The company is pursuing the manufacture of layers with high performance and low cost not by using a powder that has homogeneous particle sizes, but rather by using one that mainly contains micron sized particles (the island component) whose spaces are filled with nano-sized particles (the sea component). The company has implemented layer manufacture technology, for example by using auxiliary additives. However, they have found it difficult to achieve homogeneous dispersion and dense deposition of fine particles.
On the other hand, layer manufacture technologies that yield dense structures made of particles are being pursued throughout the world in various fields such as biology, catalysts, and precision machinery, and examples of such applications are increasing every year. Therefore, believing that many useful technologies for solving this problem exist, the company has issued this open request in order to further accelerate their technology development. The company anticipates acquiring the necessary technology from organizations that already possess it, or receiving promising development proposals based on joint development or contract development.

Anticipated approaches include dispersion and deposition Technologies (A) and component technologies (B). Responses may combine elements from both A and B.
A: Dispersion and deposition Technologies
- Application of printing technologies (such as screen and inkjet printing)
- Spray methods
- Roll coating methods
- Spin coating methods
- Fluidized bed methods
B: Component Technologies for Optimum Dispersion and deposition Technologies
- Technologies that optimize dispersion or deposition parameters (such as particle size distribution, inter-particle forces, and particle shapes)
- Simulation technologies as a basis for parameter design
- Technologies for evaluating dispersions and layers.

The following approaches are not under consideration at the present time:
" Any process that utilize vacuum conditions

Technical Specifications / Specific technical requirements:
Coating Composition " Particle size distribution: having peaks around 10 to 100 nm and around 1 µm " Shape: irregular " Chemical components: inorganic " Magnetic property: not magnetic " Specific gravity: approximately 4-7

Substrate Composition
" Glass or metal
- It is expected that a resin, ultra-thin glass, or metal foil will ultimately be used, so technologies that can be applied to such materials are preferred.

Coating Requirements
" Layer thickness: 1 to 5 µm " Homogeneity and density: It is preferred that there be as few voids as possible. A heat treatment of 400ºC to 600ºC is applied to improve the cohesion between the particles after the dispersion and deposition process; therefore, it must be possible to maintain the homogeneity and density after a heat treatment. " Size of substrate to be processed: width of several cm (it is expected that the width will ultimately be = 50 cm, so a technology that can be scaled up with ease is preferred). " Restrictions on the deposition method: it is expected to be applicable to roll-to-roll manufacturing methods; however, at the present time, batch processing would be acceptable.
In addition to new processing technologies, the company will consider proposals for component technologies for optimizing the particle size distribution of the inorganic powder to ultimately create a densely structured thin layer coating. For example, technologies for analyzing or simulating the distribution of shapes and particle sizes in the powder are of interest. The particle size distribution and shapes are not restricted to those of the reference figure.

 

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