GE Creates Superhydrophobic Nano-Coatings to Prevent Icing on Wind Turbines and Jet Aircraft

 Joseph Vinciquerra, a project leader in the Mechanical Integration & Operability Laboratory at GE’s Global Research Center in Niskayuna, New York,  and his team have for the past several years been working with nanotechnology to understand and exploit superhydrophobic materials in an attempt to make surfaces resistant to atmospheric icing, or ice that forms at certain altitudes or on the ground in cold weather climates.

By superhydrophobic,  GE means creating materials that are super water repellent. It’s similar to “nano pants” that are spill or stain resistant. It’s amazing… you can spill coffee or juice and the liquid just rolls off the clothing without causing a stain. At GE interests are much different. GE products like wind turbines and aircraft engines come into contact with water all the time, often in the form of ice.

For a wind blade that’s 200 feet up in the air, ice buildup can cause significant drag on the blade and reduce the turbine’s energy production. For aircraft engines flying at 30,000 feet, engineering solutions are used to prevent icing, but they typically cost significant engine efficiency. But what if we could place special nano-coatings on a wind blade or on aircraft engine parts that could repel water? And what if these coatings also could repel ice? If we could eliminate the need for expensive, energy intensive systems to prevent icing, we could realize a big improvement in efficiency. In the case of the wind turbines, for example, this would enable much higher energy production says Vinciquerra.

What GE has essentially done is re-create how atmospheric icing occurs in a lab environment to test its superhydrophobic materials.  GE created a test facility that simulates these specific conditions within novel wind tunnels, which allow them to conduct experiments on new materials in the icing conditions of interest. GE also has numerous facilities and test methods that allow us to simulate a vast array of harsh environments – like high-speed sand erosion and artificial UV exposure – to make sure the materials they’re developing are robust enough for the real world. With these tools at its disposal, and a multi-faceted team of chemists, material scientists, aerospace and mechanical engineers (to name a few), GE has made substantial progress toward new coatings that not only dramatically reduce the adhesion strength of atmospherically-formed ice, but also hold up to rigors of real-world operating conditions.

In the video shown here, GE shows two generic airfoils side-by-side in one of its icing wind tunnels. The specimen on the left-hand side is made of titanium, and the specimen on the right-hand side is made of aluminum coated with a thin layer of one of our coatings. At the start of the video, you can see ice forming on the upper-most edge of both specimens as the air flows over each airfoil from the top of the screen toward the bottom. As the ice accumulates, you’ll see both airfoils rotating toward you as the air is allowed to act against the ice that has formed. As you can see, our coating technology greatly affects the way ice tries to adhere to the surface!

In this example, GE relies on the aerodynamic forces of the wind acting against the ice to release the ice from the structure. Thus, we have developed a true “de-icing” material that does not require any additional power or heat from the system. While this already offers exciting possibilities for some of the world’s toughest icing challenges, our team continues to refine these materials for a multitude of potential applications, while also working to create new “anti-icing” surfaces (those where ice does not form at all!) based on similar principles.

New Nike Lunar Wood TZ Running Shoe Features P2i Water Repellent Nanocoating

The Nike Lunar Wood TZ will feature technology by P2i, the world leader in liquid repellent nano-coating technology.  Nike’s new lightweight and comfortable running shoe will keep wearers dry during the wettest of winters using P2i’s ion-mask™ nano-coating.

P2i’s ion-mask™ technology applies a nanoscopic protective polymer layer to the whole shoe, on which water forms beads and simply rolls off, instead of being absorbed. Because ion-mask™ gives the whole shoe (including the stitching) superior water repellency, it delivers two crucial benefits; one, it stops external water getting in and two, it encourages evaporated perspiration to flow out. As a result, shoes dry out more quickly, won’t get heavier over time, and maintain the natural airflow of their construction material. By optimizing temperature and ‘breathability’ for feet, ion-mask™ will ensure that the Lunar Wood TZ shoes keep wearers feet more comfortable and dry in the most challenging performance conditions.

Users can’t see or feel the ion-mask™ protection because it is one thousand times thinner than a human hair. However, because the protective layer is molecularly bonded to the whole shoe surface it is extremely durable. In practice, ion-mask™ lasts as long as the shoe material itself and is not compromised by everyday flexing during wear. Plus, by resisting the absorption of water, ion-mask™ helps guard against stains and dirt residue.

Finally, but importantly, ion-mask™ is a climate-friendly choice. Its application process is solvent-free, PFOA-free, uses only tiny quantities of protective agent, does not require lots of energy and generates minimal waste.

Stephen Coulson, CTO of P2i, comments: “We are delighted that our revolutionary ion-mask™ liquid repellent nano-coating technology has been chosen to protect Lunar Wood TZ. Current approaches simply cannot match the amazing levels of performance that ion-mask™ has been shown to deliver.”

Nike will launch the Lunar Wood TZ at selected global Nike Sportswear retailers on 19 December 2009.

Argonne Researchers Reveal Secrets of Superinsulation: "Multi-Stage Energy Relaxation" in Titanium Nitride

 An electron microscopy image of titanium nitride, on which the effect of superinsulation was first observed.

 Image Source:  Argonne National Laboratory

Scientists at the U.S. Department of Energy's Argonne National Laboratory have discovered the microscopic mechanism behind the phenomenon of superinsulation, the ability of certain materials to completely block the flow of electric current at low temperatures. The essence of the mechanism is what the authors termed "multi-stage energy relaxation."

Traditionally, energy dissipation accompanying current flow is viewed as disadvantageous, as it transforms electricity into heat and thus results in power losses.  In arrays of tunnel junctions that are the basic building units of modern electronics, this dissipation permits the generation of current.

Argonne scientist Valerii Vinokour, along with Russian scientists Tatyana Baturina and Nikolai Chtchelkatchev, found that at very low temperatures the energy transfer from tunneling electrons to the thermal environment may occur in several stages.

“First, the passing electrons lose their energy not directly to the heat bath; they transfer their energy to electron-hole plasma, which they generate themselves,” Vinokour said. “Then this plasma 'cloud' transforms the acquired energy into the heat. Thus, tunneling current is controlled by the properties of this electron-hole cloud.”

As long as the electrons and holes in the plasma cloud are able to move freely, they can serve as a reservoir for energy—but below certain temperatures, electrons and holes become bound into pairs. This does not allow for the transfer of energy from tunneling electrons and impedes the tunneling current, sending the conductivity of the entire system to zero.

“Electron-hole plasma disappears from the game and electrons cannot generate the energy exchange necessary for tunneling,” Vinokour said.

Because the current transfer in thin films and granular systems that exhibit superinsulating behavior relies on electron tunneling, the multistage relaxation explains the origin of the superinsulators.

Superinsulation is the opposite of superconductivity; instead of a material that has no resistivity, a superinsulator has a near-infinite resistance.  Integration of the two materials may allow for the creation of a new class of quantum electronic devices.  This discovery may one day allow researchers to create super-sensitive sensors and other electronic devices.

An earlier paper on the discovery of superinsulation was published in Nature on April 3, 2008. A paper on the mechanism behind superinsulation has been published in Physical Review Letters.

Argonne National Laboratory seeks solutions to pressing national problems in science and technology. The nation's first national laboratory, Argonne conducts leading-edge basic and applied scientific research in virtually every scientific discipline. Argonne researchers work closely with researchers from hundreds of companies, universities, and federal, state and municipal agencies to help them solve their specific problems, advance America 's scientific leadership and prepare the nation for a better future. With employees from more than 60 nations, Argonne is managed by UChicago Argonne, LLC for the U.S. Department of Energy's Office of Science.

For more information, please contact Brock Cooper (630/252-5565 or media@anl.gov) at Argonne.

P2i Targets $3 billion Global Hearing Aid Market for Lqiuid Repellant Nano-Scale Polymer Coating

Materials science innovator P2i has created Aridion™, a revolutionary liquid-repellent nano-coating technology that protects consumer electronics devices against damage from water and sweat, to improve their performance in challenging applications. P2i's multi-patented liquid repellent technology employs a special pulsed ionized gas (plasma), created within a vacuum chamber, to attach a nanometer-thin polymer layer over the entire surface of a product. 

On surfaces protected with Aridion™ , a nano-scale polymer coating one thousand times thinner than a human hair -- water forms beads and simply roll off. Thanks to this, Aridion™ can transform the reliability of consumer electronics devices containing delicate, expensive components at high risk of liquid damage.  

Although Aridion™ has the potential to protect all kinds of consumer electronics devices, it is initially being targeted at manufacturers in the $3 billion global hearing aid market. Thanks to the protection Aridion™ provides, manufacturers will be able to improve profitability through reduced repair and replacement costs, will increase user confidence through improved reliability, and will deliver clear product benefits that support premium pricing. All of these factors combine to enhance brand image, sharpen competitive edge and increase market share.  

Stephen Coulson, Chief Technology Officer of P2i, comments: “We’re excited to have developed Aridion™ as a unique protective nano-coating technology concept for consumer electronics, and delighted that we have found such a ready market for our benefits, within the world’s fast growing hearing aid business. We are already achieving excellent results with two of the world’s largest hearing aid manufacturers, who have recognized how our revolutionary technology will increase reliability and improve the user experience with their products.” 

Aridion™ can be cost-effectively applied to finished products using compact, high-throughput P2i processing machines. These integrate seamlessly and effortlessly with existing assembly lines, are easy to scale-up, and can be operated by ordinary workers at the touch of a single button. In a typical production environment, one P2i machine can treat a hearing aid in less than ten seconds.

Although the Aridion™ coating is imperceptible to users and does not affect hearing aid acoustic properties, it physically bonds to the product surface at a nanoscopic level and thus is as durable as the material it protects. Plus, because Aridion™ effectively coats every aspect of a finished product, it protects much more thoroughly than alternative approaches where individual product components are treated prior to manufacture.

Superior protection is particularly important to hearing aid manufacturers marketing the latest receiver-in-canal (RIC) behind-the-ear (BTE) hearing instruments to new generations of users. Market share of these instruments, with their discreet appearance and comfortable open-ear fitting, rose from 26.4% in 2004 to 43.8% in 2006 (source: Hearing Aid Market: Low Penetration Offers Development Opportunities, Koncept Analytics 2008). 

However, younger users have high expectations of reliable, extended performance as part of an active outdoor lifestyle, bringing an increased risk of warranty failures and inadvertent accidental liquid damage. Because RIC/BTE devices are delicate and contain expensive digital electronics, repair costs (to manufacturers via warranty failure, or users via accidental damage) are potentially very high, especially given the current trend towards wearing binaural devices; one for each ear. 

Aridion™ helps minimize these costs by providing „one-shot‟ protection against steam and humidity as well as sweat. The superior protection afforded by Aridion™ includes improved battery life (by avoiding moisture short circuits), and preventing component failure due to saline corrosion (sweat).

 Aridion™ also helps reduce the risk of inconvenience due to component failure, which is a significant user-acceptance issue. In a survey reported by Koncept Analytics, 56% of users rated “fewer breakdowns” as highly desirable. Plus, thanks to its superior protection, Aridion could also benefit hearing aids aimed at children, people suffering cognitive disorders and people working in hazardous environments, due to the higher risks of damage in each case.