Column

No.

05

“If we want to change something, we have to take the lead.” This is how the beautiful nature of Tsugami
Shindo was protected.

Mt. Asahidake in the Northern Alps. Due to the attitude differences, whichrange from 0 meters at sea level to 2,500 meters in the mountains, it has
a wide range of vegetation. The late Ken Ono, a member of Denka’s Omi
Plant, is the one who created this road.
After joining the company in 1956, Ono worked in limestone mining.
During that period, he felt overawed by the mountain range around Mt.
Asahidake. However, at the time, it was still uncharted territory. There
wasn’t even a mountain trail, much less a plan to build a road that would
divide nature. “If we want to protect nature, we have to do it ourselves.”
Dreaming of new frontiers, Ono gathered a group of mountain-loving
colleagues and formed a mountain climbing club. Their unprecedented
goal was to create a path through the mountains. Ono was motivated by apioneering spirit and a sense of duty to protect nature.
The plan was launched in 1962, but none of them had any experience.
Instead of trying to do the entire 27km of the mountain at once, Ono
decided to go one step at a time. At the end of each workday, the club
would meet up, gather their tools, and begin cutting through the vegetation.
It was backbreaking work. Nevertheless, the sense of accomplishment
after the work and the richness of the nature in the undeveloped area
made it all worth it. Their labors brought them closer together and theyburned with passion for their dream. Ten years later, in 1971, the road was
the Tsuga Forest and the Sea of Japan the “Tsugaumi Shindo.”“We considered what we needed to be done for the future and took
action.” This is one of Denka’s guiding principles. With a dream andpassion, one can overcome even the steepest of mountains. Denka willcontinue to be a pioneer that paves the way towards the future.
Source: Ken Ono “Pioneering Tsugaumi Shindo: Betting Our Youth on Our Dream Route.” Yama-kei Publishers

Unauthorized
reproduction prohibited

finally opened. Having realized his dream, Ono named the road connecting

Published: October. 1, 2020/ Publisher: Corporate Communications Dept., Denka Co., Ltd. / Editor-in-chief: Satoshi Fukuoka /Nihonbashi Mitsui Tower, 2-1-1 Nihonbashi-muromachi, Chuo-ku, Tokyo 103-0022

Tsugaumi Shindo is a mountain road that connects the Sea of Japan andAutumn
2020

Vol.

05

Vol.05

The Pioneer of
Tsugami Shindo

The DenkaWay

2020

Paving a Path Towards the Future

The DenkaWay Autumn

GunbaiMaterials That Pave the Way to the 5G Era
Contents

2 Challengers for Denka Value-Up
Production process reforms to share knowledge around the world
Our Reforms and What Lies Beyond

8 Think INNOVATIONTo Make Unprecedented Discoveries

by Takaaki Kajita, Physicist

9 Amazing the World with Innovation
Materials That Pave the Way to the 5G Era
17 DENKA TOPICS
18 LINK GLOBALLY, LINK FUTURE
20 Gunbai Column

Production process reforms to share knowledge around the world

Our Reforms andWhat Lies Beyond

1Specialty-Fusion
Company
Becomes a Specialty-Fusion
Company with a Strong Global
Presence

This issue’s theme:

2

Production process reform policies:・Revitalizing next generation smart factories
with ICT

Sustained
Growth・Building and managing data platforms inreal time

Denka Group is carrying out production process reforms to achieve “sustained growth by significantly
enhancing productivity through innovative processes”—part of the threefold vision under the Denka Value-Up management plan.
At each of Denka’s bases around the world, employees are taking on new challenges to improve productivity and free up more time for “creative” work.

Maintain Sustained Growthby Significantly Enhancing
Productivity through Innovative Processes

・Improving productivity and achieving ahigh level of operational stability

Denka’s process reforms around the world

3

Fukuoka

Our Threefold Growth
Vision3Sound
GrowthSecure Sound Growththrough Work Style
Reformsp6

Omuta Plant

1

Singapore

Omi

p4

Omuta

Denka Chemicals Holdings Asia Pacific3

Promoting Digitalization
5

2

Chiba

Automating Visual Inspections ofCeramic Substrates Using AI

4

2

4

Chiba

Niigatap7

Omi PlantSuzhouA Carbide Chain Information
Management System

p5

Chiba Plant

5

Enhancing Diagnostics and Sensors
at the Styrene Monomer Plant

Suzhoup7

Denka Advanced Materials (Suzhou) (DAS)1Singapore

Labor-saving Technologies for
Packaging

Using digital technology to improve productivity
and free up more time for “creative” work
The common goal of the Denka Group’s production process reforms is to double labor productivity by 2022 (compared to FY2017). We
are aiming to significantly boost productivity by utilizing digital technologies such as AI (artificial intelligence) and IoT (Internet of Things)
tailored to each site’s specific circumstances.
Though production process reform, Denka Group is also coming together to change the way that we work. In order to become acompany that is truly needed by society, we must eliminate the unnecessary and focus on the essential. By carrying out reforms that willallow employees to switch from routine work to intellectual production, we will establish a system that allows for more “creative” work.
2

The Denka Way | 2020 Autumn

2020 Autumn | The Denka Way

3

The Frontlinesof Production Process Reforms

Here, we will cover the frontlines of the production process, where digital technology
is being used to carry out activities tailored to each site.
Challengers for

Scene 1

Singapore

Denka Chemicals Holdings Asia Pacific (DCHA)

Scene 2

Project Falcon: Realizing a Smart Factory
Stable operations supported
by digital eyes

plants, cameras have been installed and AI diagnostic
image analytics employed to monitor and record theGeneral Manager
Digital Transformation
Group Technology
DCHA

Ng Hock Cheong
Head of Maintenance
Department
Seraya Plant
Denka Singapore

Project Falcon is the DCHA’s smart factory transformation

the burners is an important parameter that determines

plan for its four plants in Singapore. With the support

quality and uniformity of products. Tan, who helped installof the Singapore’s Economic Development Board

the system, says, “Previously, we checked this manually,(EDB), they have been focusing on four areas: digitalbut using cameras has improved accuracy by eliminating

infrastructure, smart factories, digital HSE, and value

human error and inconsistences.”chain management. During this 5-year transformation
plan that started in 2017, their goal is to increase
productivity through stable operations.

Keep thinking and don’t be afraid of
mistakes

In 2020, the third year of the plan, they have installed

The Project Falcon is still an ongoing process. Goingsensors in various parts of the plants and established aforward, they plan to install more sensors and work on

system to check the operational status of equipment via

the Proof-of-Concept for the new systems. The four

the cloud. According to Hock Cheong, who’s in charge

plants are closely collaborating to promote this project.

of plant maintenance, the sensors were installed in coreWada, who is in charge of the project, says, “Every year,

facilities that would affect overall plant operations if not

we share our knowledge, review the previous year’s

functioning correctly, such as cooling towers, steam

activities, and make corrections as we go forward.

traps, and centrifugal pumps. Vibration testing and other

Although there are some challenges, such as operations

data is used to prevent wear and tear on the equipment,

and staff training, I believe everything is always

extending its life and reducing the cost of maintenance.

unprecedented until it happens for the first time. So, it’s

The digital “eyes” also contribute to ensuring stable

important to be constantly thinking of new ideas and not

quality. At Denka Advantech Tuas Plant, one of the four

Chiba Plant

Upgrading Diagnostics and Training Up
Human Resources

gas flow readings of rotameters. The amount of gas in

Mitsuhiro Wada

Chiba

be afraid of making mistakes.”

Yasuhiro Nagasato
Production Dept. 1
Chiba Plant

Ensuring safe and stable operations of theplant’s “main artery”

Introducing ICT technology and developing
human resources

Since 2017, Chiba Plant has been transforming itself

Through the introduction of this new early warning

into a smart factory using ICT technology in order tosystem, improved diagnostics methods, and better

achieve “specialization in key operations” as set forthmeasures for continuous operations, they are trying toin Denka Value-Up. Their goal is to detect anomalies inextend the styrene monomer plant’s normal two-year

temperature, pressure, flow rate, and vibrations at any

repair cycle to four years. However, as a result, there are

early stage by comparing real-time data captured by thefewer opportunities for operators to start/stop the plant.

sensors to past models of normal operations.

To ensure that operators get enough experience, they

“Our mission is to ensure safe and stable plant

have introduced training simulators. These simulators

operations,” says Yasuhiro Nagasato, a member ofallow users to build a model plant on a PC and to

Production Dept. 1. Styrene monomers are used as

experience various non-routine tasks. Nagasato says,

raw materials for a variety of products, so this facility is“Implementing ICT technology and developing our humanessentially the Chiba Plant’s “main artery.” “The mostresources are equally important for production process

important thing is to catch a problem before it becomes

reform. We are proud to be involved with the styrene

serious.” Following the launch of full-scale operations inmonomer plant and will continue to improve our technical2018, they have been working on improving the accuracy

capabilities.”of predictions by factoring in the plant’s operating
rate and other factors such as outside temperatures.
Meanwhile, they have also installed wireless sensors to
improve equipment diagnosis and inspection efficiency.

*A basic chemical used as a raw material for plastics, rubber, andpaint.

Tan Chia King
Advisor, Special Projects
Tuas Plant
Denka Singapore

4

The Denka Way | 2020 Autumn

Data is acquired from an AI diagnostic image analytics
camera installed near the gas flowmeter, and themeasured values are confirmed on a monitor in thecontrol room. The flowmeter valve is then adjusted
based on the analysis results.

The DCS (Distributed Control System). Plant operations are constantly monitored and adjusted in theoperations room.

A worker checks pump discharge pressure in the plant. Providing workers with
opportunities to gain experience in the field is important for human resources development.

2020 Autumn | The Denka Way

5

Scene 3

Fukuoka

Scene 4

Omuta Plant

Omi Plant

Checking the Status of the Carbide Chain at a Glance.
Increased Productivity through Enhanced Coordination.

Productivity Tripled withan AI Inspection System
Steady results with AI built
on human efforts

Niigata

the system’s accuracy improved day by day, andAt Omi Plant, a “carbide chain” has been establishedplant, environment, and safety data allows for earlier

we were delighted when it finally achieved an

to produce chloroprene and lime nitrogen, starting

detection of anomalies and improved inter-departmental

accuracy level equivalent to that of a human.”from a hydroelectric plant and limestone mines. Sincecoordination. “Collaboration between departments has

In 2018, the Omuta Plant introduced a new

Following the introduction of a new mass-

this production line includes various departments

improved, making it possible to take quick action when

AI-based inspection system. Inspections of the

production machine in FY2021, inspection

scattered across a vast site, sharing information abouta problem is detected. This information is also available

ceramic substrates used in power modules were

efficiency is expected to triple. In February, theits operational status was an issue. Therefore, in orderto head office and has led to increased productivity

previously carried out manually with workers

Omuta Plant established the Omuta Innovation

to strengthen cooperation, they began working on aacross Denka,” explains Yasuhiro Kyogoku, a member

shining lights on them and looking for defects.

Hub, which has revitalized communication

Yasuhiro Kyogoku

system that collects and visualizes information on theof the Production Management Dept. Moving forward,

However, with deep learning (DL)*, an AI is able tobetween departments. Moving forward, they

operational status of each plant in the carbide chain.

they will continue expanding the types of data collected“learn” a vast number of images and store themplan to carry out even more process reforms

In February 2019, they completed a system thatand further refine the usage environment to stabilize

as data. This data can then be compared withthroughout the plant. “We hope to develop and

Production Management
Dept.
Omi Plant

visuals captured by a high-precision camera toapply this AI technology in fields other thanidentify defective products.

ceramic substrates. We will continue making“As we expanded our business, we desperately
needed to improve inspection efficiency,”

AI to learn was a laborious process. However,operations.

signage in the Omi Innovation Hub. The sharing ofsteady process as a pioneer of production

Scene 5process reforms within Denka Group.”

explains Nakamura, a member of the Production
Technology Dept. “Gathering image data for theperiodically collects data and displays it on digital

All employees can check the status of operations
on digital signage (top). When a problem occurs, alldepartments can access information regarding plant
shutdowns, etc. on their own computers (bottom). Minor
signs of anomalies not included in reports are also
shared, allowing for earlier detection of problems.

SuzhouDenka Advanced Materials (Suzhou) (DAS)“We are the changemakers.” Using AutomaticTransferring Machines to Improve Labor Productivity*A state-of-the-art AI technology that identifies patterns indata and uses them to make decisions and predictions.

Bottom sheet slit* are the core product of DAS. This

Production Dept., says, “Previously, nobody wanted

packaging operation required employees to carry

to do this job. Seeing how much things have been

25kg boxes and lift them onto pallets—heavy physicalimproved with the introduction of a robot has been eye-labor that needed to be repeated many times a day.

opening.” Currently, they are working on automating

Yuki Nakamura

The company began working on a solution in 2016.

the front-end packing process. Once this is completed,

Production Technology
Dept.
Omuta Plant

After discussions within the department, an automaticthe entire packaging process will become easier, andtransferring machine was installed. This machine

the number of personnel required will be reduced from

Lihua Zhang

reduces the distance that the boxes need to be carried

eight to four, doubling the labor productivity. Moving

Electronic Materials
Production Dept.
DAS

by a third. What is more, it is capable of loading

forward, they will continue tackling problems andindividual boxes onto pallets, reducing the amount ofchanging themselves for the better.

By visually checking samples (left) and photographing ceramic substrates with atesting equipment (right), we collect image data for the AI to learn.

bending and lifting work to zero.
Lihua Zhang, a member of the Electronic Materials*A packaging material for electronic components. It is made by
cutting raw plastic material to a certain size and winding it up.

Denka’s BCP for
torrential rains

In July 2020, Japan was hit with heavy rains and flooding. Up to 116 mm of rain feel on Omuta Plant per hour. Since the main roads

Omuta Plant

continuity plans (BCP) in place, and these preparations helped to minimize the damage. We will implement further disaster risk

Before (top) and after (bottom) the automatictransferring machine was installed. The heavy lifting isleft to the robot, realizing better labor productivity.

were flooded, the company asked the approximately 500 employees, including part-timers, to stay overnight for safety reasons.
Having recognized the risks posed by production stoppages due to the increase in storms and typhoons, Denka had a business
management measures in the future to prepare for heavy rains. In addition to securing means of communication and flooding
countermeasures, we are working on a system that will allow us to confirm the safety of employees and their families and stockpiling
supplies for emergencies. We will also review our disaster prevention system and methods of sharing information with head office

Production process reforms are monitoredfrom the Omuta Innovation Hub, a new
office that facilities communication.

6

The Denka Way | 2020 Autumn

departments to ensure the safety of our employees and the stable operation of the plant.

During the flooding, the water was up to our hips
(left). Water bars were installed as an emergency
measure (right).

2020 Autumn | The Denka Way

7

Think INNOVATION
Introducing articles that provide hints for innovation

Special Feature

No.05

To Make Unprecedented Discoveries
Physicist

Takaaki Kajita

Born in 1959. Graduated from Saitama University’s Faculty of Science. Obtained his Ph.D. at the University of Tokyo.
In 1999, he became a professor at the Institute for Cosmic Ray Research. In 2008, he became director of the Institute.
In 2015, he was jointly awarded the Nobel Prize in Physics with Arthur B. McDonald for their discovery of “neutrino oscillations,” which prove that subatomic neutrinos have mass.

An unwanted stone turned out to be a diamondin the roughThe leeway to consider possibilities for the future
After that, in 1988, we published “The Possibility of Neutrino Oscilla-

In the mid-1980s, I was studying proton decay with a device called thetions.” In 1996, the Super-Kamiokande was completed, speeding up

Kamiokande. Our goal was to prove that protons have a lifespan. To

our research. In 1998, we published “Evidence for Neutrino Oscilla-that purpose, we were trying to capture the faint light produced by thetions” at an international conference and were subsequently awarded

decomposition of protons in water. We checked our observational data

the Nobel Prize in Physics.

over and over, but we failed to make any discoveries.
So, I set about trying to improve our system for observing proton
decay. I created a software program that would remove unwanted inter-

Why was I able to discover neutrino oscillations when nobody else
could? I think there were two reasons: I took advantage of a lucky findand I had time on my side.

Materials That Pave
the Way to the

5G

ference called “noise” and only

The first important thing is theextract the proton decay signals.

ability to discern a diamond from

After completing the prototype,a rock. If you can’t see what’s

I decided to use the noise data

important in your experimen-

to make sure the software wastal results and data, then you

working properly. That’s when I

won’t be able to take advantage

discovered something amazing.

of good fortune when it comesHowever, my discovery wasn’t

your way. This also helps you toabout proton decay; it was about

believe in yourself in the face ofneutrinos*. It was clear that there

criticism. One of the keys to not

It is called “5G*.”

were fewer muon neutrinos thanletting go of good fortune is tothere theoretically should havestick to your guns.

The performance of 5G, which far surpasses that ofbeen.

I believe that “innovation” and“Did I err in my calculations?”
I thought at first. However, after
repeated tests, I determined that

Super-Kamiokande detector©Kamioka Observatory, Institute for Cosmic Ray Research, The University of Tokyo

The communication system is now undergoing a dramatic evolution.

conventional mobile communication systems, has great potential to change our society.

“discoveries” are more or lessDenka’s materials are paving the way to 5G era.

the same thing. The common*The Fifth-Generation Mobile communications system.

denominator is finding some-

my software was working correctly. That was when I realized that I had

thing that will prove beneficial in the future. To that purpose, you needdiscovered something incredible. Fewer muon neutrinos indicated theleeway. There are many types of leeway, such as financial or emotional

possibility of neutrino oscillation. That would prove that neutrinos haveleeway. However, what I had in the 80s was the breathing room to con-mass, overturning the standing theory at the time. What I thought wasduct my research in peace. We were able to do research with an eye on

an unwanted stone turned out to be a diamond in the rough.

the future, rather than just chasing short-term results. If we had been
under pressure to produce results within a year, I might not have devel-*A neutral subatomic particle that has no electrical charge. They are one of the mostabundant subatomic particles in the universe, with hundreds of trillions of them passing
through our bodies every second.

Era

oped that system. The room to look at things from a broad perspective

Amazing
theis the starting point for innovation and discovery.

with Innovation
8

The Denka Way | 2020 Autumn

2020 Autumn | The Denka Way

9

INTERVIEW

How will our lifestyles and workstyles change?

What is thevalue of

5G?

Virtual yet realistic
sports experiences

The features of the 5G communication system include: higher speed, higher
capacity, multiple simultaneous connections, and lower latency. It is 100 times
faster (increased speed and capacity) than the mobile communication systems
that we use today. And it is capable of connecting to tens of thousands of devices
simultaneously and enabling remote control with reduced time lag. We spoke with
Seiichi Sampei, who is at the forefront of this 5G trend, about the true value of 5G.

Seiichi Sampei

Monitoring automatic
operations remotelyProfessor,
Division of Electrical, Electronic andInformation Engineering,
Graduate School of Engineering,Osaka University

5G unleashes“remote” possibilities

Many years of research experience on
telecommunication systems. Chairman of the 5GMF
Technical Committee.

Building a new society. That’s
what 5G can do.

10of COVID-19 has forced us to change ourand industry by removing the assumption thatlifestyles to adapt to a new normal. There ispeople need to be physically present. 5G will

still no end in sight for COVID-19, and webe an important part of the infrastructure for

The 4G system we use today and the new

are also at risk of new infectious diseases inrealizing a new society.

5G system were developed for different

the future. We are now facing a significant

purposes. The 4G was developed as achallenge to maintain our lives and industries

communication system to connect toin the face of restrictions on gathering andsmartphones. On the other hand, 5G ismovement.

Predicting and detecting anomalies in plant
operations by using cameras and sensors

The latency of 5G is expected to reduce to 1/1000th of a second in the future. In a car, there will be little
difference between remote control and manual control from the driver’s seat. This will allow users to remotely
control vehicles, work equipment, and even medical devices.

Sub6 and mmWave. What will
happen in the different frequency
bands?

easily blocked by buildings and objects.

with 5G, there are no doubt many applications

Therefore, it will be necessary to set up many

that nobody has thought of yet. The key totelecommunication base stations to cover theunlocking these possibilities lies not withareas where radio waves cannot to reach.

communication system developers, but withCurrently, 4G mainly uses a frequency band

In addition, high frequency bands, suchelectronic device manufacturers and users. I

of successors in various industries andbelow 6 GHz, which is called Sub6. The Sub6

as mmWave, tend to generate heat in thehope that Denka, which is involved with many

infrastructure affected by a declining birthrate

will also be used in 5G. However, as the IoT

electronic devices that receive them. Solving

companies in its extensive supply network,

5G will also help us address a shortage

and aging population. By combining 5G withexpands, more and more machines andthese problems is essential for the spread ofwill be able to discover hints to create thedesigned to connect to systems related to

5G can help solve these issues with its

high-precision sensing technology, we will

vehicles will be connected to the internet, and

5G. I hope that Denka will develop materials

future of communication systems.

daily life and industry. It is a system thatthree features. In particular, the lower-latency

be able to detect and predict anomalies thatthe amount of communication will increase.

that address challenges unique to 5G andconnects previously unconnected “things” toenables better remote control, allowing

cannot be detected by human perception. The

As a result, this will put pressure on Sub6

higher frequency bands and provide a stable

the internet and aims to expand the IoT that

us to virtually participate in international

impact of the COVID-19 crisis is expected

frequency band. The solution is to use a highsupply of these materials.

acquires, analyzes and controls information.

conferences and musical events fromto further fuel these trends. For companies,

frequency band from 30 GHZ to 300 GHz,

It is predicted that we will see the next

5G aims to separate “people” from

home, to remotely control cars, trains, and

5G is an effective technology in managing

or mmWave. However, the characteristics

generation communication system 6G in less“experiences,” i.e., to break the constraint

ships from a control room, and to automate

business-related risks and costs.

of Sub6 and mmWave are different. The

than a decade. However, with developmentthat operators or participants must be

machinery used in factories and workplaces.

disadvantages of mmWave are that they

still underway, we still have no idea how it will

physically present. In 2020, the spread

By using 5G, we can change the norms of life

cannot reach over long distances and are

be used or what the possibilities are. Even

The Denka Way | 2020 Autumn

Amazingthewith Innovation

2020 Autumn | The Denka Way

11

New
Materials

TECHNOLOGY

Denka’s Electronic Circuit
Board Related Materials

LDM and LCP films

Help prevent
degradation oftransmission
quality

Electronic circuit boards are found in every electronic device, from communication infrastructure such as servers
in data centers and antennae on wireless base stations to more familiar devices such as gaming consoles andsmartphones. Denka’s materials play a large role in the quality and performance of these circuit boards.

Circuit boards are made up of layers of resin, copper, and other materials.

Spherical alumina fillers

With the spread of 5G, we will see increased use of higher frequency
bands, leading to degradation of transmission quality. Therefore, resin

Helpdissipate heatmaterials such as varnishes and films are used for insulation layers to*The photos are all LDM.

help prevent this degradation. Denka will create new products for solving
various issues that cannot be solved with conventional materials.

Development

202X

Amazing
theCurrently under development

Combined with copper foil, they will be used tocreate electronic circuit boards for 5G
Copper foilwith Innovation
LDM or LCP films

With increased data transmitted at faster speeds, electronic devices are producing more heat thanever before. To solve this problem, Denka developed spherical alumina fillers, a heat dissipationmaterial, using the high-temperature melting and spherification technologies cultivated throughfused silica, a semiconductor sealant launched in 1971. Denka also offers spherical magnesia
fillers and hexagonal boron nitride to meet the needs of the expanding market.

Among spherical fillers

What are fillers?
Development

A substance mixed
with resin to add
functionality. It is
possible to add
electrical conductivity,

share in the global market

1

2004

No.

Applications: Mixed with resin, they enhance heat dissipation ofcopper clad laminates
Copper foil

improve thermal
conductivity, andenhance processability.

12

The Denka Way | 2020 Autumn

Spherical
alumina fillers

Resin
Copper foil

Top cover tapes and sheet for ca rrier tapeProtect against
static electricity
andcontamination

Semiconductor integrated circuit parts are covered by top cover tapes andcarrier tape sheets during transportation. The challenges are preventing static
electricity and contamination by foreign matter. Static electricity can cause theparts to stick to the cover tapes, leading to problems during mounting on circuit

A market leader for
approx. 40 years!
Development

1980

Global share
Sheets:40 %Tapes:

30 %Applications: Protecting semiconductor parts during delivery to semiconductor manufacturers.

boards, and contamination by foreign matter can negatively affect performance.
By taking advantage of Denka’s integrated approach to everything from raw
material composition, development to mass production. We will manufacture
products that contribute to the stable supply of semiconductor parts.
2020 Autumn | The Denka Way

13

PROJECT STORY

The
Are

Possibilities ofLimitless

5G

Amazingthewith Innovation

Newly developed products for 5G-compatible electronic circuit boards

Denka has a proven track record with

New Materials 1

fused silica and spherical alumina. This silica

Low DielectricTangent Silica

has already been adopted by a major board

5G will realize new standards of living and working that were not possible with conventional communication systems.
Denka is using its new materials to tackle a variety of obstacles standing in the way.

Transmission loss Low

manufacturer, and customer evaluation is

Usability

Electrical properties don’t change when bent.
Not prone to warping and cracking.
Great potential for electronic circuit boards.

currently underway. Development will be further
accelerated in order to begin supplying themarket.

A long-neglected material
paves the way for the future of 5G
Copper clad laminates, which are made up of

A substrate material
with a low dielectric
tangent, low watercontent, and lowtransmission loss isneeded.

Electromagnetic
waves

layers of resin and copper foil, are used for

Low heat
generation

High heatgeneration

Electromagnetic
waves

High
moisturecontent

Substrate

Applications

electronic circuit boards. Yamamoto says that

Before Conventional material

Substrate

Low
moisturecontent

High

Antenna base station, etc.

LDM, a type of resin developed by Denka, canimprove its functionality.
“Currently, the main resins used in copper
clad laminates for high frequency applications
are polyimides and fluoropolymers. The former
has a high dielectric tangent, resulting inhigh transmission loss, while the latter has
the disadvantage of being difficult to attach

INTERVIEW

Takuto Okabe

Naoki Ogawa

Shota Yamamoto

Advanced Materials
Research Department
Advanced Technologies
Research InstituteInnovation Center
Denka

Advanced Polymer
Research Department
Isesaki Plant

Advanced Polymer
Research Department
Advanced Technologies
Research InstituteInnovation Center
Denka

to copper foil. In comparison, LDM is easy toattach to copper and has little moisture andlow transmission loss due to its low dielectric
tangent. In addition, many of the resins

currently used for semiconductor applications

ago but has remained relatively unknown andare hard resins, which are not malleable

unused. That is, until a few years ago, when

and thus prone to warping and cracking.

developers came up with the idea of applying it

However, LDM is a soft resin that can be used

for 5G. And thus, a long-neglected material has

in combination with other resins to prevent

been brought to the frontlines to pave the way

warping and cracking, thus making it applicablefor the future of 5G.

for a wide range of applications. As such, it canalso be used for flexible printed circuit boards(FPCs) and wearable devices.”

Supporting thin, soft substrates
with LCP film

In fact, LDM was developed about 10 years
Due to its low dielectric tangent, heat resistance,and low moisture absorption, LCP film has been

Transmission loss Low
Moisture absorption Low

New Materials 2

attracting attention as a material for flexible

Attach to copper Easy

printed circuit boards (FPCs). However, Ogawa
says that the number of manufacturers who

LDM
Does the “microwave” principle
diminish the strength ofcommunication signals?
Insulating materials that reduce transmission

waves of a higher frequency (mmWave)

1/10,000 unit of moisture content in resin or athan conventional 3G and 4G technologies.

substrate can affect transmission loss. Okabe

Therefore, it requires materials with a low
dielectric tangent, as these are effective inmoisture content by utilizing the ceramic

reducing transmission loss.

development and manufacturing technologies

loss are essential for realizing the full potentialof 5G. Transmission loss is energy loss. Whenelectromagnetic waves hit an object, they cause
the water molecules in the object to vibrate andthat Denka has cultivated over the years.

Reducing energy loss by removing
1/10,000 unit ofmoisture content

produce heat. Microwaves work by the same14

says that he took on the challenge of reducing“This silica has been specially treated

Doesn’t absorb
moisture

Low dissipation tangent resultsin low transmission loss. Can
be used in a wide range ofapplications from flexible to hard.
Elastic

particles. It maintains physical properties
such as its thermal expansion coefficient and

Low dielectric tangent silica is a filler thatease of mixing with resin while also reducing

the molecules vibrate. 5G uses electromagnetic

suppresses the generation of heat. Even atransmission loss when used in substrates.”

can process it is limited due to the high level ofmanufacturing technology required.

LDM

Before Conventional material

Fluorine

Polyimide

CopperEasy to attach to copper

Applications

Smartphones

Difficult to
attach tocopper“LCP (liquid crystal polymer) is a material
with a rigid molecular structure. That makes
it difficult to turn into a film and can result ina mesh of holes after processing. Additionally,
since boards are made of resin and copper,

to the reduce the moisture content in its

principle. The higher the frequency, the stronger

The Denka Way | 2020 Autumn

Not prone to warping and cracking.
Great potential for flexible terminals and wearable devices.

Wearable devices, etc.

Easy to attach tocopper. However,high water
absorption andtransmission
lossmaterials with different properties that arebonded together by heating, warping anddistortion is likely to occur. However, thanks
to Denka’s film technology, we were able toproduce prototypes that met our customers
standards.”
2020 Autumn | The Denka Way

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Denka is already planning to sell prototype

New Materials 3

Transmission loss Low

LCP films for FCPs. Moving forward, thecompany aims to develop new markets

LCP Film

which are used for automotive radars andindispensable for automated driving.

New developments sometimes face thechallenge of a lack of established evaluationResin

LCP Film

Metal

Metal

Applications

Introducing Denka Group news topics from April to June 2020

Before Conventional material

Denka's film forming
technology enables
molding without
warping or distortion.

Challenges in evaluation andmeasurement

DENKA TOPICS

Moisture Low

Its excellent low dielectric properties do not change with temperatureand humidity.
Great potential for antenna cables for smartphones and vehicle radars
for automatic driving.

by releasing materials for rigid substrates,
communication base stations, both of which are

Heat resistance HighJul.

Company-wide policy for work style reforms
formulatedJul.

Completion of the Omi Plant’s Seiwa employee
dormitory for bachelors

The combination of materials withdifferent properties results in warpingand distortion.

Smartphone antenna

Vehicle radars, etc.

and measurement methods. “LCPs, whichhave excellent dielectric properties and exhibit
a thermotropic liquid crystalline phase, have a

Outside the dormitory

thermal expansion coefficient and other physicalfeedback. “Fillers and films. Denka is unique inunique molecular structure and are difficult toproperties generally stay the same, but thisthat it can approach problems from both sides.”dissolve in solvents. Therefore, it is impossible

silica’s properties change depending on the size

(Ogawa) “Combining new products with existing

to analyze LCP using conventional methods, andof the particles. That makes it difficult to predictproducts or other new products can lead to

we struggled to come up with a new approach.”results and obtain reliable data.” (Okabe)

new exciting possibilities in material creation.”(Ogawa)(Okabe) “Collaborating with the Business“As a soft material, LDM is easily deformed,
so obtaining accurate dielectric tangent
measurements was difficult” (Yamamoto)

From raw materials to development
and mass production.
Denka’s collective strengths“Low dielectric tangent silica is difficult to

In July, we formulated a company-wide policy for work style reforms. In light of the
new normal brought about by the spread of COVID-19, we at Denka are pursuing
new ways of working with the goal of becoming a company that is truly needed bysociety. We will seek the essential aspects of our work and encourage everyone tochoose optimal methods to improve overall productivity.

Inside the dormitory (cafeteria)

On July 15, the new Seiwa Dormitory for bachelors was completed in Omi
Plant. This facility was renovated to provide a better living environment andwork-life balance for young employees. The new facilities include high-speed
internet access and a system that allows employees to order meals with theirsmartphones. We hope the new facility will serve as a place where residents cansocialize, relax physically and mentally, and invigorate themselves for tomorrow.

Development Dept. helped us to quickly andaccurately identify market needs.” (Yamamoto)
The electronic materials field moves quickly.
Some are already considering 6G. Leveraging

measure as a powder in the mmWave range, so

Three young researchers struggling to overcome

the Group’s collective strengths, Denka will

we evaluate it by mixing it with resin. However,problems. They say they were able to reaffirm

continue to shape the future of these new

the processing accuracy of the resin can

the collective strengths of Denka Group bycommunication systems.

influence the results. For our other silica, theevaluating each other’s prototypes and providing

With the evolution of communications systems,
new ways of living and working will appear.

Jul.

We have taken several
actions to prevent the spreadof COVID-19. After filing for
approval in July, we received
permission to manufactureand sell a new COVID-19 rapid
antigen test in Japan. Marketingof this kit began this August. We COVID-19 rapid antigen test kit
QuickNavi™-COVID19 Ag
have also been working with the
Taiwanese company PlexBio on an AMED grant project concerning COVID-19. We
will continue working to improve the COVID-19 testing system.

Aug.

Denka’s new materials will help

pave the way for the future of 5G.

AmazingtheMeasures against COVID-19

Investment of approx. 3.7 Billion yen toward GHG
emission reduction goal

In August, we decided to invest
approx. 3.7 billion yen in the Chiba
Plant, our core petrochemical
production facility, to install highly
efficient gas turbines and generatorsfor in-house power generation. This
investment represents part of ourefforts based on ESG management
to reduce greenhouse gas emissions A full view of the Chiba Plant
by over 12,000 tons per year. Improving energy efficiency will also help the plant
improve its cost competitiveness. We will continue our efforts to preserve theenvironment and contribute to realizing a sustainable society.

Aug.

Donation of 10,000,000 yen to Omuta City
for 2020 heavy rain disaster relief

We donated 10 million
yen to Omuta city inFukuoka Prefecture
for disaster relief for
the torrential rains that
occurred in July 2020.
Mr. Watanabe, Omuta
Plant Manager, officially
Mr. Watanabe symbolically presenting
the donation
donated the money ata ceremony on August 6. The gift will be used for relief and reconstruction of thedisaster-affected areas.

Sep.

Endorsed TCFD recommendations to further
promote climate-related information disclosures

On September 14, we announced
our endorsement of the Task
Force on Climate-related Financial
Disclosures (TCFD) recommendations
to strengthen our governance basedon ESG management. The TCFD’s
recommendations encouragecompanies to disclose financial
information on climate-related risks. While participating in the consortium run by
TCFD with other companies and financial institutions, we will promote disclosureof climate-related financial and management information through our website andother media.

with Innovation
16

The Denka Way | 2020 Autumn

2020 Autumn | The Denka Way

17

No complaints!

I want to drive all over the country after COVID-19
pandemic ends!
I love baking cakes and reading manga!
Joined the company in 2007. As Head of General Affairs, he is
responsible for managing inventory, raw materials, and partnercompanies, purchasing equipment, and improving operations.

To prevent heat-sealing errors on plastic bags, we haveintroduced a temperature monitoring system. Mistakes canbe caused by seal adhesion or inadequate temperatureJapan
Ken Sato
General Affairs Division
Denka Azumin Co., Ltd.

Joined the company in 2019. She is responsible to managing orders inGermany and coordinating with the Japanese, Singaporean, Chinese,and U.S. offices.

How are thingsin Germany,
Susan?

We are currently looking for creative ways of creating aworking environment that prevents infections. Due to theadjustments. However, since we seal approximately 1,000

COVID-19 pandemic, some of our Japanese colleagues

bags per hour, it can be difficult to monitor all of them,

returned to Japan and we introduced a telework system,

and a member of staff always needs to be present. Our
new system hasn’t yet been optimized, but it has already
reduced the burden on
staff. We will aim for further
improvements by working

Germany

which changed our work styles dramatically. Since August,Joined the company in 2008. As a Deputy SalesManager, he is responsible for acquiring new users andaims to create a highly motivated team.

situation allows us to see each other andGeneral Affairs Dept.
Denka Chemicals G.m.b.H

appreciate the little things, which is whatreally matters.

production floor.

Have fun and be cheerful!

I love music!

we have been gradually returning to the office. I’m very
happy to be able to work with everyone again. This

Susan Miekow

together with staff on the

How are things
in Japan,Sato?

Improving business operations
using remote technologies

How are thingsin Shanghai,Min?

LINK GL OBALLY,
LINK F UTURE

We are using WeChat and Web conferencing
tools to follow up with customers. On-site

Shanghaicompounding and guidance are essential

Min Jinyi

have been implementing new communication

Sales Dept.
Denka Infrastructure Technologies
Shanghai Co., Ltd.

methods in cases where business travel is not

How are thingsin Singapore,Tan?

The Denka Group has 6,000 employees around the world.
We posed the following question to members from different countries.

Recently Started Initiatives

SuzhouWe have started a new employee health initiative to take

18

them.

I enjoy watching TV and playing soccer and volleyball!
We are currently preparing to construct the largest 3D
concrete structure in Southeast Asia in Singapore. As aconstruction materials manufacturer, we are constantly
researching and developing materials and gradually

How are thingsin Suzhou,
Xu?

As a result of the COVID-19 pandemic, many annual exhibitions

How are thingsin the USA,
Jules?

and face-to-face business meetings were canceled or postponed.
Therefore, we decided to use our database of previous exhibition

walks during lunch breaks. I feel that this light physicalcontacts to ensure the continuation of our existing business andactivity improves our moods, gives us opportunities tothe creation of newcommunicate, and strengthen our connections. Since

opportunities. Although

Chinese New Year, we have also been implementing

these are difficult times,

COVID-19 preventative measures such as checking

we have been working

temperatures, washing hands, wearing masks, ventilation,

hard to capture sharesdisinfection, and improving hygiene awareness amongof growing markets such

employees.

as electric vehicles.

The Denka Way | 2020 Autumn

we use distributors to sell to local dry-mortar

Joined the company in April 2018. Responsible for sales andmarketing in ASEAN and providing technical support to clients.
Sometimes he visits construction sites to get direct feedback on
products.

Joined the company in August 2015. As manager of Electronics and Innovative
Products, he is responsible for promotion, sales, and new business development of
power electronics, semiconductor, and automotive materials in the Americas.

I love jogging! I’m also interested in calligraphy.
Joined the company in March 2011. As a member of both generalaffairs and accounting, he is responsible for payments and humanresources. He also follows up with R&D through general affairs.

possible due to COVID-19. In extract sales,

I love watching the city from tall buildings!

Xu Lijuan
General Affairs Dept.
Denka Chemicals Development Suzhou
Co., Ltd.

as quick-drying cement and extracts, so wemanufacturers, so we don’t have to travel toGroup members around the world, working toward the future of Denka
Themefor sales of special cement additives such

USA

Singapore
Tan Wei Yi

improving construction methods by using the latest
technologies, such as 3D printing, to reduce the burden
on the work site. Moving forward, we intend to create
exquisite structures with ascetically pleasing designs.

Special Cement Additives
Denka Infrastructure Technologies

Jules Dim
Electronics and Innovative Products
Denka Corporation USA

2020 Autumn | The Denka Way

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