production of low-cost controlled-morphology metal- oxides for multifunctional coatings soydan ozcan...
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Production of Low-Cost Controlled-Morphology Metal-Oxides for Multifunctional Coatings
Soydan Ozcan
Materials Science and Technology Division
Eugene R. Cochran
Commercialization Manager
Yuan Lu, Aaraon Armentrout
Materials Science and Technology Division
Tolga Aytug
Chemical Sciences Division
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Strategic Innovation (Technology)
Research & Demonstration
Business Plan
Outline
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Conservative market estimates and emerging applications for metal oxide nanoparticles
270,041 tons
1,663,168 tons
2012
2020
Ref: The Global Market for Metal Oxide Nanoparticles to 2020Published: March 2013
• Metal oxides are used in wide range of high-tech industries• Poses excellent magnetic, optical, catalytic and electronic properties • Potential applications depend greatly on their size, structure, and shape
Catalysts Batteries Color Pigments Electrochromics Photovoltaics Fuel Cell Medical Science Gas Sensor Coating Technology Cosmetics Ceramics Electronics
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Physical vapor deposition
Vacuum required
Limited target size
High cost and poor scalability
Chemical vapor deposition
Improved scalability
Hazardous byproducts (CO, H2)
High cost
Solid state sintering
Nanoparticle sintering
Excellent scalability
Low cost
Metal Oxide Film Fabrication
Technology Evolution for Metal Oxide FilmD
ecrease in cost /Increase in scalability
Nanoparticle synthesis is the key for solid state sintering
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Current Industrial Manufacturing Practice for Metal Oxide
Precursor in water
Acetic acid added
Ground/ calcinated
Ball milled in ethanol
Ethylene glycol added
Filtered/ Recalcined
Dry to form a gel
ORNL’S Technology: A Cleaner, Cheaper Way to Make Metal-oxides particles and films
Metal ion conjugation to CNF in water
(2 mins)
CNF Film with controllable density and 3D
distribution of metal ions
Remove
water
Heat
SinteredParticles
Controlled Morphology
ORNL’S Pioneering Technology
Clean Technology
Cost Effective
Transformational
:Cellulose Nanofibrils (CNF)
:Metal cation
Current TRL level: 4
Inorganic solvents, strong acids, many lengthy steps
• Patent Application No. 14/551,460 filed on Nov 24, 2014
• Patent Application No. 62/132,178 filed on March 12, 2015
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Manufacturing Steps
A detailed cost analysis study for manufacturing is completed for various level of production capacity
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20 30 40 50 60 70 80
2 (deg)
In
ten
sity (
a.u
.)
High quality metal-oxide (ITO) is achieved using ORNL process
CNF/ITO film
Heat
NI Formation/assembly
Heat
HeatNo NI
formation
Heat
Heat
Heat
A
B
C
Particle formation
CNF Metal ion ITO NI
73 ± 5 nm
268 ± 35 nm
650 ± 65 nm
Narrow size distribution Tunable size, shape, and morphology
ORNL product
Commercialproduct
ORNL’S Pioneering Technology (con’t)
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200 400 600 8000
10
20
30
40
50
60
70
80
90
100
Tra
nsm
itta
nce
(%
)
Wavelength (nm)
ITO-Coated (Octahedrons)
UncoatedLow resistivity :3.8 × 10-3 Ω/cm, The sheet resistance: 150 Ω/□
The resistivity of this ITO film is comparable to that of films prepared using radio frequency magnetron sputtering
The most important two properties are transparency and electrical conductivity rather than cost
Metal oxide coated glass
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• Manufacturing: ORNL technology is superior to current commercial practices in terms scalability, low-cost capital investment, (e.g., PVD, CVD, sol-gel)
• Controlled Shape: ORNL process has distinct economics and manufacturing advantages over existing technologies to control shape and morphology (e.g., Photolithography, Microfludic Synthesis, and Molding)
Preliminary interactions with private sector is attracted significant interest
Displays Lighting Solar energy Bio-imaging
Environmentally friendly way of making technologically important materials at low-cost
Technology Leadership
Metal oxide nanotechnology is practically applied to almost all areas of the society
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Scale-up: Demonstrate process scalability up to ½ kg nanomaterials (March 30, 2015).
Process refinement: Establish the technology on other strategically important metal oxides (June 30, 2015).
Strategic demonstration: Demonstrate the product performance with business partners. (Coating on curved/irregular surfaces as well as as on polymeric substrate) (Sept 30, 2015).
Scale-up: Build scaled-up manufacturing line (March 30, 2016).
Characterization: Develop a spec. sheet for the ORNL product and cost analysis (May 30, 2016).
Research Plan
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Intellectual Property Landscape
3M
GE
Samsu
ng
Universi
ty of C
aliforn
ia
Korea In
stitu
te of S
&T
Xerox C
orporati
on
Baker
Hughes
Cabot C
orporati
onIBM M
IT0
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19992000
20012002
20032004
20052006
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603M
GE
Samsung
University of California
Korea Institute of S&T
Top assignees have the highest revenue stream from licensing intellectual property
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f Pat
ents
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f Pat
ents
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Application Description
Target Customers Current Practice
1 Low-cost ITO coating for electronics
• ~97% of transparent conducting oxides market is ITO in 2011.
• Market: US$ 4.1 billion (2014) US$ 6.3 billion (2024)
Physical and chemical vapor deposition
2 ITO coating for defrosting windshield
Projected market: US$ 3.5 billion (2018)Smart glass coatings used in automobile and aircrafts
Physical vapor deposition
3 ITO films for energy efficient windows (IR blocking)
Energy efficient window market: US$ 40 billion (2014)Large market to penetrate
Spray coating, physical vapor deposition
Target Applications
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Technology Feature
ORNLTechnolog
yPVD CVD Co-
Precipitation Sol-Gel
Low capital investment
Scalability
Manufacturing ease
Environmental friendly
Low Cost
Competitive Differentiation
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Working Prototypes
Founding Team
Proof of Concept
Target Market
Business Plan
Applied Research
Basic Research
Engineering Prototypes
Supplier Contractors
Production Prototypes
DistributionContracts
ProductIntroduction
Revenue Growth
Net Cash Flow
Stages of Venture Development and Collaboration
Start-up Cost : Lower
Users : Bigger
Transactions $$$ : Better
Reduced risk, potential for quick and high return!
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Market Opportunity
US$ 0.8 Billion
> US$ 4 Billion
2012
2020
Applications in wide range of high-tech industriesTiming is correct: The market is expanding in rapid paces
Government and private support is in favor of newly developing businessIt is a suitable technology for a small business start-up
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THANK YOU!
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Low-Cost, Sustainable Multifunctional CoatingsPatents Available for Licensing
• Soydan Ozcan and Yuan Lu, Method of
Making Controlled Morphology Metal Oxides
US Patent Application No. 14/551,460 filed on
Nov 24, 2014
• Soydan Ozcan and Amit Naskar, Infrared
Blocking Nanocellulose Aerogel Windows
US. Patent Application No. 62/132,178 filed
on March 12, 2015
Inventor Point of Contact• Soydan Ozcan • Materials Science and Technology Division• Oak Ridge National Laboratory• (865) 241-21 58, [email protected]
Licensing Point of Contact• Eugene Cochran• Technology Transfer Division• Oak Ridge National Laboratory• (865) 576-2830, [email protected]