Technologies of SHOWA DENKO
March 28, 2016 Corporate R&D Department Showa Denko K.K.
Ver. 2015-2 Main Businesses of SHOWA DENKO
Lithium-ion battery(LIB) materials, building products, and general Petrochemicals trading, etc. 31% Olefins(ethylene and propylene) and organic chemicals(ethyl acetate), etc.
Others 2014 21% Consolidated net sales Chemicals 876.6 billion 15% yen Aluminum Functional chemicals, industrial gases, basic chemicals, and 11% Electronics electronic chemicals (specialty Rolled products (high-purity foils), gases), etc. specialty components (cylinders Inorganics 15% for LBPs), and beverage cans, etc. 7%
Hard disks (HDs), compound semiconductors, and Rare Graphite electrodes, and ceramics earth magnetic alloys, etc. (alumina and abrasives), etc. 2 Inventory/Summary of Technologies Strength ＝ Diversified Range of Core Technologies
Existing Businesses Projects Advanced Petro- Chemicals Inorganics Aluminum Electronics Battery R&D chemicals Segment Materials otnosycs Rods Continuously-cast Anode Material for Lithium for Material Anode Plant Growth Facilities Growth Plant Biodegradable Biodegradable Plastics High–purity Gases for High-brightness LEDs Functional Monomers LIB Packing Materials lmnmHydroxide Aluminum Ion Secondary Batteries Secondary Ion Molding Compounds Rare Earth Magnetic Resins for Electronic Functional Cosmetic Graphite Electrodes Cubic Boron Nitride Carbon Coated Foil i ptxa Wafer Epitaxial SiC Printed Electronics Organic Chemicals Transparent Film Heat Exchangers Hard Disks (HD) Aluminum Cans Titanium Oxide HPLC Columns Aluminum Foil Heat-resistant ● Core Technologies Raw Materials High-purity Electronics Materials
○ Application Technologies Alloys
Technology Core Technologies Classification
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 ○○○ ○ ○ Membrane/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 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 Basic Control Petrochemicals Olefin Molecular Structure Derivatives Design
Molding/ Casting Heat-resistant Organic Chemicals Transparent Film Ethyl Acetate SHORAYAL™ Allyl Alcohol Derivatives
4 Chemicals-1 〜Gas Products〜
High-purity Gases/Solvents High Corrosion for Electronics Resistant Plating SOLFINE™ Clean-S™ Surface Purification Treatment
Specialty Gas Chemicals
Mixing/ Dispersion Fluorine Chemicals
High-heat Silicon Semiconductors Processing
Supercritical Carbon Plastic recycling Compound Semiconductors Dioxide(CO2) Liquid SHOWA DENKO GAS PRODUCTS crystals
Industrial Gases Solar Batteries ECOANN™ 5 Chemicals-2 〜Functional Products〜
Functional Monomers Karenz™ NVA Surface Treatment HPLC Columns Molecular Shodex™ Structure CIM™ Design Autoprep™
Functional Cosmetic Raw Materials Apprecier™ Purification
Polymerization Control Water-soluble Polymers VISCOMATE ™ PNVA ™ 6 Chemicals-3 〜Resin Products〜
Chlorinated Polyethylene Elaslen™
Resins for Electronic Materials Ripoxy™ Mixing/ Dispersion
Functional Resin Resins for Composite Design Materials Substrate solder ™ ™ Molding/ Rigolac , Ripoxy mask Casting Nippon Polytech Corp. Polymerization Ccontrol
Synthetic Resin Emulsion Polysol™ Molding Biodegradable Compounds Plastic Rigolac™ Molding Bionolle™ Material 7 Inorganics ~Ceramics~
Aluminum Hydroxide
HIGILITE™ Thermal Conductive Fillers Titanium Oxide Alumina ™ SHOBN™ SUPER-TITANIA Surface Purification SHOBN™ Treatment
High-heat Processing
Micro- Molecular particulation Structure Design
SBN™
Cubic Boron Nitride Abrasive Photocatalytic ™ Titanium Oxide SBN™ MORUNDUM SHOROX™ LUMI-RESH™ 8 Inorganics ~Carbon~
Graphite Grain
Shocaraiser™ Mixing/
Dispersion Whole grain-M
Graphite Electrodes Carbon Structure Control
High-heat Processing
Purification
Molding
9 Aluminum Heat Automotive Exchangers Cooling Devices Skyve heat sink™
Metallic Materials
Heating/ Purification Cooling High-purity Control Aluminum Foil High-heat Processing
Laminate/ Casting/ Printing Molding Extrusion and Drawing Tubes Mixing/ Dispersion Continuously- Cast Rods SHOTIC™ SU610 Aluminum Cans AHS™
10 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/ Membrane/ Cooling Crystal Control Growth
High-brightness Purification LED AlInGaP LED AlGaAs LED Rare Earth GaP LED Magnetic Alloys GaAs LED Nd-Fe-B alloy 11 Advanced Battery Materials
Separators Artificial Graphite Negative Electrode Materials SCMG™ High-heat Casting/ processing Molding
Mixing/ Dispersion Carbon Coated Foil
™ Carbon SDX Structure Control
Membrane/ Laminate/ Crystal Printing LIB Packing Growth Materials ™ Micro- SPALF particulation Showa Denko Vapor-grown Packaging Co., Ltd. Carbon Fiber VGCF™ 12 Projects
SiC Epitaxial Wafers Plant Growth Facilities SHIGYO™ Method (Fast Cultivation Method) Surface ™ Treatment SHIGYO Cultivation Unit
Membrane/ Crystal LED Growth Technology
Specialty Gas Chemicals
High-heat Casting/ Processing Molding
Aluminum Technology
13 R&D
Ag Nanowire Ink Molecular Structure
Functional (Printing performance) Resin Line/Space Printed Design =110/70μm Electronics Membrane/ Polymerization Crystal Control Growth
Metallic Mixing/ Materials Dispersion
Micro- Laminate/ Particulation Ag Nanowire Printing
High-heat Processing
Printed Electronics 14 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
15 Solutions
Ideas, hopes and dreams for your happily ever after.
For inquiries, contact Inoue, Corporate R&D Department, Showa Denko K.K. [email protected]
16 Index
Segment Product/Technology Page Segment Product Page Organic Chemicals １８ Petro- Inorganics Graphite Electrodes ３８ chemicals Heat-resistant Transparent Film １９ ~Carbon~ High–purity gases/solvents for High-purity Aluminum Foil ３９ ２０ electronics Heat Exchangers ４０ Chemicals-1 Aluminum ~Gas Fluorine Chemicals ２１ Automotive Cooling Devices ４１ Products~ High Corrosion Resistant Plating ２２ Continuously-cast Rods ４２ Supercritical Carbon Dioxide (CO ) ２３ Hard Disks (HD) ４３ 2 Electronics Chemicals-2 Functional Monomers ２４ Rare Earth Magnetic Alloys ４４ ~Functional HPLC Columns ２５ Anode Material for Lithium Ion Products~ Advanced ４５ Functional Cosmetic Raw Materials ２６ battery Secondary Batteries Resins for Electronic Materials ２７ materials Carbon Coated Foil ４６ Department Synthetic Resin Emulsion ２８ LiB Packing Materials ４７ Chemicals-3 Resins for Composite Materials ２９ SiC Epitaxial Wafer ４８ ~Resin Projects Products~ Molding Compounds ３０ Plant Growth Facilities ４９ Biodegradable Plastics ３１ R&D Printed Electronics ５０ Solder Mask for Flexible Board ３２ Computational Science and ５１ Aluminum Hydroxide ３３ Fundamental Information Center technology & Thermal Conductive Fillers ３４ Analysis & Physical Properties Inorganics business ５２ ~Ceramics~ Cubic Boron Nitride ３５ assistance Center Titanium Oxide ３６ Safety Evaluation Center ５３ Photocatalytic Titanium Oxide ３７
17 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 18 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™
19 High–purity gases/chemicals for electronics 〜 for most advanced semiconductors 〜 Example products Our technologies
High-purity gases / chemicals are used in the Using purification technologies of “distillation, electronic industry for, for example, most extraction, and filtration,” high-purity gases for advanced semiconductor manufacturing semiconductors are manufactured. processes and FPD production 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)
20 Fluorine Chemicals
Example products Our technologies Fluorine compounds are used for dry- Fluorine is an atom that can easily combine with cleaning, whereby the dirt adhering to the any element. Utilizing such characteristics of reactor of semiconductor manufacturing fluorine, our fluorine technologies are applied to devices is converted into gaseous various products. substances to clean the devices. We own technologies including the following: Taking advantage of such characteristics, Fluorine synthesis technology (2HF → F2 +H2) fluorine chemicals are used for dry-cleaning, whereby the dirt adhering to the reactor of Fluorine compound synthesis technology (gas phase) semiconductor manufacturing devices is Fluorine compound synthesis technology (liquid phase) converted into gaseous substances to clean Sensitive analysis technologies (LC, GC, ICP-MS) the devices. Plant construction and mass production technology
Plasma Fluorine compounds
Semiconductor/FPD manufacturing instrument Plant for synthesizing fluorine compounds 21 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 device We have also developed our own passive components, vacuum pumps (molecular state treatment technology to form NiF2 films pumps, dry pumps), and plastic injection through the reaction of fluorine gas, thus 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 22 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 23 Functional Monomers 〜Karenz™〜
Product Example Our technologies
Polyfunctional secondary thiol compound ■ Molecular structure design technology
Contributing to Coatings To meet the demand for higher performance, coating performance UV ink we design and provide various functional improvement monomers. (curability, Resist ink adhesion) Improving adhesion Improving curing reaction performance Providing polymerization ability Multipurpose isocyanate monomer Providing water solubility Reducing odor, etc. Useful to O O synthesize O O Molecular design of organic high O NH compounds performance OC O resins HN CO • Introducing highly reactive functional groups O O O • Providing polyfunctionality O O フィルム・コーティング材に！ For films and coating Development of an optimal ＭＯＩＥＧ materials synthesis process
Special water-soluble monomer High-performance • Minimal step synthesis water-soluble polymer • Knowhow to select a reaction catalyst Raw material for our original resin, Establishment of an PNVA industrializing process • Protecting reaction functional groups •High purification (N-vinylacetamide) PNVA NVA • Water amount control 24 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
25 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 26 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
27 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 28 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
29 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. 30 Biodegradable Plastics 〜Bionolle™ 〜
Product Example Application that utilize the biodegradability Our technologies of Binolle™ (PBS: polybutylene succinate), as well as its physical properties similar to Mulch films those of polyethylene. ■High molecular ■Degradability and weight products No need to collect the films after harvesting flexibility control Using our unique polymerization Degradability and flexibility can be technology, we successfully adjusted according to the application manufactured high molecular by selecting a raw material weight PBS. monomer and adjusting its Now, various products can be formulation. manufactured using a general machine for polyethylene. Four months later, films Improvement of have biodegraded into processability tatters. Alteration of the molecular Packaging materials structure makes it possible to (Plastic shopping bags, garbage bags, etc.) manufacture the grade suitable for foaming and In various countries, there are lamination process. restrictions on the use of non- biodegradable single-use bags to protect the environment.
Long-branched structure ™ Bionolle™ has been authorized Bionolle 1903MD the international certifications that prove its biodegradability. ■ Blending with starch and polylactic acid We have established technology to blend starch in a high Biodegradability in compost concentration (>30wt%). We named the product STARCLA™. It is not necessary to separate kitchen garbage and garbage The biomass ratio not only reduces the cost, but also increases bags in composting facilities. the tear strength significantly. Of course, the bags also degrade in nature. The biomass feedstock, polylactic acid, which is poor in flexibility, brittle, and hard to mold, as blended with Bionolle™, and established the compound showing good moldability and 1 week later 2 weeks later 3 weeks later 4 weeks later physical properties. We named the product KIYOYUKI™ 31 Solder Mask for Flexible Board
Product Example Nippon Polytech Corp. Permanent insulating layer for high precision circuits (COF: Chip on Film) mounted with IC Our technologies driving LCD. We can design functional polymers that satisfy various Taking advantage of its excellent insulation required characteristics according to customersʼ demands, reliability and durability, the film improves the and also design ink and paint products that adapt to the image quality of LCD TVs and smartphone LCD panels. customerʼs process by using formulation and dispersion technologies. Achieving high resolution, downsizing, long life, and low price Product Example: insulating film of COF Functional resin design technology (green part) ・High insulation properties ・Flexibility ・High durability LCD panel ・High reliability ・Reactivity ・Toughness COF
Formulation technology ・Process compatibility design ・Printability ・Curability control IC driving LCD Printed circuit board Mixing/dispersion technology ・Dispersed particle size control ・Contaminant management ・Stable quality
High-performance insulating ink High image quality LCD TV for COF
32 Aluminum Hydroxide 〜HIGILITE™〜 Product example Our technologies
™ HIGILITE is aluminum hydroxide [Al(OH)3]. We own technology for precipitation from the liquid phase Its general characteristics are: and powder processing technology, and manufacture ・White powder various kinds of products. ・Amphoteric substance ・Contains crystal water Standard particle aluminum hydroxide → an endothermic reaction occurs when heated. Changing deposition conditions Calcination Particle size/impurity 20μｍ control
Fine particle High-purity Alumina Taking advantage of these characteristics, products products HIGILITE™ is used as a raw material of chemicals, flame-resistant fillers, and artificial marble fillers. Breaking Used as a fire /crushing retardant for wire covering, etc. Fine particle products
Surface Blend/classification treatment (Airflow, sifter, etc.)
Products with better Products with adjusted Used as a raw material of aluminum workability particle size distribution salt and aluminate after reaction with acid and alkali *Photo: Zeolite In addition, we possess technologies for powder • • • Na2O Al2O3 SiO2 nH2O transportation, filtration, and drying during processing. 33 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 Low soda alumina (AL) Roundish alumina (AS) Grinding/classification technology 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 Compounded products with the combination of technology suited for various resins, we can provide 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- requirements, such as viscosity and heat conductivity. dissipating silicone sheet 34 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 35 35 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. 36 Photocatalytic Titanium Oxide 〜LUMI-RESH™〜 Product example Our technologies LUMI-RESH™ is a visible-light- Titanium oxide photocatalyst sensitive photocatalyst with excellent manufacturing technology antibacterial and antiviral We use our high-purity fine particle titanium oxide characteristics. “SUPER-TITANIA™” to manufacture high activity visible- light-sensitive photocatalyst materials through, for example, metal modification. LUMI-RESH™ has been used for photocatalytic indoor-use membrane materials (Taiyo Kogyo), Dispersion technology photocatalytic curtains (Lilycolor), antibacterial and antiviral fibers (Shikibo), and others. In response to customer feedback that the catalyst is hard to use in powder form, we have developed slurrying technology. We not only provide the catalyst in a water slurry form but can also disperse the catalyst in an organic solvent if required.
Photocatalyst evaluation technology We can correctly evaluate visible-light-sensitive photocatalysts for: Above: Taiyo Kogyo ・ VOC decomposition activity Product name “Hikari-Protextile” ・ Antibacterial activity ・ Antiviral activity Right: Lilycolor, Photocatalytic curtain Photocatalyst application technology We are also conducting joint studies with customers on the application to other development products, such as paint, films, fiber We have a solid track record of joint development with processing agents, and decorative sheets. We many customers on the practical application of can also introduce customers of such finished photocatalysts. Please consult us if you have technical goods. problems with particular applications. 37 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.
Exhaust gas device
38 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.
Organization 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) 39 Heat Exchangers 〜Skyve heat sink™〜
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. Industrial use oil cooler We can perform integrated manufacturing from heat design ・Lubricant oil cooler and compressed air and material production to assembly. cooler for various industrial machines We have the manufacturing ability to ensure no complaints arise in the market. We can design the structure and specifications suitable for the customerʼs usage environment. (Hydrophilic surface treatment, low frost formation structure, etc.)
High-precision heat sink Wide/light/thin Large size/low cost High design freedom ・Heat sink for cooling control panels of various industrial machines
Skyve heat sink Extruded heat sink Brazed heat sink High heat diffusion performance
Examples of high-precision heat sinks Roll bond panel type Heat pipe heat sink heat pipe container 40 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
LiB battery We own aluminum rolling/extrusion Ceramic molding technologies. insulating substrate We own joining technologies, such as welding and brazing. Vehicle-installed secondary battery Thin panels can save space. cooling device Either an internal fluid LLC or cooling Water-cooled LLC or medium can be used. air conditioning RB (roll bond) cooling medium panel aluminum
41 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 organization of Al-eutectic Si alloy
Track record of replacing iron parts with aluminum (Swash plates, suspensions, brake pistons, etc.) Brake caliper & Track record of improving aluminum casting functionality piston (Compressor pistons, engine pistons, etc.)
42 Hard Disks (HD)
Product Example Our technologies The annual number of hard disk drives (HDD) Ultra-thin film formation technology shipped worldwide is about 500 million, and about one billion 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 25% share (250 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) 17% Company S (in-house) Company W About one 28% (in-house) billion units 25% Company F SHOWA DENKO 5% 10 to 15 layers 25% Magnification: x4 M Magnification: x 800 K
Substrate Period from April to June, 2014 ＠IDEMA JAPAN 43 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 44 Anode Material for Lithium Ion Secondary Batteries 〜SCMG™〜 Product example Our technologies Lithium ion secondary battery negative-electrode ™ material SCMG (Structure Controlled Micro Graphite) Fine particle treatment technology 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 Artificial Mesoscopic Heat treatment technology graphite graphite
100 Our original technology developed for manufacturing graphite electrodes 80 Natural Primary calcination technology with atmospheric control 60 SCMG™ graphite Secondary calcination technology to control the carbon Natural graphite structure
Battery capacityBattery 40 residual ratio (%) ratio residual 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 structure controlled We provide a negative-electrode carbon material that suffers no degradation by charge-discharge cycles. 45 Carbon Coated Foil 〜SDX™ 〜 Product example Our technologies Current collector for Lithium ion & battery electric double-layer capacitor ■ Material design technology Optimum design of aluminum foil, carbon particle, and binder Current collector with high-conductivity carbon resin particles and binder coated on aluminum foil ⇒ Products that integrate metals, inorganics, and organics SEM photo ■ 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 Various patterns printable Design providing an anchor effect ⇒ High quality, mass-production, cost competitive (Continuous coating, intermittent (Film thickness < 1 μm, coating) Amount of coating < 1 g/m2) Significant reduction of the interface resistance ■ Battery production/evaluation technology between the active material layer and current Comprehensive evaluation of not only carbon coated foils but collector achieves lower resistance, fast also batteries charge/discharge, and longer life. ⇒ Proposal of recipes to customers, resolution of technical 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 2,000 mAh 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 SiC Epitaxial Wafer
Product example Our technologies
Using the epitaxial method, SiC thin film Epitaxial technology is formed on the SiC substrate of wafers We own the technology to uniformly form SiC thin film using for power semiconductor applications. Si material gas and C material gas at high temperatures of 1,500 to 1,600°C.
6” 4” 3” 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 Final applications: ・ Surface contamination inspection technology ・Server power supply ・Solar battery power inverter ・Electric railway vehicle inverter Simulation technology We own the technology to simulate the temperature ・Automotive inverter distribution, gas flow speed, and other items to overcome the difficulty of in-situ measurement at high temperatures of 1,500 to 1,600°C. 48 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 SHIGYO Unit Antibacterial alumite
SHIGYO™ Unit Mini
Cultivation technology
Fast cultivation Increase of varieties Quality improvement Through the combination of technologies and Higher functionality products of SHOWA DENKO, we provide various products and materials for closed-type Conventional plant growth facilities. fluorescent lighting SHIGYO Method 49 Printed Electronics
Product Example Our technologies
Using Ag nanowire ink, transparent Utilizing our accumulated metallic, inorganic, and pattered wiring and sensors can be formed organic material technologies, we can offer by the conventional printing process. functional raw materials to meet customersʼ demands. Moreover, in cooperation with external organizations, we can provide various inks suitable for photo curing technology and the most advanced printing technology.
Display device Functional ink Activation Overcoat resin Touch sensor Ag nanowire
Using Ag nanoparticle ink, ultra-thin film with low-resistance can be printed. Cu-Ag composite ink is suitable for the highly-reliable conductive circuits.
50 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 51 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 52 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. 53