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 GLASS- CERAMICS... 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 THERAPUETICS, LLC... 220 TAASI CORPORATION... 220 3M COMPANY... 221 TPL, INC.... 221
YTC AMERICA, INC.... 222