CONDUCTIVE POLYMERS: TECHNOLOGIES AND GLOBAL MARKETS

Transcription

1 CONDUCTIVE POLYMERS: TECHNOLOGIES AND GLOBAL MARKETS PLS043D September 2016 Andrew McWilliams Project Analyst ISBN: BCC Research 49 Walnut Park, Building 2 Wellesley, MA USA (toll-free within the USA), or (+1) information@bccresearch.com

2 TABLE OF CONTENTS CHAPTER 1 INTRODUCTION 2 STUDY GOALS AND OBJECTIVES 2 REASONS FOR DOING THE STUDY 2 SCOPE OF THE STUDY 2 METHODOLOGY 3 ANALYSTS' CREDENTIALS 3 RELATED BCC REPORTS 3 BCC RESEARCH WEBSITE 4 DISCLAIMER 4 CHAPTER 2 SUMMARY 6 SUMMARY TABLE GLOBAL MARKET FOR ELECTROACTIVE POLYMERS, THROUGH 2021 (MILLION POUNDS/$ MILLIONS) SUMMARY FIGURE GLOBAL MARKET FOR ELECTROACTIVE POLYMERS, ($ MILLIONS) 6 6 CHAPTER 3 ELECTROACTIVE POLYMER OVERVIEW 9 OVERVIEW 9 BACKGROUND 9 INHERENTLY CONDUCTIVE POLYMERS 9 INHERENTLY DISSIPATIVE POLYMERS (IDPS) 10 CONDUCTIVE PLASTICS 10 CHAPTER 4 INHERENTLY CONDUCTIVE POLYMERS 12 OVERVIEW 12 ADDITIONAL TECHNICAL DETAILS 12 SYNTHESIZING CONJUGATED POLYMERS 12 CONCEPT OF RESISTIVITIES 13 OVERVIEW 13 TABLE 1 RESISTANCE SPECTRUM FOR METHODS OF MAKING PLASTICS CONDUCTIVE (OHMS/SQ)1 CONCEPTS AND NOMENCLATURE 14 BARRIERS TO APPLICATIONS 14 A HANDY WAY OF CATEGORIZING ICPS 14 TABLE 2 CATERGORIZING INHERENTLY CONDUCTIVE POLYMERS 15 ICP HISTORICAL PERSPECTIVE 15 PRIOR TO POST-1990 PERIOD 16 BY TECHNOLOGIES 17 OVERVIEW 17 PREPARATION OF ICPS 18 ENERGY BAND STRUCTURE 18 CHAIN STRUCTURE 18 COMPARISON OF CONDUCTIVITIES OF ICPS WITH METALS, SEMICONDUCTORS, AND INSULATORS 13 19

3 TABLE 3 CONDUCTIVITIES OF DOPED ICPS COMPARED WITH METALS, SEMICONDUCTORS, AND INSULATORS DOPING DETAILS 20 Background 20 Overview 20 Chemical and Electrochemical Methods 20 Reversal of Doping Process 21 Types of Dopants 21 Goal of Narrow Band Gaps 21 Effect on Color and Optical Properties 22 TABLE 4 COLOR OF DOPED AND UNDOPED CONDUCTIVE POLYMERS 22 IMPORTANCE OF MOLECULAR WEIGHT AND DISTRIBUTION IN CONDUCTIVE POLYMERS IMPROVING HIGH TEMPERATURE CONDUCTIVITY AND TEMPERATURE STABILITY ALLOYING AND BLENDING CONDUCTIVE POLYMERS WITH CONVENTIONAL RESINS PERFORMANCE ENHANCEMENTS SOUGHT THROUGH ICPS 23 Conductivity 23 Electrochromic Effects 24 Electroluminescence 24 Photoconductivity 24 Thermochromic Effects 24 PROCESSING CONDUCTIVE POLYMERS 25 Background 25 Problems and Challenges 25 Processing Options for ICPs 26 TABLE 5 ICP PROCESSING TECHNIQUES 26 TABLE 6 STABILITY AND PROCESSING ATTRIBUTES OF KEY ICPS 26 CONDUCTIVE POLYMER TYPES 26 OVERVIEW 26 POLYTHIOPHENES 27 Nature of the Material 27 Polythiophene Derivatives 28 Poly(3-alkylthiophene) 28 PEDOT 28 PEDOT/PSS Complex 28 EDOT 28 Suppliers 29 Heraeus 29 American Dye Source 29 Solvay 29 Applications 29 POLYANILINES 30 Background 30 Overview 30 Synthesis 30 Nature of the Material

4 Processing 31 Doping 31 FIGURE 1 THE FOUR OXIDATION STATES OF POLYANILINE 32 Characteristics and Properties 32 Overview 32 Blending with Commodity Polymers and Elastomers 33 Optical Properties 33 Applications 33 Suppliers 33 Recent Developments 34 Polyaniline Nanowires 34 Polyaniline-Carbon Nanoblend 34 POLYPYRROLES 35 Nature of the Material 35 Processing 35 Potential Applications 36 Suppliers 36 Recent Developments 36 Use of Polypyrrole in Printed Circuit Boards (PCBs) 36 Polypyrrole Material for Artificial Muscles 37 POLYACETYLENES 37 Background 37 Preparation 37 Processing 37 Problem of Environmental Instability 38 Potential Applications 38 OTHER INHERENTLY CONDUCTIVE POLYMERS 38 Polyphenylene Vinylene (PPV) 38 Overview 38 Background 38 Processing 39 Applications 39 Polyfluorenes 40 Polyphenylene Sulfide 40 Phthalocyanines 40 RECENT DEVELOPMENTS IN CONDUCTIVE POLYMERS 41 Second and Third Generation Versions 41 Improved Printing 41 Solar Cell Advances 41 INHERENTLY DISSIPATIVE POLYMERS (IDPS) 41 Overview 41 Technologies 42 Other Technological Aspects and Problems 42 Suppliers 43 Applications 43 CHAPTER 5 ICP COMPETITIVE RESIN SYSTEMS: CONDUCTIVE PLASTICS 45

5 BACKGROUND 45 OVERVIEW 45 LIMITATIONS OF A PLASTIC COMPOUND S RESULTING ELECTRICAL PROPERTIES 45 TECHNIQUES FOR MAKING PLASTICS CONDUCTIVE 46 TABLE 7 HOW TO MAKE PLASTICS CONDUCTIVE 46 RESISTIVITIES 46 TYPES OF CONDUCTIVE PLASTIC MATERIALS 47 FORMULATION OPTIONS 47 COMPOUNDING CONDUCTIVE PLASTICS 48 CONDUCTIVITY TESTS 48 EXAMPLES OF COMPANIES PRODUCING CONDUCTIVE PLASTICS 49 TABLE 8 8SELECTED KEY COMPANIES PRODUCING CONDUCTIVE PLASTICS 49 CONDUCTIVE PLASTIC ADDITIVES 49 OVERVIEW 49 ESD COMPOUNDS 50 ANTISTATIC ADDITIVES 50 Fibers and Powders 50 Carbon Fibers and Powders 50 Overview 50 Carbon Fibers 51 Carbon Blacks 51 Metal Fibers 52 Overview 52 Advantages 52 Metal Fiber Conductivity 53 Metalized Glass Fibers 53 Nickel-Coated Graphite Fibers 53 Background 53 Advantages 54 Stainless Steel Fibers 54 Overview 54 Technology 54 Effect on Processing 55 Fiber Forms 55 Advantages and Disadvantages 56 TABLE 9 ADVANTAGES AND DISADVANTAGES OF STAINLESS STEEL FIBERS 56 Copper Fibers 57 CARBON NANOTUBES 57 Overview 57 Usage in Producing Electrically Conductive Composites 58 Overview 58 Technical Problems 58 Carbon Nanotube Producers/Suppliers 58 TABLE 10 SELECTED KEY SUPPLIERS OF CARBON NANOTUBES 59 GRAPHENE 59 Overview 59 Properties 59

6 Suppliers 59 TABLE 11 COMPANIES DEVELOPING GRAPHENE COMPOSITE MATERIALS AND APPLICATIONS Usage in Producing Electrically Conductive Composites 60 Applications 60 TECHNICAL ISSUES 60 COSTS 61 RESINS USED 61 CONDUCTIVE FILLER SUPPLIERS 62 TABLE 12 CONDUCTIVE FILLER SUPPLIERS 62 RECENT DEVELOPMENTS IN CONDUCTIVE PLASTICS 62 NEW METHOD OF MAKING CONDUCTIVE PLASTICS 62 PLASTIC COATED METAL FIBER-FILLED CONDUCTIVE PLASTICS 63 OTHER CONDUCTIVE PLASTIC SYSTEMS 63 CONDUCTIVE PAINTS AND COATINGS 63 Background 63 Overview 63 Performance of Alternate Conductive Coatings 64 Background 64 Copper 64 Silver 64 Nickel 64 COATED PLASTICS FOR ESD CONTROL 64 Background 64 Comparisons 64 Other Aspects 65 Conductive Coating Cost Comparisons 65 CONDUCTIVE FILMS 65 EXAMPLES OF COMPANY PRODUCTS 66 Donatech VCF Series 66 Z-Flo Conductive Films 66 CONDUCTIVE ELASTOMERS 66 EXAMPLES OF CONDUCTIVE ELASTOMER PRODUCTS 67 Conductive Composites - Heber City, Utah 67 Laird Technologies - Chesterfield, Mo. 67 Leader Tech - Tampa, Fla. 67 NEW DEVELOPMENTS 67 Electrically Conductive Polyacetal Nanotubes 67 Electrically Conductive Soft TPEs 68 COMPOUNDING CONDUCTIVE PLASTICS 68 KEY SUPPLIERS AND EXAMPLES OF THEIR CONDUCTIVE PLASTIC PRODUCTS 68 BOEDEKER PLASTICS 68 CABOT 69 CIBA SPECIALTY CHEMICALS 69 SABIC 69 LUBRIZOL ADVANCED MATERIALS 69 POLYONE 70 RTP 70 60

7 PREMIX THERMOPLASTICS 71 CHAPTER 6 APPLICATIONS OF ICPS AND CONDUCTIVE PLASTICS 73 OVERVIEW 73 TABLE 13 APPLICATIONS OF ICPS AND CONDUCTIVE PLASTICS 73 CAPACITORS 73 OVERVIEW 73 MATERIALS 74 COMMERCIAL STATUS 74 ELECTROMAGNETIC AND RADIO FREQUENCY INTERFERENCE SHIELDING AND STATIC PROTECTION OVERVIEW 75 MATERIALS 75 Conductive Plastics 75 Inherently Conductive Polymers 76 Inherently Dissipative Polymers 77 COMMERCIAL STATUS 77 SENSORS 77 OVERVIEW 77 Fiber Optic 78 Microbalances 78 Conductive Polymers 78 MATERIALS 78 Remotely Readable Indicators 79 Gas Sensors 79 Odor Sensors 79 Chemical Sensors 79 Biosensors 80 Use of Microelectrodes 80 COMMERCIAL STATUS 81 ANTICORROSION COATINGS 81 OVERVIEW 81 MATERIALS 81 TEXTILES/FABRICS (ELECTROTEXTILES/CONDUCTIVE TEXTILES) 82 OVERVIEW 82 MATERIALS 82 COMMERCIAL STATUS 83 ORGANIC LIGHT-EMITTING DIODES 83 OVERVIEW 83 TABLE 14 MAJOR OLED TECHNOLOGIES 83 MATERIALS 83 COMMERCIAL STATUS 84 SOLAR CELLS 84 OVERVIEW 84 MATERIALS 85 COMMERCIAL STATUS 85 SEMICONDUCTOR TRANSISTORS 85 OVERVIEW 85 75

8 MATERIALS 86 COMMERCIAL STATUS 86 BATTERIES 86 OVERVIEW 86 MATERIALS 87 Market Environment 87 OTHER APPLICATIONS 88 AUTOMOTIVE PARTS 88 MEMBRANES 88 AVIATION/AEROSPACE 89 FUEL CELLS 89 RFID TAGS/LABELS 89 MEDICAL/PHARMACEUTICAL APPLICATIONS 90 Artificial Muscles 90 Microfluidics 90 Drug Delivery 90 Neural Regeneration 91 MISCELLANEOUS APPLICATIONS 91 Polymer Lasers 91 Microtools 92 Printing Plates 92 Smart/Electrochromic Windows 92 Camouflage Coatings 93 Solders 93 Electroluminescent Lamps (EL Lamps) 93 CHAPTER 7 MARKET BY TYPE OF CONDUCTIVE POLYMER 95 INHERENTLY CONDUCTIVE POLYMERS 95 OVERALL MARKET BY VOLUME 95 TABLE 15 GLOBAL ICP MARKET VOLUME BY RESIN TYPE, THROUGH 2021 OVERALL ICP MARKET BY VALUE 95 TABLE 16 GLOBAL ICP MARKET VALUE BY RESIN TYPE, THROUGH 2021 ($ MILLIONS) ICP MARKET ESTIMATES BY APPLICATION 96 Overview 96 Polythiophenes 96 TABLE 17 GLOBAL POLYTHIOPHENE MARKET BY APPLICATION,THROUGH 2021 Polyanilines 97 TABLE 18 GLOBAL POLYANILINE MARKET BY APPLICATION, THROUGH 2021 Polypyrroles 97 TABLE 19 GLOBAL POLYPYRROLE MARKET BY APPLICATION, THROUGH 2021 Other ICPs 98 TABLE 20 GLOBAL MARKET FOR OTHER ICP APPLICATIONS, THROUGH 2021 CONDUCTIVE PLASTICS

9 TABLE 21 GLOBAL CONDUCTIVE PLASTIC MARKET VOLUME BY RESIN TYPE, THROUGH 2021 TABLE 22 GLOBAL CONDUCTIVE PLASTIC MARKET VALUE BY RESIN TYPE, THROUGH 2021 ($ MILLIONS) OVERALL MARKET SUMMARY 100 TABLE 23 GLOBAL ELECTROACTIVE POLYMER MARKET IN VOLUME, THROUGH 2021 TABLE 24 GLOBAL ELECTROACTIVE POLYMER MARKET IN VALUE, THROUGH 2021 ($ MILLIONS) CHAPTER 8 CONDUCTIVE POLYMER MARKET BY APPLICATION 103 SUMMARY 103 TABLE 25 GLOBAL ELECTROACTIVE POLYMER MARKET BY APPLICATION, THROUGH 2021 ICP MARKETS BY APPLICATION 103 OVERVIEW 103 TABLE 26 GLOBAL ICP MARKET BY APPLICATION, THROUGH 2021 (THOUSAND POUNDS) CAPACITORS 104 TABLE 27 GLOBAL CAPACITOR MARKET BY ICP PRODUCT TYPE,THROUGH 2021 ESD/Antistatic Packaging 105 TABLE 28 GLOBAL ESD/ANTISTATIC PACKAGING MARKET BY ICP PRODUCT TYPE, THROUGH 2021 CORROSION PROTECTION 106 TABLE 29 GLOBAL CORROSION PROTECTION MARKET BY ICP PRODUCT TYPE, THROUGH 2021 SENSORS 106 TABLE 30 GLOBAL SENSOR MARKET BY ICP PRODUCT TYPE, THROUGH 2021 OLEDS 107 TABLE 31 GLOBAL OLED MARKET BY ICP PRODUCT TYPE, THROUGH 2021 SOLAR CELLS 107 TABLE 32 GLOBAL SOLAR CELL MARKET BY ICP POLYMER TYPE, THROUGH 2021 TEXTILES/FABRICS 108 TABLE 33 GLOBAL TEXTILES/FABRICS MARKET BY ICP PRODUCT TYPE, THROUGH 2021 ORGANIC SEMICONDUCTORS 109 TABLE 34 GLOBAL ORGANIC SEMICONDUCTOR MARKET BY ICP PRODUCT TYPE, THROUGH 2021 BATTERIES 109 TABLE 35 GLOBAL BATTERY MARKET BY ICP PRODUCT TYPE,THROUGH 2021 MISCELLANEOUS APPLICATIONS 110 TABLE 36 GLOBAL MARKET FOR MISCELLANEOUS APPLICATIONS BY ICP TYPE, THROUGH 2021 CONDUCTIVE PLASTICS MARKET BY APPLICATION 110 TABLE 37 GLOBAL CONDUCTIVE PLASTICS MARKET BY APPLICATION, THROUGH

10 CHAPTER 9 RECENT CONDUCTIVE POLYMER PATENT ACTIVITY 113 OVERVIEW 113 FIGURE 2 NUMBER OF ICP-RELATED U.S. PATENTS AND PATENT APPLICATIONS ISSUED BY TYPE OF MATERIAL THROUGH JULY 1, 2016 PATENT SUMMARIES 114 FULLY INTEGRATED ORGANIC LAYERED PROCESSES FOR MAKING PLASTIC ELECTRONICS BASED ON CONDUCTIVE POLYMERS PRINTING OF ORGANIC CONDUCTIVE POLYMERS CONTAINING ADDITIVES 114 WATER DISPERSIBLE POLYPYRROLES MADE WITH POLYMERIC ACID COLLOIDS FOR ELECTRONIC APPLICATIONS MULTIFUNCTIONAL 3,4-ALKYLENEDIOXY THIOPHENE DERIVATIVES AND ELECTRICALLY CONDUCTIVE POLYMERS CONTAINING THEM BARRIER LAYERS FOR COATING CONDUCTIVE POLYMERS ON LIQUID CRYSTALS 115 DEVELOPMENT OF NOVEL PROTON-CONDUCTIVE POLYMERS FOR PROTON EXCHANGE MEMBRANE FUEL CELL (PEMFC) TECHNOLOGY DISPERSIONS OF INTRINSICALLY CONDUCTIVE POLYMERS AND METHODS FOR THE PRODUCTION THEREOF FLUORESCENT, SEMICONDUCTIVE POLYMERS, AND DEVICES COMPRISING THEM IMPLANTABLE HEART VALVE PROSTHETIC DEVICES HAVING INTRINSICALLY CONDUCTIVE POLYMERS WATER DISPERSABLE POLYANILINES MADE WITH POLYMERIC ACID COLLOIDS FOR ELECTRONIC APPLICATIONS COMPOSITIONS OF ELECTRICALLY CONDUCTIVE POLYMERS AND NONPOLYMERIC FLUORINATED ORGANIC ACIDS POLYTHIOPHENE AND ELECTRONIC DEVICES COMPRISING THE SAME 116 SOLUBLE POLYTHIOPHENE DERIVATIVES 117 SEMICONDUCTOR COMPOSITION INCLUDING A SEMICONDUCTING POLYMER 117 MEMBRANE COMPOSITIONS AND METHODS FOR MAKING AND USING THEM CHAPTER 10 COMPANY PROFILES 119 ABTECH SCIENTIFIC INC. 119 AGFA-GEVAERT GROUP NV 119 AMERICAN DYE SOURCE INC. 120 BASF INC. 120 BOEDEKER INC. 121 CAMBRIDGE DISPLAY TECHNOLOGY 121 CELANESE CORP. 122 CENTRAL CORP. 122 E.I DUPONT DE NEMOURS AND CO. 123 EEONYX 123 EVONIK DEGUSSA GMBH 123 HERAEUS PRECIOUS METALS 124 HYPERION CATALYSIS INTL. INC. 124 KEMET CORP. 124 KLOCKNER PENTAPLAST OF AMERICA 125 LNP ENGINEERING PLASTICS 125 LUBRIZOL ADVANCED MATERIALS 126

11 MERCK KGAA 127 PLASTIC LOGIC GERMANY 127 POLYONE 127 PREMIX OY 128 RIEKE METALS INC. 128 RTP CO. 129 SHIN-ETSU POLYMER EUROPE BV 130 STERLING FIBERS 130 UNIVERSAL DISPLAY CORP. 131 VORBECK MATERIALS 131 WESTLAKE PLASTICS CO. 132 XG SCIENCES INC. 132 CHAPTER 11 ACRONYMS 134

12 LIST OF TABLES TABLE HEADING SUMMARY TABLE GLOBAL MARKET FOR ELECTROACTIVE POLYMERS, THROUGH 2021 (MILLION POUNDS/$ MILLIONS) TABLE 1 RESISTANCE SPECTRUM FOR METHODS OF MAKING PLASTICS CONDUCTIVE (OHMS/SQ)1 TABLE 2 CATERGORIZING INHERENTLY CONDUCTIVE POLYMERS 15 TABLE 3 CONDUCTIVITIES OF DOPED ICPS COMPARED WITH METALS, SEMICONDUCTORS, AND INSULATORS TABLE 4 COLOR OF DOPED AND UNDOPED CONDUCTIVE POLYMERS 22 TABLE 5 ICP PROCESSING TECHNIQUES 26 TABLE 6 STABILITY AND PROCESSING ATTRIBUTES OF KEY ICPS 26 TABLE 7 HOW TO MAKE PLASTICS CONDUCTIVE 46 TABLE 8 8SELECTED KEY COMPANIES PRODUCING CONDUCTIVE PLASTICS 49 TABLE 9 ADVANTAGES AND DISADVANTAGES OF STAINLESS STEEL FIBERS 56 TABLE 10 SELECTED KEY SUPPLIERS OF CARBON NANOTUBES 59 TABLE 11 COMPANIES DEVELOPING GRAPHENE COMPOSITE MATERIALS AND APPLICATIONS TABLE 12 CONDUCTIVE FILLER SUPPLIERS 62 TABLE 13 APPLICATIONS OF ICPS AND CONDUCTIVE PLASTICS 73 TABLE 14 MAJOR OLED TECHNOLOGIES 83 TABLE 15 GLOBAL ICP MARKET VOLUME BY RESIN TYPE, THROUGH 2021 TABLE 16 GLOBAL ICP MARKET VALUE BY RESIN TYPE, THROUGH 2021 ($ MILLIONS) 96 TABLE 17 GLOBAL POLYTHIOPHENE MARKET BY APPLICATION,THROUGH 2021 TABLE 18 GLOBAL POLYANILINE MARKET BY APPLICATION, THROUGH 2021 TABLE 19 GLOBAL POLYPYRROLE MARKET BY APPLICATION, THROUGH 2021 TABLE 20 GLOBAL MARKET FOR OTHER ICP APPLICATIONS, THROUGH 2021 TABLE 21 GLOBAL CONDUCTIVE PLASTIC MARKET VOLUME BY RESIN TYPE, THROUGH 2021 TABLE 22 GLOBAL CONDUCTIVE PLASTIC MARKET VALUE BY RESIN TYPE, THROUGH 2021 ($ MILLIONS) TABLE 23 GLOBAL ELECTROACTIVE POLYMER MARKET IN VOLUME, THROUGH 2021 TABLE 24 GLOBAL ELECTROACTIVE POLYMER MARKET IN VALUE, THROUGH 2021 ($ MILLIONS) TABLE 25 GLOBAL ELECTROACTIVE POLYMER MARKET BY APPLICATION, THROUGH 2021 TABLE 26 GLOBAL ICP MARKET BY APPLICATION, THROUGH 2021 (THOUSAND POUNDS) TABLE 27 GLOBAL CAPACITOR MARKET BY ICP PRODUCT TYPE,THROUGH 2021 TABLE 28 GLOBAL ESD/ANTISTATIC PACKAGING MARKET BY ICP PRODUCT TYPE, THROUGH 2021 TABLE 29 GLOBAL CORROSION PROTECTION MARKET BY ICP PRODUCT TYPE, THROUGH 2021 TABLE 30 GLOBAL SENSOR MARKET BY ICP PRODUCT TYPE, THROUGH

13 TABLE HEADING TABLE 31 GLOBAL OLED MARKET BY ICP PRODUCT TYPE, THROUGH 2021 TABLE 32 GLOBAL SOLAR CELL MARKET BY ICP POLYMER TYPE, THROUGH 2021 TABLE 33 GLOBAL TEXTILES/FABRICS MARKET BY ICP PRODUCT TYPE, THROUGH 2021 TABLE 34 GLOBAL ORGANIC SEMICONDUCTOR MARKET BY ICP PRODUCT TYPE, THROUGH 2021 TABLE 35 GLOBAL BATTERY MARKET BY ICP PRODUCT TYPE,THROUGH 2021 TABLE 36 GLOBAL MARKET FOR MISCELLANEOUS APPLICATIONS BY ICP TYPE, THROUGH 2021 TABLE 37 GLOBAL CONDUCTIVE PLASTICS MARKET BY APPLICATION, THROUGH

14 LIST OF FIGURES FIGURE TITLE SUMMARY FIGURE GLOBAL MARKET FOR ELECTROACTIVE POLYMERS, ($ MILLIONS) FIGURE 1 THE FOUR OXIDATION STATES OF POLYANILINE 32 FIGURE 2 NUMBER OF ICP-RELATED U.S. PATENTS AND PATENT APPLICATIONS ISSUED BY TYPE OF MATERIAL THROUGH JULY 1,