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Toray's Advanced Materials Toray Advanced Materials Symposium 27,Sept. 2006 TorayToray ’’ss AdvancedAdvanced MaterialsMaterials -- InnovationInnovation byby ChemistryChemistry -- TorayToray Industries,Industries, Inc.Inc. ExecutiveExecutive ViceVice PresidentPresident andand RepresentativeRepresentative DirectoDirectorr HiroakiHiroaki KobayashiKobayashi 1 Innovation by Chemistry ⅠⅠ.. TechnologyTechnology InnovationInnovation SupportedSupported byby MaterialsMaterials InnovationInnovation 2 SocietySociety inin 2121 st CenturyCentury && IndustrialIndustrial CircumstanceCircumstance St Society in 21 Century Information Safety & Tele- Healthcare Environment Energy Industrial Circumstance communication Security Ubiquitous Network Global Warming Taylor-made Solar Cell Personal Identification CO 2 Emission Medicine High Speed Wind Power Newly Created Communication Pollution Regenerative Air/Water Purification Industrial Fields Medicine Fuel Cell Next Generation Oil Supply Safer Construction Displays Etc. Nursing Care Materials Etc. Etc. System Etc. Etc. Globalization Global Competition, Rising Korean & Chinese Companies,Entering Chinese Market CSR Corporate Governance, Compliance, Risk management, Safety/Disaster Prevention/Environment IP IP Management, Employee Inventions, Technology Transfer, International Harmonization New Value Creation Product Design Strength Solution for Social Problems Global Competitiveness Nanotechnology provides solutions for 21 st century 3 AdvancedAdvanced MaterialsMaterials LeadLead AdvancedAdvanced IndustriesIndustries ～～～19 th Century 20 th Century 21 st Century Natural Materials Emergence and Development of New Materials Advanced Materials Iron & Steel Stainless Steel High Tensile Steel Aluminum Duralumin Metal Glass Alkali-free Glass Semiconductor Germanium Silicon Compound Semiconductors Carbon Materials CFRP Materials Inorganic Nanocarbon C60 CNT Organic/Inorganic Hybrid Materials Wood & Natural Fibers Synthetic Polymers Synthetic Fibers Engineering Plastics Non-petroleum Plastics Precision Polymers Optical Materials Organic Materials Functional Organics Photopolymers Biocompatible Materials Vacuum Electronic Electronics Transistor LSI LCD PDP Tube Paper Automobiles & Synthetic Hybrid Vehicle FC Vehicle Airplane Aircrafts Rubber Tire Next-generation Airplane Life Science Contact Catheter Bio-tool 4 Lens Artificial Kidney DDS InnovationInnovation byby PursuingPursuing LimitsLimits Social imperative InnovationInnovationInnovation Environmental issue Food Scarcity Energy Depletion Health & Healthcare TheThe deeper,deeper, thethe newernewer Increasing Social Value Pursuing of Technology Limits Higher Strength Increasing Higher Heat Resistant Science & Technology Economic Value Finer Structure Value Creation Higher Sensitivity Innovative Product & New New Technology Universal Versatility Create New Field Feedback 5 Innovation by Chemistry Ⅱ． TorayToray ’’ss RR && DD ActivityActivity 6 TorayToray ’’ss TechnologyTechnology FieldsFields && ProductsProducts Advanced Fiber Tech. Synthetic fibers Materials先端材料 Textile Tech. Textiles, Apparel Core Micro-fiber Tech. Synthetic suede Technology Film Tech. Film Processing High-performance films Molding Plastic, Polymer Polymer High- Engineering plastics 高分子化学 performance Science Design Polymer Fine Patterning Electronic materials Specialty Polymers Printing materials Carbonization Carbon fibers, Organic Technology Advanced composite materials Synthetic Chemistry Fine and Composite Industrial materials Technology Amenity materials Nanotechnology Synthetic raw materials Bio - Microstructure technology Control High-performance membranes Medical devices Fine chemicals Medicinal Chemistry Pharmaceuticals 7 TorayToray ’’ss ChallengeChallenge forfor TechnologyTechnology InnovationInnovation PursuitPursuit ofof LimitsLimits Technology Main finer, thinner, stronger, more ･････････ TechnologyTechnology MainMain InnovationInnovation StrategicStrategic Area Area ““TheThe Deeper,Deeper, thethe NewerNewer ”” Information & NewNew MaterialMaterial Information & TelecommunicationTelecommunication InnovationInnovation Automobile byby Nano-materialNano-material Automobile ChemistryChemistry /Aircraft/Aircraft BiotechnologyBiotechnology LifeLife ScienceScience Core Technology of Toray OrganicOrganic SyntheticSynthetic EnvironmentEnvironment PolymerPolymer ScienceScience ProcessProcess ChemistryChemistry /Water/Energy/Water/Energy NanotechnologyNanotechnology BiotechnologyBiotechnology 8 -- ExampleExample ofof TorayToray ’’ss AdvancedAdvanced MaterialsMaterials -- Main重重重Main重重重点点点点点点 Strategic Strategic戦戦戦戦戦戦 略略略略略略 Region領領領 Region領領領 域域域域域域 TechnologyTechnology IT-relatedIT-related AutomobileAutomobile EnvironmentEnvironment Life Science InnovationInnovation MaterialsMaterials ・・・・・・AircraftAircraft Life Science ・・・・・・WaterWater ・・・・・・EnergyEnergy Optical Circuit Carbon Fiber Innovative Synthetic Organic NewNew Board Materials Composite Materials pharmaceuticals Semiconductor MaterialsMaterials New Optical Film New transparent Bio-mass heat-resistance resin Fibers Nano–multilayer Nano-composite Nanofibers PLA Polymers NanoNano Films MaterialMaterial CNT Nanoalloy DDS Membrane Bio- pharmaceuticals BiotechnologyBiotechnology Green Chemistry Bio-tools LCD Next Generation NanoNano Color Filters Next Generation Human-friendly Recycling ProcessProcess PDP-related Molding Material Materials MBR 9 -- ExampleExample ofof TorayToray ’’ss AdvancedAdvanced MaterialsMaterials -- Main重重重Main重重重点点点点点点 Strategic Strategic戦戦戦戦戦戦 略略略略略略 Region領領領 Region領領領 域域域域域域 TechnologyTechnology IT-relatedIT-related AutomobileAutomobile EnvironmentEnvironment Life Science InnovationInnovation MaterialsMaterials ・・・・・・AircraftAircraft Life Science ・・・・・・WaterWater ・・・・・・EnergyEnergy Optical Circuit Carbon Fiber Innovative Synthetic Organic NewNew Board Materials Composite Materials pharmaceuticals Semiconductor MaterialsMaterials New Optical Film New transparent & Bio-mass heat-resistance resin Fibers Nano–multilayer Nano-composite Nanofibers PLA Polymers NanoNano Films MaterialMaterial CNT Nanoalloy DDS Membrane Bio- pharmaceuticals BioBio Green Chemistry Bio-tools LCD Next Generation NanoNano Color Filters Next Generation Human-friendly Recycling ProcessProcess PDP-related Molding Material Materials MBR 10 New Materials Innovation Carbon Fiber PursuitPursuit ofof UltimateUltimate Composite Materials StrengthStrength andand ModulusModulus 10 Diameter=7um Merit of Carbon Fiber Carbon Fiber ・・・Lightweight Specific gravity=1.8 5 Glass :2/3 of Al Fiber ・・・Rust resistance Aramid Fiber ・・・Chemical resistance Steel Wire ・・・High conductivity Strength(GPa) Nylon Fiber ・・・Dimensional stability 0 0 200 400 600 800 etc Modulus(GPa) IndustrialIndustrial processprocess andand technologytechnology forfor pursuitpursuit ofof ultimateultimate performanceperformance PAN polymerization Oxidization Carbonization Sizing Carbon and spinning （（（200 ～～～300 ℃℃℃）℃））） (Graphitization) Fiber （（（1000 ～～～3000 ℃℃℃）℃））） Polymer design Control of defect Control of graphite 11 Control of fiber structure Orientation by draw crystalline （（（size, orientation ））） New Materials Innovation Pursuit of Ultimate Strength Carbon Fiber Pursuit of Ultimate Strength Composite Materials // ControlControl ofof SurfaceSurface DefectDefect 10 Image of fiber surface at nano-size(STM) 8 Size of defect 6 Nano 4 Sub-micron Strength(GPa) 2 Micron 0 nm 1970 1980 1990 2000 2010 12 New Materials Innovation Carbon Fiber PursuitPursuit ofof UltimateUltimate StrengthStrength Composite Materials /Control/Control ofof GraphiteGraphite CrystallineCrystalline 800 Surface(STM) 700 600 500 400 300 200 Modulus(GPa) Orientation 100 95% 1nm 0 6nm 1970 1980 1990 2000 2010 Graphite Cross Section Orientation Crystalline (TEM) Fiber Axis 80% 10nm 2nm 13 New Materials Innovation PursuitPursuit ofof UltimateUltimate WeightWeight Carbon Fiber ReductionReduction ofof AircraftAircraft StructureStructure Composite Materials －－－CFRP ：：： Carbon Fiber Reinforced Plastics －－－ ReplacementReplacement of of 50% 50%ofof structure structure with with CFRP CFRP yields yields 20% 20%reductionreduction of of whole whole structural structural weight weight versusversus aluminum aluminum alloy. alloy. 40 1.0 ● CFRP ● ● ● SignificantSignificant 30 ● AdvantageAdvantage forfor ● ● ● ● ● LightLight StructuresStructures Boron Fiber 20 ● ● ● 0.5 Composites ● ● GFRP Titanium Alloy 10 Steel Specific Specific Strength (GPaSpecific / gravity) Aluminum Alloy Wood Whole WeightWhole Reduction versusaluminum structure [%] 0 0 0 20 40 60 80 100 0 100 Specific Modulus CFRP Weight Ratio in Structure [%] [GPa / Specific gravity] Resin Fiber (7 μμμm dia.) Prepreg Cured Resin CFRP Carbon Fiber Cross section 14 Prepregging (Fiber / Resin Film) Lay-up Cure Cured Part New Materials Innovation Carbon Fiber ExpansionExpansion ofof AircraftAircraft ApplicationApplication Composite Materials B777B777 B787B787 Tail Fin Floor Beams “All-composite-materials Aircraft” Wings Fuselage Tail Fin Wing Horizontal Mount Stabilizer Fuselage Engine Covering Components using composite materials Fuselage Fairing Introduction 1982 1995 2008 Mode B767 B777 B787 Primary structures Primary structures Section using CFRP Secondary (tail assembly etc.) (main wings, tail assembly,etc.) structures Secondary structures Secondary structures Using CF type T300H T800H T800S CFRP utilization (wt%) 3 12 50 CFRP utilization/plane (ton) 1.5 9.6 35 15 New Materials Innovation Carbon Fiber ExpansionExpansion ofof AutomobileAutomobile ApplicationsApplications Composite Materials NewNew
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