Bruno Schäfer

A new water-based silica sol was developed to provide single-layer anti-reflective (AR) coatings. The combination of nanoparticle-based aqueous coating and wiping-coating method facilitated to reduce the solvent waste. The wiping-coating process requires only 35 ml sol to cover a large glass substrate (80 × 160 cm). Samples coated on one side show an improvement in light transmission in the visible range: the maximum transmission is 95.12 ± 0.33% on float glass and 92.48 ± 0.25% on display glass. This is an excellent performance compared to the extra 99.04% maximum transmission of samples coated on both sides. The layer thickness distribution defined by the ellipsometry of 98 samples (10 × 10 cm) shows homogeneity (77.4 ± 2.2 nm) over the total area. Homogeneous films with good surface wetting were applied on glass, polycarbonate (PC), and acrylic glass (PMMA). The cured layers were successfully tested against dry heat, damp heat (40 °C/98% RH), and climatic change (−40 °C–40 °C/98% RH) on all three substrate materials. No delamination from the substrate was observed. The changes in the minimum reflection after exposure to damp heat and climatic change were minimal (ΔR = ±0.6%) in the wavelength range of 400–1000 nm. The addition of Levasil nanoparticles into the water-based silica sol improved coating hardness on glass sheets up to 3H pencil hardness without significant loss in transmission.

Aluminum Nitride (AlN) is a well-known compound piezoelectric material with high Complementary Metal-Oxide Semiconductor process compatibility. Previous results show that the piezoelectric coefficient correlates with the c-axis orientation of AlN. In this work, the optical properties of reactively sputtered AlN thin-films have been investigated to find a relation with the structural properties of the film (i.e. c-axis orientation) using spectroscopic ellipsometry. The results show that for almost the same film thickness, highly c-axis orientated films have higher refractive indices compared to films with low c-axis orientation or amorphous layers. A relationship between (002) peak intensity measured with x-ray diffractometry and refractive index is shown. At 546 nm wavelength, the refractive index decreased from 2.15 for films with high (002) peak intensity, to 2.11 for films with about half the peak intensity, and further down to 1.90 for films without preferred orientation. Additionally, with the same sputtering conditions, the variation of the film thickness seems to have no significant effect on the refractive index. The results of AlN thin-film mass density obtained from x-ray reflectivity measurements are consistent with refractive index measurements. The mass density of AlN thin-films with high c-axis orientation that resulted in a higher refractive index is 2.99 g/cm−3, compared to 3.23 g/cm−3 for epitaxial grown AlN layers. This value decreased to 2.82 g/cm−3 for films with poor c-axis orientation.

For the next generation of handling systems, reversible adhesion enabled by micropatterned dry adhesives exhibits high potential. The versatility of polymeric micropatterns in handling objects made from various materials has been demonstrated by several groups. However, specimens reported in most studies have been restricted to the laboratory scale. Upscaling the size and quantity of micropatterned adhesives is the next step to enable successful technology transfer. Towards this aim, we introduce a continuous roll-to-roll replication process for fabrication of high-performance, mushroom-shaped micropatterned dry adhesives. The micropatterns were made from UV-curable polyurethane acrylates. To ensure the integrity of the complex structure during the fabrication process, flexible templates were used. The compression between the template and the wet prepolymer coating was investigated to optimize replication results without structural failures, and hence, to improve adhesion. As a result, we obtained micropatterned adhesive tapes, 10 cm in width and several meters in length, with adhesion strength about 250 kPa to glass, suitable for a wide range of applications

Continuous roll-to-roll fabrication is essential for transferring the idea of bio-inspired, fibrillar dry adhesives into large-scale, synthetic, high-performance adhesive tapes. Toward this aim, we investigated process parameters that allow us to control the morphology and the resulting adhesion of mushroom-shaped micropatterned surfaces. Flexible silicone templates enabled the replication process of the polyurethane acrylate pre-polymer involving UV-light-induced cross-linking. For this paper, we particularly tailored the polyurethane acrylate pre-polymer by adding chemical components to tune UV curing kinetics and to reduce oxygen inhibition of radicals. We found that higher intensities of the UV light and faster reaction kinetics improved the quality of the microstructures, i.e., a larger cap diameter of the mushroom tips was achieved. The polymer blend U6E4 exhibited the fastest curing kinetics, which resulted in a micromorphology similar to that of the Ni-shim master structures. Best adhesion results were obtained for adhesive tapes made from U6E4 with 116 kPa pull-off stress, 1.4 N cm−1 peel strength and 71 kPa shear strength. In addition, repeated attachment–detachment tests over 100,000 cycles demonstrated strong robustness and reusability.

Coating on large surfaces is a critical issue in both academic studies and industrial production. This work proposes a novel method of coating a large flat substrate (50 × 100 cm2) via a wet chemical process using a very small amount (20 ml) of coating solution. The sol material consisted of surface-modified silicon dioxide (SiO2) nanoparticles (10–30 nm), which have the optimal antireflective (AR) function in the visible spectral range for thin films with a thickness ranging from 110 to 120 nm. Ellipsometry results demonstrate a homogeneous thickness of the AR coating on glass (109.4 ± 2.7 nm). A deviation of less than 3% over a large coated surface was observed. Crack-free coatings with homogeneous morphology on the surface of the coatings were observed using scanning electron microscopy. The AR effect was confirmed with UV–vis measurements, with an average transmittance of 91.1% and 94.7%, respectively, in visible wavelengths for the one-sided and double-sided AR coatings (in comparison to 88% for uncoated glass).