NEW YORK, June 26, 2012 /PRNewswire/ -- Reportlinker.com announces that a new market research report is available in its catalogue:
Sol-Gel Processing of Ceramics and Glass
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REPORT SCOPE
INTRODUCTION
STUDY BACKGROUND
The term "sol gel" was coined in the late 1800s. It generally refers to a low-temperature method using chemical precursors that can produce ceramics and glass with higher purity and better homogeneity than high-temperature, conventional processes. This process has been used to produce a wide range of compositions (mostly oxides) in various forms, including powders, fibers, coatings and thin films, monoliths and composites, and porous membranes. Organic/inorganic hybrids, in which a gel (usually silica) is impregnated with polymers or organic dyes to provide specific properties, also can be made.
One of the most attractive features of the sol-gel process is that it can produce compositions that cannot be created with conventional methods. Another benefit is that the mixing level of the solution is retained in the final product, often on the molecular scale.
The applications for sol gel-derived products are numerous. One of the largest application areas is for coatings and thin films used in electronic, optical and electro-optic components and devices, such as substrates, capacitors, memory devices, infrared (IR) detectors and waveguides. Antireflection coatings also are used for automotive and architectural applications. Protective and decorative coatings have been developed as well for glass, metal and other types of substrates.
Powders of single- and multicomponent compositions can be made with submicron particle size for structural, electronic, dental and biomedical applications. Composite powders have been patented for use as agrochemicals or herbicides. Fibers also can be spun or drawn from precursor solutions or coated with thin films. Both optical and refractory fibers are used for fiber optic sensors and thermal insulation. In addition, sol gel can be used to infiltrate fiber preforms to make composites. Abrasives, used in a variety of finishing processes, are made using a sol-gel type process.
Glass monoliths/coatings and inorganic/organic hybrids have various potential optical applications, including optical filters, chemical sensors, passive and nonlinear active waveguides and lasers. Membranes for separation and filtration processes have been developed, as well as catalysts. More recently, biotechnology applications have been developed in which biomolecules (such as proteins, enzymes, antibodies, etc.) are incorporated into sol-gel matrices. Applications include biochemical processes monitoring, environmental testing, food processing and drug delivery for medicine or agriculture. Other biomedical applications include coatings for metal implants and bone grafting materials. Cosmetic applications include sunscreen lotions and makeup that incorporate UV absorbers.
A previous BCC report, published in 2006, analyzed potential markets and applications. Since then, the industry has continued to develop, as the demand for existing sol-gel applications has expanded and new applications have been commercialized.
STUDY GOALS AND OBJECTIVES
This report is an update of the 2006 report, and its goal is to provide the reader with the most current information on the status of and markets for sol-gel technology. Specific objectives of this report include
To provide an overview of the various commercial products made with the sol-gel process and their applications.
To identify the technological and business issues related to the development and commercial production of sol-gel–derived products.
To analyze the domestic and foreign competition among companies involved with sol-gel products and competing products.
To determine the current size and future growth of the total U.S. and worldwide markets for sol-gel products and applications.
To identify and profile companies and other entities involved in the development and commercialization of sol gel-derived products.
INTENDED AUDIENCE
This report is directed to producers and users of materials and applications related to sol-gel processing. These include
Companies involved in the development, manufacturing and supplying of advanced materials.
Developers and producers of ceramic powders for electronic and structural applications.
Companies involved in the development and manufacture of structural ceramic components, including composites.
Developers and producers of ceramic and glass fibers.
Producers and suppliers of advanced electronic and optical components and devices.
Producers and suppliers of sensors and sensing devices.
Producers and suppliers of medical implants and dental ceramic/glass materials.
Advanced material companies interested in diversification.
Producers and suppliers of glass and glass components.
Chemical companies supplying alkoxides and other precursor materials.
Venture capital companies and financial institutions interested in new investments.
SCOPE AND FORMAT
The report provides a detailed technology review for sol gel-derived products, including processing methods, properties and applications. Market analyses are provided for each application segment for the U.S. and the world.
METHODOLOGY AND INFORMATION SOURCES
Both primary and secondary research methodologies were used in preparing this report. The conclusions of this report are based on information derived from interviews with experts in the field, including those in industry and academia. Extensive literature, Internet and patent searches were conducted to obtain an overall assessment of the technology. Other information was obtained from trade publications, technical journals, the National Science Foundation, the U.S. Department of Commerce, the U.S. Department of Energy, the U.S. Department of Defense, European Commission research databases and trade associations. Approximately 120 companies, universities and other institutions were contacted directly.
ANALYST'S CREDENTIALS
This report is an update of an earlier (2006) report prepared by Dr. Thomas Abraham. Dr. Abraham was formerly vice president and director of the Advanced Materials Group of BCC. A graduate of Columbia University, Dr. Abraham worked for the University of Denver and Brookhaven National Laboratory prior to joining BCC Research. Dr. Abraham has been a frequent invited speaker on the state of the advanced material industries at American Ceramic Society (ACS) meetings, as well as numerous other conferences and events held by various associations involved in the ceramics and advanced materials industries. One of the most important studies Dr. Abraham undertook was for the Office of Technology Assessment of the U.S. Congress on the "Strategies for Advanced Ceramic Materials in the U.S."
The analyst responsible for updating the report is Andrew McWilliams, a partner in the Boston–based international technology and marketing consulting firm, 43rd Parallel LLC. Mr. McWilliams is the author or co-author of numerous other BCC studies, including studies in related fields such as AVM025G Diamond, Diamond-Like and CBN Films and Coating Products; NAN015F Advanced Ceramics and Nanoceramic Powders; NAN021E Global Markets for Nanocomposites, Nanoparticles, Nanoclays, and Nanotubes; NAN040A Nanomaterials Markets by Type and AVM008B Synthetic Gems and Minerals.
TABLE OF CONTENTS
CHAPTER ONE: INTRODUCTION 1
STUDY BACKGROUND 1
STUDY GOALS AND OBJECTIVES 2
INTENDED AUDIENCE 2
SCOPE AND FORMAT 3
METHODOLOGY AND INFORMATION SOURCES 3
ANALYST'S CREDENTIALS 3
RELATED BCC REPORTS 4
BCC ON-LINE SERVICES 4
DISCLAIMER 5
CHAPTER TWO: EXECUTIVE SUMMARY 6
SUMMARY TABLE U S AND WORLD MARKETS FOR SOL-GEL
PRODUCTS, THROUGH 2017 ($ MILLIONS) 6
SUMMARY FIGURE U S AND WORLD MARKETS FOR SOL-GEL
PRODUCTS, 2011–2017 ($ MILLIONS) 7
CHAPTER THREE: INDUSTRY AND MARKET OVERVIEW 8
U S MARKET 8
TABLE 1 FORECAST FOR THE U S SOL GEL MARKET BY
APPLICATION, THROUGH 2017 ($ MILLIONS) 9
FIGURE 1 U S SOL-GEL MARKET SHARES BY APPLICATION, 2011–
2017 (%) 9
FIGURE 1 (CONTINUED) 10
WORLD MARKET 10
TABLE 2 GLOBAL FORECAST FOR THE SOL-GEL PRODUCTS
MARKET BY REGION, THROUGH 2017 ($ MILLIONS) 11
FIGURE 2 GLOBAL MARKET SHARE BY COUNTRY/REGION, 2011
AND 2017 (%) 11
FIGURE 2 (CONTINUED) 12
COMPETITION 12
RESEARCH AND DEVELOPMENT 13
U S INDUSTRY STRUCTURE 14
TABLE 3 U S COMPANIES INVOLVED IN SOL GEL 14
TABLE 3 (CONTINUED) 15
U S INDUSTRY STRUCTURE (CONTINUED) 16
CHAPTER FOUR: TECHNOLOGY OVERVIEW 17
HISTORY 17
HISTORY (CONTINUED) 18
TABLE 4 CHRONOLOGICAL HIGHLIGHTS OF SOL-GEL PRODUCTS 19
TABLE 4 (CONTINUED) 20
TABLE 5 SELECTED COMMERCIAL PRODUCTS AND
APPLICATIONS 21
TABLE 5 (CONTINUED) 22
DESCRIPTION OF THE ALKOXIDE SOL-GEL PROCESS 22
TABLE 6 ADVANTAGES AND DISADVANTAGES OF THE
CONVENTIONAL SOL-GEL PROCESS 23
ADVANTAGES 23
Lower Processing Temperatures 23
Lower Costs 24
Doping 24
TABLE 7 DOPANTS AND RESULTANT PROPERTIES 24
TABLE 7 (CONTINUED) 25
DISADVANTAGES 25
Long Processing Times 25
Preferential Hydrolysis 26
Cracking 26
Precursors 27
Precursors (Continued) 28
TABLE 8 CHEMAT TECHNOLOGY'S SOLUBLE POLYMERIC METAL
ORGANIC OXOALKOXIDE PRECURSORS 29
Additives 30
THE AQUEOUS SOL-GEL PROCESS 31
THE CONVENTIONAL METHOD 31
Applications 32
OTHER METHODS 32
FIGURE 3 PROCESS FOR WATER-BASED ZIRCONIA SOLS 33
END PRODUCTS 34
FIGURE 4 GENERIC FLOWCHART OF THE SOL-GEL PROCESS 35
TABLE 9 CHARACTERISTICS OF SOL-GEL PRODUCTS 36
POROUS SOLIDS 36
POWDERS 37
TABLE 10 POWDER PRECURSORS AND RESULTANT
COMPOSITIONS 38
TABLE 10 (CONTINUED) 39
TABLE 10 (CONTINUED) 40
Oxide Powders 40
FIGURE 5 FLOW CHART FOR THE FLAKE MANUFACTURING
PROCESS 41
Oxide Powders (Continued) 42
Pigments 43
FIGURE 6 FLOWCHART FOR MAKING VANADIUM-BASED
PIGMENTS 44
FIGURE 7 PROCESS FOR MAKING PINK PIGMENTS 45
FIGURE 8 PROCESS FOR MAKING YELLOW/GREEN PIGMENTS 45
Nonoxide Powders 46
Nonoxide Powders (Continued) 47
COATINGS AND THIN FILMS 48
TABLE 11 COATING PRECURSORS AND RESULTANT
COMPOSITIONS 48
TABLE 11 (CONTINUED) 49
Application Methods 50
Dip Coating 50
FIGURE 9 SCHEMATIC OF DIP COATING 51
Spin Coating 51
FIGURE 10 SCHEMATIC OF SPIN COATING 52
Meniscus Coating 52
FIGURE 11 SCHEMATIC OF MENISCUS COATING 53
TABLE 12 ADVANTAGES AND DISADVANTAGES OF SOL-GEL
COATING METHODS 54
Other Methods 54
Thick Coatings 55
TABLE 13 PROCESSES FOR MAKING THICK COATINGS 55
Heat Treatments 56
TABLE 14 COMPARISON OF COATING METHODS 57
Process Parameters 57
Dense Coatings 57
TABLE 15 COATING THICKNESSES FOR A VARIETY OF COATINGS 58
FIGURE 12 SCHEMATIC OF LIQUID PHASE DEPOSITION 59
Porous Coatings 60
Coatings for Plastics 61
Applications 61
TABLE 16 APPLICATIONS OF SOL-GEL FILMS AND COATINGS 61
TABLE 16 (CONTINUED) 62
GLASS 62
TABLE 17 APPLICATIONS OF SOL-GEL GLASSES 63
Silica 64
Type V Silica 64
Type VI Silica 65
Doped Silica 65
Silicates 65
Nonsilicates 66
Nonsilicates (Continued) 67
MONOLITHS 68
Aerogels 68
TABLE 18 TYPICAL PROPERTIES OF AEROGELS 69
TABLE 19 APPLICATIONS OF AEROGELS 70
Silica 71
Silica Nanocomposites 72
Other Oxides 73
Carbon Aerogels 73
TABLE 20 TYPICAL PROPERTIES OF STANDARD AEROGEL
PRODUCTS 74
Controlling Properties 75
Limitations 75
Xerogels 75
Controlling Properties 76
Silicate and Ceramic Foams 77
Colloidal Inks that Form Self-Supporting Scaffolds
through Robocasting 78
Hydrogel Nanoparticles for Optically Tunable Photonic
Crystals 79
Monolithic Dry Gels Produced Using Sol-Gel Technology 80
FIBERS 81
Compositions 81
FIGURE 13 PROCESS FOR MAKING 3M CERAMIC FIBERS 82
TABLE 21 COMPARISON OF PROPERTIES OF COMMERCIAL
REINFORCING FIBERS 83
Compositions (Continued) 84
Properties 85
COMPOSITES 85
FIGURE 14 COMPOSITE PROCESS INCORPORATING DIFFERENT
FABRICS AND MATRICES 86
FIGURE 15 FLOWCHART FOR MAKING FIBER LAMINATE
COMPOSITES 87
Control of Microstructure 87
TABLE 22 TAILORED COMPOSITES USING SOL GEL 87
TABLE 22 (CONTINUED) 88
TABLE 23 MECHANICAL PROPERTIES OF SOL-GEL COMPOSITES 88
Interfacial Coatings 89
TABLE 24 SOL-GEL COATINGS FOR FIBERS 90
Infiltration for Densification 91
TABLE 25 TYPICAL COMPOSITE PROPERTIES MADE FROM
FREEZE GELATION 92
Glass Matrix 92
Ceramic Matrix 93
Nanocomposites 94
Nanocomposites (Continued) 95
ORGANIC/INORGANIC HYBRIDS 96
Ormosils 97
Ormacers 97
Hybrid Systems 98
TABLE 26 ORGANIC/INORGANIC MATERIAL SYSTEMS AND
PROPERTIES 98
TABLE 26 (CONTINUED) 99
Control of Properties 99
Other Methods 100
Other Methods (Continued) 101
A New Sol-Gel Route to Organic/Inorganic
Hybrid Materials 102
CHAPTER FIVE: APPLICATIONS AND MARKETS 103
OPTICAL/OPTOELECTRONIC APPLICATIONS 103
TABLE 27 OPTICAL AND OPTO-ELECTRONIC PRODUCTS AND
APPLICATIONS 104
FIGURE 16 SCHEMATIC OF THE EMBOSSING PROCESS 105
COATINGS 105
Antireflection/Solar Reflective Coatings 106
Automotive 107
Lasers 108
Solar Collectors and Solar Cells 109
FIGURE 17 SCHEMATIC OF TITANIA SOLAR CELL 110
Transparent Electronic Conducting Coatings 110
Transparent Electronic … (Continued) 111
Flat Panel Displays 112
TABLE 28 PROPERTIES OF NHC SERIES FOR PROTECTION OF
ELECTRODES 112
Electrochromic Coatings for Smart Windows 112
CHEMICAL SENSORS 113
Chemical Sensors (Continued) 114
Chemical Sensors (Continued) 115
pH Sensors 116
Metal Ion Sensors 117
Spectroelectrochemical Sensor 117
Biosensors 117
Spectroelectrochemical Sensor (Continued) 118
SOLID-STATE DYE LASERS 119
TABLE 29 SUMMARY OF SOL-GEL LASER SYSTEMS 120
HIGH-POWER LASERS 121
NANOMETER-RANGE MEDIA FOR POWDER LASERS 121
OPTICAL FIBERS AND DEVICES 122
Optical Fiber Overcladding 122
FIGURE 18 SCHEMATIC FOR MAKING OPTICAL FIBER 123
Waveguides 124
Fiber Amplifiers 125
Other Developments in Optical Fibers and Devices 125
Simax's Boron Doped Silica Material Reduces
Panda Fiber Cost 125
Chemical Solution Gelation/Deposition for Optical
Fibers and Devices 126
PHASIC Technology for Integrated Optics 126
Integrated Sol-Gel Fiber-Optic Sensors 127
LUMINESCENT LIGHT/POWER SOURCES 127
Fluorescent Lighting 128
Carbon-activated Phosphors 129
Phosphors for Flat and Plasma Displays 130
Phosphors for Flat…(Continued) 131
FIGURE 19 FLOW DIAGRAM FOR SRAL2O4: EU, DY VIA SOL GEL 132
GRADIENT INDEX LENSES (GRINS) 132
TABLE 30 COMPARISON OF GRIN PROCESSING METHODS 133
OPTICAL MARKETS 134
ELECTRONIC/ELECTRO-OPTIC APPLICATIONS 134
FERROELECTRIC THIN FILMS 135
Applications 135
TABLE 31 MATERIALS AND APPLICATIONS FOR FERROELECTRIC
THIN FILMS 135
TABLE 31 (CONTINUED) 136
Deposition Methods 137
Other Compositions 138
FIGURE 20 FLOWCHART OF SBT FILM PROCESS 139
Thick Films 140
DIELECTRIC THIN FILMS 141
ELECTRONIC POWDERS/COMPONENTS 142
Electronic Powders/Components (Continued) 143
FIGURE 21 METHOD FOR MAKING ZNO POWDERS 144
CAPACITORS 144
SUBSTRATES 145
PACKAGES AND DEVICES 146
MAGNETICS 146
SUPERCONDUCTORS 147
Powders 147
Thin and Thick Films 148
ELECTRODES AND BATTERIES 149
Membranes for Batteries 150
NASICON Thin Films for Batteries 151
Aerogels 152
ELECTRONIC MARKETS 152
STRUCTURAL/HIGH-TEMPERATURE APPLICATIONS 153
ABRASIVES 153
3M's Cubitron 153
FIGURE 22 SCHEMATIC OF CUBITRON 321 PROCESS 154
TABLE 32 COMPARISON OF ABRASIVE PROPERTIES 155
St Gobain 155
TABLE 33 ADVANTAGES OF SG WHEELS 156
Other Abrasives 156
PROTECTIVE COATINGS 157
Protective Coatings (Continued) 158
Protective Coatings (Continued) 159
FIGURE 23 PROCESS FOR MAKING SILICA-TITANIA FILMS 160
Other Developments 161
Sol-Gel Techniques Help to Form Hybrid Glass
Coatings 161
Sol-Gel Route for the Protection of Carbon in Hot
Oxidizing Atmosphere 162
High Temperature Insulation of Wires and
Thermocouples 163
Pink Colored Film for Automobile Windows Using
Sol-Gel Process 163
Sol Gel-Derived Abrasion Resistant Coatings with
a Long Shelf Life 164
Abrasion-Resistant Optical Coatings 164
THERMAL INSULATION 165
Aerogel Windows 165
Lumira Insulation 166
Flexible Aerogel Blanket 166
Cyrogenic Insulation 166
Solar Collectors 167
TABLE 34 ANNUAL PERFORMANCE OF FLAT SOLAR COLLECTORS 167
Replacement for CFC Insulating Foams 167
REFRACTORY/HIGH TEMPERATURE 167
Fibers 168
TABLE 35 PROPERTIES OF NEXTEL FIBERS 169
TABLE 36 APPLICATIONS AND MARKETS FOR NEXTEL FIBERS 170
Heat Exchangers and Related Applications 171
TABLE 37 STRENGTH OF TECHNIWEAVE COMPOSITES 171
BIOMEDICAL APPLICATIONS 172
DENTAL SEALANTS AND FILLERS 172
BIOACTIVE GLASSES 173
TABLE 38 APPLICATIONS OF BIOACTIVE GLASSES AND GLASSCERAMICS
173
Bioactive Glasses (Continued) 174
Bioactive Phosphates 175
Encapsulation of Living Cells 176
Encapsulation of…(Continued) 177
Micro-encapsulation and Delivery 178
COSMETIC APPLICATIONS 178
CHEMICAL APPLICATIONS 179
CATALYSTS 179
Catalysts (Continued) 180
Catalysts (Continued) 181
TABLE 39 MATERIAL SYSTEMS AND APPLICATIONS FOR
CATALYSTS 182
NUCLEAR APPLICATIONS 183
SEPARATION MEMBRANES AND FILTERS 184
TABLE 40 TYPICAL APPLICATIONS OF CERAMIC MEMBRANES 184
Separation Membranes … (Continued) 185
FIGURE 24 PROCESS FLOWCHARTS FOR MAKING SOL-GEL
MEMBRANES 186
Separation Membranes … (Continued) 187
Separation Membranes … (Continued) 188
OTHER APPLICATIONS 189
DECORATIVE COATINGS 189
TABLE 41 COMPARISON OF DECORATIVE COATINGS 190
INK JET FILM FOR TRANSPARENCIES 191
SOL-GEL COATINGS FOR ART CONSERVATION 191
Sol-Gel Coatings for … (Continued) 192
CHAPTER SIX: OVERALL U S MARKETS 193
OPTICAL APPLICATIONS 193
TABLE 42 FORECAST FOR THE U S OPTICAL APPLICATIONS
MARKET, THROUGH 2017 ($ MILLIONS) 194
ELECTRONIC APPLICATIONS 194
TABLE 43 U S MARKETS FOR SOL-GEL IN ELECTRONIC
APPLICATIONS, THROUGH 2017 ($ MILLIONS) 195
STRUCTURAL APPLICATIONS 195
TABLE 44 FORECAST FOR THE U S STRUCTURAL APPLICATIONS
MARKET, THROUGH 2017 ($ MILLIONS) 196
CHEMICAL APPLICATIONS 196
TABLE 45 FORECAST FOR THE U S FOR CHEMICAL
APPLICATIONS MARKET, THROUGH 2017 ($ MILLIONS) 197
BIOMEDICAL APPLICATIONS 197
TABLE 46 FORECAST FOR THE U S BIOMEDICAL APPLICATIONS
MARKET, THROUGH 2017 ($ MILLIONS) 198
CHAPTER SEVEN: FOREIGN COMPETITION 199
FOREIGN COMPETITION 199
JAPAN 199
TABLE 47 SOL-GEL PRODUCTS COMMERCIALIZED IN JAPAN 200
EUROPE 200
EUROPE (CONTINUED) 201
WORLD MARKETS 202
TABLE 48 GLOBAL FORECAST FOR THE SOL-GEL PRODUCTS
MARKET, THROUGH 2017 ($ MILLIONS) 203
APPENDIX 204
PROFILES OF SELECTED COMPANIES INVOLVED IN SOL-GEL
TECHNOLOGIES AND PRODUCTS 204
AJJER, LLC 204
ALBANY INTERNATIONAL TECHNIWEAVE, INC 204
ASPEN AEROGELS, INC 204
CABOT CORPORATION 205
CALIFORNIA HARDCOATING CO 205
CERAMEM CORPORATION 206
CHEMAT TECHNOLOGY, INC 206
CLEVELAND CRYSTALS, INC 207
COOPER BUSSMAN 208
CORNING, INC 208
DOW CORNING CORP 209
EASTMAN KODAK 209
E I DUPONT DE NEMOURS & CO , INC 209
FORD MOTOR CO 210
FUEL CELL ENERGY 210
GELEST, INC 210
HYBRID GLASS TECHNOLOGIES 211
LAWRENCE BERKELEY NATIONAL LABORATORY 211
LAWRENCE LIVERMORE NATIONAL LABORATORY 212
LIGHT PATH TECHNOLOGIES INC 212
MAGNA INTERNATIONAL INC 213
MARKETECH INTERNATIONAL INC 213
MARSHALL SPACE FLIGHT CTR 213
MATECH 214
MATERIALS MODIFICATION INC 214
NANOPORE INCORPORATED 215
NEO MATERIAL TECHNOLOGIES 216
OAK RIDGE NATIONAL LABORATORY 216
OCEAN OPTICS 216
PHYSICAL OPTICS CORPORATION 217
PPG INDUSTRIES, INC 217
QUANTUM DOT CORPORATION 217
RATH INC 218
READE ADVANCED MATERIALS 218
SAINT GOBAIN ABRASIVES, INC 218
SANDIA NATIONAL LABORATORIES (SNL) 219
SOL-GEL TECHNOLOGIES LTD 220
SOLGENE THERAPEUTICS, LLC 220
TAASI CORPORATION 220
3M COMPANY 221
TPL, INC 221
YTC AMERICA, INC 222
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