Vol.2 No.2 2009

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Research paper : A strategy to reduce energy usage in ceramic fabrication (K. Watari et al.)−141−Synthesiology - English edition Vol.2 No.2 (2009) and dispersed in the solvent along with the raw materials and auxiliaries, and no new step is added. Also, the binder we used is abundantly available, and the cost of material can be kept low.3 Relationship between the elimination of organic binders and the introduction of inorganic bindersComment and question (Toshimi Shimizu)You stated that the objective for the realization of energy-saving process is reduction or elimination of organic binders. Does this mean “elimination = introduction of inorganic binders”?Answer (Koji Watari)It is as you have indicated. The introduction of inorganic binders is the elimination of organic binders, and this leads to significant reduction of CO2 emission in the ceramic manufacturing process.4 Relationship between material production and assessment technologyComment and question (Nobumitsu Murayama)In the development of the inorganic binder, first the binder assessment technology was developed, then followed the development of the inorganic binder. This research progression is very interesting. In ordinary material process research, first, the material is developed and then assessed. However, in the research for a new function, it is necessary to establish the assessment technology of that new function. Please comment on the relationship between material production and assessment.Answer (Takaaki Nagaoka)In the R&D of material and process through search of materials and their optimization, it is necessary to conduct tests for assessments. In this research, however, there were two limitations. One was that there was a lack of assessment method for binder functions. As a result, “ultimately it was determined by actually extruding the product on the machine.” Second was that high quantity (several hundred grams) of samples was needed per assessment on an actual machine. Although that amount may be small at the site of production, it was difficult at AIST when considering the time and labor needed. This was more pronounced when several assessments had to be done. Therefore, we set the definition of binder functions (shape retention and fluidity) for extruding, and developed a method for assessing the functions with minimum amount of samples. As a result, we could easily and quickly narrow down the prospect samples using small amounts of samples.When searching for new material functions, if there is no function assessment technology at the laboratory level, then the researchers themselves must establish the assessment technology. Although this seems to be taking the long way around, by simultaneously developing the assessment technology, the researcher can think deeply about the meaning of the expressed function, and can work on material production from the same perspective as the person doing the assessment. Moreover, by accumulating the assessment technology, the developed technology and material together become a bundle of highly original, advanced knowledge.5 Significance of scientifically investigating the know-how technologyComment and question (Nobumitsu Murayama)It can be said that this research is a scientific investigation of the know-how technology for binders. While this will certainly promote the advancement of manufacturing process, disclosure of the companies’ know-hows, which is the primary practice in the ceramics industry, may lower the competitiveness of these companies. Please comment on the significance of scientific investigation of a technology that was dependent on experience in the material process field.Answer (Koji Watari)As the reviewer indicated, the basic and core research of binder technology is a scientific consideration of a technology that relied on corporate experience, and in the future, this may lower the competitive edge of the Japanese ceramics companies. Therefore, as a research leader, I considered the contents of patent and paper that will be publicized, explained carefully to the companies engaging in joint research, and disclosed some of the research results with their approval.Scientific investigation of a technology that relied on experience, i.e. understanding the scientific basis of a technology, systematization of a technology, and extraction of the major factors, are extremely important outcomes of a public research institution like AIST, which is a collection of research professionals. Also, one of the roles of AIST is to find how to overcome the “valley of death” in a scientific perspective, and I think we can provide appropriate elemental and alternative technologies by scientific investigation of a technology that was dependent on experience.Many of the companies that engaged in joint research with us set the ultimate objective as “development of high value-added product and improvement of production efficiency through basic and core research.” They became aware of the importance of basic and core research and demanded better research results. I think this is an indication that the companies want to make better products and improve production efficiency by scientifically investigating their know-hows that were dependent on experience. On the other hand, technological know-hows are important assets for the companies, and must be handled with care.6 Technological transfer of innovative material process that requires total change in the manufacturing lineComment and question (Nobumitsu Murayama)To overcome the economic valley of death that you mentioned, I am certain that it is more efficient if “the technology developed is technology that can be incorporated into the existing process, and the existing manufacturing equipment can be used.” However, there is always a possibility of technological transfer of innovative material process that requires total change in the manufacturing line. In case of the latter, one of the ways may be for a public research institute like AIST to have a prototype manufacturing line. Can you comment on this.Answer (Koji Watari)Many private companies are reluctant to invest newly in their manufacturing line. Considering the importance of the technology and its dissemination, it may be greatly significant for a public research institute like AIST to create a prototype manufacturing equipment for trial manufacturing. However, investment is large. Therefore, before making the new investment, it is necessary to set up a business model including the possibility of alternative technology, procurement of user and cost of maintenance, extraction of key application, and understanding of market trend.

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