Example 1

Dry lubricant coating

A professional tool manufacturer for carpenters wants to find an alternative solution to the hard chromium coating in the projection cylinders.

Task

The tools are made of aluminum cylinders in which a segmented piston slides. The aluminum cylinders emerging from the foundry are nickel-plated and then chromium-plated, before undergoing a final boring. The project is to develop a dry-lubricating (sol-gel) coating that replaces metallic coatings.

Goal

Develop a sprayable composite sol-gel coating bonded to aluminum or magnesium foundry. This coating must withstand a temperature of about 150-200 ┬░C and must lubricate the piston rings in the cylinder for 200 000 uses.

Results

A composite sol-gel based on organosilanes and a lamellar material has been developed. Spray deposition allows to obtain micronic layers perfectly adherent on aluminum or on magnesium with a controlled thickness. The technology meets the requirements with a simplest process and at lower costs. It allows a weight gain of the tools when aluminum is substitute by magnesium.

Technology Readiness Level: 4

Example 2

Anti-abrasion coating

An manufacturer wants to benchmark an abrasion resistant coatings for optical lithography masks.

Task

UV masks for lithography are made up to a glass plate coated with a chromium layer. The chromium layer is chemical etched to reveal UV-opaque micro-grooves. Although chrome is a hard material, the intensive use of these masks abrades micro-engravings and alters the definition of lithographed objects. An abrasion resistant coating is required.

Objectives

Develop a UV-resistant, abrasion-resistant coating easy to apply and adherent to glass and chrome. This coating must be able to be applied by simple techniques and the layer must have a uniform thickness on the mask.

Results

A sol-gel based on silane is developed, meeting the specifications. It is applicable by spin coating and is effective after simple steaming. The coating increases the lifetime of optical lithography masks by a factor of two.

Technology Readiness Level: 4

Example 3

 Replacing alodine

An industrialist wants to evaluate alternatives to alodine 1200 for light aluminum alloys.

Task

Develop a thin uniform colored coating with similar performance to alodine 1200 in terms of adhesion, corrosion resistance and conduction. The solution must be Chromium free.

Objectives

Develop a conductive, highly-adhesive sol-gel coating on 2024 alloys, applicable by spray or brush, and effectively protect against corrosion (180 to 500 h of BS)

Results

We Develop of a hybrid composite coating with anti-corrosion properties (BS 500h), with transverse electrical resistance meeting the MIL-DTL-81706 standard. The work focused on mastering the synthesis of the conductive elements and the hybrid matrix, from the laboratory scale to the pre-industrialization.

Technology Readiness Level: 4-5 Technological Maturity: TRL 4-5

Example 4

Antibacterial coating

The persistence of nosocomial diseases (1/ 20 patient in France hospitals) necessitates a broad spectrum biocidal coating. Bacterial resistance to antibiotics translates into 25 000 deaths a year in Europe and is leading to an upsurge in the market for antibacterial surface coatings.

Task

Since the transmission of pathogens is mainly through manual contact, the mission is to propose robust broad spectrum biocidal coatings applicable to any type of surface.

Objectives

Propose versatile biocidal coatings for the sectors involved in the construction and equipping of hospitals, retirement homes, kindergarten, etc. The biocidal sol-gel coating must be have a long term effect, invisible when deposited on any type of material, resist to abrasion, heat or solvents and detergents. Its application must be easy both in production line and on site.

Results

R&Dnano has developed innovative formulations based on a sol-gel composite incorporating anchored metal microwires. The biological efficacy already proven on several types of nosocomial strains is combined with robustness and compatibility with many types of surfaces (metal, plastic or glass).

Technology Readiness Level: 4-5