 |
|
|
|
|
|
The challenge continues through changing
shapes and forms
In the
business field of chemicals and plastics, we are engaged in
the development of materials that match specific market demands
in such fields as basic chemical products, catalysts, molding
materials, and coating materials, as well as the development
of processes for the efficient manufacturing of these products.
The R&D activities are supported from the extensive researchers
of the Corporate Research Laboratories, the Yokohama Research
Laboratories and the Resin Development Center, etc. |
|
|
|
 |
|
R & D has focused on
the development of the most competitive industrial process
for MMA (methyl methacrylate) by new catalyst in later stage
which has improved yields about the C4 direct oxidizing method.
This pioneering process has achieved significant results.
We have developed the technology for efficiently extracting
FCC-derived low concentration isobutylene, and new facilities
based on this technology are operating at our plant in Thailand.
In addition we have developed new low cost manufacturing methods
for dozens of monomers through the transformation of alcohols
to MMA side chains. We are also applying our wide-range expertise
in synthesis technologies to synthesize new monomers.
AN(Acrylonitrile) is produced by propylene
ammoxidation reaction using catalysts developed by Mitsubishi
Rayon. AAm(acrylamine), an AN derivative, is manufactured
using the first industrial process to employ biocatalysts.
We have recently begun use of a novel process technology that
dramatically improves productivity. This bioprocess provides
high quality AAm at a lower cost than other industrial processes,
and is now being adopted worldwide. In the near future about
one-third of the AAm produced in the world will be manufactured
using our process. |
|
|
|
 |
|
| ACRYPET, a methacrylic resin
molding materials and SHINKOLITE (ACRYLITE), methacrylic resin
sheets are with outstanding transparency and weatherability.
ACRYPET is used primarily for construction materials, automobile,
household electric appliances, optical products such as light
guide plates for LCDs and optical lens. Moreover our research
is focusing on the application of copolymerization, emulsion
polymerization, suspension polymerization, and compounding
technologies with the object of providing materials with functional
properties, such as ultra-high heat resistance and high impact
resistance. SHINKOLITE(ACRYLITE) is enjoying strong growth
in the promising IT market, where it is used in the windows
of cellular phone, PC front panels, and diffusion plates for
LCD backlighting. In addition to study aimed at improvement
of surface properties, we are also conducting research to
improve its environmental friendliness, including technologies
for conversion of waste polymers into monomers, and the construction
of a recycling plant ahead of our competitors. |
|
 |
| Diffusion plates for LCD backlighting |
|
The polyester resins DIANITE
and TUFPET are used in films, bottles, and other container
and packing materials. In addition, when compounded with reinforcing
materials, modifiers, and additives, they are used as engineering
plastics in electrical and automobile components. Using our
exclusive copolymerization technology, we have developed a
unique lineup of products with superior transparency, heat
resistance and other advanced functions.
The
carbon-fiber reinforced thermoplastic resin PYROFIL pellet
with a strength and modulus of elasticity enabling it to serve
as a metal substitute. Because of its superior dimensional
stability, heat resistance, wear resistance, and fatigue resistance,
as well as its ability to shield against electromagnetic waves
due to its high conductivity, we are developing various high
functional grades for use in electrical and electronic components
and in precision equipment.
ACRYPLENE
is a line of acrylic films that with their unique beautiful
luster, transparency, and colorability. These films, which
were developed as soft cover materials that prevent degradation
of base materials by blocking out ultraviolet radiation, are
available in grades from clear to non-glossy types, allowing
for use in a full range of designs. They have found wide use
as paint alternatives (paintless film) that contain no organic
solvents, or as reflecting material in optical applications.
R&D is focusing on providing them with even superior functions. |
|
 |
| Both CYCOLAC, as ABS resin,
and DIALAC, as ASA(acrylonitrile-styrene-acrylic rubber) resin
are impact resistance resins that are highly regarded as materials
for use in automobiles, electrical equipment, and construction.
We are also moving ahead with research on UMG ALLOY, a polymer
alloy based on these resins, that when reinforced with carbon
fibers will contribute to improved functionality in notebook
PC casings and mechanical parts. |
| CYCOLAC is a trademark of the General Electric
Company and DIALAC and UMG ALLOY are trademarks of UMG AMB
Company. |
| Coating materials are applied
to materials such as metals, plastics, and paper to provide
them with a variety of functions and greater added value. |
|
 |
|
DIANAL is a functional acrylic
copolymer used in a wide range of applications, including
coating materials, inks, and adhesives. It has gained an excellent
reputation in automotive top-coat applications, which require
outstanding appearance, resistance to acid rain and scratches,
durability, and resistance to chipping. The DIANAL BR series
is a line of solid bead resins produced by suspension polymerization,
used world-wide on a scale of 20,000 tons per year.
Mitsubishi Rayon is actively engaged in
the development of environmentally friendly materials. Our
Focus on low VOC products and measures to combat sick houses
has led to a number of new products such as silicone-acrylic
emulsions with high weatherability for use in construction
materials and non-tin antifouling paints for ships. We also
developed a powder for acrylic sol as an alternative for PVC
sol (polyvinylchloride sol). Because of its high functionality
as an automobile undercoat, this acrylic sol is now used worldwide.
We have developed resins with high flexibility and storage stability, even though
they use a non-phthalate ester plasticizer. Their utilization as sol inks is
now expanding.
Our methacrylic resins have also attracted much attention
in the IT field and other fields as calcination materials
that burn out at a high temperature. In the field of toners,
in addition to our main styrene acrylic resins, the DIACRON
series of polyester resins, which exhibit outstanding low-temperature
fusing and durability, has been growing year by year.
 |
| Coating material for CD-R |
DIABEAM and ACRYKING,
which are resins cured by irradiation of ultraviolet rays
(UV) or electronic beams (EB), have found use in a wide range
of applications as highly functional coating materials with
resource- and energy-saving properties. Our organic/inorganic
hybridization technology has led to the development of RAYQUEEN,
a super hard coat that has been well received. RAYQUEEN
improves the scratch resistance of such products as optical
disks and FPD (flat panel display). ACRYCON,
which is an example of a product for non-coating applications,
features excellent transparency and durability and has been
used in casting and as a material for use in dental care.
Also, our high-purity acryl polymer Lithomax for semiconductor resists has superior sensitivity and resolution, as well as capability to provide process margins and various other features. It is used in the manufacture of half-pitch 90nm and 65nm circuits, the current state of the art, for which it has been evaluated highly.
Mitsubishi Rayon is developing pharmaceutical intermediates for new drugs, exploiting the technology we have developed in cyanides, biology, and precision organic compound synthesis.
 Our pharmaceutical intermediates homepage is http://www.mrc.co.jp/fine/fine_top.html
As
the needs of the market grow diverse and greater functionality
is demanded, the field of coating materials has continued
to grow both in Japan and across the world. We have production
facilities in the US, Thailand and Indonesia, are aiming for
greater worldwide market share, and are building new production
facilities in China. Mitsubishi Rayon is pushing forward with
even greater globalization.
When our resin modifier METABLEN is added to a wide variety
of resins from ordinary types to engineering plastics, key plastic properties
such as impact strength and processability are dramatically improved. Recently,
in order to decrease environmental burden, we have been researching into alloys
of METABLEN ,
poly lactic acid (PLA, a plastic derived from plants), and our methacryl resin
molding material ACRYPET . These mixtures have been recognized for their
good transparency, heat resistance, and impact strength, producing superior plastics.
Also, much attention has been given to fluidity modifiers we have been developing
in order to meet the need for large-size or thin-walled injection molded products
made with polycarbonates, whose demand has been increasing remarkably in recent
years. |
|
|
|
|
|
|
