R&D

Recent Achievements

Chemical and Plastics

Development of SHINKOLITE (ACRYLITE) MR 0.8 mm grade

Cellular phone panels
   SHINKOLITE (ACRYLITE) MR is an acrylic resin sheet given a hard coating using our proprietary technology. Sales of the product have been increasing, primarily for use in cellular phone panels. While these applications have mainly involved products with a thickness of 1.0-1.5 mm, the miniaturization of cellular phones has created a demand for even thinner sheets. We have made further improvements to our continuous sheet production technology, enabling the manufacture of a 0.8-mm grade. This technology has given cellular phone manufacturers greater freedom of design, and we expect this grade to assume a dominant position in this field.
Development of scratch-resistant hard-coat materials for optical disks and flat panel displays

   Because photocurable paints are highly functional paints consuming fewer resources and less energy, they have continued to show strong growth in such fields as automobile parts, IT equipment parts, containers and coatings for resists. We have developed and brought to market RAYQUEEN, a hard-coat material that satisfies the market demand for coatings with an even higher level of scratch resistance. RAYQUEEN is an organic-inorganic hybridized superhard coating material comprising nanosize inorganic particles that are surface treated using our proprietary technology. Because the inorganic microparticles form a strong crosslinked structure with the organic component, these results in a novel hard-coat material providing a variety of functions unattainable with conventional materials, including excellent weather resistance and contamination resistance, in addition to scratch resistance and endurance. Market evaluation of the product is high.
The structure of organic-inorganic hybrid hard-coating (basic concept)

The abrasion proof nature of organic-inorganic hybrid hard-coating

Expanded use in automobiles of environmentally friendly acrylic powder for acrylic sol

   Because of the burden placed on the environment by vinyl chloride resins, we have developed alternative, environmentally friendly materials, manufacturing and marketing the DIANAL LP series of acrylic powders for sols. To meet growing customer demand, we increased the production capabilities of the Otake Production Center to enable it to produce 15,000 tons annually, and the plant has been operating smoothly since inception of production in July 2003. The acrylic powder is a highly functional product that, by combining mutual solubility/insolubility with a plasticizer, has achieved an excellent balance of storage stability in a plasticizer, plasticizer retaining ability in a gelled film, and film forming ability. Further, in addition to improving the physical properties of the sol, we have also improved the handleability of the powder by causing cohesion of primary particles into easily collapsible secondary powders. At present, acryl powders are primarily considered to be very suitable for use in automobile undercoats. However, we are developing resins which exhibit good flexibility and storage stability even when non-phthalate ester molding agents are used. Also, we are expanding applications of materials without vinyl chloride and without phthalates, such as sol inks.
Development of METABLEN S2100, modifier for impact resistance, giving plastics superior external appearance and clear color.

   In order to improve mechanical strength, METABLEN Series S, C, E, and W, modifiers for impact resistance are added. Recently, in order to meet the varied needs of our customers with regard to design and appearance, modifiers for impact resistance that produce vivid colors has been desired.
   Mitsubishi Rayon has made the best use of unique polymerization, formulation and morphology control technology for silicon rubber to develop METABLEN S2100, silicon based modifier for impact resistance giving plastics both superior impact strength and clear color, which has enjoyed good sales.
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Information Materials

Development of POF (Plastic Optical Fibers) for onboard LAN

POF cable
   We have developed novel cables as POF cables for onboard LAN. Our POF has reduced loss from sharp bending and improved long-term reliability. As a result, the cables can be used in narrow spaces into which they are inserted with a small curvature radius and are suitable for applications involving severe humidity and heat-related conditions, allowing for a greater freedom in installing the cables in automobiles.

   The key points in this development include POF structure design, development of novel materials suitable for POF filaments and POF cords, and research of optimum manufacturing conditions for increasing transmission characteristics and mechanical properties. We have put to use over 30 years of POF design and development expertise to achieve this product.
Development of an optical fault detection device for optical films and optical glass

an optical fault detection device
an optical fault detection device
   We have developed an optical fault detection device for optical films and optical glass, the Eska Optical Tester Lighting Unit Table. This table with a lighting unit comprising a light source and a special plastic optical fiber light guide amplifies the luminance of specific defects in various types of optical film and glass such as small scratches, surface unevenness, spots, foreign substances, and stains, making them easier for the inspector to find. It was exhibited in the 16 th Flat Panel Display R&D/Manufacturing Technology Show held at the Tokyo Big Site convention center on April 19-21, 2006, and has received many inquiries from users.
Development of plate lenses

plate lenses
plate lenses
   Rodlens is a cylindrical gradient-index rod lens, comprising an optical fiber cut to a specific length and having a refractive index gradient in the radical direction. This lens produces an erect same size and actual object image. This RODLENS, the first such plastic lens developed in the world, can be lined up side-by-side to form an array which can be used in the image-pickup devices of such commercial products as fax machines, multi-use printers, and scanners.
We have recently developed Platelens, consisting of several RODLENS lined up two-dimensionally to form a plate. Platelens is distinctive in that it can make the image at the lower part of the lens appear to stand out three dimensionally.   We expect that this lens will be installed as display elements of instruments for the most advanced engineering fields, such as information processing technology, automobiles, and medical treatment devices, in the future. Through our R&D we have combined the technology we have nurtured in our development of plastic optical fibers and our exclusive refraction gradient formation technology to achieve the highest possible resolution and a lineup of products expanded to meet all applications.
Development of high-luminosity waveguide plates for total reflection type backlight systems

   We have developed and brought to market waveguide plates for backlight systems for 15-inch notebook PCs that are designed for optimal use in total-reflection prism sheets. Using these plates in combination with the above-mentioned Y-type prism sheets creates a backlight system with unprecedented high luminosity.
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Fibers

Development of the world's only core-in-sheath composite spinning technology with wet-spun acrylic yarn

    We have developed the world's only core-in-sheath composite spinning technology with wet-spun acrylic yarn. This composite yarn is named Corebrid™ , and the Corebrid Series we have developed includes Corebrid Lumo™ incorporating a temperature stabilizing polymer in the core, Corebrid Elequil™   in which a fine white conduction powder is dispersed to suppress static electricity, Corebrid Thermocatch™ in which light-absorbing white powder is dispersed to covert light energy into heat, and Corebrid Propearl™ in which acetate is added to provide suitable moisture absorption and odor extinguishing capability.
Development of VENTCOOL fibers, triace/diace conjugate fibers that contract or expand under the effect of moisture and automatically adjust air permeability in clothing; application of such fibers for sportswear and innerwear materials

   Acetates can be of two types: diacetates and triacetates. If raw materials of those two types are integrated into one thread by a method called composite spinning, then only the diacetate portion of the thread will effectively absorb water and will be chemically converted into cellulose, which expands if water is absorbed. Because triacetate does not absorb water, this difference in properties causes spring-like twisting which results in contraction or expansion.

   If knit products using such fibers are worn, when a person perspires because of heat, the moisture is sensed (absorbed) and the thread expands, causing meshes in the product to expand and improving air permeability, thus creating a refreshing feeling. When the perspiration dries, the meshes again become closed and warmth-retaining ability is increased. The yarns thus act as a breathing human skin. "Senken Shinbun" (March 29, 2004).
VENTCOOL (PCY) which expands immediately upon absorbing perspiration, and contracts as it dries
Various improvements to A.H.Y. suitable for cationic dyeing under normal pressure; investment and expanded sales in the field of materials to replace rayon, such as lace curtains or inner lace

   A.H.Y., polyester filaments suitable for cationic dyeing under normal pressure, is a material with a long history, as almost 20 years have passed since they first appeared on the market in 1984. It rose to prominence due to changes in the environment. This was because, 1 Kuraray Co. and Asahi Chemical Co. withdrew from production of rayon filaments, and the suitability of A.H.Y. as a rayon replacement was confirmed; 2 as compounding with materials became commonplace, there was greater demand for materials suitable for dyeing at normal temperature and under normal pressure; and 3 in addition to excellent dyeability, A.H.Y. has a low Young's modulus (half that of regular polyesters) providing for unique softness and flexibility.

   Further, within last two years, A.H.Y. has been further improved and its application, primarily as a replacement for rayon, has expanded. Thus, these filaments are now employed for easily dyeable yarns, lightweight yarns, self-stretching yarns, ultrahigh-gloss yarns, Y-section yarns (absorbed moisture can be dried at a high rate), hollow yarns (lightweight), full-dull yarns, and light-storing yarns, and are also used in POY and in consignment production of staple fibers for other companies. Main applications include apparel and ornaments, lace curtains, inner lace, bathing suits, fabric for clothing, and sweaters. "Sen'i News" (March 7, 2004).
The use application of A.H.Y., polyester filaments suitable for cationic dyeing under normal pressure
Development of new raw yarn for carpets, Pylen

    For our polypropylene filament yarn PYLEN we have developed a variety of new raw yarns for carpets. Our variable contraction mixed yarn POLYPHONY contributes to excellent carpet appearance and has a soft texture and good erectness under pressure, and our Arupoto yarn which has excellent bundling properties due to unique heat setting behavior caused by the lightness and distinctive shape of the yarn with three hollow central spaces that take up much of the cross section area are used in optional car floor mats etc. Recently, we have developed a new raw yarn mixing flattened cross section yarn with conventional Y-section yarn. The flattened yarn contributes to excellent outer appearance and a soft texture, and is suitable for use in the home as well as in the car.
The PP carpet ARUPOTO
The hollow core section The section of carpet
(conventional)
The section of carpet
(ARUPOTO)
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Carbon fibers and composite materials

Development of carbon fiber composite materials for commercial airplanes

Airbus
   Composite materials for airplanes, in contrast with composite materials for sporting goods such as tennis rackets and golf shafts, must have excellent heat resistance, impact resistance, and resistance to moisture in order to ensure structural reliability of the airplane.

   Using the expertise that we have accumulated over many years in applications for commercial airplanes, we have successfully improved the main physical properties of carbon fibers, interface characteristics of carbon fibers and resins, and properties of resins used in composites, and thus have developed technology for the fabrication of composite materials meeting the requirements of airplane applications. The development of this technology has made us a manufacturer of materials supplied for Airbus Co. and we expect there will be growing demand for airplane applications.
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Water-related applications

New development of faucet-connecting water purifier "02 CLEANSUI CSPX" with an easy-to-read LCD

02 CLEANSUI CSPX
   A high-performance water purifier eliminates the 13 Substances to be Removed as specified in the Household Device Quality Display Law, and the 2 Substances to be Removed as specified in the standards of the Water Purifier Association.
   Functions have been improved to make the water purifier easier to use, the LCD which informs at a glance when to exchange the cartridge being made easier to read.
The world's first separate-unit type alkali ion-adding water purifier !
02 CLEANSUI Alkali AL001, using replaceable <complete removal of 13 harmful substances> cartridges, recently put on sale

02 CLEANSUI Alkali AL001
02 CLEANSUI Alkali AL001
    This, the world's first separate-unit type alkali ion-adding water purifier, has the purification capability to eliminate the 13 Substances to be Removed as specified in the Household Device Quality Display Law including soluble lead and tri-halide-methane, and produces alkali ion water or acidic water in a three step process.
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Building materials(Ryoko)

Acrysirup, a low-odor floor coating material

    We have developed a methacrylates based resin for floor coating and put it into market. The Acrysirup is, consisted only monomers (without solvent) minimized their odor and has excellent properties such as quick hardening at room temperature, resistance to chemicals, abrasion, and good weatherability.

    It has Fstarstarstarstar grade as formaldehyde diffusion and is environmental friendly product.

    Acrysirup has a wide range of possible uses including food-related facilities, service facilities and housing, which have been difficult to use.
Solaris, a sunlight tracking and collecting system

   The ecology system Solaris utilizes natural energy sources to the maximum extent by automatically tracking the sun with a high performance light sensor and collecting sunlight.
The sun tracking device keeps the sunlight at the same angle, for efficient light collection. A large light collection surface is realized through concurrent use of a mirror and a prism sheet. Through an optical diffusion device using a Fresnel lens, the range of incident light can be adjusted. Further, use of solar batteries makes an external electric supply completely unnecessary.
Solaris
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IT Related materials(Ryoko)

Development of the sophisticated surfacing process Clearlight, allowing high transparency, stain prevention, anti-refrection, and electromagnetic wave prevention through thin film processing of plastic surfaces

   Using our exclusive resin surface improvement technology, we have developed this sophisticated product which combines functions for anti-refrection, electromagnetic wave prevention, reflection reinforcement, and multi-halfcoat. It has comes in [CL] grade for   coating production methods, [CLV] grade for vacuum deposition methods, and also [GLG] grade for press production methods.
This product is suited for applications in such fields as medical treatment, devices installed in cars, and digital monitors, where demands for high resolution, high luminosity, and large size are increasing.
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New business

Development and start of sales of DNA chips for analysis of micro RNA, GENOPAL MICH and GENOPAL MICM

Micro RNA analysis DNA chip
GENOPAL MICH
GENOPAL MICM

Inspection machine of DNA chip
   we have developed a DNA chip for micro RNA analysis.

Micro RNA are small functional RNA molecules which do not code proteins but have specific roles with regard to vital functions, such as controlling gene expression, aiding in organism growth and cell differentiation and propagation.
They have also been found to play a role in various diseases, and these new functions are drawing attention recently.
Mitsubishi Rayon started development of a DNA chip for analysis of micro RNA at an early date, and has completed a micro RNA analysis DNA chip exploiting the features of our GENOPAL â . This DNA chip should contribute to R&D of new micro RNA.
GENOPAL â for applications other than micro RNA analysis are now being developed, entering into the health care, environment, and foods fields.