R&D Achievements. Nano Material / Metal Parts

Transcription

1 R&D Achievements Nano Material / Metal Parts

2 Organic/Inorganic Nano-hybrid Material Technology Hybrid varnish Acryl Resin/Silica Hybrid Varnish Kang Dong-pil Sol-gel Reactor Film Coating Equipment Nano-hybrid Varnish-coated Cu Coil 110 PAI/Silica Nano-hybrid Varnish Insulation Layer by Wet Coating - Organic/inorganic nano-hybrid is a nano-level hybridized material obtained through a chemical network between nano-sized ( meters) inorganic substances and organic resin, which overcomes the inherent limitations of each organic and inorganic component. - Organic/inorganic nano-hybrid material shave many advantages such as low-temperature curing, ultra-thin coating, and improved properties over conventional composite materials owing to their dense structure created via a chemical network, enabling nano-hybrid materials to be used in various industrial fields like optics, energy, and the environment. - Organic/inorganic hybrids are based on advanced nano-technology. These nano-hybrid materials have unique characteristics overcoming such organic material disadvantages as poor heat-resistance and low stiffness (scratch-resistance), and such inorganic material disadvantages as brittleness and high-temperature processing requirements. - Nano-hybrid materials comprise high-content inorganic (ceramic) Sol dispersed in organic resin which can be fabricated by a heat-induced or UVinduced curing (formation of polymeric network by 3-dimensional molecular cross linking) method in relatively low-temperature processing conditions. - Nano-hybrid coating material shave remarkable improvement in electrical properties (high insulation, delectricity, arc/surge-resistance), thermal properties (heat-resistance, high thermal conductivity), mechanical properties (wear-resistance, scratch-resistance, adhesiveness, stiffness), and optical properties (transparency, anti-discoloration, refractive index), compared to organic materials, and are expected to be of value in theelectric/electronic/optic industries. At present, it is possible to apply these hybrid materials to high-stiffness transparent systems with solidlubricancy, wear-resistance, and printability, as well as insulating process materials for semiconductors and micro-devices. Varnish Coating Equipment Hybrid Coating Film Sol-gel TiO2 Synthesis - Equipment for manufacturing inorganic (ceramic) sol Organic/inorganic hybrid material is in a solution state as a wet type nano-material, which forms a solid coating after the curing process. Hybrid solutions, equipment for coating process, and coated samples are as follows. - Film-coating equipment for nano-hybrid varnish coating coil Specifications: tube voltage 70 kvp, tube current7 ma, X-ray effective focal size <400 um - As opposed to nano-composite materials, nano-hybrid materials have a relatively low viscosity even with high inorganic component loading, which facilitates process ability, and thus enables wide application in various fields using high-tech materials - Nano-hybrid materials can be applied to various films (optical, window), hard-coatings, scratchresistant coatings for plastic films, scratch-resistant and corrosion-resistant coatings for metal foil, electrical insulating coatings for flexible substrate, and electrical insulating varnish for motor/transformer metal coils, etc. Of note, when hybridized with heat-resistant resin, these hybrid materials show excellent heat-resistance as well as improved thermal conductance and chemical resistance, and can be applied to sealing materials and various kinds of core component materials, such as electrical components for EV, printable electronic devices (TFT, RFID), integrated semiconductor devices, flexible displays (OLED, electronic paper), thin-film solar cell, plane light sources, and film batteries. Furthermore, even wider application in these industrial fields is expected via wet printing which is becoming a more prominent process. In the near future, demand for highelectrical power materials will increase in high-voltage or current systems, and these new hybrid materials will contribute to an increase in the reliability of high-voltage motors, transformers, generators, large-scale electric heater systems, and more. - Photo sensitive resin composition with organic/inorganic hybrid and liquid display devices using a manufacturing method incorporating organic/inorganic hybrid sol solutions composed of polymeric resins with inorganic nanoparticles modified by organosilanes, and materials derived thereof. 111

3 Lee Geon-woong Carbon Nanotube-based Transparent Conducting Film Technology Transparent electrode coating technology using a Carbon Nanotube (CNT)/ binder mixture solution - Touch screen panels, ESD film, EMI shielding film, transparent heaters - Transparent, conductive and super-hydrophobic coating, flexible displays, solar cells, smart window - Film-type light sources, thin film heaters, cold emitters Thin Film based CNT-TCF Market Volume Carbon Nanotube CNT/Binder coating solution Transparent conducting film We developed CNT coating solutions containing up to five components such as CNT, solvents, binder, stabilizer, and dispersants, for transparent conducting electrode fabrication. The transparent and conductive films fabricated with our CNT solution can replace traditional ITO film. CNT-based transparent electrode technology has potential applications in alternative electrode materials for touch panels and e-paper in display technologies, solar cells, flexible electronic devices, automobiles, and optical devices. - Innovative transparent thin film electrode fabrication process creating a nm thickness in a one-step coating - Fabrication of transparent conducting electrode film for resistive or capacitive touch screen panels via a spraying or roll-to-roll process on flexible substrates - World record CNT-based transparent electrode optoelectrical properties (transmittance 90%, sheet resistance 80 Ω/sq) Transparent Conductive Coating Technology for Touch Panels via a One Component CNT/Binder Solution - Manufacturing method for transparent conductive films containing carbon nanotubes and binder, and transparent conductive film manufactured thereby - Polymer binder composition for transparent conductive films containing carbon nanotubes - Fabrication method for ESD films using CNTs and ESD films - Fabrication method for transparent conductive films containing carbon nanotubes and polymer binders and transparent conductive films - Fabrication method for transparent heaters containing carbon nanotubes and binders, and transparent heaters - Transparent conductive polycarbonate films coated with carbon nanotubes and touch panels using same - Manufacturing method for conductive coatings with metal oxide-wrapped carbon nanotubes and conductive coating derived thereby

4 Anodic Nanostructure Technology for Clean Environment Jeong Dae-yeong World Hemodialysis Market in 2009 Reached USD B, and is Expected to Reach USD B in 2016 by a 7% Annual increase. - Fabrication technology of nanostructures with uniform-size pores from a few to a few hundred nm using chemical etching processes including anodizing - Fabrication technology for super-hydrophobic and super-oleophobic surfaces, including the formation of mixed nano and micro-structure surfaces World Market for Filtering Blood, Viruses, Leukocytes, and Protein Reached USD 1.8 B, and is Expected to Reach USD 2.3 B in 2012 FE-SEM Images Taken on AAO Membrane with Nano Pore of Several Hundreds nm of Magnitude, Fabricated Using a Hard Anodization Method - MF and UF membrane technology featuring world record water permeability - MF and UF membrane technology featuring high selectivity due to very uniform pore sizes - Through-hole-pore membranes minimizing flow path - Simplest and cheapest fabrication technology for nano and micro-structure surfaces for super-hydrophobic and super-oleophobic surfaces FE-SEM Images Taken on AAO Membrane with Nano Pore of Several Tens nm of Magnitude, Fabricated Using a Mild Anodization Method Anodizing Equipment (for Fabricating Membranes of 15 and 50 mm in Diameter) - MF and UF membranes with water permeability three times greater than the current world record - Very cheap fabrication process - New ceramic composite membranes compatible with polymeric ones in production costs - New polymer/ceramic and metal/ceramic composite membranes - Simplest and cheapest fabrication process for super-hydrophobic surfaces - Aluminum oxide imprints for fabricating super-hydrophobic films - Super-hydrophobic PDMS films using aluminum oxide imprints - Planar nanoporous oxide ceramic membranes and filters using same - Composite membranes comprising planar nanoporous oxide ceramic membranes and multi-functional filters using same - Apparatus for high-field fabrication of anodic nanostructures - Method for high-field fabrication of anodic nanostructures - Asymmetric alumina membranes of uniform size pores and method for fabricating same - Method to fabricate nanoporous alumina membranes with through-hole pores open at both ends - Manufacturing methods for nanoporous structure through high temperature anodization of Al - Composite membranes consisting of nanoporous anodic metal oxide membranes and metallic mesh, and method to fabricate same - Fabrication method for composite membranes consisting of metallic supporters and metal oxide mem-branes using metals patterned with protrusions and depressions - Super-hydrophobic surfaces comprising homogeneously mixed nano and micro-structures - Composite membranes comprising metallic supporters and metal oxide membrane using metal sheets patterned with protrusions and depressions using lithography and their fabrication method TiO2 Membranes (Nanotubes, Mesosponge Structure) Low energy-cost MF and UF membranes for water treatment - Filters for viruses, proteins, etc. and templates for the proliferation of osteoblast cells, super hydrophobic protection films for photovoltaic cells, super-hydrophobic automobile bodies, super-hydrophobic overhead lines sheaths, pipelines with super-hydrophobic inner walls, insulators with super hydrophobic 115

5 Cho Chu-hyun Process of Silver Wire Extrusion in Water (Hi-speed Camera) Production of Highly Dispersed Nano Powders <Nano Powder Production by Wire Explosion in Liquid Media> - Metallic wire of less than 1mm in diameter is extruded by pulsed high current. The material changes state from solid to liquid to vapor - to plasma in very short time (5 to 20 usec). - The vapor and plasma are cooled by collision with ambient molecules and condensed to particles. - Nanoparticles of less than 100nm in diameter are produced through rapid cooling and condensing into liquid. We produce various kinds of pure metal or oxide metal powers with a combination of wire materials and liquid media. - The most important advantage of this technology is the existence of highly dispersed nanoparticles in the dispersive liquid, such as binder material, for the fabrications of laminate electrodes. - Mass production of various nano powders such as Ag, Cu, Ni, Sn, etc. with the same method and apparatus. - Production of highly dispersed and pure nano powders by environmentally friendly physical processes. - Smaller particle size than conventional methods in air and safe manufacturing process for people regarding exposure. - Production of graphite or Si nano powders via the same method - Conductive paste and electrode materials Ag, Ni, Cu - Conductive inks for printed electronics (Display, RFID): 30 billion$ (2012) (Nano markets Res. Rept. 2005) (Ag, Cu etc.) - Graphite and Si nano powders for Li-ion batteries (mobile, electric vehicle): USD 22 B (2015) (Battery R&D Association of Korea Applications : Electrode Materials for the MLCC (Ni), Conductive Patterns on a Circuit Board (Cu, Ag) Conductive Inks for Printed Electronics (Cu, Ag) - Method and apparatus for nano powder synthesis by wire extrusion in liquid - Method and system classifying and collecting magnetic nano powders prepared by wire explosion in liquid - Method and system for mass production of nano powders by wire extrusion in liquid - Method for the preparation of nano-powders by wire extrusion in liquid with improved dispersibility - Method and apparatus for semiconductor nano powder synthesis by wire extrusion in liquid - Method and apparatus for graphite nano powder synthesis - Method and apparatus for metallic nanoparticle size classification using pulsed magnetic fields - Method and apparatus for synthesis of metal nano powders by wire extrusion Apparatus for Mass Production of Nano Powders with Automatic Wire Feeder Size Distributions of Ag Nanoparticles Produced in Air and in Water

6 Nano-template Technology for Tunable Density Nanowire Arrays Ha Yoon-cheol Nano-template technology based on electrochemical anodization has been widely used as a template for 0-dimensional or 1-dimensional nanostructures and devices. - Depending on the thickness of the anodized film, the technology can be divided into mild and hard anodization. Typical self-ordering regimes for mono-sized nano pores in each anodization method are as follows: Condition Template with 25 nm Pores Template with 200 nm Pores A Schematic of Low Density Nano template with 25 nm Pores 118 H2SO4 ElecH2C2O4 trolyte H3SO4 Mild anodization Hard anodization Voltage Interpore distance Voltage Interpore distance 19~25V 50~65 nm 40~80 V 90~140 nm 40V 100~110 nm 110~150 V 160~195V 405~500 nm 220~300 nm - Film growth rate 2~6 /h 30~70 /h Current density 2~5 ma/cm (constant) 30~250 ma/cm (decreases with time) 2 - This technology is based on asymmetric anodic alumina membrane technology (patent pending) combining mild and hard anodization. Control of voltage, temperature, and concentration is critical for implementation of the new nano-template. - In particular, by varying the range of final voltage between 25 and 500 V, the density of nano pores can be tuned to a maximum of 1/ (20)2 of those by the conventional constant voltage anodization process. The figure below shows live and dead pores during density lowering to 1/25 with a final voltage of 140 V. 2 - Tunable nano-template technology based on a high-field anodizer developed by KERI (refer to list of patents). - Due to the ultra-high pore density of anodized nano-templates, i.e., 108~1012/cm2, and ease of filling of the pores with various materials, they have been used for next generation 0-D or 1-D electric or electronic devices. - However, for 3-D nanostructured devices, which will take place of the current thin-film technology, the nano pore should mostly serve as a current collector and the remaining space after removing the template should accommodate other active materials, where demand for a novel template with large free space occurs. - Nano-templates with low or tunable density nano pores developed by this research team provides a solution for such matters based on a combination of different anodization schemes for which only a part of total pores are active in nanowire growth, as shown below. The growth rate of the template is sufficiently high for mass production. This novel nano-template technology has no prior application for nano devices, but the template itself will be a value-added product for research societies like universities and research institutes. Particularly, this technology will enable next-generation 3-D nanostructured electric and electronic devices and so will the related market. - Asymmetric alumina membrane having monosized pores, and manufacturing method thereof - Apparatus for high-field anodization of anodic nanostructures - Apparatus for tubular high-field fabrication of anodic nanostructures - Method for high-field fabrication of anodic nanostructures - Apparatus for high-field fabrication of anodic nanostructures 119

7 Nano Hybrid Enamel Insulation Technology for High Efficiency Electric Machines Han Se-won Following current trends in insulation coating technology for power industries: Polymer to nano composite - High performance and efficiency for electric machines via nano hybrid enameled wire in KERI - Coil winding property for electric motors: Increasing space factor by 20% via nano hybrid enameled wire - Thermal property for transformers: Increasing thermal conductivity by 5% via nano hybrid enameled wire - Organic and inorganic nano hybrid insulation via the Sol-gel method: Increasing the reliability of magnetic enameled coil via chemical bonding between organic and inorganic interfaces Magnetic Coil for High Efficiency Electric Motors Coil for Advanced Acoustics Micro-coil for Personal Computers Samples of hybrid materials and enameled wire Coil for Micro-transformer Machines Enameled Insulation Resin and Test Coil Samples by Nano Hybrid Manufacturing Method Cable and Coil for Communications Systems Magnetic Coil for Hybrid Electric Vehicles (HEV) - Manufacturing method and materials for polyamidimide silica hybrid for electric insulating coatings - Manufacturing method for high density winding coil treated with fluorosilane, coating materials thereof and coil coating the coating materials - Magnetic wire for EV (electric vehicles) or EHV (hybrid electric vehicles) motors - Magnetic wire for anti-surge in high efficiency motors - Insulation coating for conductors in high performance transformers - Insulation coating for macro-machines and precision parts)

8 Non-heat Treated High Conductivity and High Strength Al Alloy Kim Byung-geol Non-heat treated Al alloy with high conductivity and high mechanical strength Large Area & High Quality Graphene-based Transparent Conducting Films Lee Geon-woong Heat resistance and high conductivity - 30% production cost savings and 300% productivity increase thanks to nonheat treatment process - Composition development for new material alloys - Characterize properties of developed alloys - Fabricate proto-type conductor and testing - Heat resistant Al alloy for overhead conductors (sales volume, domestic, overseas / capacity increase and over 500 billon USD in global market) - High mechanical strength and high conductivity Al alloy for refrigerators - Al alloy wire made via non-heat treated process / Capacity increase and over 300 billon USD in the global market Commercialization of graphene based transparent conducting film through solution-processed production of high quality exfoliated graphene and dispersed solutions with large area and low defects Preparation Technology for Large Area, High Quality Graphene Shear stress Graphene oxide (large area/low defects) Graphene area Dispersion Technology for Highly Concentrated Graphene Dispersed solution of highly concentrated graphene Al Alloy Wires Produced by Non-heat Treatment Process Fabrication Technology for Graphene Based TCFs and Electrical/Electronic Devices - Preparation of solution-processed graphene and dispersed solution, and formation of graphene with large area and low defects through exfoliation of graphite by induced shear stress - A possible solution-based process with a top down approach, high performance electrode and device fabrication through stable dispersion of high quality graphene in organic/inorganic solvent - Formation of solution-processed large area, high quality graphene, high concentration graphene solution, fabrication of high performance transparent conducting film - ACS Nano 2011, 5, 870. IF= (Title: High-Performance Transparent Conductive Films Using Rheologically Derived Reduced Graphene Oxide) - Development of solution processed technologies such as spray, dip-coating, gravure, screen printing, and mass production of graphene solution through high quality graphene formation with large area and dispersed solution at high concentration - Currently, possible nanomaterial for ITO substitution and various applications, including transparent conducting electrode and film, electrodes for solar cells, electrical/electronic devices (high electron mobility transistors, photo detectors, bio/gas sensors, etc.) as well as electromagnetic interference, electrostatic dissipation for composites - Non-heat treated Al alloy production method for overhead conductors - Non-heat treated Al alloy for ampacity gain overhead conductors Manufacturing method for a single-layered reduced graphene oxide dispersion solution using shear stress and single-layered reduced graphene oxide dispersion solution derived thereby - Stable dispersion of reduced graphene oxide and its reduced graphene oxide solution - Graphene-based field emitters and their manufacturing method 123

9 CNT-based Light Emitting Source Manufacturing Technology Piezoelectric Device and Driven Scanning System Lee Geon-woong CNT-based emitter technology with CNT/binder mixture coating solution via cathode spraying, for application in back light units and light sources Jeong Soon-jong Conventional magnetic actuators have been used in laser ganavometers. We have alternatively designed a new micro galvanometer in which a piezoelectric actuator is driven. This new piezoelectric galvanometer has advantages including faster response and more precise control than conventional ones. Advantage exists in that a very thin film emitter showing high emission current density and long emission stability can be fabricated for a large area through a low cost processes This piezoelectric machine exhibits a high resolution (theoretical 10-fold improvement) and has a low cost in comparison with conventional machines. Homogeneous Field Emission Application of Large-sized Lamp This technology can be applied to thin high resolution displays (LCD and BLU for 3D TVs) or environmentally-friendly light sources (for industry, exhibitions, households), for which market share will be won 1 Tr for displays in 2012 and84 bil. for light sources. Piezoelectric Devices Laser Scanner Driven by Piezoelectric Device Scanning area: 30 x 30 mm (XY) and resolution: < 0.01 mm Combination of piezoelectric-driven scanning module, controlling hard- Ware, and software. Low Turn-on voltage (1.5V/um) High Emission Current Density High Current Stability Long Life Time of CNT Emitter Scanning System Applicable to piezoelectric actuator-based high precision positioning systems, optical systems, semiconductor inspection systems, laser marking machines, and more - Manufacturing method for electron emitters containing carbon nanotubes and binders and the carbon nanotube electron emitters manufactured thereby - Manufacturing method for carbon nanotube electron emitters for low voltage operations and the carbon nanotube electron emitters manufactured thereby Low activation voltage of 0.5V/μm High emission current density High current stability Long life CNT emitter Uniform large area surface emission Large lamps Marking by Laser Beaming Name: Lea-free piezoelectric ceramic compositions for sensors and actuators