitive to surrounding gases. The sensitive layer conductivity is a function of the gas concentration to be detected.

CONDUCTOMETRIC CHEMICAL SENSORS

High sensitivity

Fast response & recovery

Small size

Low fabrication cost

Robustness & long term stability

Easy insertion in the electronics

Main Advantages

Control of atmospheric pollution in an urban envi-ronment (indoor or outdoor): NO2 detection, Ozone detection, CO …

Safety in an industrial environment: fire detection, hydrogen leak detection

Control of the processes in industrial environment: regulation of combustion

Safety in the domestic environment: CO and com-bustible gas leak detection

Indoor Air Quality Control: smoke, formaldehyde detection …

Air purifiers, ventilation control

Automotive applications: alcohol breath tests, air quality control in the cockpit, exhaust emissions control

Applications

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SURFACE TREATMENT BY PLASMA

EFFECTIVE, ECONOMICAL SURFACE TREATMENT WITHOUT EFFLUENTS

SURFACE TREATMENT BY PLASMAEFFECTIVE, ECONOMICAL SURFACE TREATMENT WITHOUT EFFLUENTS


DEPOSITION OF THIN FILMS PVD allows the deposition of inorganic thin films (metals, alloys, oxides, nitrides, carbides) with adaptable prop-erties (composition, microstructure, surface topology, hardness, friction coefficient, color).

PECVD allows the deposition of inorganic, organic or hybrid thin films at low temperature. This technique enables the deposition of “plasma polymer” films with a very high and tunable crosslinking degree with turned up chemical function (NH2, OH, CF…) at their surface. Both techniques could just as easily be considered for the coating of flat substrates or 3D objects of all types (metal, glass, polymer…).

DEVELOPMENT OF CUSTOMIZED POWER SUPPLYMateria Nova has developed different pulsed power supplies (HiPIMS, BHV) capable of generating impulses which can control the flux and the energy of ion impinging conductive as well as insulating substrate.

POWDER MODIFICATIONSpecial configuration of PVD and PECVD coaters, oper-ating at low or atmospheric pressure, was developed to treat not only flat macroscopic objects but also small 3D objects with different shapes like powders, flakes, beads or fibers. Such systems can modify the surface

of powders or fibers, presenting a size ranging from 50 nm to 1 cm. New functionalities like antimicrobial, biocompatibility, corrosion and wear resistance or optical tuning can be obtained by such treatment.

ION IMPLANTATIONIon implantation is a process that modifies the composition and structure of a materials surface (few microns) by interaction with a beam of ions. This technology is used to create, at the surface, a re-alloy, an amorphization, a nano-restructuration, a nano-hammering and chemi-cal modification (nitriding, carburizing) of all materials (metals, ceramics, polymers). Ion implantation allows to increase hardness, fatigue limit, corrosion resistance, decrease the friction coefficient and control the cross-link-ing degree of polymers.

ATMOSPHERIC PLASMAAtmospheric plasma torch is a spotted and powerful treatment operating in air and working with dry air or oxidizing and reducing gases. It allows surface cleaning by removing the carbon pollution, metallic oxide reduction in surface or ceramics deposition like SiOx to protect different substrates. Recent development on this tech-nology allows to treat very stable materials like PTFE and to make deposition of metallic coating on all types of substrates (metal, polymer, glass ...).

SKILLS

To improve materials properties...

APPLICATIONSMateria Nova has developed plasma technologies to modify the surface of materials. This powerful technology can develop new solutions for direct industrial applica-tions. Materia Nova is specialized in the development of technological solutions for creating new surface properties through thin film deposition, decoration with nano-domains, ion implantation, grafting of chemical functions, structuration of the surface and cleaning.

Obtainable properties include:

Mechanical: hard films, weak friction coefficient, diffusion barrier, anti corrosion, …

Optical: anti reflective, athermic, absorbent, surface selective, …

Chemical: improved adhesion, polymer functionalization, hydrophobic, hydrophilic, …

Biological: biocompatible, cell growth, differentiation, bactericide, …

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STRUCTURED SURFACES

FOR SMART OR MULTIFUNCTIONAL SURFACES

STRUCTURED SURFACES

Nanostructured surfaces developed by using particles (nano or submicron, nanospheres,…) and a hybrid coating formulation. The coating can be obtained by two different techniques: plasma (dry) and sol- gel (wet).

We use the natural instabilities existing in elastic or viscoelastic thin layers to generate surfaces with complex morphologies at sub-micrometric scales.

MaNo develops and controls structuration methods of surfaces:

One-layer system by sol-gel: (nano)particles dispersed in a mixture of solvent and fluori-nated alkoxide precursors;

Multi-layer systems: (nano)particles spin-coated and covered with a hybrid coating obtained by PECVD; chemically modified polymers.

SKILLS


SUPERHYDROPHOBIC AND SELF-CLEANING SURFACES

Structuration of materials to make surfaces with superhy-drophobic properties which can be useful in the following domains :

Aeronautics (to avoid freezing phenomena),

Construction (self-cleaning surfaces),

Medical (“easy to clean” surfaces in surgical units).

PHOTONIC SURFACES

Development of coatings concentrating diffuse light in order to increase the efficiency of solar cells in cloudy conditions (fluorescent concentrator).

Improvement of the luminescence of OLEDs (organic electroluminescent diodes).

SCOPES OF APPLICATION ZnO on glass

Sol-gel + ZrO2

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WHITE BIOTECHNOLOGY

CELLS FOR MATERIALS AND MATERIALS FOR CELLS

WHITE BIOTECHNOLOGYCELLS FOR MATERIALS AND MATERIALS FOR CELLS


Durable and profitable products and processes issued from biomass

Replacement of traditional production processes for chemicals and nanomaterials by more environmentally friendly ones or based on a circular economy scheme

Focus on high added-value molecules for application as materials in chemical, packaging, cosmetics, food and agricultural sectors

Replacement of traditional antifouling or antimicrobial solutions with more sustainable ones

APPLICATIONS

FERMENTATION & BIOCATALYSIS

Production of building blocks for polymers with bacteria using synthetic biology

Production of high added-value molecules, enzymes and nanomaterials

Down-stream processing and formulation

Development of novel bacterial and fungal culture strategies

ANTIFOULING & ANTIMICROBIAL

Development of novel antifouling agents and strategies (non-toxic)

Testing: anti-biofilm, anti-algal, anti-bacterial, anti-fungal

BIOMASS

Physico-chemical characterisation of biomass-derived biopolymers (polysaccharides, lignin, proteins)

Identification, extraction, fractioning and development of applications for high added-value molecules

Use of environmentally friendly catalysis to transform biomass into fer-mentation friendly substrate or into simple and/or bio-sourced materials

Development of tailor made approaches for bioactive oligosaccharides production

SKILLSFull bioprocess development from nano-scale research (idea) to pre-industrial scale production (150 L)

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MULTIFUNCTIONAL SURFACESHIGH DURABILITY COATINGS

MULTIFUNCTIONAL SURFACESHIGH DURABILITY COATINGS


Surface preparation and cleaning Hard, scratch and wear resistant coatings Optical/Thermal tunable properties layers Smart enhanced corrosion resistant coatings Low friction coefficient layers TCO’s and TSO’s thin films Easy to clean, Anti fingerprint and Anti-graffiti coatings Bioactive, Biocompatible and Anti-bacterial films Aesthetic surfaces

GLASSES, METALS AND POLYMERS TREATMENT

Enhanced wettability

New chemical elements added

Fine tuning composition

New functionalities Protective layers

POWDERS AND FIBERS MODIFICATION

Semi industrial and industrial production Dedicated characterization and analysis platform Pilot systems design support On-site assistance High power bipolar power supplies

TECHNICAL SUPPORT

PVD magnetron, μwaves reactors and PECVD: fine tunable properties, very good adhesion…

Sol-gels: hybrid and composite solutions, new curing processes, formulation tuning regarding the application methods and substrates…

Atmospheric plasmas: surface cleaning and preparation, deposition processes…

Hardion Ion gun: no added layers, any materials might be treated…

Electrochemical processes: controlled sur-face structuration by anodization, formulation of non toxic electrolytes for metal plating,…

TECHNOLOGIES

UV protection : functionalized clays

Homogeneous coating on particles

High grafiti resistance coating

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ELECTROCHEMICAL COATINGS

ENVIRONMENTALLY FRIENDLY PROCESSES

ELECTROCHEMICAL COATINGSFROM ELECTROPLATING TO ANODIZATION MATERIA NOVA DEVELOPS NEW COATINGS AND ELECTROLYTE FORMULATIONS FOR SEVERAL APPLICATIONS AND OFFERS SUPPORT AND SERVICES TO THE INDUSTRY.


Formulation of cya-nide-free electrolyte for batch and continuous silver electroplating.

ALTERNATIVE SILVER PLATING

Coating parameter optimization, coloration, alternative sealing or top coat process (sol gel).

ANODIZATION (ALUMINIUM, TITANIUM)

PRECIOUS METAL PLATING

Formulation of environment-friendly electrolytes for metal plating

Plating facilities: plates (up to A4) and small pieces (barrel) of technical coatings or precious metals

Characterization platform: chemical analysis, morphology and structure, interaction with environment, durability

SKILLS / KNOW-HOW

Protection of metals against wear and corrosion

Decorative coatings

Black coatings for absorbers

APPLICATIONS

Formulation of an environ-ment-friencly electroplating electrolyte based on trivalent chromium and optimization of process parameters to obtain crack-free thick lay-ers of hard chromium.

HARD CHROMIUM

Development and applica-tion of post-treatment for increased plating lifetime with conservation of the aesthetical aspect.

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METALLIZATION

METALLIZATIONBY USING AND DEVELOPING HIGH POTENTIAL TECHNOLOGIES, MATERIA NOVA OFFERS INNOVATIVE SOLUTIONS FOR THE DEPOSITION OF METALS AND THEIR COMPOUNDS ON DIFFERENT SUBSTRATES

CONTACT: [email protected] (Program Leader) / + 32 (0)65 37 44 28

Low pressure and atmospheric plasma techniques for the deposition of metals and ceramics (oxides, carbides, nitrides)

Deposition on 2D and 3D substrates. Developement of customized solutions for particular shapes and problematic substrates (powder, hollow substrates).

Formulation of environment-friendly electrolytes for metal electroplating

Characterization platform: chemical analysis, morphology and structure, interaction

ELECTROPLATING: flat substrates (up to A4) or small pieces

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SKILLS/KNOW-HOW COATING FACILITIES

Protection of metals against wear and corrosion

Conductive coatings for electronic applications and EMI shielding

Decorative coatings

Coatings for optical properties

APPLICATIONS

PHYSICAL VAPOR DEPOSITION: flat substrates, 3D objects and powders (specific design of barrel)

ATMOSPHERIC PLASMA TORCHES: surface cleaning, preparation (chemical)

Development of green solutions to metal-lize non-conductive materials: incorpo-ration of conductive charges (composites) or surface prepara-tion and activation by efficient and environ-mental alternatives to chromic acid based treatments.

PLASTIC METALLIZATION

LIFE CYCLE THINKING

SUSTAINABILITY ECO-DESIGN

ENVIRONMENTAL IMPACT UNITECO-DESIGN IN R&D PROJECTS THROUGH LIFE CYCLE THINKING


Life Cycle Assessment (LCA) is a tool for evaluating the environmental impacts of a product or a process. LCA methodology, ruled by the ISO 14040 and 14044 standards, consists of identifying and quantifying the flows (raw materials, greenhouse gas emissions…) exchanged between the environment and the system on its entire life cycle (from raw materials extraction to waste treatment) and translating these flows into impacts on indicators such as global warming, resource consumption, eutrophication, human health…

Validate the presupposed greenness of the innovation project

Quantify and optimize the environmental benefits

Identify hotspots in order to focus eco-design efforts where they are most relevant

Help companies in their eco-design approach

Cellulose nanocrystals extraction with ionic liquids

Flax-based insulating materials

Polylactide production process

Antifouling paints

CrVI-free surface treatments

Plasma-assisted conversion of CO2

Bio-based paints

and more…

BENEFITS OF THE LCA APPROACH

PAST AND PRESENT STUDIES

A project on bio-based insulating materials made of flax by-products was the first one in Materia Nova to benefit from the LCA approach. The LCA study led to identify the process steps to optimize in order to minimize the environmental footprint of the products under development. This approach was then used in an increasing number of projects.

LCA, A REAL TOOL FOR ECO-DESIGNING INNOVATION IN R&D

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First prototype After process optimization

PU reference

1 Kgcradle2grave - PLA

injected device

5,38 Kg CO2 eq

1,05 KgPLA - DE, with german maize

3,68 Kg CO2 eq

0,7 Kginjection of PLA - DE

1,51 Kg CO2 eq

7 MJ market for electricity,

low voltage DE

1,41 Kg CO2 eq

14,6 MJ market for electricity, medium voltage DE

2,92 Kg CO2 eq

2,63 KgMaize - Germany

1,48 Kg CO2 eq

1 KgPLA injected device

5,22 Kg CO2 eq

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FABRICATION OF DEVICES - Deutsche Messe...

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