Toray Advanced Materials Symposium 27,Sept.

2006

Toray’s Advanced Materials

- Innovation by Chemistry -

Toray Industries, Inc.

Executive Vice President and Representative Director
Hiroaki Kobayashi

1
 Innovation by Chemistry

Ⅰ. Technology Innovation Supported

by Materials Innovation

2
 Society in 21st Century & Industrial Circumstance
Society in 21St Century Information
Healthcare Environment Energy Safety &
Tele-
Industrial Circumstance communication Security
Ubiquitous Network Global Warming Taylor-made Solar Cell Personal
CO2 Emission Medicine Identification
High Speed Wind Power
Newly Created Communication Pollution Regenerative Air/Water
Fuel Cell Purification
Industrial Fields Medicine
Next Generation Oil Supply
Etc. Safer Construction
Displays 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

3
Nanotechnology provides solutions for 21st century
 Advanced Materials Lead Advanced Industries
～19th Century 20th Century 21st Century
Natural Materials Emergence and Development of New Materials Advanced Materials
Iron & Steel Stainless Steel High Tensile Steel
Metal

Aluminum Duralumin
Glass Alkali-free Glass
Inorganic
Materials

Semiconductor Germanium Silicon Compound Semiconductors

Carbon Materials CFRP
Nanocarbon C60 CNT
Organic/Inorganic Hybrid Materials
Wood & Natural Fibers
Synthetic Polymers Synthetic Fibers Engineering Plastics Non-petroleum Plastics
Materials
Organic

Precision Polymers
Optical 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
 Innovation by Pursuing Limits

Social imperative Innovation

Innovation

Environmental issue

New Technology & New Product

Food Scarcity

Energy Depletion

Health & Healthcare The
The deeper,
deeper,
the
the newer
newer Increasing
Social Value
Pursuing of
Technology Limits

Higher Strength Increasing

Higher Heat Resistant
Science & Technology Economic Value

Finer Structure
Value Creation
Higher Sensitivity

Innovative

Universal

Versatility

Create New Field Feedback

5
 Innovation by Chemistry

Ⅱ． Toray’s R & D Activity

6
 Toray’s Technology Fields & Products
Advanced
Fiber Tech. Synthetic fibers 先端材料
Materials
Textile Tech. Textiles, Apparel

Core Micro-fiber Tech. Synthetic suede

Technology
Film Tech. Film Processing High-performance films

Plastic,
High- Molding Engineering plastics
Polymer Polymer performance
高分子化学
Science Design Polymer

Nanotechnology
Fine Patterning Electronic materials
Specialty
Polymers Printing materials

Organic Carbonization Carbon fibers,

Technology Advanced composite materials
Synthetic
Chemistry Fine and Composite Industrial materials
Technology Amenity materials

Synthetic raw materials

Bio-
Bio- Microstructure
High-performance membranes
technology Control
Medical devices

Fine chemicals

Medicinal Chemistry Pharmaceuticals

7
Toray’s Challenge for Technology Innovation
Pursuit of Limits
finer, thinner, stronger, more ･･･
Technology
Technology Main
Main
Innovation
Innovation Strategic
StrategicArea
Area
““The
The Deeper, the Newer ”

Information
Information &
&
New
New Material
Material Telecommunication
Telecommunication
Innovation
by Nano-material
Nano-material
Automobile
Automobile
Chemistry /Aircraft
/Aircraft

Biotechnology
Biotechnology Life
Life Science
Science
Core Technology of Toray
Organic
Organic Synthetic
Synthetic Process Environment
Environment
Polymer
Polymer Science
Science Chemistry
Chemistry
Process /Water/Energy
/Water/Energy
Nanotechnology
Nanotechnology Biotechnology
Biotechnology

8
 - Example of Toray’s Advanced Materials -
重
重点
Main
Main 戦戦略
点Strategic 領領域
略 Region
Strategic 域
Region
Technology
Technology IT-related
IT-related Automobile
Automobile Environment
Environment
Innovation Materials ・・Aircraft Life
Life Science
Science ・・Water・
・・Energy
Innovation Materials Aircraft Water・ Energy

Optical Circuit Carbon Fiber Innovative Synthetic Organic

New
New Board Materials Composite Materials pharmaceuticals Semiconductor
Materials
Materials New transparent
New Optical Film heat-resistance Bio-mass
resin Fibers
Nano–multilayer Nano-composite Nanofibers PLA Polymers
Nano
Nano Films
Material
Material CNT Nanoalloy DDS Membrane

Bio-
pharmaceuticals
Biotechnology
Biotechnology Green Chemistry
Bio-tools

LCD Next Generation

Nano
Nano Color Filters Next Generation Human-friendly Recycling
Process PDP-related Molding Material
Process Materials MBR

9
 - Example of Toray’s Advanced Materials -
重
重点
Main
Main 戦戦略
点Strategic 領領域
略 Region
Strategic 域
Region
Technology
Technology IT-related
IT-related Automobile
Automobile Environment
Environment
Innovation Materials ・・Aircraft Life
Life Science
Science ・・Water・
・・Energy
Innovation Materials Aircraft Water・ Energy

Optical Circuit Carbon Fiber Innovative Synthetic Organic

New
New Board Materials Composite Materials pharmaceuticals Semiconductor
Materials
Materials New transparent &
New Optical Film heat-resistance Bio-mass
resin Fibers
Nano–multilayer Nano-composite Nanofibers PLA Polymers
Nano
Nano Films
Material
Material CNT Nanoalloy DDS Membrane

Bio-
pharmaceuticals
Bio
Bio Green Chemistry
Bio-tools

LCD Next Generation

Nano
Nano Color Filters Next Generation Human-friendly Recycling
Process PDP-related Molding Material
Process Materials MBR

10
New Materials Innovation
Carbon Fiber
Pursuit of Ultimate
Composite Materials Strength and Modulus
10
Diameter=7um Merit of Carbon Fiber
・Lightweight
Strength(GPa)

Carbon Fiber
Specific gravity=1.8
5 Glass :2/3 of Al
Fiber
・Rust resistance
Aramid Fiber
・Chemical resistance
Steel Wire ・High conductivity
Nylon Fiber
・Dimensional stability
00 200 400 600 800 etc
Modulus(GPa)
Industrial
Industrial process
process and
and technology
technology for
for pursuit
pursuit of
of ultimate
ultimate performance
performance

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 （size, orientation）
crystalline（ ）
New Materials Innovation
Carbon Fiber
Pursuit of Ultimate Strength
Composite Materials / Control of Surface Defect
10
Image of fiber surface at nano-size(STM)
8 Size of defect
Strength(GPa)

6 Nano

4
Sub-micron
2
Micron
0 nm
1970 1980 1990 2000 2010

12
New Materials Innovation
Carbon Fiber
Pursuit of Ultimate Strength
Composite Materials /Control of Graphite Crystalline
800 Surface(STM)
700
600
Modulus(GPa)

500
400
300
200
Orientation
100 95% 1nm
0 6nm
1970 1980 1990 2000 2010

Graphite Cross Section

Fiber Axis 80%
Orientation
Crystalline (TEM)

10nm
2nm
13
New Materials Innovation Pursuit of Ultimate Weight
Carbon Fiber
Composite Materials
Reduction of Aircraft Structure
－CFRP ： Carbon Fiber Reinforced Plastics －

Replacementofof50%
Replacement 50%ofofstructure
structurewith
withCFRP yields20%
CFRPyields 20%reduction
reductionofofwhole
wholestructural
structuralweight
weight
versus
versusaluminum
aluminumalloy.
alloy.
40
1.0
CFRP
versus aluminum structure

(GPa / Specific gravity)

Significant
Whole Weight Reduction

● ● ● Significant

Specific Strength
30 ● Advantage
Advantage for
for
●
●
● ● ●
Light
Light Structures
Structures
● Boron Fiber
20 ●
●

●
0.5 Composites
●
GFRP Titanium Alloy
10 Steel
Aluminum Alloy
[%]

Wood
0 0
0 20 40 60 80 100 0 100
Specific Modulus
CFRP Weight Ratio in Structure [%] [GPa / Specific gravity]
Resin
μm dia.)
Fiber (7μ
Prepreg
Cured Resin

CFRP
Carbon Fiber
Cross section
14 Prepregging (Fiber / Resin Film) Lay-up Cure Cured Part
New Materials Innovation
Carbon Fiber
Composite Materials
Expansion of Aircraft Application

B777 B787
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
Secondary Primary structures Primary structures
Section using CFRP structures (tail assembly etc.) (main wings, tail assembly,etc.)
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 Expansion of Automobile Applications
Composite Materials

New Target：：From
NewTarget Fromexterior
exteriorpanels
panelsto
tomain
mainstrictures
strictures
Trunk lid(-5kg)
First full-scale test of
CFRP passenger car ）
Roof(-10kg）
Rear spoiler(-4kg)
Front side member made of CFRP Impact beam(-3kg)

：6kg
weight：
Defuser( -10kg)
Hood(-12kg)
Propeller shaft(-5kg)
Front side member (-6kg)

Platform(-144kg)

Approx. 200 kg weight reduction

Total weight ：2060kg CFRP Application Sections and Weight Reduction
Test speed ：47km/h
（ ）comparisons with conventional materials such as steel

★ Approx. 200 kg weight reduction and improved safety by use of CFRP

16 ※“Innovation Global Warming Countermeasure Technology Program” (METI: 2003 to 2007)
 - Example of Toray’s Advanced Materials -
重
重点
Main
Main 戦戦略
点Strategic 領領域
略 Region
Strategic 域
Region
Technology
Technology IT-related
IT-related Automobile
Automobile Environment
Environment
Innovation Materials ・・Aircraft Life
Life Science
Science ・・Water・
・・Energy
Innovation Materials Aircraft Water・ Energy

Optical Circuit Carbon Fiber Innovative Synthetic Organic

New
New Board Materials Composite Materials pharmaceuticals Semiconductor
Materials
Materials New transparent &
New Optical Film heat-resistance Bio-mass
resin Fibers
Nano–multilayer Nano-composite Nanofibers PLA Polymers
Nano
Nano Films
Material
Material CNT Nanoalloy DDS Membrane

Bio-
pharmaceuticals
Bio
Bio Green Chemistry
Bio-tools

LCD Next Generation

Color Filters Next Generation Human-friendly Recycling
Process
Process PDP-related Molding Material
Materials MBR

17
Nano Material
Innovation
Nanofibers
Pursuit of Ultimate Thin Fibers
μ ｍ)
10,000nm(10μ μm）
1,000nm(1μ ） 100nm 10nm

μm
6μ
Conventional Fibers Microfibers
（Polyester、Nylon et.al.） （Polyester、Nylon et.al.）

～50μ
Hair (～ μm)

Man-made
Suede
18
Nano Material
Innovation Innovation of Synthesis of Microfibers
Nanofibers

Polymer-mosaic fibers Removing sea

component Microfibers
( Islands in sea fibers )

sea

each island μm
3μ μm
40μ μm
20μ
hair Microfibers

Applications

μm
10μ Industrial
Man-made Suede Garments Car interiors Furniture Materials
(launched at 1970)
19
Nano Material
Innovation
Nanofibers
Pursuit of Ultimate Thin Fibers
μ ｍ)
10,000nm(10μ μm）
1,000nm(1μ ） 100nm 10nm

μm
6μ
Conventional Fibers Microfibers Nanofibers
（Polyester、Nylon et.al.） （Polyester、Nylon et.al.） (Nylon,Polyester et.al.)

Bundles （ Aggregation ）

～50μ
Hair (～ μm)

Fiber Dispersion
Man-made
Suede
20
Nano Material
Innovation
Nanofibers
Nanofibers
Pursuit
PursuitofofUltimate
UltimateThin
ThinFibers
Fibers
（ m2 g-1）

100
100

Conventional fibers
Microfibers
80
80

Nanofibers
Surface area（

60
60

40
40
Amount of fibers
20
20 to reach the moon
00 Microfibers ：450g
10
10 100
100 1000
1000 10000
10000 100000
100000
Nanofibers：：0.15g
Diameter (nm)
Features Applications ◆
◆ commodity
commodity polymers
polymers
fineness textile Nylon
Nylon
Polyester
Polyester
adsorption abrasive cloth Polyolefin
Polyolefin et.
et. al.
al.
absorption filter ◆
◆ using
using existing
existing plants
plants

100nm slow release medical device

Side view of N6 nanofibers cosmetics Launched

Launched in
in 2006
2006
21
Nano Material
Innovation
Nano-Scale Technology
“NanoMATRIX” for Processing Textile
(Policy) Pursue and develop “Seeing and finding nano-processing technology”
“Wearing and understanding innovative function” in Toray’s textile
‘nano-scale technology for processing textile’.
Coating on the single fiber surface by
“NanoMATRIX” functional material. Thickness : 10～30nm
Continuous Coating
on the single fiber surface
by functional material

Expected advantages
Level up function
Improve durability of function 200nm
Keep soft handle SEM Photograph of Coated functional
material on the single fiber TEM photo of Coated
Bring a new products single fiber cross-section
to market
★“BEAULAVAGE”（ （2004）
）
;Easy to wash out of rouge and etc. even if they stick
★“ANTI POLLEN” NT （2005）
）
22 ; Easy not to stick pollens and easy to shake off
Nano Material
Innovation
Nano- multilayer Films
Nano-multilayer Films
1000nm 3 layers ～2000 layers
（=1μ
μm） ） 100nm 10nm 1nm
Thermal Shrinkage(%)

Better
Tear Resistance
■
1 600
Nano Effect 5nm PET

(N / mm)
■ Copolymerization PET
400
■
■
Better

Nano Effect 200

■

1 10 100 1000 10000

Single Layer Thickness (nm)

Expanding
ExpandingApplications
Applications
◆ Glass Protective Films
(for safety & security)
◆ Electronic Materials
◆ Optical Functional Tapes

23
Nano Material
Innovation
Nano- multilayer Films
Nano-multilayer Films
1000nm 従来技術 新技術
（=1μ
=1 μm） Ball
Falling 100nm 10nm 1nm
Falling BallPenetration
PenetrationTest
Test
(Height 3m , Weight 2.2kg)
縦方向 熱収縮率（

■
1 Failed
ナノ効果
ナノ効果 600 Succeeded
■
400
■
Penetrated ■
200
％）

1 10【PET100
Film】 1000 10000 【Newly Developed Film】
平均層厚み
平均層厚み (nm)

Expanding
ExpandingApplications
Applications
◆ Glass Protective Films ★ Launched in 2004
(for safety & security)
◆ Electronic Materials
◆ Optical Functional Tapes
24
Nano Material
Innovation Separation Membrane for Water Treatment
Membrane - Types and Surface Morphologies-
Size 1 nm 10 nm 100 nm 1000 nm
Ions, Small molecules Polymers
Colloids
Target

Organic matter
Monovalent ions Viruses Coliform
Multivalent ions
Trihalomethanes Bacteria

RO NF UF MF
(Reverse Osmosis) (Nanofiltration) (Ultrafiltration) (Microfiltration)
Membrane

500 nm 500 nm 2000 nm

Fine pores of RO Membrane (0.6~0.8nm)
Seawater Desalination Drinking Water production
Drinking Water Production (Removal of suspended solids & microorganisms)
(Removal of hardly decomposed substances) Wastewater Reclamation & Reuse

Pursuit of limitation by deepening & fusion of membrane and

25 microorganism technology
Nano Material
Innovation
High Boron Rejection RO Membrane
Membrane (Separation Membrane for Seawater Desalination )
Densification of membrane structure by using precise
New
Newtechnology
technologypoints
points molecule design & nanofabrication technology
Concept Performance of Membrane
RO Membrane

Boron Removal (%)

Boron (Diameter : 0.4nm) 100
100
High Boron Rejection Membrane
Support layer 9595 ● ●
● ●
●
●
Substrate 9090 ●
Conventional Membrane
Pore
8585
0.4 0.5 0.6 0.7 0.8
［Positron Annihilation Spectroscopy］ ］ 0.4 0.5 0.6 (m3/m2/day)
Water Production 0.7 0.8
/ Nanostructure analysis technology by TRC
Proof of correlation between pore size & boron
removal (The world’s first quantification)
Intensity(exist.%)

0.01
0.010

Increase of boron
相対強度（存在確率） / a.u.

removal rate
0.005
0.005

0.000
0
0.20 0.25
0.5 0.30
0.6
空孔半 径 R / nm
0.35
0.7 0.40
Seawater RO desalination plant
図１ 支持膜付き RO膜の空孔 半径分布曲線
Pore diameter in each RO membrane
26
Nano Material
Innovation
High Boron Rejection RO Membrane
Membrane (Separation Membrane for Seawater Desalination )
Densification of membrane structure by using precise
New
Newtechnology
technologypoints
points molecule design & nanofabrication technology
Concept Performance of Membrane
RO Membrane

Boron Removal (%)

Nano-pore Hollow FiberBoron
Membrane 100
(Diameter : 0.4nm)Polymer 100
Electrolyte Membrane
High Boron Rejection Membrane
for Artificial Kidney for Fuel95
Cells (Direct Methanol Type)
Support layer 95 ● ●
● ●
●
Substrate Fuel Cells (Cell) ●
Artificial 9090 Conventional
Non-freezing
● water
Membrane
Kidney Pore （Proton Conduction）
）
Anode 8585
Cathode ＋
0.4 0.5 0.6 Ｈ0.7 0.8
［Positron Annihilation Spectroscopy］ ］ 0.4 Methanol
Water 0.5 0.6 (m3/m2/day)
Production 0.7 0.8
/ Nanostructure analysis technology by TRC
Proof of correlation between pore size & boron
Nano-pore
removal 50nm
(The world’s first quantification) Electrolyte
Membrane
Poymer
Intensity(exist.%)

（Radius : ~5nm）
0.01 0.010 Membrane
Increase of boron surface (Non-Fluorine)
相対強度（存在確率） / a.u.

removal rate
Specific removal of uremic substance High ionic conductivity and low methanol
0.005
from blood （first β2-microglobulin
0.005
cross over (1/10 of conventional membrane)
removal in the world） ） （world top level）
）
0
0.000
0.20 0.25
0.5 0.30
0.6
空孔半 径 R / nm
0.35
0.7 0.40
Seawater RO desalination plant
図１ 支持膜付き RO膜の空孔半径分布曲線
Pore diameter in each RO membrane
27
26
Nano Material
Innovation
Nanoalloy
Polymer Alloy／Nanoalloy
Conventional Alloy
High impact PA
Polymer Polymer Transmission Electron High impact PBT
＋
A B Microscope photo
(cross section of polymer) High impact PPS
Phase-inversed Alloy

Low water
absorption PA
Polymer Design
Compatibilizer Design
＋ High thermal
Nano-dispersed Alloy
Nano-dispersing resistant PLA
Technology High thermal
resistant PET
Flexible PLA

Nano-co-continuous
Alloy High chemical
resistant PET
Innovative
／PC
PBT／

28
27
Nano Material
Innovation
Nanoalloy
Nano-co-continuous Alloy
Toray
Toraysucceeded
succeededin
indeveloping
developingaaworld’s
world’sfirst
firstnano-alloy
nano-alloytechnology
technologywhich
whichmakes
makes
ititpossible tocombine
possibleto combineonly
onlythe
thebest
bestproperties
propertiesof
oftwo
twodifferent
differentpolymers.
polymers.

Conventional Alloy Tensile

TEM photo 3D-model image 1
Strength

Heat
Chemical Resistance
6
Resistance 2

400nm Nanoalloy
Conventional
Alloy
（Development material）
Nanoalloy（ ） Wet heat5 3
Impact
TEM photo 3D-model image Resistance Strength
℃)
(-30℃
Practical
4
Strength
Comparison of Properties between
Conventional Alloy and Nanoalloy
400nm （PBT/PC system） ）

We plan to place the material on the market within one year, especially for
automobile parts, electric and electronic parts, and transparent sheet and so on.
29
28
Nano Material
Innovation
Development of
PLA Polymers Non-petrochemical Raw Materials
Fossil material Nylon Fibers & Textiles
Refining / Synthesis Polymerization
Polyester Films
Raw material Acrylics Plastics
Polyurethane others
others

Biotechnology Nanotechnology
Polymerization
Lactic acid Polylactic
Polylactic acid
Polylactic acid
acid
Polylactic acid

Polymerization Examples of PLA plastics products

Plant-based 1,3-propanediol
raw materials (+TPA) 3GT
3GT
Toray’s
Flexible
Flexible
Business
Photosynthesis Plant oil heat
heat resistant
resistant Domain
films
films

Water, Carbon Dioxide

★ Toray is developing non-petrochemical raw materials

30
29 making full use of Toray’s technologies.
Nano Material
Innovation Example of Application of PLA Polymer
PLA Polymers
High
High heat-resistance
heat-resistance Non-halogenated
Non-halogenated flame-retardant
flame-retardant
Improved
Improvedheat-resistance
heat-resistanceand
andrealized
realized
Improved
Improvedheat-resistance
heat-resistancewith
withoriginal
original high–level
high–level of flame-retardancywith
of flame-retardancy with
nanoalloy technology nanoalloy technology and non-halogenated
nanoalloy technology and non-halogenated
nanoalloy technology flame-retardant
flame-retardanttechnology
technology

℃））））

Heat Resistance （（（（℃））））

better
better
120

Heat Resistance （（（（

8080 60

after Ignition （（（（s)

Burning Time
100
80 6060 4040
60

better
4040 2020
Conventional Nanoalloy 40
Alloy 20 2020 00
PLA Nanoaloy PLA Nanoalloy PLA Nanoalloy

★Enhancing performances of PLA for electronics use with Toray’s original

nanoalloy technologies.
★Toray has contributed to global environment thorough reduction of CO2
31 emission and fossil resources consumption.
30
 - Example of Toray’s Advanced Materials -
重
重点
Main
Main 戦戦略
点Strategic 領領域
略 Region
Strategic 域
Region
Technology
Technology IT-related
IT-related Automobile
Automobile Environment
Environment
Innovation Materials ・・Aircraft Life
Life Science
Science ・・Water・
・・Energy
Innovation Materials Aircraft Water・ Energy

Optical Circuit Carbon Fiber Innovative Synthetic Organic

New
New Board Materials Composite Materials pharmaceuticals Semiconductor
Materials
Materials New transparent &
New Optical Film heat-resistance Bio-mass
resin Fibers
Nano–multilayer Nano-composite Nanofibers PLA Polymers
Nano
Nano Films
Material
Material CNT Nanoalloy DDS Membrane

Bio-
pharmaceuticals
Bio
Bio Green Chemistry
Bio-tools

LCD Next Generation

Color Filters Next Generation Human-friendly Recycling
Process
Process PDP-related Molding Material
Materials MBR

32
31
Bio Innovation
Bio-pharmaceuticals Interferon
Natural
NaturalHuman β
HumanInterferon-ββ::Feron
Interferon-β
*
Feron*
Establishment of large scale
production technology The
The world
world first
first interferon
interferon product
product
(Beads culture)
Launched in 1985 (Toray, Daiichi)

Indication: Interferon Stereo Structure

Indication: Hepatitis
Hepatitis B
B&&CC
Structure elucidation of mouse
Melanoma/Brain
Melanoma/Brain tumors
tumors β
interferon-β
Fibroblast cells on the beads (Tokyo Univ. & Toray)

NNew
ew Drug
DrugResearch
Research
~140 nm
We discovered the optimum binding site of PEG on IFN (●)
4 nm
●
β(World’s first)
Innovated the active PEGylated IFN-β
Polyethylene Glycol
・・Improved
Improved and
and durable
durable therapeutic
therapeutic effects
effects Interferon
(PEG)
・・Many （（Start
Many indications（
indications（ Start clinical
clinical trial
trial in ））
in 2008）
2008）

33
32
Bio-Innovation
Bio-Tools DNA Chip
Appearance Magnified detection area Performance of Toray’s DNA chip
High performance
DNA chip
：：100-fold
Sensitivity：
Sensitivity： 100-foldhigher
higherthan
than
conventional
conventionalchip
chip
μm
100μ
sensitive
1.0
“3D-Gene” Columnar structure Toray’s

Signal/Noise
DNA chip
Feature of TORAY DNA chip 0.5
Flat substrate Columnar structure Conventional
（conventional）） (newly developed) chip
Probe
DNA Probe 0
DNA 1
0.01 0.1
Conventional
glass chip
Next generation
plastic chip
（μｇ）
RNA amount（

Columnar
Columnar structure
structure
High
High Magnified Magnified
Increased
Increased probe
probe DNA
DNA sensitivity
sensitivity
Accelerated
Accelerated reaction
reaction
Scanned image Scanned image

34
33 ※This project is partially supported by NEDO.
Bio-Innovation
Bio-Tools Lab-on-a-Chip
Rapid
Rapidtesting
testingwith
withLab-on-a-Chip (within
Lab-on-a-Chip (within15
15mins））
mins）

Blood Sampling Drop on the chip Measuring System Complete !!

Structure
StructureofofLab-on-a-Chip
Lab-on-a-Chip 44Key -Technologies
Key-Technologies
Sample Port Micro-Valves 1.
1. Surface
Surface Modification
Modification
Waste Port ※Adsorption of proteins to the plastic
Channels surface were reduced to 30-fold less
than non-modified surface
Reaction Chamber
2.
2. Micro
Micro Fabrication
Fabrication
20μm 3.
3. Biological
Biological Measurement
Measurement
μm
20μ
Micro-Channels Micro-Beads 4.
4. Micro
Micro Engineering
Engineering
（Collaborators）
）Osaka Univ. Prof.Kawai, Nagoya Univ. Prof Baba

★ We have developed the diagnostic use Lab-on-a-Chip

35
34 made of plastics. (Only-one in the world)
Bio Innovation
Bio-tools R&D Strategy of Bio-tools
Patient

Conventional Specimens(cells and tissues) Blood

Academia
Academia diagnostic Tests

Kyoto Univ. Genetic Info. Proteome Info.

(cancer) Clinical Info.
et. al. (DNA Chip) (Lab-on-a-chip)

Creation of Integrated Database Development of

Toray
Toray Bio-tools

Focused Disease related Genes/Proteins

Diagnostic Markers Evidence Drug Target Molecule

by inspection

Development of Exam/Diagnostic Tools Development of

*High-performance DNA Chips
*High-performance Protein Analysis New Drugs
36
35
 - Example of Toray’s Advanced Materials -
重
重点
Main
Main 戦戦略
点Strategic 領領域
略 Region
Strategic 域
Region
Technology
Technology IT-related
IT-related Automobile
Automobile Environment
Environment
Innovation Materials ・・Aircraft Life
Life Science
Science ・・Water・
・・Energy
Innovation Materials Aircraft Water・ Energy

Optical Circuit Carbon Fiber Innovative Synthetic Organic

New
New Board Materials Composite Materials pharmaceuticals Semiconductor
Materials
Materials New transparent &
New Optical Film heat-resistance Bio-mass
resin Fibers
Nano–multilayer Nano-composite Nanofibers PLA Polymers
Nano
Nano Films
Material
Material CNT Nanoalloy DDS Membrane

Bio-
pharmaceuticals
Bio
Bio Green Chemistry
Bio-tools

LCD Next Generation

Nano
Nano Color Filters Next Generation Human-friendly Recycling
Process PDP-related Molding Material
Process Materials MBR

37
36
Nano Process
Innovation Pursuit of Particle Dispersion Technology
Particle Dispersion

Nano-level Particle Dispersion

μm
10μ μm
1μ 100nm 10nm 1nm
Particle
Size
Micro
Micro size
size
particles
particles

wavelength
light wavelength
Light
Nano
Nano size
size
Particles
Particles

Opaque Transparent

Visible light
Light
Aggregating
Aggregating

Visible
nano
nano size
size
particles
particles
Light
Aggregate
Aggregate

★Expected Effect of Deepening of Nano Dispersion Technology ：

Control of refractive index, Improvement of Optical property,Fulfill New function
38
37
Nano Process
Innovation Pigment of LCD Color Filter (CF)
LCD Color Filter
Structure
Structureof
ofLCD
LCD Clear, Bright Display
R G B
Suppression of Light
CF
Scattering by CF
LCD TV (Measure: Contrast Ratio)
TFT Liquid
Crystal
Back Key Point: Nano-dispersion
Light of Pigment Particle

Stabilization
Stabilizationof
ofNano-Dispersion
Nano-Dispersionfor
forNano-Pigment
Nano-Pigment Aggregated
Nano-Pigment
Toray’s Conventional
8 Technology
Frequency(%)
Technology
6
4
100nm 0 100nm
10
0.01 100
0.1 10001
Contrast Ratio: 1.8 Pigment Particle Size (nm) Contrast Ratio: 1.0

★ 1.8 times higher Contrast Ratio → Already Applied to Mass Production

39
38
Nano Process
Innovation
PDP-related Materials
PDP Rear Panel Paste Materials
Structure
Structureof
ofPDP
PDP TORAY’s
TORAY’s technology
technologyfor
forforming
formingbarrier
barrier
rib
ribby
byapplying
applyingphotosensitive
photosensitiveglass
glasspaste
paste
ｶﾞﾗｽ基板

Mask Exposure Development Firing

Glass
substrate
Photosensitive glass paste

ｶﾞﾗｽ基板 1. Short process & High productivity

Barrier rib Electrode 2. Flexibility of pattern shape
PDP-TV Phosphor Dielectric
layer 3. High accuracy forming

Rear
RearPanel
PanelPaste
PasteMaterials
Materials
Full high definition
Photosensitive
Photosensitive barrier
barrier rib
rib paste
paste (barrier rib pitch)
Photosensitive
Photosensitive electrode
electrode (silver)
(silver) paste
paste
μm (HD)
270μ
Dielectric
Dielectric paste
paste
Phosphor paste （（Red,
Phosphor paste Red, Green, Blue））
Green, Blue μm(Full HD)
<150μ
μm
500μ

40 ★Supply to the world largest factory of the MPDP (250,000 sets/month)

39
 Toray’s Challenge for Technology Innovation

Technology
Technology Main
Main
Pursuit of Limits Innovation
Innovation Strategic
StrategicArea
Area
Information
Information &
&
New
New Material
Material Telecommunication
Telecommunication
Innovation
by Nano-material
Nano-material
Automobile
Automobile
Chemistry /Aircraft
/Aircraft

Biotechnology
Biotechnology Life
Life Science
Science

Environment
Environment
Toray ’s Core
Toray’s Core Technology
Technology Process
Process /Water/Energy
/Water/Energy

Aiming at the Most Excellent Company for Advanced Materials

by Challenging Technology Innovation
41
40
Advanced Materials for Pioneering 21st Century

Pursuit
Pursuit
Biotechnology of
of Nanotechnology
Biotechnology Limits
Limits
Nanotechnology

Generation
Generationofof
Advanced
AdvancedMaterials
Materials
with
withTechnology
Technology
Innovation
Environment, Innovation Integration
Environment, Integration
Safety
Safety of
of
& Technology
Technology
&Security
Security

Innovative Solutions and Products Only Come with Innovative Materials

42
41