Vol.2 No.2 2009

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Research paper : A strategy to reduce energy usage in ceramic fabrication (K. Watari et al.)−138−Synthesiology - English edition Vol.2 No.2 (2009) Various conditions became clear as the research progressed and the elemental technologies were refined. By conducting R&D for the expression of plasticity in inorganic binders and R&D of the particle surface analysis technology using AFM colloid prove method, the relationship between the particle surface and water was investigated from macro and micro levels. As a result, the importance of water in the plasticity of ceramics, as well as the ways of selection of inorganic binders to increase the water content were demonstrated quantitatively, and we were able to approach the technologies for reduction and elimination of organic binders based on scientific evidence. These researches correspond to the core and basic researches of the Type 2 Basic Research.The flow of inorganic binder research for the reduction and elimination of the organic binder with plasticity shifted from: (1) development of binder assessment technology, (2) process research of inorganic binders, (3) research of water-particle interface, and (4) clarification of process factors that control the inorganic binder technology. As a result, it was shown that inorganic material with high water content could be used as an inorganic binder expressing plasticity. This is the outcome of the Type 2 Basic Research.Discussions within the group of the importance of water in clay minerals and inorganic binders led to the organic binder with hydrophilic properties or those that contain water as candidates of organic binders that reacted to microwave, and this led to the development of a microwave reactive binder. Although the roles of water in inorganic binders and microwave reactive binders are different, in the greater concept of binders, “water” was an important keyword.Based on the results and findings obtained, a product was realized by a major material company through joint research. These researches correspond to Product Realization Research, and the efficacy of the developed technology was tested in the manufacturing lines.The advantages of the developed binder include its technological excellence as well as the low cost of incorporating this technology. Since the reactive and inorganic binders can be placed in solvent along with the raw materials and auxiliaries and then mixed and dispersed, no new step is added. Moreover, the binder is used in large amounts for other purposes, and the cost of material is low.7 Evaluation of result and future developmentsAs a result of engaging in research to fulfill the demand of society and industry such as adaptation to the existing process, use of existing equipment, and low cost, we believe we were able to develop a technology that can be put to actual practice, as the boundary conditions of the technology as well as the elemental technologies became clarified. Extraction of core technology is to find “simplicity in complexity” of the manufacturing process that seems to be complexly intertwined. If the boundary conditions of the research and the core of the technology to be developed are known in the early phase of R&D, resources can be introduced efficiently Fig. 7 Building of low-environment load process and mutual relationship in existing ceramic manufacturing steps.Defining research themeProcess research and assessment researchfor reduction or elimination of organic binderType 2 Basic ResearchLow melting point auxiliary technologyDispersion technologyHydrate material technologyHigh density forming technologySurface coating technologyEstablishment of reactivebinder technologyParticle surface analysistechnologyReaction trigger technologyProductrealizationtechnology・ Maintain function and property・ Cost reduction・ Use of existing equipment・ Application to existing processResponse to social and industrial demandEstablishment of hydratebinder technologyExtraction oftechnologyShrinkage rate control technologyBinder technologyNanoparticle handling technologyResearch developmentElemental technology to realize energy-saving processBasic and core researchType 1 Basic ResearchTime axisLow-temperature sintering technologyNew binder technologyInorganicOrganicProductrealizationtechnology

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