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updated on March 24, 2017

We have developed heat radiation components which take into account features of organic materials. For example, interfacial thermal resistance can be substantially improved through our newly-developed electrically insulating and electrically conducting polymer composite materials with high thermal conductivity.

Takagi Chemicals Inc.

Project name R&D of eco-friendly LED heat radiation components using new, high thermal conductivity composite materials
Target downstream fields Automobile、Environment
Response to the needs of downstream companies High function (improved precision / performance)
High durability (improved heat resistance / corrosion resistance / abrasion resistance)
Mass reduction (size / weight reduction)
Environmental considerations (removal and detoxification of impurities / waste reduction / CO2 reduction)
Reliability / safety (realization of highly reliable inspection technologies etc.)
Specific numerical values relating to the above needs Thermal conductivity of 20 W / mK or above (hot disc method)
Thermal resistance of 200 degrees Celsius or above
Weight reduction: Weight is reduced to 80% of that of an aluminum component of the same shape
Rare earth elements can be easy collected
Thermal cycle stability (thermal expansion coefficient and added tenacity of metal and ceramics)
Project implementation period 2011~2013
Commercialization status Undergoing supplementary research (Project undergoing research toward completion)
Target materials High thermal conductivity polymer composite material

Project details

Project background
Most automobiles today use discharge-type headlights, but high intensity / power LED lights are becoming popular with the development of high intensity / power LED elements that realize energy-saving, long life, design flexibility, controllability, and reduced environmental burden. However, heat radiation is a serious issue for high intensity / power LED lights. Conventional thermally conductive materials used in heat radiation components include ceramics, high thermal conductivity materials and metals, but there are still many issues to solve and a solution which can fully satisfy the markets needs has yet to be found. Development of new materials is desperately needed.

Points of R&D
Conventional thermally conductive materials have many issues. For example, high thermal conductivity ceramics cannot be easily processed into complex shapes and are fragile, with low dimensional stability. Materials with high thermal conductivity (fillers) are limited and vary in quality. Metals and so on have issues such as electrical conductivity, risk of short circuit, interface contact, low heat radiation, and the difficulty of collecting rare metals. To overcome these issues, an all-resin heat component for high intensity / power LED lights will be developed by using new high thermal conductivity polymer composite materials with a thermally conductive bus, with features such as reduced weight, ability to be processed into complex shapes, and easy rare metal recycling.
Specific R&D results
As a result of the R&D of new thermal conductive composite materials, a new material was produced which, while anisotropic, achieved high thermal conductivity through the hot disk method: 30 W / mK or above for the electrical conductor case and approximately 20 W / mK for the insulator case. The polymer material allows flexible product design and enables light-weight production with easy processing and molding. Because integral molding of different materials is possible, resistance at interfaces can be significantly reduced and the use of screws becomes unnecessary. Device packaging may be possible by heat sealing between components.

Anticipated fields / products etc. to which this technology may be applied in the future
As a product line-up using new high thermal conductivity polymer composite materials, products in block or sheet configurations with either insulating or conducting characteristics can be provided. Also, heat radiation components combined with copper plates and radiation fins by integral molding can be produced. Heat radiation fins with conducting properties are aimed at the field of LED lights, sheet materials with insulating properties are aimed at the field of motors and power modules.

Work toward commercialization

Activities related to intellectual property and publicity Intellectual property: PCT international application submitted, entering the national phase in the United States.
Publicity: JRCM News (No.316), TechBiz EXPO 2012, 62nd SPSJ Annual Meeting, 63rd Thermosetting Plastics Symposium, TechBiz EXPO 2013, 22nd SPSJ Polymer Materials Forum, 21st Japan Polyimide & Aromatic Polymer Conference
Future outlook Because the new thermal conductive composite material is still new to us, sample evaluations by downstream users need to conducted, and we need time to consider this. Cost reduction by applying other raw materials is being considered to address the issues of cost in replacing inexpensive aluminum. In addition, technical issues must be identified and resolved to meet the needs of downstream users, who tend to prefer introducing new materials in next-generation products rather than replacing materials in conventional products. To begin with, we plan to expand the business with prototypes.
Level of achievement based on the original goal, and new challenges High thermal conductivity of organic polymer materials (resins), which was considered difficult, was achieved through the project, and manufacturing and molding techniques as well as their evaluation methods were outcomes. The high thermal conductivity resin is gaining intense interest as a solution to the urgent problems facing downstream automobile manufacturers. Currently, improvements are being made based on discussions with users. Specifically, the thermal conductivity and tenacity (elongation) have been improved and measurement methods are currently under consideration. Results of past consideration have been useful in these improvements, but it is taking time. We are also considering cost reduction for LED radiation components, as they must be competitive in price.
Inquiries from downstream industries As for inquiries received from downstream companies, including those relating to derived technologies, sample evaluations are currently in progress. And market needs are being identified in the process. We have discovered that besides performance in thermal conductivity, there is a demand for improved tenacity.

System of R&D

Organization managing the project The Japan Research and Development Center for Metals
Certified business operators Takagi Chemicals Inc.
Institutions conducting the research Takagi Chemicals Inc., Toyohashi University of Technology, Aichi Center for Industry and Science Technology

Promotion comments

As a result of the R&D of new thermal conductive composite materials, a new material was produced which, while anisotropic, achieved high thermal conductivity through the hot disk method: 30 W / mK or above for the electrical conductor case and approximately 20 W / mK for the insulator case. The polymer material allows flexible product design and enables light-weight production with easy processing and molding. Weight reduction of 30% is possible compared to an aluminum component of the same shape. Because integral molding of different materials is possible, resistance at interfaces can be significantly reduced and the use of screws becomes unnecessary. Device packaging may be possible by heat sealing between the components. Through this project, the material can be used in heat radiation components for LED headlights, large floodlights, power devices, and applications in a wide range of fields that require heat radiation and thermal conductivity are expected.

Corporate information

Company name Takagi Chemicals Inc.
(Corporate Number:1180301001546)
Address 21-1 Aza-horita, Obata-cho, Okazaki-shi, Aichi-ken, 444-3502, JAPAN
Phone number +81-564-48-3016
Number of employees 128(male  90,female  38)
Capital 30 million yen
Business category Chemical industry
Business content In pursuit of discovering the new potential of a material, and with the aim of realizing a better world by developing technology to utilize limited resources, we produce PET short fibers with recycled PET.
URL http://www.takagi-kagaku.co.jp/
Production base area Domestic location:Okazaki-shi, Aichi-ken 
Overseas production response Not available
Main clients Itochu Corporation, Toyota Tsusho Corporation, Marubeni Corporation etc.
Department handling inquiries for this project Technological Development Division, Katayose Factory
yuusuke.nagatani@takagi-kagaku.co.jp
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