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