Dr. Dirk Beckelmann

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.

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.