AIST Stories No2

From AIST to the Innovative World6using technology to increase competitiveness.Will this become a key technology for deploying next-generation energy?!Solidification at room temperature means that despite no large-scale equipment being required, the AD method being able to realize low-cost yet high-quality coatings. In 2004, a high transparency ceramic thick film measuring 60 cm by 60 cm was fabricated and at present, roll-to-roll manufacturing is possible. In what areas is this technology likely to be applied going forward?“Initially, application is likely in energy-related components, including lithium ion batteries. Research is underway to fabricate thin sheet batteries by solidifying the normally liquid electrolyte using this technology. In addition, light and flexible dye-sensitized solar cells (DSC) may be commercialized in the next one to two years.”Toyota Motor is developing all-solid-state lithium ion batteries. The issue of fuel holds an important key to market penetration of hybrid vehicles and electric vehicles; Toyota Motor is conducting R&D on revolutionary next-generation batteries whose performance exceeds that of inert towards chemical reaction and by densely coating metal and glass components with yttria, which is highly resistant to plasma abrasion, chip yields are improved dramatically.”Previously, thermal spraying*4 was used to coat yttria; although the resulting film was quite rough, it was still more effective than no coating at all. However, coating using the AD method results in a high density film with a nano-level crystalline structure that is an order of magnitude finer, with a four-fold increase in performance as well. Having said so, it has only been over the last one to two years that interest has actually increased. The needs of the times have finally caught up with this technology one might say. Currently, TOTO is expanding its factory and driving production. Through the marketing prowess and efforts of this joint development partner, superior performance and favorable coating cost have been simultaneously achieved, utilizing the potential of the current AD method; this can be said to be a case study of 1994A phenomenon whereby ceramic particles can form a dense, solid film at room temperature is accidentally discovered.Ca. 1999The phenomenon (room temperature impact consolidation phenomenon) is verified.Ca. 2001The fact that a solidified body of ceramic particles becomes transparent is verified (successful fabrication of large high transparency film in 2004)Ca. 2002A large-scale national project (in Japan Nano-technology program) is promoted with the objective of application development for this technology jointly with six private-sector companiesCa. 2006Fundamentals of the mechanism of the room temperature impact consolidation phenomenon are elucidated, and basic rules are established leading to commercial-scale production technology 2007TOTO commercializes coating technology for semiconductor fabrication equipment using the AD methodPhotograph: TOTOPresentEnergy technologies such as lithium ion batteries (Toyota Motor Co.) and dye-sensitized solar cells (Sekisui Chemical CO.,LTD) are being developed. Furthermore, application is planned in fashion and design fields.Energy creationFilm-type dye-sensitizedsolar cellAll-solid-state lithiumion battery applicationJoint research with Sekisui Chemical (considering market debut)Joint research with Toyota MotorRoll-to-roll film forming AIST’s original technology (AD method)Energy storageLarge area film formation examplenano tech2012 AD method for large area film formation and application in the energy sector▲ Examples of AD method application. Application is advancing for all-solid-state lithium ion batteries and film-type dye-sensitized solar cells.Photograph: Sekisui Chemical *4 Thermal spraying: Heating and transforming a thermal spraying material into a molten or close to molten state using a gas flame or electrical energy as a heat source, and spraying it onto a substrate to form a thick film.Development history