PROJECT STORY
project story
Episode 02
Web with Porous Carbon*Transport without touching
"Air bearing roll"
project story
Episode 02
Web with Porous Carbon*Transport without touching
"Air bearing roll"
*Thin, sheet-like materials like film are called "webs."
In search of the infinite possibilities hidden in carbon
Air bearing rolls are made from porous carbon with controlled permeability. This is a roll that floats and conveys the web by emitting air from Porous Carbon. Since there is no contact between the web and the rolls, wear and friction can be prevented, and the occurrence of wrinkles and scratches caused by conveyance can be significantly reduced.
By achieving stable levitation, we have created a product that not only prevents production loss but also contributes to improving production speed. Let's take a look at the secret story behind its development.
By achieving stable levitation, we have created a product that not only prevents production loss but also contributes to improving production speed. Let's take a look at the secret story behind its development.
PROJECT MEMBER
Product developmentKFMoreSan
After joining the company, he was assigned to the product development department.
Involved in the overall development of mechanical seals and porous carbon products.
After joining the company, he was assigned to the product development department.
Involved in the overall development of mechanical seals and porous carbon products.
Material developmentTISan
After joining the company, he was assigned to the materials development department.
Involved in the development of carbon materials used in our products.
After joining the company, he was assigned to the materials development department.
Involved in the development of carbon materials used in our products.
SalesNHSan
After joining the company, he was assigned to the sales department.
We are capturing new demand through sales activities for our products.
After joining the company, he was assigned to the sales department.
We are capturing new demand through sales activities for our products.
SalesTNSan
After joining the company, he was assigned to the design department and then transferred to the sales department.
He makes proposals based on his experience as a designer.
After joining the company, he was assigned to the design department and then transferred to the sales department.
He makes proposals based on his experience as a designer.
Taking advantage of carbon's excellent properties
Open a new path to development
Open a new path to development
Q1
How did the idea for air bearing rolls come about?
Also, to start a new project
Please tell us about the efforts in each department.
Also, to start a new project
Please tell us about the efforts in each department.
The manufacturing method for liquid crystals was at a technological turning point, moving from single-wafer to roll-to-roll technology, and by applying porous carbon's floating conveyance technology, roll-shaped products were created.
The Research and Development Department was in charge of material development, product development, and experimental equipment development in anticipation of larger diameters, longer lengths, and mass production in the future. Since this was a product that had never existed before in the world, we created technical materials that accurately conveyed the product's functions and conducted repeated experiments to confirm the product's safety.
The Research and Development Department was in charge of material development, product development, and experimental equipment development in anticipation of larger diameters, longer lengths, and mass production in the future. Since this was a product that had never existed before in the world, we created technical materials that accurately conveyed the product's functions and conducted repeated experiments to confirm the product's safety.
Based on inquiries from customers, we developed ring-shaped carbon by utilizing existing flat plate manufacturing technology.
Air bearing rolls are floating transport rolls, and the balance between carbon strength and permeability is important, so we focused on basic experiments to determine how each raw material affects the roll.
Air bearing rolls are floating transport rolls, and the balance between carbon strength and permeability is important, so we focused on basic experiments to determine how each raw material affects the roll.
We have developed products in response to customer requests. A customer who had previously used the product on a flat surface requested that the film be conveyed without contact. Therefore, after much trial and error to develop a roll-shaped product, we were able to commercialize it.
Product development departments and design personnel focused on developing new products. At the same time as the product was completed, we also built a test machine and collected performance data. Based on this data, the sales department announced new products at exhibitions, established points of contact with customers, and carried out PR activities.
Product development departments and design personnel focused on developing new products. At the same time as the product was completed, we also built a test machine and collected performance data. Based on this data, the sales department announced new products at exhibitions, established points of contact with customers, and carried out PR activities.
Before the birth of air bearing rolls, products that handled flat workpieces, such as those used for levitated conveyance of glass, were mainly used. As glass becomes thinner year by year, there was a demand for a roll that could handle film-like work, so we began development.
The design and development department worked on building the basic technology with the cooperation of the university.
Sales staff listened to the needs of customers who requested roll-shaped products, and developed the necessary functions for commercialization.
The design and development department worked on building the basic technology with the cooperation of the university.
Sales staff listened to the needs of customers who requested roll-shaped products, and developed the necessary functions for commercialization.
Q2
As we proceed with the development of air bearing rolls,
What challenges did you face?
Also, how was it resolved?
What challenges did you face?
Also, how was it resolved?
When selling a new product to an industry with which there has been no prior contact, customers will not be able to adopt it even if they want to unless you prove that you can solve their problems. Therefore, we developed an experimental device that could be demonstrated, and we asked customers to bring in their own films, and we worked together to solve problems.
In order to produce carbon with the performance required by our customers, we adjusted the carbon material manufacturing process to create a variety of carbons and found the optimal manufacturing conditions.
Q3
In order to meet customer demands,
Where does your attitude to take on challenges one after another come from?
Do you think you are born?
Where does your attitude to take on challenges one after another come from?
Do you think you are born?
We believe that manufacturing better products will lead to a more prosperous society.
As the product improves, we will elicit the next demands from our customers, which naturally leads to one challenge after another.
I think we are operating within this upward spiral.
As the product improves, we will elicit the next demands from our customers, which naturally leads to one challenge after another.
I think we are operating within this upward spiral.
Because our company develops products from raw materials, we are able to create variations, which allows us to provide more suitable materials.
Although it is difficult to fulfill all customer requests, the relevant departments gather together to exchange opinions and make the best possible proposals within the company.
Although it is difficult to fulfill all customer requests, the relevant departments gather together to exchange opinions and make the best possible proposals within the company.
I believe that the team's willingness to take on challenges is due to their desire to contribute to society with Carbon products based on the Carbon Research Institute's genes. We work together to solve your problems. We also have an attitude of actively entering new fields and taking on challenges as a team.
I believe that at the root of this is Tanken's corporate culture of ``If you do it, you will succeed.''
Development of the PCP product began in 2005 as a new product, and we have progressed step by step through repeated failures and successes. I think air bearing rolls are progressing in a similar way.
Development of the PCP product began in 2005 as a new product, and we have progressed step by step through repeated failures and successes. I think air bearing rolls are progressing in a similar way.
Q4
What is the customer's reaction to the product?
How does it compare to when it first started selling?
How does it compare to when it first started selling?
At the initial sales stage, the product was very poorly known and was completely unknown. However, due to our careful approach and active participation in exhibitions, we gradually became recognized by our customers. Furthermore, we have built up a track record and have begun to use it on production lines.
Currently, we have gained a certain level of recognition, and I feel that the number of employment opportunities is increasing.
When it was first released, there was little awareness of the product, and it was difficult for people to understand its good performance, but I believe that after repeated promotions using demo machines, it has been well received.
When it was first released, there was little awareness of the product, and it was difficult for people to understand its good performance, but I believe that after repeated promotions using demo machines, it has been well received.
Q5
Carrying the burden of the future
For new employees.
For new employees.
The only thing we are looking for is breakthrough power.
Given the nature of the department, it is important to make sure that once you formulate a hypothesis, you actually carry it out.
Given the nature of the department, it is important to make sure that once you formulate a hypothesis, you actually carry it out.
I think it's the same with any development, but material development can take time to complete.
Although the challenges are often difficult, I would be happy if you can maintain an interest in materials and work with the spirit of ``If you have a dream, a path will open.''
Although the challenges are often difficult, I would be happy if you can maintain an interest in materials and work with the spirit of ``If you have a dream, a path will open.''
We live in a time of very rapid change. I want them to grow and be able to respond flexibly to changing situations and quickly adapt to new challenges.
As the saying goes, "stagnation is degeneration."
I want you to move forward one step at a time.
I want you to move forward one step at a time.
Development timeline
Timeline
Timeline
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