Technologies of SHOWA DENKO Group
Corporate R&D Department Showa Denko K.K.
Ver. 2018 Main Businesses of SHOWA DENKO
Petro- chemicals 26％ Lithium-ion battery(LIB) materials Olefins(ethylene and propylene) and organic chemicals(ethyl acetate), etc.
Others 2016 Chemicals 19％ 20％ Consolidated net sales
671.1 billion Electronic chemicals(specialty JPY gases), functional chemicals, Aluminum Electronics industrial gases, and basic Rolled products (high-purity foils), chemicals, etc. casted components, 14％ 14％ and beverage cans, etc. Inorganics 7%
Hard disks (HDs) and Rare Graphite electrodes, and ceramics earth magnetic alloys, etc. (alumina, titania and abrasives), etc. 2 Inventory/Summary of Technologies Strength ＝ Diversified Range of Core Technologies
Advanced Petro- Chemicals Inorganics Aluminum Electronics Battery chemicals Segment Materials otnosycs Rods Continuously-cast Anode Material for Lithium for Material Anode High–purity Gases for High-brightness LEDs Functional Monomers LIB Packing Materials Ion Secondary Batteries Secondary Ion Molding Compounds Rare Earth Magnetic Resins for Electronic Functional Cosmetic Graphite Electrodes Carbon Coated Foil i ptxa Wafer Epitaxial SiC Organic Chemicals Transparent Film Heat Exchangers Aluminum Oxide Hard Disks (HD) Aluminum Cans Titanium Oxide HPLC Columns Aluminum Foil Heat-resistant Raw Materials Boron Nitride High-purity Electronics Elastomer
● Core Technologies Materials ○ Application Technologies Alloys
Technology Classification Core Technologies
High-performance Catalysts ●○ Specialty Gas Chemicals ●○○● Molecular Structure ○● ●●●● ● ○ ● Material Functional Resins ●●● ○○ Design Metallic Materials ●●●●●●● ○○ Inorganic Materials ○●●● Carbon Structure ●●● Polymerization Control ○●●●
Synthetic Purification ○○○○○○○○●● ○○ Process Micro-particulation ○○○ ○ Film/Crystal Growth ●● ● Element Manufacturing ○○ High-heat Processing ●●●●●●●● ● ●● Mixing/Dispersion ●○ ○ ○ ○○ Manufactu- Casting/Molding ○ ●○ ●●●●● ring Process Surface Treatment ○○ ○ ○ ○ ● ○ Interface Bonding ○ Heating/Cooling Control ○○ ○○○ ○ ● ○○ Laminate/Printing ○●● Fundamental Technology & Computational Science and Technology Information Center, Business Assistance Analysis & Physical Properties Center, Safety Evaluation Center 3 Index
Segment Product/Technology Page Segment Product/Technology Page Petro- Organic chemicals 6 High-purity Aluminum Foil 34 chemicals Heat-resistant Transparent Film 7 Heat Exchangers 35 High-purity gases/solvents for 9 Automotive Cooling Devices 36 electronics Aluminum plate with High Heat 37 Aluminum Fluorine Chemicals 10 Conduction and High Strength Chemicals-1 High Corrosion Resistant Plating 11 Large-sized Extrusions 38
Supercritical Carbon Dioxide (CO2) 12 Continuously-cast Rods 39 Aluminum Cans 40 Functional Monomers 14 Hard Discs (HD) 42 Versatile Isocyanate Monomer 15 Electronics High Brightness LED 43 Water-soluble Monomers, Polymers 16 Chemicals-2 Rare Earth Magnetic Alloys 44 HPLC Columns 17 Anode Material for Lithium Ion 46 Advanced Secondary Batteries Functional Cosmetic Raw Materials 18 Battery Carbon Coated Foil 47 Materials Resins for Electronic Materials 20 LIB Packing Materials 48 Synthetic Resin Emulsion 21 SiC Epitaxial Wafer 50 Projects Chemicals-3 Resins for Composite Materials 22 Plant Growth Facilities 51 Molding Compounds 23 Strategic Carbon Material 53 Solder Mask for Flexible Board 24 Technologies Catalyst 54 Abrasives 26 Printed Electronics 56 R&D Glass Polishing Material 27 Redox Flow Battery (RFB) 57 Inorganics-1 Cubic Boron Nitride 28 Computational Science and 59 Fundamental Information Center Thermal Conductive Fillers 29 Technology & Analysis & Physical Properties 60 Titanium Oxide 30 Business Center Assistance Inorganics-2 Graphite Electrodes 32 Safety Evaluation Center 61 4 Petrochemicals
技術 Material Design Technologies Common Technologies: Center 技術 Synthetic Process Technologies Peculiar Technologies: Next to the Products 技術 Manufacturing Process Technologies
High- performance Surface Catalysts Treatment
Purification Polymerization Control Basic Petrochemicals Molecular Olefin Structure Derivatives Design
Molding/ Casting Heat-resistant Organic Chemicals Transparent Film Ethyl Acetate SHORAYAL™ Allyl Alcohol Derivatives 5 Organic Chemicals
Example products Our technologies Ethyl acetate We own the following technologies: ⇒ Printing ink, paint, thinner, adhesive Catalyst design Vinyl acetate Catalyst analysis ⇒ Raw materials for PVA, EVA, paint n-propyl acetate Catalyst performance evaluation ⇒ Printing ink, paint, thinner Using the catalysts we have developed, we are Allyl alcohol promoting the acetyl chain business at the Oita ⇒Raw materials for ophthalmic lenses, complex. perfume material, intermediate of medicine, epoxy resin, PBT
Acetaldehyde
Ethylene Ethyl acetate
Acetic acid Vinyl acetate Propylene Allyl acetate
Allyl alcohol n-propyl acetate Ethyl acetate plant 6 Heat-resistant Transparent Film 〜 SHORAYAL™ 〜 Example products Our technologies Taking advantage of its high transparency Molecular/catalyst design technologies combined and heat resistance, the film is expected with polymerization/molding/surface treatment to be applied to display-related technologies enable the manufacture of functional components. films superior in transparency and heat resistance.
Example of application to ■ Molecular design ■ Molding control protective film technology + Roll-to-roll film formation “SHORAYAL-GUARD™” + Property control
■ High-performance ■ Surface treatment technology catalyst technology +Functionalities added +Polymerization (Hardness, tactile impression, control optical characteristics)
SHORAYAL™
7 Chemicals-1 〜Gas Products〜
High-purity Gases/Solvents for Fluorine Electronics Chemicals SOLFINETM Gases for Electronics
Purification
Electrolysis Surface Electrolysis Treatment Chlorine High Corrosion Hydrogen Specialty Resistant Plating Gas Clean-STM Industrial Chemicals Gases Plastic Recycling Inorganic ECOANNTM Materials Design High- Temperature Heat Treatment
Mixing/ Supercritical Dispersion Abatement System Carbon Dioxide for Specialty gases SHOWA DENKO GAS PRODUCTS CO.,, LTD. 8 High–purity gases/chemicals for electronics 〜 for semiconductors 〜 Example products Our technologies
High-purity gases / chemicals are used in the Using purification technologies of “distillation, electronic industry for semiconductor extraction, and filtration,” high-purity gases for manufacturing processes and FPD production semiconductors are manufactured. processes. To ensure the quality of the products, we own technologies including the following: Technology to treat and clean the inside of containers Sensitive analysis technology (LC, GC, ICP-MS) Plant construction and mass production technology
Plant to fill high-purity Sensitive analysis solvents instrument(ICP-MS)
9 Fluorine Chemicals
Example products Our technologies Fluorine compounds are decomposed in Fluorine is an atom that can easily combine with plasma and react with materials such as any element. Utilizing such characteristics of silicon to form vapor materials. fluorine, our fluorine technologies are applied to various products. Taking advantage of such characteristics, fluorine chemicals are used for dry etching We own technologies including the following: in semiconductor manufacturing process Fluorine synthesis technology (2HF → F2 +H2) and dry cleaning of the chambers. Fluorine compound synthesis technology (gas phase) Fluorine compound synthesis technology (liquid phase) Sensitive analysis technologies (LC, GC, ICP-MS) Plant construction and mass production technology
Plasma Fluorine compounds
Semiconductor/FPD manufacturing instrument Plant for synthesizing fluorine compounds 10 High Corrosion Resistant Plating 〜Clean-S™〜 Example products Our technologies ■ Surface treatment technology We undertake the treatment of metal surfaces We own the technology to improve corrosion to prevent corrosion, such as cylinders, pipes, resistance performance by forming nickel and valves. alloy films on SUS and aluminum using an electroless plating process. Such treatment is used for various applications, such as semiconductor manufacturing We have also developed our own passive equipment components, vacuum pumps state treatment technology to form NiF2 films (molecular pumps, dry pumps), and plastic through the reaction of fluorine gas, thus injection molding machines. achieving high corrosion and abrasion resistance. H type
Ni-P NiF2 film Metallic material Metallic material
(Ni-P nonelectrolytic plating) AF type F2 NiF2 Metallic material Ni-P Metallic material Metallic material 11 Supercritical Carbon Dioxide (CO2)
Product Example SHOWA DENKO GAS PRODUCTS CO., LTD.
The use of supercritical CO2 enables Our technologies processes that conventionally needed Supercritical CO2 application technology organic solvents as well as processes not possible with organic solvents. Features of supercritical CO2
(1) Dissolves organic substances well. (2) Can be dissolved well in resins to reduce their viscosity. (3) Can be discharged as a gas when the pressure is Supercritical CO2 painting system reduced to atmospheric pressure.
Raising temperature/pressure
Applications of supercritical CO2 (1) Cleaning/drying: Precision removal of even infinitesimal amounts of ingredients (2) Dyeing/impregnation: Transferring effective ingredients to nano-sized spaces (3) Painting: Alternative to a dilution solvent
Supercritical painting device (Painting pump unit, CO2 unit) (4) Creating a fine powder: Using the bubbling and cooling effects when sprayed (5) Macromolecular polymerization: Reaction field with no residual solvent 12 Chemicals-2 〜Functional Products〜
Functional Monomers Karenz™ AOI-VM™ Surface Treatment HPLC Columns Molecular Shodex™ Structure CIM™ Design Autoprep™
Functional Cosmetic Raw Materials Apprecier™ Purification
Polymerization Control Water-soluble Polymers VISCOMATE ™ PNVA ™ 13 Functional monomers 〜KarenzTM〜 Product examples Our technologies Multifunctional secondary thiol compound ■ Molecular structure design technology Coatings To meet the demand for higher performance, we Improves UV ink design and provide various functional monomers. coating Resist ink performance Improving adhesion Improving curing reaction performance Providing polymerization ability Applications: Providing water solubility • Epoxy curing agent (cold & rapid curing, low yellowing, hydrolytic stability) Reducing odor, etc. • UV curing additive (higher sensitivity, less oxygen inhibited polymerization, deep curing, adhesion) • Ene-thiol reaction (high transparency, deeper curing) Molecular design of organic compounds Monomer containing isocyanate groups Useful for • Introducing highly reactive functional groups synthesizing • Providing multifunctionality high performance R=Me Karenz MOITM resin Development of optimal R=H Karenz AOITM For film synthesis process coating materials Applications: • Minimal step synthesis (1) Synthesizing polymers with NCO pendant (2) Introducing unsaturated groups • Knowhow to select a reaction catalyst after reacting unsaturated groups after reacting NCO Establishment of industrial process
Crosslinking agent • Protecting reactive functional groups (Example) • High purification Thermosetting resin Radically curable resin • Control of water amount 14 Versatile isocyanate monomer 〜AOI-VMTM〜
Product example Our technologies Automotive coating (OEM coatings, refinishing, interiors), ■ Production technology construction, painting/coating for electronics, adhesive, etc. Based on the production technology for Karenz, mass production technology for AOI-VMTM using a AOI-VMTM continuous plant reduces the price.
■ Application: thermosetting resin composites Broader customer applications Applicable to versatile paints and coatings, Copolymer using AOI-VM Poriol Add functionality ◆ which require low cost
60°C or higher
Low-temperature thermo curing Providing value Automotive coatings Electronics Adhesives
◆ The only compound (group) that can synthesize polymers with aliphatic NCO pendant
◆ Adding functionalities such as low-temperature rapid curing
◆ Providing a new development approach 15 Water-soluble monomers, polymers 〜NVA, PNVATM〜
Product examples Our technologies
NVA (N-Vinyl acetamide) ■ NVA NVA is an amphiphilic, nonionic, water-soluble O Raw material of water- monomer produced commercially by our unique soluble polymers technology. N Hydrophilization of ◆ Characteristics as a solubilizer H hydrophobic polymers ◆ Nonionic Material of UV curing ◆ Water-soluble, solvent affinity composites 3D structure of PNVATM (red spheres: O atoms) ■ PNVATM PNVATM (Poly-N-Vinyl acetamide) PNVATM is a water-soluble polymer produced Thickening agent commercially from NVA by our unique technology. CH2 CH Dispersant ◆ Stable thickening over a wide range of pH Gelatinizer ◆ Thickening of polar organic solvents Binder NHCCH3 ◆ Thickening of high salt concentration solutions Coating agent ◆ Resistant to acids and alkalis O Adhesive, pressure- Viscous and adhesive sensitive adhesive ◆ Applications: ◆ Resistant to heat, UV ●CMP ●Conductive paste ◆ Nonionic ●Water-based ink, paint ●Emulsion thickening ●Capacitor, secondary battery ●Binder for sintering ceramics ●Dispersant for CF, resin kneading ●Inkjet ink absorbing layer ●Thickening agent for ●Coating agent for heat exchangers acid/alkaline detergent Hydrogen bonding PNVA 16 HPLC Columns 〜Shodex™〜
Product Example Our technologies
High-performance liquid chromatography (HPLC) Surface modification technology plays an active role in various fields, including Gel synthesis technology Product quality inspection The interaction of each ingredient in the sample Factory process and the gel filled in the column causes separation. inspection, and Environmental analysis. Polymer gel manufacturing technology
Gel size control Analysis of sugar content in apple juice Fine pores size control Fine pores quantity control Sample: Apple juice 5uL Surface hydrophobicity control 1. Sucrose 2. Glucose 3. Fructose 4. Sorbitol Gel synthesis Surface modification Column: Shodex SUGAR Monomer selection Selection SC1011 ・Styrene ・Alkylation Eluent: H2O ・Methacrylate ・Alkoxylation Flow rate: 0.6mL/min ・Vinyl alcohol Gel ・Halogenation Detector: RI ・N-vinyl acetamide ・Sulfonation Column temp.: 85℃ ・Carboxylation ・Amination ・Affinity ligand
17 Functional Cosmetic Raw Materials
Product Example Our technologies The products feature functionality and high quality. ■ From chemical compound design to industrial Both physiological data and prescribing production information can be provided together. We can create high functional derivatives from a parent compound with a highly safe physiological active Cosmetic raw Physiological Prescribing substance. material data information We also own the technology to produce such derivatives on an industrial scale. + Select Parent Derivative compound Functional Physiological cosmetic active substances raw materials Stabilized vitamin C derivative, amphipathic vitamin C derivative, water-soluble vitamin E derivative, amphipathic carnitine Chemical compound design, derivative, etc. Vitamin, organic acid, chemical modification Stabilization, sugar, amino acid water solubilization, improved penetration of skin These materials are contained in various quasi- ■ Physiology evaluation drugs and cosmetics both in Japan and abroad We own the technology to evaluate functional cosmetic and help improve the quality of life of users. raw materials created using biochemical techniques based on dermatology. ■ From properties to prescription We offer a range of services, from product property analysis to prescription examination.
Gene expression Skin model analysis culture Protein analysis 18 Chemicals-3 〜Resin Products〜
Chlorinated Polyethylene Elaslen™
Resins for Electronic Materials Mixing/ Ripoxy™ Dispersion
Functional Resin Resins for Composite Design Materials Unsaturated Molding/ Polyester Resins Casting Rigolac™, Ripoxy™
Polymerization Ccontrol
Synthetic Resin Emulsion Molding ™ Polysol Compounds Rigolac™ Molding Material 19 Resins for Electronic Materials 〜 Ripoxy™ 〜 Product Example Our technologies Binder resin for color filters Polymer design technology Contributing to realizing high-definition LCD. Providing photocuring and thermosetting resins with various characteristics Developability, heat resistance, solvent resistance, flexibility, high refractive index, adhesion, optical transparency, dispersibility, etc.
Polymer design meeting the required Black matrix Black performance Red Green Blue Image of functional group in a polymer molecule Liquid crystal display Enlarged view of a color filter Example of color filter manufacturing process using photocuring reaction. Black matrix
Glass substrate (1)Black matrix formation Required Color resist layer performance
(2)Apply resist ink. Photocuring Development (The figure shows red Heat resistance ink.) Photomask Light (3)Place mask and the part ■ Family of products constituting Ripoxy™ exposed to light and examples of applications irradiation is cured. ・Epoxy acrylate resin (4)Remove the part not Applications: Solder resist, various paints, dicing tape cured for patterning. ・Acrylic resin (5)Repeat steps (2) to (4) for Applications: Color filter resist, semiconductor resist green and blue ink to ・Urethane acrylate resin complete the manufacturing process. Applications: Adhesive for optical use
20 Synthetic Resin Emulsion 〜 Polysol™ 〜 Product Example Our technologies
We optimize the synthetic resin emulsion “Polysol™” to suit various applications.
Polymer design technology Adhesive for tapes (Acrylic, vinyl acetate, ethylene-vinyl acetate) Morphology control technology (Particle diameter, particle shape, heterophase structure) Synthetic resin emulsion
Fiber processing resin Adhesive for building materials
Emulsion design Modification technology Measuring technology
Paint binder for exterior materials
Processing technology 21 Resins for Composite Materials 〜Rigolac™, Ripoxy™〜 Product Example Our technologies Synthesis technology With a focus on unsaturated polyester resin, vinyl ester resin, and urethane-acrylic resin, we own resin synthetic technology meeting such requirements as flexibility, hardness, high strength, and high heat resistance. We can also develop new resin systems. Compounding technology Chemical tank FRP waterproofing While considering the final usage environment and purpose, we can propose usage methods such as compounding additives, including fillers, curing agents, and accelerators, while also drawing up construction specification proposals, for example. Physical property evaluation We can evaluate the basic properties of products and make various measurements while considering the actual usage conditions. Technical guidance Resin concrete Pipe lining To prevent troubles when the products are used, we can attend and provide technical guidance as required when the products are used. If any trouble arises, we will study countermeasures.
Improve
Technical Evaluate Floor material Heat-proof paint Develop guidance
22 Molding Compounds 〜Rigolac™ molding compounds〜 Product Example Our technologies Formulation technology We provide optimally formulated thermosetting molding materials that meet customersʼ requirements.
Body BMC (Bulk Molding Compound)
This is a BMC molded part.
SMC (Sheet Molding Compound) Moldability evaluation technology We own various molding machines and can mold prototypes and will propose molding conditions that optimize the physical Head lamp reflector Motor for HV/EV properties. Injection Compression molding molding Die (Screw-type)
Material
Physical property evaluation technology We can evaluate various physical properties of molded parts in- Breaker Motor for home house, such as mechanical properties, electrical properties, and (Heavy electric parts) appliances chemical resistance. 23 Inorganics-1 〜Ceramics〜
Thermal Conductive Fillers
TM ALUNABEADS CB Mixing/ Titanium Dispersion Oxide
SUPER-TITANIATM Purification
High- Temperature Cubic Boron Nitride Heat Treatment TM SBN Structure Micro- Design particulation
Molding
Surface Treatment Glass Polishing Material
SHOROXTM Abrasives
MORUNDUMTM 24 Abrasives 〜Sinter MORUNDUMTM SR-1〜
Product example Our technologies Crushing and classifying technologies Sinter MorundumTM SR-1 Since our technologies of crushing and classifying A high-purity alumina sintered abrasive grains are highly effective, both body used for heavy polishing pulverization and productivity can be achieved. heavy grinding stones Kneading and extrusion molding technologies We own kneading technology for evenly kneading several kinds of abrasive grains and extrusion molding technology to achieve high yield with specific grain sizes.
High-temperature sintering technology Our high-temperature sintering technology Appearance of abrasive grains Fracture cross-section of abrasive grains developed over the years produces stable and uniform abrasive grains. Heavy grinding is a process for snagging or peeling using grinding stones before the Evaluation technology rolling process in iron manufacturing. We evaluate the bonding Heavy grinding, which is conducted under strength between a resin layer and abrasive grains, the extremely high load, requires high abrasive capacity, and hardness, high strength, and high heat abrasive grain properties. resistance of abrasive grains. Abrasive grains: resin molding 25 Glass Polishing Material 〜SHOROXTM〜 Product example Our technologies
TM SHOROX Crushing, sintering, classifying technologies TM SHOROX is a CeO2 abrasive made from Our crushing, sintering, and classifying technologies we have rare-earth compounds. There are two types of developed over the years allow us to produce CeO2 abrasives product: containing fluorine, or without fluorine. with various levels of hardness and particle size distribution, It is provided as a dry powder or slurry. and to design optimal abrasives for glass polishing.
SHOROXTM is used as an abrasive for polishing various glass substrates, such as liquid crystal displays, hard disks, photomasks, optical lenses, and Polishing evaluation technology crystal, to a mirror-smooth and highly precise finish. Our polishing evaluation technology is used to evaluate the polishing quality of abrasives in accordance with customers’ requirements. We use our experience gained from evaluations for quality improvement, process improvement, and technology development.
Technology development First Polish Final Polish Customers require high quality in terms of polishing speed, scratches, and slurry state. Using our polishing evaluation capability as well as production knowledge and technology we have developed over the years, we rapidly develop excellent products and stabilize their quality in accordance with customers’ requirements. SHOROXTM A polishing surface SHOROXTM V polishing surface
26 Cubic Boron Nitride 〜SBN™ 〜
Product example Our technologies
Taking advantage of its characteristics of high Ultrahigh pressure/temperature technology hardness second only to diamond and no reaction with iron, cBN (cubic Boron Nitride) is used as a We own ultrahigh pressure/temperature sintering material of grinding and cutting tools for iron-based technology exceeding 5 GPa and 1200°C. high hardness materials.
We manufacture sintered compacts from cBN Composite sintered compact production abrasive grains and offer a range of grades for technology grinding and cutting various materials. We own fine particle mixing technology to mix submicron particles together with high dispersion.
™ cBN grains cBN fine powder SBN Sintered compact design/manufacturing technology We not only design and manufacture sintered compacts in accordance with customersʼ demands but also manufacture the worldʼs thickest-class solid cBN sintered compacts.
Sintered compact SBN K-TIP™ Tools
SEM image of cBN sintered compacts Worldʼs largest-class special solid cBN 28 27 Thermal Conductive Fillers 〜Alumina, SHOBN™〜 Product example Our technologies We have a lineup of various heat dissipation fillers. High-temperature heat treatment technology We can manufacture various fillers with the particle shape and size controlled through chemical and physical reaction in various kilns and reacting furnaces capable of high-temperature heat treatment.
1μｍ Grinding/classification technology Low soda alumina (AL) Roundish alumina (AS) The smashing and classification technology we have cultivated over many years allows us to manufacture fillers with various particle sizes and distributions and to design optimal particle sizes.
Spherical alumina Hexagonal boron nitride Compounding/surface treatment technology (ALUNABEADS™ CB) (SHOBN™ UHP) By compounding fillers and using surface treatment technology suited for various resins, we can provide Compounded products with the combination of the above are also under development. fillers with a high filling ratio in the resin.
Evaluation technology In addition to evaluating the physical properties of Mix and mold with resin. fillers, we can also evaluate various thermosetting resin compounds in accordance with customersʼ Application example: Heat- dissipating silicone sheet requirements, such as viscosity and heat conductivity. 28 Titanium Oxide 〜SUPER-TITANIA™ 〜
Product example Our technologies SUPER-TITANIA™ is used as a material of multilayer Fine particle synthesis technology ceramic capacitors (MLCC). ・ Gas phase method: We own the technology to synthesize titanium oxide suitable for MLCC by using equipment we Example of MLCC mounted MLCC have developed. Particle size control technology allows us to manufacture multiple grades.
Functions of MLCC ・ Liquid phase method: We own the technology to ・Stabilizing voltage synthesize titanium oxide in which the crystalline ・Eliminating noise properties and dispersibility of fine particles can be better ・Retrieving necessary signals controlled than by the gas phase method. etc. Cross section Fine particle facilities technology
Dielectric layer (BaTiO3) We own the facilities and quality control technology that enables stable production of high-purity fine particles based External electrode on almost 30 years of developing gas phase technology.
Fine particle evaluation technology Internal electrode We own the technology to evaluate and analyze fine particles from various perspectives to meet customersʼ requirements. The results are used to improve quality and processes and to develop technologies. TiO2+BaCO3 → BaTiO3 The following are required for titanium oxide Technology evolution as a material of MLCC: Taking advantage of our wealth of experience with fine ・Fine particles with uniform particle diameter particle synthesis technologies using gas phase and liquid ・High purity phase methods, we are constantly developing technologies ・Excellent dispersibility to synthesize characteristic fine particles. 29 Inorganics-2 〜Carbon〜
Granular Graphite
Shocaraiser™ Mixing/
Dispersion Granular-M
Graphite Electrodes Carbon Structure Control High- Temperature Heat Treatment
Purification
Molding
30 Graphite Electrodes
Product Example Our technologies Graphite electrodes are conductive members of an electric steel-making furnace, which High-temperature heat treatment technology recycles scrap iron to manufacture steel products. Raw materials are extruded, baked and then heat-treated at high temperature in a graphitizing furnace. Since graphite electrodes are used under high temperature and oxidation atmosphere, they We have the know-how (energization schedule, inter- require low electric resistivity and thermal electrode connection method, protection of the furnace shock resistance. body from high heat, etc.) to control the properties of the final products and heat-treat the materials with good yield. The product is a large-size pillar-shaped graphite material with a maximum diameter of 800 mm and length of 3,000 mm.
Graphitization Furnace
31 Aluminum
Aluminum Can
High-purity Aluminum Foil Showa Aluminum Can Corp.p Extrusion and Drawing Tubes Laminate/ Printing
Casting/ Purification Molding Automotive Cooling Devices Metallic Materials Large-sized High- Extrusions Heating/ Temperature Heat Cooling Heat Treatment Control Exchangers
Mixing/ Skyve heat TM Dispersion sink
Continuously Aluminum plate with high heat Cast Rods conduction and high strength SHOTICTM ST60 32 High-purity Aluminum Foil
Product Example Our technologies
High-purity aluminum foils are used as electrode foils Refining technology of aluminum electrolytic capacitors after surface “Cojunal method” is a refining technology utilizing the enlargement treatment by customers, thus playing an segregated solidification principle, which we were the first essential role for electric and electronic products. in the world to commercialize successfully. Refining ability: 99.9% Al → 99.998% Al
Molten metal treatment technology The “GBF method” is an excellent molten metal treatment technology, whereby inert gas is blown into molten metal as ultrafine bubbles to efficiently remove hydrogen and non-metal inclusions in the molten metal.
Structure control technology In the case of, for example, high-voltage capacitor anode foil, since surface enlargement treatment is applied using cube orientation, cube texture control is needed. Anode aluminum foil Lead wire (Terminal) Aluminum lead Cathode aluminum foil Non-cube Cube orientation orientation area area Electrolytic paper
Etching photo of the non-cube orientation and cube orientation Basic structure of the element areas (Cross section) 33 Heat Exchangers 〜Heat sink・Evaporator〜
Product example Our technologies The use of aluminum for all components minimizes weight. Refrigerator evaporator ・Evaporator for household/industrial We own aluminum rolling/extruding technology. use refrigerator-freezer We can design excellent heat-exchange performance. (Highly heat-conductive oil circuit and cooling fin structure) We own junction technologies, such as welding and brazing. (Strength, airtightness) We use the potential difference of materials to achieve high- corrosion resistance in material design. We can perform integrated manufacturing from heat design and material production to assembly. High-precision heat sink We have the manufacturing ability to ensure no complaints arise ・Heat sink for cooling control panels in the market. of various industrial machines We can design the structure and specifications suitable for the customerʼs usage environment. (Hydrophilic surface treatment, low frost formation structure, etc.)
Wide/light/thin Large size/low cost High design freedom
Skyve heat sink Extruded heat sink Brazed heat sink High heat diffusion performance
Examples of high- precision heat sinks Roll bond panel type heat Heat pipe heat sink pipe container 34 Automotive Cooling Devices
Product Example Our technologies
Vehicle-installed inverter We own the technology of aluminum bulk cooling device brazing of the ceramic insulating substrate and the heat sink. Direct cooling type cold plate We own aluminum forming technology, i.e., extrusion, rolling, forging, and press method.
Down-sizing and space-saving can be achieved thanks to the improved PCU performance. (Power control unit)
IGBT element
We own joining technologies, such as LiB battery Ceramic welding and brazing. insulating substrate Thin panels can save space. Vehicle-installed Either an internal fluid LLC or cooling secondary battery medium can be used. cooling device Water-cooled LLC or air conditioning Cooling device cooling medium
35 Aluminum plate with high heat conduction and high strength 〜ST60〜 Product examples Our technologies Heat sinks for FPD ■ Hardening and aging technologies • Back panels for ST60-HSM® is an aluminum plate with high strength PDP and LCD developed using our hardening, aging, and rolling technologies.
■ Thermal diffusion evaluation technology Our measurement, evaluation, and simulation Heat sinks in electronic devices technologies are used to evaluate thermal diffusivity. • Heat sinks for PCs, car ■ Aluminum rolling technology navigation Our seamless facilities from melting and casting to systems, and rolling processes are used to produce various coils game machines and plates. Manufacturing process for Enclosures for mobile devices ST60-HSMTM • Enclosures for smartphones and Melting, Cold Trimming, Hot rolling Cutting tablet devices casting rolling reforming
Hardening Aging Annealing
36 Large-sized extrusions
Product examples Our technologies ■ Alloy design technology High-precision production of large products Technology to optimize alloy compositions and using a 7,000-ton press, the largest in Japan achieve requirements for various applications
Automobile parts A5083 T bar for ships ■ Die technology (100 × 300 mm) Our abundant design data and advanced design technology allow us to produce various products with complicated cross sections.
■ CAE technology We use our simulation technology for optimizing the settings and conditions of extrusions and die design, in order to produce products with Vehicle structure (width: 570 mm) complicated shapes faster and more precisely.
Fast
Heat sink Tongs ratio: 14
Slow Example of simulated speed distribution of an extrusion 37 Continuously-cast Rods 〜SHOTIC™〜
Product Example Our technologies
Gas-pressurized hot-top continuous Body of high- casting process Valve pressure pump OCV sleeve retainer for direct- for VVT Gas-pressurized completely horizontal injection engine continuous casting process Propeller Engine piston shaft yoke The gas-pressurized completely horizontal continuous casting process has evolved from the gas-pressurized hot-top continuous casting process to produce thinner SHOTIC™ rods with higher productivity. Our technological capability is world-leading.
Comparison Shrinkage Eutectic Eutectic Si materials SHOTIC™ Si cavity Eutectic Si
Car air compressor parts
(Si content = 11%) Pore (Si content = 11%) (Si content = 11%) Intermetallic AHS-2 continuously-cast rod ADC12 die cast compound AC8A casting
Upper arm of the suspension Microscopic structure of Al-eutectic Si alloy
Proved in replacing iron parts with aluminum (Swash plates, suspensions, brake pistons, etc.) Brake caliper & Improving aluminum casting functionality piston (Compressor pistons, engine pistons, etc.)
38 Aluminum can 〜can body, can lid〜
Product examples Our technologies Showa Aluminum Can Corporation Aluminum can body (2-piece can) Our high-speed molding technology for thin • Applications: Beer/low-malt beer, RTD, drinks walls ensures stable quality. (soft, carbonated, retort) • Size: Slim type (202 dia.): 190 mL/250 mL, Main molding technologies: Standard type (211 dia.): 250 mL/350 mL/500 mL Drawing, ironing, trimming, necking, transferring • Lid dia.: Slim: up to 200 dia., Can manufacturing speed: Standard: up to 204 dia./206 dia. Can body: up to 2,000 units/min. Aluminum can lid (stay-on tab) Lid: up to 8,000 pieces/min. Our various printing technologies satisfy • Applications: Beer/low-malt beer, RTD, drinks (soft, carbonated, retort) customers’ requests for precise printing. • Size: 204 dia. for beer, 206 dia for RTD/drinks, Our internal coating technology for food 200 dia. for slim can packaging stabilizes the quality of the contents. Our high-speed transfer technology enables mass production without degradation of appearance. Our high-speed 100% inspection system prevents the outflow of defective products. IoT technology that collects and analyzes production conditions and quality data enables timely and stable production management. Our lid seaming technology contributes to customers’ stable production.
39 Electronics
Surface Molecular Treatment Structure Design Hard Disks (HD) Specialty Gas Mixing/ Chemicals Dispersion Charge-dissipating Agent for Electron Metallic Beam Lithography Materials ESPACER™ Heating/ Film/ Cooling Crystal Control Growth
High-brightness Purification LED IR LED Rare Earth Magnetic Alloys Nd-Fe-B alloy 40 Hard Disks (HD)
Product Example Our technologies The annual number of hard disk drives (HDD) Ultra-thin film formation technology shipped worldwide is about 400 million, and about 900 million HD recording media are required. We produce hard disks by growing epitaxial crystals at the atomic level while forming over ten layers of We lead the world in terms of maximum capacity, ultra-thin films with a total film thickness of no more and have gained a 23% share (200 million units) than 0.1 um at high speed (2000 pcs/hr) with as a specialized manufacturer of HDD recording Angstrom accuracy. media ranging from those for PCs to those for data centers. Ultra-smooth substrate polishing technology The flying height of HDD read/write heads is 10 nm or less and so the presence of foreign particles of this height is not allowed. In addition, ultra-smoothness of Ra ≒ 2Å or less is required for the surface roughness . We produce hard disks using advanced substrate polishing and cleaning technologies.
Company H (in-house) 20% Company S (in-house) Company W About 900 33% (in-house) million units 21% Company F SHOWA DENKO 4% 10 to 15 layers 23% Magnification: x4 M Magnification: x 800 K
Substrate 2016 TSR 41 High-brightness LED 〜Invisible light in various applications〜 Product example Our technologies ■ A broad range of LED chip products, from Wide application area: Infrared LED yellow green to infrared light
Non- Light-emitting Disc Fixed slit Photo transistor Light-emitting transparent Transparent diode ■ The double-junction technology enhances diode Feature 1 resin resin (white (black resin) resin) output, especially of infrared LED chips. High- shaft (8-bit resolution speed /pure binary code) response Photo • High-purity crystal transistor growth technology Frame Structure of an absolute encoder enables various High-speed response photo coupler Encoder wavelengths based on optimal elemental Authentication Band gap [eV] Wavelength [nm] compositions. Feature 2 • Lattice parameters and Harmless band gaps are to the independently human controlled. body Lattice parameter [Å]
Iris authentication Pulse oximeter TEM cross-sectional image Dark-colored layer: Feature 3 150 Å • Film thickness control Light-colored layer: technology of Angstrom Reach 450 Å order Long- distance
Night vision Surveillance camera 42 Rare Earth Magnetic Alloys 〜 Nd-Fe-B sintered magnet 〜 Product example Our technologies
Composition design technology We own technology for designing the composition of Nd- Fe-B sintered magnets. Nd-Fe-B sintered magnet We design the composition of rare earth materials and other metallic constituents to satisfy the magnetic IT devices strength (magnetization intensity/maximum energy product) and heat resistance (coercivity) required by customers.
Heat resistance Mobile phone Hard disk
Automobiles
Motor, dynamo Electric power steering
Others product energy Maximum
MRI Coercivity 43 Advanced Battery Materials
Artificial Graphite Anode Materials Separators SCMG™
High- Temperature Casting/ Heat Molding Treatment
Micro- Mixing/ particulation Dispersion Carbon Coated Foil Carbon SDX™ Structure Control
Laminate/ Printing Vapor-grown Carbon Fiber LIB Packing Film/ Materials VGCF™ Crystal ™ Growth SPALF
Showa Denko Packaging Co., Ltd.
44 Anode Material for Lithium Ion Secondary Batteries 〜SCMG™〜 Product example Our technologies Lithium ion secondary battery negative-electrode Fine particle treatment technology material SCMG™ (Structure Controlled Micro Graphite) For EV, PHEV, HEV, ESS Technology to control the particle size in accordance with BH XR-s various materials Soft carbon AF-C ™ Hard carbon SCMG Heat treatment technology Artificial Mesoscopic graphite graphite Our original technology developed for manufacturing graphite electrodes 100 Primary calcination technology with atmospheric control 80 Natural Secondary calcination technology to control the carbon 60 SCMG™ graphite structure Natural graphite TM
Battery capacityBattery 40
residual ratio (%) ratio residual SCMG 0 100 200 300 Charge/discharge cycles For mobile phones Charge/discharge Charge/discharge cycle characteristics Capacity Before cycles After 300 cycles ™ SCMG
2”φ Natural graphite
Heat treatment facilities Fine particles with carbon We provide a negative-electrode carbon material that suffers structure controlled no degradation by charge-discharge cycles. 45 Carbon Coated Foil 〜SDX™ 〜 Product example Our technologies Current collector for Lithium ion & battery ■ Material design technology electric double-layer capacitor Optimum design of aluminum foil, carbon particle, and binder resin ➢ Current collector with high-conductivity carbon ⇒ Products that integrate metals, inorganics, and organics particles and binder coated on aluminum foil ■ Paint-making technology Optimization of mixing and dispersion treatment of materials ⇒ Viscosity control, sedimentation prevention, measures to deal with coarse particles ■ Printing technology Thin-film, uniform, and high-speed gravure printing technology ⇒ High quality, mass-production, cost competitive Various patterns printable (Continuous coating, intermittent coating) ■ Battery production/evaluation technology ➢ Significant reduction of the interface resistance Comprehensive evaluation of not only carbon coated foils but between the active material layer and current collector also batteries ⇒lower resistance, fast charge/discharge, and longer ⇒ Proposal of recipes to customers, resolution of technical life. issues DC resistance of lithium-ion battery
Impression cylinder Positive electrode: LFP Negative electrode: SCMG™ Print materials Aluminum foil only Separator: PP Electrolyte: EC/EMC Ink Ink LiPF6 Capacity: 100 mAh Doctor blade Cell: Laminate-type Plate Drop the extra Pouch LiB cylinder ink adhering to ™ the plate SDX used cylinder
Ink
Amount of conductivity aid (%) Gravure printing Quoted from Showa Denko Packaging website 46 LiB Packaging Materials 〜SPALF™〜 Showa Denko Product example Our technologies Packaging Co., Ltd. Example of SPALF™ constituents Pouch LiB ONY (Nylon film) Paint (Coating technology)
Adhesive ・ Thin film coating technology Substrate treating agent Laminate (Lamination technology) Aluminum foil ・ Lamination technology suitable for constituent SPALF™ Substrate treating agent materials Adhesive Create (Molding technology)
CPP (Sealant film) ・ Die design technology to realize product shape ・ Adhesive evaluation technology suitable for product Development of Pouch LiB Application applications 2000 2015
Characteristics of SPALF™ ・Light weight ・Unrestricted product shape ・Good formability ・Insulation properties Dry laminator/coater
Showa Denko Packaging (SPA) Corporate Philosophy: We can offer products created by “paint, laminate, create” technology to the world, and contribute to the development of society. 47 Projects
SiC Epitaxial Wafers
High Grade Epi（HGE)
Surfece Plant Growth Facilities Treatment Fast Cultivation: S Method Film/ Cultivation Unit Crystal LED Growth Technology
Specialty Gas Chemicals
High- Temperature Casting/ Heat Molding Treatment
Aluminum Technology
48 SiC Epitaxial Wafer
Product example Our technologies
Using the epitaxial method, SiC thin film Epitaxial technology is formed on the SiC substrate wafer for We own the technology to uniformly form SiC thin film using power semiconductor applications. Si material gas and C material gas at high temperatures of 1,500 to 1,600°C. We can reduce basal plane dislocation that lose reliability of Wafer size : 4 inch, 6 inch MOSFET. Evaluation technology We own the following technologies to deliver the best products to device manufacturers: ・ Optical surface inspection technology ・ Film thickness and carrier concentration measurement technology ・ Surface contamination inspection technology
Distribution of basal plane dislocation after epitaxial growth
Conventional High Grade Final applications: ・Server power supply ・Solar battery power inverter ・Electric railway vehicle inverter ・Automotive inverter
Defect density 30/cm2 Defect density 0/cm2
49 Plant Growth Facilities
Product example Our technologies
LED-related technology
Wavelength control High luminance Lighting design
SDK High-brightness LED
Aluminum fabrication technology LED plant growth facilities, Cultivation systems Structure design Fabrication & assembly Seismic-resistant design Closed Plant Antibacterial alumite Factory
S method Unit
Cultivation technology
Fast cultivation S method (S500) Increase of varieties Through the combination of technologies and Quality improvement products of SHOWA DENKO, we provide Higher functionality various products and materials for closed-type Conventional plant growth facilities. fluorescent lighting S Method 50 Strategic Technologies
Institute for Advanced and Core Technology
Nano- carbon Nanocarbon Group Thin TM Film Fullerene Process Group Catalyst Frontier Carbon Corporation Group
Purification Catalyst Carbon Molecular Structure Structure Control
High- Mixing/ Performance Dispersion Catalysts Film/ Polymerization Crystal Control Growth Thin Film Process
51 Strategic technology ~Carbon material~
Product examples Our technologies
O
tBuO N N High-temperature O O N N OtBu N reaction control Fullerene O N N OtBu N technology OtBu O Semiconductors Separation and refinement technologies Sports gear Nano lithography, Golf clubs, material Organic synthesis rackets, etc. for lower films technology Vacuum processing technology Energy Fine particle treatment Organic photovoltaic Lubricants technology panels, Additive to lubricants, Crystallization technology fuel cells waxes, etc. Dispersion technology O Measurement and O Other industrial uses evaluation technologies Additives to polymers, rubber, Surface analysis and metal; hard carbon films technology Chemical reaction simulation technology Frontier Carbon Corporation
Showa Denko K.K. Mitsubishi Corporation Nano carbon technology World-class sales and marketing ◎ ◎ ◎Able to develop, produce, and capabilities supply new products satisfying customers’ requirements Fullerene products 52 Strategic technology 〜Catalyst〜
Product example Our technologies Catalyst for Ethyl acetate Acetyl catalyst technology Using the supported heteropoly acid catalyst We have technologies for catalyst design, catalyst analysis, jointly developed with a university, we have catalyst performance evaluation, and plant operation for the following reaction processes: produced ethyl acetate from ethylene and • Ethylene + Oxygen → Acetic acid* acetic acid in one stage. • Ethylene + Acetic acid → Ethyl acetate* CH2=CH2 + CH3COOH → CH3COOCH2CH3 • Ethylene + Acetic acid + Oxygen → Vinyl acetate Since few by-products are generated during • Propylene + Acetic acid + Oxygen → Allyl acetate this reaction, the production method is eco- • Allyl acetate + Hydrogen → N-Propyl acetate friendly, resource saving and energy * Received the Minister of Economy, Trade and Industry prize of the Green & Sustainable Chemistry (GSC) Award (2007) efficient. Porous coordination polymer (PCP) PCP is a porous crystalline material formed by coordination bonds, and PCP with a flexible structure can be used for gas Ethyl acetate separation. We are developing a wide range of technologies from ligand synthesis to formation, with a view to commercialization in the PSA process. Ethylene
Absorption Desorption
Repeat Acetic acid
53 Research and Development
Redox Flow Battery Molecular Structure
Metallic Materials
Film/ Casting/ Crystal Molding Growth
Prined Mixing/ Electronics Dispersion Ag Nanowire Film/ Carbon Crystal Structure Growth Control
Functional Resin Design
Polymerization Control
54 Research and development 〜Printed Electronics〜 Product Example Our technologies Using Ag nanowire transparent Utilizing our accumulated metallic, inorganic, and organic conductive film(TCF), transparent material technologies, we can offer functional raw wiring and sensors can be formed. materials to meet customersʼ demands. Moreover, in cooperation with external organizations, we Ag nanowire TCF can provide Ag nanowire TCF.
Characteristics of Ag nanowire TCF Optical（High transparency、Low-Haze） Electrical（Low resistivity） Adhesion Robust（humidity, heat, light） Decorative forming Bendable etc.
Ag nanowire
Display Device
Touch sensor 55 Research and development 〜Redox flow battery (RFB)〜 Product example Our technologies
Power plant Facilities, - Integrating traditional technologies Charge Discharge households into new business - AC/DC converter ■ VGCFTM Developed sheet-type electrodes made of VGCFTM
Positive Negative electrolyte electrolyte tank tank ■ Bipolar plate Electrode Electrode Achieved lower resistance by developing a special electrode structure making full use Membrane TM Pump Pump of VGCF Principle of RFB ■ Cell stack A battery that charges/discharges through the Applied cell stack technology we have oxidation-reduction reaction of vanadium ions developed in the electrolysis business for 70 years
■ Vanadium recovery Achieved low cost by developing technology to recover vanadium from ash 20 kW demonstration stack from power plants
56 Fundamental Technology & Business Assistance
Fundamental Technology Analysis & Physical Assistance Properties Center
Computational Science and Technology Information Center
Chemical Analysis/ Structure Analysis
Computing Science
Safety Evaluation
Business Assistance
Safety Evaluation Center
57 Computational Science and Technology Information Center Product example Our technologies
Using various computational science technologies, we can enhance and accelerate product development and rapidly produce characteristic products.
Petrochemicals, high-function chemicals ・Quantum chemistry calculation ・First-principles calculation ・Molecular dynamics calculation Easy axis of ・Thermal stress analysis magnetization ・Fluid analysis ・Micromagnetic simulation ・Chemical reaction simulation Magnet alloys ・Lighting design analysis ・Electromagnetic wave simulation ・Electron transport calculation ・Heat transfer analysis ・Image analysis Computational science technologies Design Power semiconductors
Measurement/ Process analysis technologies Light distribution technologies Trial production/ Plant growth facilities/LED Evaluation manufacturing 58 Analysis & Physical Properties Center 〜 Example of evaluation: LiB anode material 〜 Product example Our technologies Low-temperature cycle Voltage (V) Inorganic chemical analysis characteristics ― Usual graphite Trace impurity analysis, High-precision principal ― Modification treatment method A component analysis ― Modification treatment method B ― Modification treatment method C Equipment owned: ICP-OES, ICP-MS, etc. Usual graphite Organic chemical analysis Molecular structure analysis, Separation analysis, Thermal analysis Characteristic change Equipment owned: FT-IR, NMR, GC-MS, etc. Modified graphite Structure analysis Capacity (%) Microstructural (μm to nm) analysis, Composition analysis Equipment owned: TEM, SEM, XRD, XPS, etc. Lithium Alkyl compound carbonate Various non-atmospheric exposure analyses Raman Solvent extraction LC-MS
FIB-STEM XPS
Graphite Confirmation of the correlation of SEI（degraded material coating） with battery characteristics 59 Safety Evaluation Center
Product example Our technologies
Policymaking Safety test assistance Conduct safety test, conduct study test. International Safety Manage and comment on tests. Contribution standardization information Manage company-wide to society Latest trends of Pathological test results. laws and examination regulations Toxicity information research Search, report, and comment on Appropriate hazardous information. evaluation/control method of chemical Research of laws and regulations substances on chemical substances, etc. Act on the Evaluation of Chemical Substances and Chromosomal Regulation of Their Manufacture, etc. JCIA aberration test ■Industrial Safety and Health Act Existing/new chemical substances NBCI Others: Research of laws and regulations OECD/BIAC Various in Japan and abroad Up-to-date METI requests information Support for SDS creation, MHLW MOE etc. and confirmation AIST Education, public awareness ISO-related activities R&D/Manufacturing/Sales R&D/Manufacturing/Sales activities, etc. Others Cell culturing Others: Consulting
We test and investigate the effect of products developed by Showa Denko Group on human health and environmental organisms in order to provide basic data for risk evaluation, thus helping customers to use our products safely. 60 For inquiries, contact
For inquiries, contact
FUKUYO Tomoyuki, Corporate R&D Department, Showa Denko K.K. [email protected]
61