Development of New Materials "RB Ceramics" from Rice Bran Toward Production of New Industry Based on Collaborated Research Projects

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1 Development of New Materials "" from Rice Bran Toward Production of New Industry Based on Collaborated Research Projects Professor Kazuo HOKKIRIGAWA Machine Intelligence and Systems Engineering, Graduate School of Engineering, Tohoku University The author has been doing research works on development of new hard porous materials "" from defatted rice bran. As new tribo-materials, show several advantages such as low friction, high wear resistance, etc. In this paper, development of and their application for a linear dry sliding bearing and high grip shoe sole are explained. Key Words: tribo-material,, hard porous carbon, dry sliding bearing, high grip shoe sole 1. Introduction Hokkirigawa laboratory at the School of Engineering of Tohoku University, is working on the development of RB ceramics- new hard and porous carbon materials made from defatted rice bran, and research works on their various applications. "RB" stands for the acronym of rice bran. are environmentally friendly, multifunctional, and high performance materials that have many features as new tribo-materials. With the collaborations from academic, business, and governmental circles, Hokkirigawa laboratory is striving for R&D on this new material in order to achieve the interim goal of the practical application of into various products by utilizing their features. So the final goal is the creation of new industries around Tohoku district. Some of these R&D efforts resulted in recent commercial achievements of a dry-type linear sliding bearing and slip-resistant footwear. In this report, the outline of the development of is described. 2. Significance of R&D through the Collaboration among Academic, Business, and Governmental Circles When Japanese people look back at the history of industrial structure in Japan that has continued for about 55 years after the World War 2, many of them would agree that an industry that acted as an engine and backbone for that period was the manufacturing industry, especially so called "basic industry". Figure 1 shows that the leadership position of the basic industry has been replaced by one industry to another, such as textile, steel-making, shipbuilding, automobile, and electronics industries. Now the leadership position is being taken by information technology industry (IT industry). In light of the current actual status of Japanese economy, however, the bursting growth of Japanese IT industry is coming to an end. The phrase "basic industry" literally means the backbone that supports the entire Japanese economy and can be figuratively expressed as a thick trunk of a tree. During the post-war period, such a role as a trunk was mainly played by small-to-medium-sized businesses (SMBs) that actually performed the manufacturing works outsourced from big. The industrial structure during that period had a bilateral character. When looking from outside, this trunk seemed to be composed of big. But the inside of this trunk had a dense structure composed of specialized middle-sized and many SMBs. However, such a conventional Japanese industrial structure is increasingly decaying due to fact that more and more manufacturing works are shifting to Southeast Asian countries, resulting in a current situation where de-industrialization is accelerated. Conventional economic-growth model in which Japan has made continual success of economic development is a batonpassing structure. In this structure a declining basic industry passes its baton to another one that has a power to support. Japan is now desperately struggling to find an answer to the question: "What is the next basic industry that can receive the baton from the IT industry?" The author has an answer to this question. The basic industries that have supported Japan in the late 20th century will be replaced by many mini-industries. When a new promising company appears, some other will be established in order to support the new company to form a small company group. This small company group will grow into a mini-industry. As time passes, many mini-industries will appear, providing as a whole a financial power as well as a power to create new employment, equal to those achieved by 2 KOYO Engineering Journal English Edition No.161E (2002)

qchange into venture Splitting into separate Restructuring/ bankruptcy Expansion Venture industries The 21st century Information technologies Electronics Automobile Shipbuilding Steel making Textiles

Bankruptcy/ business closing The 20th century: an age in which basic industries have emerged, grown, and matured The 21st century: an age in which various venture industries will emerge.

2 qchange into venture Splitting into separate Restructuring/ bankruptcy Expansion Venture industries The 21st century Information technologies Electronics Automobile Shipbuilding Steel making Textiles Big Basic industries Small-to-medium-sized wchange into venture company structure De-industrialization eestablishment of business Revitalization maintained through regeneration of businesses Bankruptcy/ business closing The 20th century: an age in which basic industries have emerged, grown, and matured The 21st century: an age in which various venture industries will emerge. qexpansion of big in basic industries / Separate / Venture wde-industrialization of small-to-medium subcontract / Structure change of some medium / Venture eemergence of new venture businesses / A poor environment to foster such venture businesses in Japan R&D and sales powers are indispensable for sustaining and developing venture businesses. Collaboration among academic, business, and governmental circles is needed. A system for reinforcing sales power needs to be structured. Fig. 1 Japanese industry conventional basic industries. In the 21st century, more and more mini-industries will be created out of venture businesses to be a leader that guides Japanese economy. Conversely, Japanese economy will rapidly decline unless efforts are made to create such venture industries as many as possible. In order to provide jobs, creating new industries is the most urgent task for Japan. One of the ways to achieve this task is through R&D projects and through the collaboration among academic, business, and governmental circles as shown in Fig. 2, regardless of the size of the business. industry structure science and technology (engineering) universities Significance of R&D through collaboration among academic, business, and governmental circles <The 20th century> An age in which basic industries have grown and matured local Textiles Steel making Shipbuilding Automobile Academic and research base supporting basic industries Production base supporting basic industries Subcontracted workoriented small-tomedium-sized <The 21st century> An age in which venture industries will emerge Electronics Information technologies Venture industries Academic and research base capable of creating venture industries Development base for creating new fields Development-oriented small-to-medium-sized Creation of various venture industries Governmental circle Collaboration among academic, business, and governmental circles Academic Business circle circle Fostering of developmentoriented local Fig. 2 Collaboration among university, company and government KOYO Engineering Journal English Edition No.161E (2002) 3. Background of This Research and Development Modern material science has improved through segmenting its related specific fields, with a request from the industrial field for a material that provides higher performance and function. However, this conventional technical trend is changing due to emerging needs for an environmentallyfriendly material, such as eco-friendly and recyclable materials. In other words, those engaged in the material science field is now urged to find a new way to develop a completely new material. By combining different specific fields and modifying a conventional R&D framework into a new framework, it can satisfy such environment-related needs. This change is a major change from conventional material development that involves mass consumption of oil resources, difficulty in recycling, and a large amount of industry wastes into an eco-friendly material development. This change also means that the conventional material development approach that has used its expertise for pursuing a specific function is not enough for keeping up with this technical trend in the 21st century. Annual production amount of rice in the world is said to be about 500 million tons. When rice is threshed, a large amount of rice husks and rice bran is produced as byproducts. It is estimated that about 33 million tons of rice bran is produced from this 500 million tons of rice. Japan annually produces about 10 or more million tons of rice and about 0.9 million 3

tons of rice bran, as shown in Fig. 3. On the other hand, Japan annually produces 100 million tons of steel that is a main material for industrial products.

Since Japan is a country having poor resources, rice bran can be recognized as an extremely abundant plant-derived resource. Rice bran contains about 20wt% of fat. In Japan, about 0.

3 tons of rice bran, as shown in Fig. 3. On the other hand, Japan annually produces 100 million tons of steel that is a main material for industrial products. In other words, in terms of weight, Japan's annual production amount of rice bran accounts for 1% of that of steel but accounts for as much as 15% in terms of volume. Since Japan is a country having poor resources, rice bran can be recognized as an extremely abundant plant-derived resource. Rice bran contains about 20wt% of fat. In Japan, about 0.4 million tons of rice bran is now used for manufacturing rice bran oil or wax, and for making fodder, culture medium for fungus, and pickled vegetables. In Japan, defatted rice bran, a byproduct gained from rice oil pressing, is produced in an amount of about 0.3 million tons. Since defatted rice bran is currently used only for agriculture as a fodder and fertilizer, new and effective utilization of the defatted rice bran is strongly desired. Background of development of Other countries Japan (12.79 million tons) Myanmar Thai China Vietnam Bangladesh India Indonesia Rice production amount of each rice-producing country Japan annually produces more than 10 million tons of rice. materials made mainly from defatted rice bran. As shown in Fig. 4, is a new hard and porous carbon materials that are manufactured by molding the mixture of defatted rice bran and phenolic resin and carbonizing and burning it in nitrogen gas at a temperature between 300;~1100;. are mainly composed of soft amorphous carbon and hard glassy carbon that reinforces the periphery of the amorphous carbon. In carbonization and burning of, a large amount of gas is produced. If some of the gas remains in, it may cause a large crack in the. To avoid this, Hokkirigawa laboratory appropriately provided high-precision control for the grain size of defatted rice bran, impregnate ratio of phenolic resin, molding conditions, burning temperature program and other conditions. By this way, we have reduced the crack occurrence, and succeeded in producing that have high strength, high hardness, and stable quality. Rice bran Manufacturing methods of Defatted rice bran Rice bran oil and other products For human consumption Japan annually has 0.9 million tons of rice bran. Part of the rice bran is used for production of rice bran oil and wax. About 0.3 million tons of defatted rice bran remains unused. Dry-formed rice bran Phenolic resin Formed rice bran It is strongly desired to find the effective use of the defatted rice bran, which is a byproduct of rice threshing and a reproducible plant-derived resource that is annually available. Fig. 3 Background of development of Carbonizing and burning in nitrogen gas < Characteristics > High hardness High strength Low friction Low wear Porous structure Low density Utilization of defatted rice bran, as a new industrial material, can pave a new way to an effective use of plantderived high-tech eco-material that is totally different from conventional industrial material and superior in environmental friendliness. With the above background, this research and development was started with the objective of utilizing rice bran as a new industrial material. 4. Development of Hard and Porous Carbon Material "" Made from Rice Bran In April 1996, with the collaboration of a rice oil maker in Yamagata pref. in Japan, Hokkirigawa laboratory has succeeded in producing "", porous carbon Fig. 4 Making process of Hokkirigawa laboratory have verified that has preferable performances in hardness, strength, friction, wear and other characteristics to file a patent application to Japanese Patent Office in October This was published in a newspaper in November 1996, which resulted in immediate inquiries about from more than 60. With such abundant needs, Hokkirigawa laboratory started R&D on the application of by providing sample products to the inquiring. Then a Japanese rice oil maker has provided a new plant with an intention to expand its -related businesses. 4 KOYO Engineering Journal English Edition No.161E (2002)

5. Establishment of R&D System through the Collaboration among Academic, Business, and Governmental Circles Yamagata prefecture is one of the regions that is specified as a member region of "Regional

4 5. Establishment of R&D System through the Collaboration among Academic, Business, and Governmental Circles Yamagata prefecture is one of the regions that is specified as a member region of "Regional Science Promoter" project operated by Science and Technology Agency (now Ministry of Education, Culture, Sports, Science and Technology). As a member of this project, Yamagata pref. established "Joint Research Committee for Utilization of Unused Resources" in February 1997, using Yamagata Technopolis (now Yamagata Public Corporation for the Development of Industry) as a base. This led to R&D system involving in academic, business, and governmental circles as shown in Fig. 5. The committee has a basic concept of "techno-marriage", which means that marriage between one field of academic and governmental circles and another field of agricultural and industrial circles. With this "techno-marriage", it becomes possible to create a new industry field that is necessary for the mature society in which nature and humanity can harmoniously coexist. Business circle Agriculture circle Governmental circle Administrative agencies Public research institutions Academic circle Universities and technical colleges Business circle Industrial circle In the 21st century new industries creation for forming a matured society in which nature and humanity can harmoniously coexist. Fig. 5 Production of new industry based on marriage between agriculture and industry, and based on collaboration among university, company and government As described above, the development of is promoted through the close liaison between an industrial circle, including agriculture and industry, and academic and governmental circles. Such a liaison is very effective for creating a new industrial structure through the fostering of venture businesses because such a creation cannot be achieved by a single entity under current tough economic situation suffering from the aftermath of the bubble burst. Additionally, such a liaison will subsequently provide new academic and industrial fields. 6. Characteristics of have the following main characteristics: a High hardness (Average Vickers hardness is 4 ~ 6 GPa, the similar value as that of hardened steel) s High strength (Compressive strength is 70 ~ 80 MPa) d Fewer dispersion of strength f Small density (extremely light weight 1.3g/cm 3 or less) g Porous structure (It is possible to produce that have a diameter of 200mm or more and a thickness of 20mm or more without a crack occurrence due to gas generation) h Easy molding and processing before burning process j Low friction (friction coefficient under dry and water lubrication conditions is very low, ) k Having "positive speed independency" with a friction coefficient that slightly increases relative to sliding velocity, thus providing an effect to reduce stick-slip and friction noise l Excellent wear resistance (e.g., having times higher wear resistance as compared to that of steel under dry conditions) 0 Excellent anti-corrosiveness 1 Capability to absorb electromagnetic waves 2 Capability to be controlled in electrical resistance (Capable of changing electrical resistance, by controlling the burning temperature, thus being able to change the electrical resistance in a wide range from that of insulator to that of conductor) 3 Abundant in raw materials (i.e., 0.9 million tons of rice bran is annually produced in Japan as a byproduct of rice threshing and these rice brans can be used as a raw material for and can ensure stable domestic supply) 4 Extremely ecologically friendly ( enable the effective utilization of plant-derived resources annually provided by agriculture activities and disposal of RB ceramics after being used has no harmful influence on the environment) 7. R&D of Dry Linear Sliding Bearing Using RB Ceramics First in the World In 1998, Hokkirigawa laboratory and a mechanical component maker in Yamagata pref. have succeeded in the joint development of a linear sliding bearing as shown in Fig. 6. This bearing was the world's first dry-type linear sliding bearing made from that has proved excellent performance such as oil-free and low noise, etc. After that, we have developed a low-noise uniaxial robot, using this bearing. This robot development was performed as one of the development projects specified by "Creative Research Results Fostering Project 1997" run by The Japan Science and Technology Corporation and "Regional Science Promoter Program 1997" organized by Yamagata Technopolis Foundation. This robot was introduced through TV, radio, and newspaper and we got more than 600 inquiries from various. KOYO Engineering Journal English Edition No.161E (2002) 5

Dry linear sliding bearing using Slider: Guide rail: Stainless steel Oil-free Noise-free Maintenance-free < Features > Low friction and low wear Capable of being driven at high speed Fig.

Accordingly, can be used for composite materials with various materials which enables second-step material development and wider applications.

This shoe sole is tentatively called "AQUAGRIPPER" and has improved slip-resistance when used on wet road surfaces and icy roads, providing friction coefficient to wet surface that is 2 to 5 times

5 Dry linear sliding bearing using Slider: Guide rail: Stainless steel Oil-free Noise-free Maintenance-free < Features > Low friction and low wear Capable of being driven at high speed Fig. 6 Linear dry sliding bearing by using 8. Materials Using Powder As shown in Fig. 7, also can be used in form. Accordingly, can be used for composite materials with various materials which enables second-step material development and wider applications. Hokkirigawa laboratory and three shoe makers have jointly developed a new slip-resistant shoe sole material, in which RB ceramics particles are included in rubber or other materials. This shoe sole is tentatively called "AQUAGRIPPER" and has improved slip-resistance when used on wet road surfaces and icy roads, providing friction coefficient to wet surface that is 2 to 5 times higher than those of conventional shoe sole materials. (Fig. 8) "AQUAGRIPPER", a new shoe sole material that contains RB ceramic s ("AQUAGRIPPER" is a tentative name.) RB ceramic Base material for shoe sole Hard : capable of penetrating into ice surface of 70 to 0: and being compounded with rubbers and other materials without damaging forming rolls. : water absorbing property, high adhesion strength with rubbers, etc., uniform distribution when molding because of low density like rubber. Porous structure Low Young's : being used for walking on normal dry road surfaces. modulus High strength and anti-wear property : good durability Contact between wet surface and shoe sole Conventional shoe sole Water film formation / low friction Slippery due to water film formation and low friction Shoe sole containing Water absorbing property of RB ceramics Micro-spike effect provided by RB ceramic s a Micro-spike effect in which RB ceramic s are penetrating into the surface provides high friction, resulting in a nonskid surface. s ' water film absorption effect provides high friction, resulting in a nonskid surface. Fig. 8 Anti-slip shoe sole by using A patent application regarding the AQUAGRIPPER was filed in August Men's slip-resistant shoes using this material have been sold from January And preparation for the sales of safety slip-resistant shoes is now underway. Manufacturing methods of and their applications Defatted rice bran phenolic resin Powder form Carbonizing and burning Carbonizing and burning Dry linear sliding bearing using RB ceramics phenolic resin materials RB ceramics metal Ceramics other materials Again carbonizing and burning Sintering materials of RB ceramics and phenolic resin materials of RB ceramics and metal materials of RB ceramics and other materials A wide range of applications (Complex shapes possible) Bearing, brake, clutch, seal, etc Fig. 7 Several making processes of 6 KOYO Engineering Journal English Edition No.161E (2002)

Current status of the development and utilization of toward the creation of new industries The Japan Science and Technology Corporation Rice oil makers Formed RB Ceramics material of and other

6 Current status of the development and utilization of toward the creation of new industries The Japan Science and Technology Corporation Rice oil makers Formed RB Ceramics material of and other materials Tohoku University Hokkirigawa research laboratory R&D Research cooperation Joint research Machining Joint research Ministry of Economy, Trade and Industry Mechanical component Machinery Mechanical component Industrial machinery Safety shoes Ministry of Education, Culture, Sports, Science and Technology Shoe sole Men's shoe Yamagata University Yamagata Public Corporation for the Development of Industry Automotiverelated Dry-type linear sliding bearing Sliding Sliding Automobilerelated Sliding Slip-resistant safety shoes Slip-resistant men's shoe Mechanical component Completion of development and start of sales Under developing Industrial machinery Under developing Under developing Completion of development and preparation for sales Completion of development and start of sales Fig. 9 Present situation of research projects on Preparation for the sales is on the way Completion of development and planned to be sold worldwide Business circle Academic circle Governmental circle 9. Future Prospect of Toward the Creation of New Industries As shown in Fig. 9, various R&D on the application of RB ceramics and the composite materials with are being worked on. In July 1999, Yamagata Technopolis Foundation has held a forum for new technologies named "Development Status of Hard and Porous Carbon Material [] Toward Creation of New Industries through Marriage between Agriculture and Industry" that attracted more than 100 Yamagata-based, serving as an additional inspiration to related parties who are striving for the creation of new industries. It can be said that Japan has an ideal environment for the industrial use of defatted rice bran because it has both high industrial technologies and the world's top level rice-oil manufacturing technique. As of now, has been reported more than 50 times by TV, newspapers, and magazines, resulted in increased inquiries with regard to new applications and developments. Since is a new material made from environmentally-friendly raw material and manufacturing methods, it has a lot of good reasons to be used in many applications in the time in which environmental suitability of a product is more valued. 10. Conclusion made from rice bran can be said to be a unique eco-material that can be invented only by rice-eating countries like Japan. Such a material will pave the way for the agriculture field to supply a new material to the industry field and give the agriculture field a new role of supplying industrial materials in addition to its conventional role of food supply. With the collaboration and knowledge from various fields, the author plans to clarify preferable manufacturing conditions for depending on the application and further promote R&D for their practical uses. KOYO Engineering Journal English Edition No.161E (2002) 7

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