Toray Industries, a multinational corporation specializing in advanced materials and chemicals, announced the successful development of the world’s first mass-production technology for rare-earth-free zirconia balls.
These highly durable balls have the ability to grind and mill ceramic materials for multilayer ceramic capacitors (MLCCs) and electrode materials for lithium-ion batteries. The technology breakthrough will enhance the reliability of diverse products and stabilize their supplies while reducing manufacturing costs by replacing balls less frequently.
Replacing Conventional Zirconia Balls
The prime application of zirconia balls is to disperse and powderize materials and polish surfaces. Toray Industries has developed Torayceram™ high-performance ceramics, used in ceramic materials for MLCCs and electrode materials for lithium-ion batteries. The use of zirconia balls as electrode materials for lithium-ion batteries in electric vehicles and other applications should grow in demand in the coming years. Therefore, cutting costs and developing more durable zirconia balls have become critical challenges in the industry.
Improved Durability and Reduced Emissions
Toray Industries’ technology enables the production of zirconia balls with a minimized degradation of crystal structures on their surfaces. The company has redesigned part of the structure of these balls, making them much more durable than their conventional counterparts. This minimizes contamination from zirconia balls in grinding and milling ceramic materials for MLCCs and electrode materials for lithium-ion batteries, improving and stabilizing the quality of target substances. The redesigned structure also enables sintering at 1,300°C or less, compared with 1,500°C for regular processes, leading to lower carbon dioxide emissions.
Eliminating Concerns on Country of Origin Tracing
Another key benefit of Toray’s technology is that it eliminates yttria, a rare earth metal oxide that is a common stabilizer in zirconia balls. This eliminates concerns about the country of origin tracing, adding to the technological advancement’s appeal.
Sustainability and Recycling
Toray Industries is taking advantage of the high durability of its technology by exploring ways to regrind the surfaces of zirconia balls and recycle them. The company is set to collaborate with customers in evaluating a recycling system to help reach Sustainable Development Goals.