Pesquisas em materiais poliméricos: tendências internacionais para o setor industrial / Polymeric material researches: internationaltrends for theindustry sector Palestrante: Prof. Dr. Klaus Heinemann - Thuringian Institute of Textile and Plastics Research – TITK / Alemanha

1. 7o WORKSHOP INTERNACIONAL SENAI
“MATERIAIS”
30 de ogosto 2012; Criciúma – SC – Brasil
"Tendências de Pesquisa, Desenvolvimento e Inovação
dos Materiais para Aplicações Industriais"
„Pesquisas em materiais poliméricos:
tendências internacionais
para o setor industrial”
Erich Meusel; Rüdiger Strubl; Wolfgang Müller; Ralf-Peter Gottlöber;
Nicole Klose; Frances Stöckner; Anne Böhm; Klaus Heinemann
Thüringisches Institut für Textil- und Kunststoff-Forschung (TITK) e. V.
07407 Rudolstadt - Schwarza; GERMANY
http://www.titk.de; E-Mail: heinemann@titk.de
Thüringisches Institut für Textil- und Kunststoff-Forschung (TITK) e. V. Prof. Dr. Klaus Heinemann

2. Disposition
„Polymer materials research:
International highly topical trends for the industry sector”
TITK – industrial polymeric materials research institute,
in the Free State "Thuringia"; Germany
Material design using native polymers, esp. Cellulose
the TITK
Fibre reinforced materials for the lightweight construction
ALCERU® high tech
Nano-composites – polymer materials with uncommon properties
Specialized additives aiming at "macromolecular engineering"
Fibre reinforcement
Reactive "lcp’s": Basic concept for „lc- PEIA”
Nano- composites
Selected results
Functionalized
Nano- layered silicates: PEIA- modified „nanoclays”
Specialized additives
antibacterial „nanoclays”
- reactive lcp’s
Additives enriched
- PEIA-nanoclays at filament surface: Conception – basic idea
- antibac- nanoclays Design and synthesis of the novel additives
- additives enriched
Filament properties – first results
at the surface Résumé and outlook
POLYTRONIC Functional polymer systems and "POLYTRONIC"
Fig. 02 Thüringisches Institut für Textil- und Kunststoff-Forschung (TITK) e. V. Prof. Dr. Klaus Heinemann

3. The TITK – 58 Years Industrial Research
Thüringisches Institut
für Textil- und
Kunststoff- Forschung e.V.
Chemical
Research
Plastics
Research
Textile and
Material
Research
Functional
Polymer
Innovation Competence Quality
Systems and for a progressive productive small and medium-sized industry
physical
Research
Dr.-Ing. Ralf-Uwe Bauer
Managing Director
of the TITK reg. assoc.

4. TITK – the Research Institute
for
Polymer Materials
Innovation Competence Quality

5. ThuringianThuringian Institute and Plastics Research Rudolstadt/ Germany
Institute for Textile for Plastics Research (TITK) Rudolstadt / Germany
Department of Functional Polymers Systems
“Technology triangle” Jena – Rudolstadt – Ilmenau
Friedrich-Schiller
University of Jena
Erfurt Weimar Jena
A4
B88
B85
A71
A9
Ilmenau B88
Rudolstadt
University of
Technology Ilmenau Saalfeld / ICE
Thuringia
Center for Micro- and
Nanotechnology
Rudolstadt

6. TITK - Network
TITK OMPG
Thuringian Institute for Textile and East Thuringian Material Testing Comp.
Plastics Research reg. assoc. for Textiles and Plastics
Employee: 133 Employee: 44
Member: 89
Budget: 10 million EURO Turnover: 5 million EURO
Research & Development (100% subsidiary of TITK)
regarding Materials, Materials Testing and
Processing and Technologies Characterization Services
25,1 % 28 % 33 % 50 % 34 %
Shanghai Lyocell AP®FIBRE Technologiegesell- Rubitherm
Chemical Fibre GmbH schaft Thüringen Compound
Engineering Rudolstadt mbG & Co. KG GmbH
Development Co.,
Ltd.
Fig. 06 Thüringisches Institut für Textil- und Kunststoff-Forschung

7. Thüringisches Institut für
Textil- und Kunststoff- Forschung e.V.
Ostthüringische Materialprüfgesellschaft m. b. H.
Accredited Testing of Plastics
SERVICE
Advisory Centre regarding Material Applications
Analyses of Recycling Materials
Investigations
TESTINGS ANALYSES
Thermical testings Identification of plastics
Mechanical testings
Optical testings
Flammability testings
Electrical testings
OM Chemical Analyses
Damage analyses
Particle and
Surface analyses
Rheological testings
PG
„Co- Benefactor” of the endowed professorship „Plastics technology”
at the "University of Technology Ilmenau" Fig. 07

8. TITK - Network
Research & Development regarding
Materials, Processing and Technologies
East Thuringian Material Testing Company
for Textiles and Plastics
(100% subsidiary of TITK)
Materials Testing and
Characterization Services
including: Production of
applicators for the
Cosmetic Industry
by electrostatic coating
using flock fibres
Fig. 08 Thüringisches Institut für Textil- und Kunststoff-Forschung

9. Thüringisches Institut für Textil- und Kunststoff-Forschung
Strategic Research Orientation: Industrial Utilization
Native Polymers and Textile and
Chemical Research Material Research
Functional Polymers – Composite Materials
Structural Polymers – Plastics Processing
Functional Polymer
Plastics Research
Systems Research
Research Services, providing the Expertise and Potentials of the TITK
to the small and medium-sized companies for their own developments
Portfolio
• Research and Development Services: Processes and Materials
• Materials Testing and Characterization Services
• Selling of Products and Materials resulting from previous Research and
Development Activities and produced in small scale production
• Selling of own Patents respectively Licences

10. Department: “Native Polymers and Chemical Research”
Dr. Frank Meister – Head of the department
Field of Research: Structural and functional materials
based on “Native Polymers”
Competences:
- Characterization of polymers and polymer solutions
- Shaping of native polymers
into monofilaments, multifilaments, fibres, films and beads
by means of “dry -wet” or “wet” techniques
- Chemical modification of polysaccharides and proteins
as well as their shaping for technical applications
- Technologies for production of ceramic fibres and foils
Fig. 10 Thüringisches Institut für Textil- und Kunststoff-Forschung

11. 1. “Native Polymers and Chemical Research”
ALCERU® - products – an Overview
ALCERU® duotherm
ALCERU® piezo
Thüringisches Institut
für Textil- und ALCERU® beads
Kunststoff- Forschung e.V. 0.45
0.4 Polymer/Solvent-System : Polystyrene/THF
34± 5 nm
Pore surface/pore volume : 59 ± 10 m3/cm3
0.35 Water retention behaviour: 16 cm3/g
Chemical 0.3
PSD (volume)
0.25
Research 0.2
0.15
0.1
0.05
ALCERU® ceramic
0
0 5 10 15 20 25 30 35 40 45
Information: PSS GmbH Mainz Transverse pore diameter [nm]
Plastics
Research
ALCERU® supersorb
900
800
Destw asser
700 0.9% NaCl-Lösung
Textile and 600
künstl. Blut
Material
R %
WV[ ]
500
400
Research 300
ALCERU®
200
100 conductive
ALCERU® exchange
0
0 10 20 30 40 50
SAP-Gehalt [%]
Functional
Polymer
Systems and
physical
Research REM micrograph of ALCERU®-supersorb fibres + Ag+ 2µm
Dr.-Ing. Ralf-Uwe Bauer
Managing Director
of the TITK reg. assoc. ALCERU® antibacterial

12. "Cell SolutionTM clima"
– a high potential PCM micro-composite material –
Composition: • a new textile micro-composite material with thermo regulating properties
• PCM (Phase Change Material) is directly and permanently embedded
in the fibre cross-section via dry-jet-wet spinning process
• highest heat storage capacity (up to 40 Joules per gram of fibre)
Yarn composition / Fibre characteristics
- cellulose > 47 %
- PCM component 30 - 40 % (absolute)
- minerals about 7 %
- humidity < 12 %
- finishing agent < 2 %
- fibre fineness 2.2 - 6.7 dtex (according to customers demands)
- staple length 38 - 60 mm (according to customers demands)
- tenacity > 16 cN/tex
- fibre elongation > 10 %
- typical phase change temperature* 28 - 35 C
Effectivity: • proved washing permanence up to 50 washing cycles at 60 C
• excellent textile processability and dyeable in all colour gradations
• at least 10 % of Cell SolutionTM clima fibres in blended yarn
(cotton, lyocell, viscose, wool, polyamide, polyester, ...) or fabric are recommended
• outstanding wearing comfort and micro climate because of
excellent skin temperature regulation in bed textiles & heat or cold protection clothes
Dr. Frank Meister, Head of Department Fig. 12

13. Permethrin - based Nanocomposite ALCERU®-Fiber
Requirements:
→ increasing of blocking effect
regarding blood-sucking insects
→ lower insecticide contamination
of clothes wearer
T- shirt made of yarns
containing 7 % functional fibres
Evaluation "Cell SolutionTM protection"
of fibres and fabrics made
from insect blocking fibres
demonstrate
the functionality
even after 50 washing cycles 3-Phenoxybenzyl(1RS)-cis,trans-3-(2,2-dichlorovinyl)-
and their safety 2,2-dimethylcyclopropanecarboxylate
at typical usage Permethrin
Fig. 13 Thüringisches Institut für Textil- und Kunststoff-Forschung

14. Flame- resistant melamine melt- blown fibre mats
Scheme of modified meltblown process (mini plant at TITK):
MER melamine resin granulate Constructional
Catalyst Industry
Crosslinking
Hot air
>180°C
°
Meltblown Tempering,
fibre jet + Finishing
Consolidation
(if needed)
Conveying screen
• typical value ranges: 10 µm ~1µm, 35 - 350 g/m²,
30 cm width (pilot plant)
• inherent flame resistance: LOI = 32
• don‘t shrink, melt or drip when exposed to a flame
• excellent heat dimensional stability
• high thermal & acoustic insulation properties
• textile processability
• self- bonded web
• high filtration efficiency
• Excellent chemical resistance especiallyagainst
alkali and organics; fair acid - resistant
Fig. 14 Thüringisches Institut für Textil- und Kunststoff-Forschung

15. 2. “Textile and Material Research”
Research Fields
► Fibre Reinforced Composites –
materials and their production
technologies
► Technical Textiles – textile composites,
sandwich - structures (light- weight materials)
and recycling as well as reutilization processes
► High Performance Fibres and Textile Fabrics
– Usage as reinforcing materials
and other technical applications –
► Materials Testing /Characterization
Dr. Renate Lützkendorf, Head of Department Fig. 15

16. 2. “Textile and Material Research”
Fiber reinforced composites – New developments:
Composites – reinforced with CARBON fibres
Composites – reinforced with ARAMIDE fibres
"Long fibres reinforced granulates" developments
and result in
ARAMIDE - Recycling fibres Thermoplastic Matrix fibres Long fibres
reinforced
granulates
Matrix materials: PP; PA 6; PA 6.6
ARAMIDE - content: up to 70%
Applications: - Compounding;
- Injection moulding
Industry: - Automobiles
- Tyres
Dr. Renate Lützkendorf, Head of Department Fig. 16

17. 3. “Plastics Research”
Dr. Stefan Reinemann
head of the department
Focus of Research Activities
Thüringisches Institut Compounding Injection
für Textil- und ► Development of Formulations, Moulding
Kunststoff- Forschung e.V.
Processing technologies and
Processing methods
Plastics
Research ► Characterization of the Material Behaviour of
thermoplastic polymers with the main topics:
Chemical - Nanocomposites: Carbon Nano Tubes (CNT)
Research expanded graphite
Films and Sheets
layered silicates
Textile and - Compounds using el. conductive additives – EM- Shielding
Material - Synthetic / Natural / Glass Fibre reinforced Compounds
Research
- Fire - retardant modification and testing
- in-situ-Modification of Polyesters / Polyamides
Functional - Catalysis of Polyesters / Polyamides
Polymer - “Nanocapsules” with core - shell architectures
Systems and
physical by means of DENDRITIC POLYMERS
Research
► Material specific Plastics Recycling –
Dr.-Ing. Ralf-Uwe Bauer
Conceptions, Processes, Products
Managing Director ► Transfer Centre for Technologies
of the TITK reg. assoc. of material specific Plastics Recycling Extrusion

18. 3. Department: “Plastics Research”
Fibre reinforced Polypropylene – using “Synthetic fibres”, e.g. PET or PAN
Results using PAN – fibres:
- increase of the STRENGTH: up to 30%
- enhancement of the STIFFNESS: up to 50%
- improvement of the IMPACT TOUGTNESS: up to 500%
"Falling-ball impact test" (- 30°C)
0% PAN 10% PAN 20% PAN 30% PAN
Dr. Stefan Reinemann, Head of Department Fig. 18

19. 2. Department: “Plastics Research”
Effect of
"PA 6 / PP - OMMT - Nanocomposite" – Blends
Fig. 19 Thüringisches Institut für Textil- und Kunststoff-Forschung e.V.

20. 3. Department: “Plastics Research”
Heat accumulating and Heat storing polymer granulates
„accumulating“ process loaded „pull - out“ process unloaded
• PCM – containing Polymer Granulate Material:
• Melting temperatures of the PCMs used
are determining the accumulating and the
“pull - out” temperatures of the heat storage granul es,
[e.g. (6 / 42 / 52 / 58 und 82) °C]
Applications as buffer store for:
- Thermal Solar Collectors
- Heat Pumps (cold and/or warm site) REM Foto: Einlagerung des Wärmespeicher-Paraffins
in der Polymermatrix
- Solid - phase burning oven / oil or gas burner / air-conditioning systems, engine heat
Fig. 20 Thüringisches Institut für Textil- und Kunststoff-Forschung e.V.

21. Heat accumulating and Heat storing polymer granulates
Reference and Demonstration apparatus at TITK
Station III : Floor heating zone • Heated area – office floor: ca. 60 m²
• Collector area: ca. 52 m2
• 20 Sunlight Collectors:
(BUDERUS® SKB4.0-w)
• Installed Solar power: 26 – 31 KW
• Phase Change Temperature: 42 °C
• PCM - Granulate Mass: 1000 kg
height of the granulate bed: 4 cm
• Heat power Output: ca. 40 kW
• Floor surface temperature: ca. 30 °C
Fig. 1: Schematic Plan
of the Solar – Thermal
Floor Heating
Fig. 2: Schematic Layout
of the Floor
21
Fig. 21

22. TITK- department: “Plastics Research”
“Autoclave Technology”
► Syntheses of POLYESTERS (PET, PTT, PBT and PEN)
► Modification of polyesters using Co-monomers
► "in-situ"- modification of polyesters using various additives
► Evaluation of catalyzer systems for polyester syntheses
► Equipment:
2L- Autoclave 10L- Autoclave
- overpressure up to 15 bar - overpressure up to 20 bar
- polymer yield up to 1 kg - polymer yield up to 6 kg
► Syntheses of POLYAMIDES (PA 6, PA 6.6)
► Modification of polyamides using Co-monomers
► "in-situ"- modification of polyamides using additives
► Equipment: 10L-Autoclave for (trans)esterification
and polycondensation
5L- Autoclave 10L- Autoclave (t < 320 °C)
- overpressure up to 20 bar - overpressure up to 25 bar
- polymer yield up to 3 kg - polymer yield up to 5 kg
► New equipment for "up-scaling" of polymer syntheses,
including “Finisher” to increase the melt viscosity (mbatch ~ 30 kg)
Dr. Stefan Reinemann; head of the department Fig. 22

23. Department: „Functional Polymer Systems
and Physical Research”
Head of the department: Prof. Dr. Klaus Heinemann
consists of two Research Teams:
Synthetic Functional Polymer Materials and – composites
Organic Nano - Layers and – layer systems as well as
Micro Structuring and – materials patterning technologies
for POLYMER ELECTRONIC – (IC&M – Technologies),
MICROSYSTEM–, MEDICINE– and TRANSPORT Applic.
Chemical and physico - chemical modification of
technical „High- Performance”- and „High- Tech” – polymers
using functional, migrating or reactive additives to the
generation of specific surface or interface properties
and/or special material functionalities,
including their processing to films and filaments
for the FIBRE– and POLYMER PROCESSING INDUSTRIE

24. N N
C C „Synthesis Chemistry”
O
_ n
LCP – modified polyamide and polyester resins and fibres
_ Flame - retardant polyamide and polyester resins and fibres
_ Surface - modified polymer films and fibres
_ “reactive polymer blending” and fibres thereof
_ Polymer modification by “reactive compounding” using
"chain extender" or "reactive modifier" and fibres thereof
_ Permanent hydrophobic modification of polyamides & polyesters
_ Permanent hydrophilic modification of polyamides & polyesters
_ Fluorescent polyamide and polyester fibres
_ Functional polymer systems for smart fibres and smart textiles
_ Bi- component – High temperature – melt spinning technology
with velocities up to 6.000 m/min (LOY, POY,HOY, FOY)
Fig. 24 Thüringisches Institut für Textil- und Kunststoff-Forschung (TITK) e. V. Dr. Rüdiger Strubl & Team

25. O O
C C
O O
C C
O OC CO OC CO n O
O O
ϑ = 250 °C
m = 6,5 kg / h
DZ = 200 / min
+ (2n + 2) H2N PA 6 COOH
t = 2 min
ZSK 25
Fa. Werner&Pfleiderer - ( 2 n + 2 ) H2O
O O
C C
HOOC PA N N PA COOH
C C
O OC CO OC CO n O
N N
PA PA
CO OH COOH
Reaction of lc – poly (esterimide anhydrides) with PA 6
Fig. 25
in molten state to form graft - block - copolyesterimides

26. Mode of action in polyamide fibres
UV- or light PA 6 – incompatible component
stabilizer molecule (migration causing element)
reactive lcp’s
PEIA & in reality:
Nanoclays
“Antibac – FORMATION
Nanoclays”
OF A
Additives CONCENTRATION
enriched GRADIENT !
at the surface
conception may be expected
basic idea
objectives
component with PA 6 – affinity
syntheses (anchoring segment) PA 6 – fibre surface
processing
results
Spontaneous migration of the stabilizer additives during the fibre forming process
analyses
➄ Enrichment of the stabilizer molecules nearby the boundary layer of PA fibre
résumé
outlook Immobilization of the complex additives molecule in the accomplished fibre
the TITK Improved light protection efficiency by accessibility of stabilizer molecules in the surface region
Fig. 26 Thüringisches Institut für Textil- und Kunststoff-Forschung (TITK) e. V. Prof. Dr. Klaus Heinemann

27. „Reactive Complex- forming agent s – Biocides”
Application of a novel Silver Salt – Complex in PA 6.6
Reference 250 ppm 750 ppm 1500 ppm 5000 ppm
Fig. 27 Thüringisches InstitutInstitut fürfür Textil- und Kunststoff-Forschung
Thüringisches für Textil- und Kunststoff-Forschung
Thüringisches Institut Textil- und Kunststoff-Forschung Steffi Sensfussund Team
Dr. R. Strubl

28. “Modular multifunctional apparatus for additive syntheses”
Fig. 28 Thüringisches Institut für Textil- und Kunststoff-Forschung (TITK) e. V. Dr. Rüdiger Strubl & Team

29. “Modular multifunctional apparatus for additive syntheses”
Chemical syntheses in liquid media,
also under explosion- protected conditions
► Batch- Volumes: 10 Litre (stainless steel) and 16 Litre (titanium)
► Reaction temperatures: up to 200 °C up to 300 °C
► Reaction pressures: up to 0,5 bar
► Reaction media: homogeneous and heterogeneous phases
► Isolation of products: vacuum distillation; evaporation;
phase separation; Extraction;
for: • alkylations; acylations
• halogenations; nitrations; sulphonations; epoxidations
• esterifications; transesterifications; amidations; saponification
► Online-IR-Spectroscopy for reaction analysis und -optimization ( 7 bar)
► Calorimetry of reactions, also in case of increased pressure (100 bar)
Compound separations by vacuum distillation up to 15 kg/h (offer of service)
Chemical syntheses at „Kilogram – scale“ (customer order)
Fig. 29 Thüringisches Institut für Textil- und Kunststoff-Forschung (TITK) e. V. Dr. Rüdiger Strubl & Team

30. Department of FUNCTIONAL POLYMER SYSTEMS
„Processing Equipment”
Fig. 30 Thüringisches Institut für Textil- und Kunststoff-Forschung (TITK) e. V. Dr. Rüdiger Strubl & Team

31. Micro – twin- screw – melt compounder & spinning device
Technical Parameters: - Polymer melt temperatures: ϑ ≤ 350 °C;
- Melt volume – Polymer mass: v = 5,5 cm3; m ~ 8 g !!!;
- Screw speed: n = (1 … 360) min-1
HAAKE „MiniLab”
Thermo ELECTRON GmbH
76227 Karlsruhe
Fig. 31 Thüringisches Institut für Textil- und Kunststoff-Forschung (TITK) e. V. Dr. Rüdiger Strubl & Team

32. Micro – melt spinning apparatus
Micro – extrusion system „Minitruder” (Fa. Randcastle Inc.; USA)
- Polymer melt temperatures: ϑmax ≤ 430 °C
- throughputs: 10 - 120 g/h or 80 - 980 g/h
Fig. 32 Thüringisches Institut für Textil- und Kunststoff-Forschung (TITK) e. V. Dr. Rüdiger Strubl & Team

33. Bicomponent – High temperature – melt spinning device
with winding speeds up to 6.000 m/min
Bicomponent nozzle
outer inner
annular gap
(sheath) (core)
Quelle: EMPA & Fa. Fourné
Fig. 33 Thüringisches Institut für Textil- und Kunststoff-Forschung (TITK) e. V. Dr. Rüdiger Strubl & Team

34. „POLYTRONIC”
Focus: Generation of polymer-based electronic system components
Functional Polymer Systems: „from Material – to System”
Technology developments in the direction of „upscaling“ of
explored microtechnologies of "polymer engineering" in favour of the
scientific and technical prearrangement of the serial manufacturing of:
– Polymer- based field effect transistors and integrated circuits,
– Sensors,
– Actuators,
– Photovoltaic Cells und Modules as well as
– Modules by using substances with „switchable“
electrochromic, photochromic and thermochromic properties;
for applications regarding
information-, communication- and media technology, microelectronics,
microsystems-, medical- and traffic technology, including
"Reel-to-Reel"- Technologies for - coating
and - micro structuring
Fig. 34 Thüringisches Institut für Textil- und Kunststoff-Forschung (TITK) e. V. Dr. Rüdiger Strubl & Team

35. Department: “Functional Polymer Systems”
I. Topic: Polymer Electronic Applications
Schematic View of a PFET (Polymer-Field-Effect-Transistor)
on a flexible polymer film
2 mm metal or
d: 100 - 3.000 nm Gate electrode
conducting
polymer
Insulator (d: 400 nm – 1.000 nm (PANI,
PEDOT:PSS)
Semi conductor
Poly(3-alkyl-
(d: 5 nm – 50 nm)
thiophenes)
metal, ITO or
drain conducting
polymer
source (PANI,
0,5 - 3 mm PEDOT:PSS)
PET; PI; ABS; glass
flexible polymer substrate – d: 100 - 200 µm
Fig. 35 Thüringisches Institut für Textil- und Kunststoff-Forschung (TITK) e. V. Dr. Mario Schrödner & Team

36. Department: “Functional Polymer Systems”
II. Topic: Flexible Polymer Photovoltaic
Possible Applications:
• Solar cells on tents
(esp. for aid organisations)
• Solar cells on textiles
[esp. for military and sport textiles (GPS)]
• Solar cells on credit cards
(credit cards – real „smart cards”)
Fig. 36 Thüringisches Institut für Textil- und Kunststoff-Forschung (TITK) e. V. Dr. Mario Schrödner & Team

37. II. Topic: Flexible Polymer Photovoltaic
P Possible Applications:
Portable PV-
Consumer
Modules
electronics
intelligent electronic
packaging textiles
Modules on
curved surfaces
Building Integration Smart cards
80
1 .9
23
4 56
7 0
89
* 0#
(BIPV)
Fig. 37 Thüringisches Institut für Textil- und Kunststoff-Forschung (TITK) e. V.Frau Dr. Steffi Sensfuß & Team

38. department: „Functional Polymer Systems” – "POLYTRONIC"
I. Topic: II. Topic: Polymer Solar Cell
Applications:
Polymer-Field-Effect-Transistors
Schematic Drawing PFET
III. Topic:
Micro- and Nanometre-thin Functional Layers
by „Reel - to - Reel” – Technology
Coating Equipment "LBA 200"
Fig. 38 Dr. Schrödner & Team

39. Reel – to – Reel coating equipment „LBA 200”
Antrag Lösungsmittel
IR-Feld
Beschich-
tungsmittel T
Trocknung-/
Erstarrungsstrecke
Corona
Abwicklung Aufwicklung
Steuerung
PC Rolle - zu - Rolle
Parameters:
Width of the substrate tape: ≤ 20 cm
Speed of the tape: ≤ 10 m/min
Corona Activation: 2.5 kW
Infrared – dryer: 3.4 kW
Hot air – dryer: 80 – 120 ° C
Continuous wet coating using
diluted polymer- solutions/ -dispersions
by means of „Reel- to- Reel– Technology”
Fig. 39 Thüringisches Institut für Textil- und Kunststoff-Forschung Frau DP K. Schultheis; Dr. L. Blankenburg

40. Roll-to-Roll (R2R) Coating Technology
processing flexible Polymer Solar Cells
Spin coating Doctor blading continuous coating R2R
Processing parameters R2R
Materials
- Substrate: PET/ITO (175 µm)
- Baytron PH (~100 nm)
- P3HT/PCBM (1:1) 1.2% in Chlorobenzene (~60 - 150 nm)
Technology parameters
- Corona – pre- treatment: 200 W
- Velocity of the band: 1 - 2 m/min 20
- Width of the slot: 3 - 5 cm dark
illuminated
- Dosing rate: 1 - 5 ml/min 15
- Circulating air drying: 80 °C (Baytron) ISC: 6.13 mA/cm2
10 VOC: 618 mV
current [mA/cm ]
2
FF: 0.46
Completing of the Cells - discontinuous ηAM1.5: 1.74 %
5
- Vapour deposition of the Al- electrode
- Annealing: 5 min at 100°C 0
-0,5 0 0,5 1
Measuring conditions – Cell characterisation -5
- AM 1.5
- Cell dimension: 5x5 mm² -10
bias [V]
- environmental conditions
Efficiencies: „Spincoating” = 5,4 % → „R2R” = 1,7 % → 4,5 %
Fig. 40 Thüringisches Institut für Textil- und Kunststoff-Forschung Frau DP K. Schultheis; Dr. L. Blankenburg