日建塗装工業 Product Lineup

Are you experiencing troubles such as "film sticking due to static electricity" and "frequent chocolate stops caused by wandering or entanglement" in the guide components of automatic packaging machines? ■ Multifunctional PEEK Coating "PEEKCOAT G10" Our PEEK coating "PEEKCOAT G10" is the optimal solution that addresses the challenges of wear, sliding, and static electricity all at once. It is based on PEEK resin, which boasts high mechanical strength, and has been uniquely formulated with fluororesin and conductive materials. ■ Reliable Wear Resistance Supported by PEEK Resin By adopting PEEK resin as the base matrix, we achieve wear resistance that leverages the robust mechanical strength of PEEK. ■ Smooth and Slippery Surface Thanks to the effects of the blended fluororesin, the surface of the PEEK film is endowed with low friction properties similar to those of a fluororesin coating. ■ Antistatic Function By incorporating conductive materials, we effectively discharge static electricity generated during sliding. We fundamentally suppress transport troubles caused by static electricity, alleviating the unexpected burden on on-site workers. This contributes to the creation of an "unstoppable line" in automatic packaging lines.

The guide components of automatic packaging machines experience significant wear due to constant high-speed friction with films and transported items, leading to major challenges such as "short-term component replacement" and "increased maintenance labor and costs associated with replacements." In the case of the customer we consulted with, they had been applying fluororesin coating to the guide components, but the issue arose that conventional fluororesin coatings have soft films that quickly reach the end of their lifespan in harsh environments. ■ Proposal for PEEK Coating "PEEKCOAT G10" Therefore, we proposed PEEKCOAT G10, which has excellent wear resistance and mechanical strength. - A high-durability sliding coating that uniformly combines fluororesin with a tough PEEK resin film. - Unlike pure fluororesin, the film does not easily wear away, maintaining a "smooth and slippery surface" for an extended period even in harsh high-speed sliding environments. ■ Implementation Effect: Compared to conventional specifications, durability is improved by 3 to 4 times. By significantly extending the component replacement cycle, we achieve both a reduction in spare parts costs and a decrease in equipment downtime associated with maintenance (improving operational efficiency), dramatically enhancing overall cost performance.

In the manufacturing process of packings and other products using a resin extrusion molding machine, fluororesin coating is essential to prevent resin adhesion to the die (mold), which is the core component, and to ensure smooth extrusion. ■ Issues with Conventional Specifications The wear load from molten resin is extremely high, and conventional fluororesin coatings have the problem of peeling off in just two weeks. This is particularly problematic in narrow inner diameters of Φ10mm or less, where blast treatment is difficult to apply uniformly, leading to early peeling. ■ Unique Technology "Thermo Pro Release" - Strong Adhesion Our original fluororesin coating "Thermo Pro Release" not only provides a physical anchor effect to the substrate but also employs a special formulation that enhances adhesion to the base material (metal). Even in narrow inner diameter surfaces where blast treatment may be insufficient, it boasts more than three times the adhesion strength of conventional fluororesin coatings. - Wear Resistance With an optimal formulation of wear-resistant binders, it is resistant to wear even in high-temperature and high-pressure sliding environments, maintaining initial release and lubrication performance for an extended period. The lifespan of the die, which was two weeks, has been extended to approximately three months, achieving about six times the duration and enabling planned line operations.

In the extrusion molding of "resin packings" that maintain airtightness in general industries and the chemical and food sectors, the fluidity inside the mold (die) significantly affects product quality. If the slip properties of the die surface are poor, or if the resin stagnates or adheres, it can lead to the occurrence of "eye mucus (protrusion defects)" and "line scratches (line defects)" on the product surface, resulting in reduced yield. ■ Measures Against Eye Mucus and Line Scratches To prevent these issues, fluororesin coatings are often used; however, if they peel off early due to high-load resin flow, it defeats the purpose. Our unique technology, "Thermo Pro Release," is a coating solution that maximizes "adhesion strength" and "wear resistance" while maintaining excellent release properties and slip characteristics. Traditionally, the pre-treatment blasting (roughening) for coatings was difficult to apply to fine hole inner diameters of Φ10mm or less, which was a cause of early peeling. However, our proprietary binder technology allows for a strong adhesion that is more than three times the strength of typical fluororesin coatings. ■ Introduction Effects It effectively shuts out resin stagnation and adhesion inside the die, thoroughly preventing the occurrence of eye mucus and scratches. This stabilizes the quality of delicate molded products and directly contributes to a significant increase in the good product rate in manufacturing sites.

In automatic transport lines, including beverage manufacturing plants, the reduction in slip properties of the "dead plate" installed at the joints between conveyors can cause products to snag or topple, leading to serious bottlenecks that result in line stoppages (chocolate stops). This time, we will introduce the resolution of transport troubles using PEEK coating "PEEKCOAT G10." ■ Fusion of the toughness of PEEK resin and the slip properties of fluororesin "PEEKCOAT G10" uniformly combines the excellent lubricity of "fluororesin" within the robust framework of "PEEK resin," which boasts overwhelming toughness. As a result, even in harsh environments where heavy items, such as cardboard containing 2L PET bottles, continuously rub against each other, the film does not wear out and peel off as it does with typical fluororesin coatings. ■ Maintaining lubricity even when worn Even if wear progresses, the fluororesin (lubricating component) uniformly dispersed within the film continues to be exposed, allowing the initial smooth slip properties to be maintained for a long time. This thoroughly eliminates transport delays and damage to workpieces, as well as the associated unexpected downtime, strongly supporting the continuous stable operation and throughput improvement of the entire factory.

The dead plate of an automatic transport line is a crucial component for smoothly transferring products. However, due to intense friction from heavy items, the surface treatment tends to wear out quickly, leading to significant hassle and costs each time it is necessary to "stop the line, retrieve the parts, and perform repainting (recoating)." ■ PEEK Coating Sliding Grade "PEEKCOAT G10" Our sliding-specialized coating "PEEKCOAT G10" is a highly durable solution that directly contributes to dramatically reducing maintenance costs and preservation labor. ■ Technical Features The exceptional mechanical strength of the underlying super engineering plastic "PEEK resin" exhibits high physical resistance to continuous rubbing from heavy items (such as cardboard boxes containing 2L PET bottles). Since the coating itself is difficult to wear away, it greatly exceeds the limitations of conventional fluoropolymer coatings, achieving an astonishing long life that is 3 to 4 times greater. ■ Implementation Effects By significantly extending the frequency of part replacements and maintenance cycles, the total running costs—including management expenses for spare parts, outsourcing costs for disassembly and recoating, and labor costs for maintenance personnel—are dramatically reduced. This contributes to improving cost structure and ensuring sustainable profits for the factory.

In metal stages (such as aluminum) for precision inspection equipment, "the application of PEEK resin molded products" was performed to prevent scratches on the workpieces (such as glass substrates and wafers) during transport. However, the attachment process for large stages measuring 1 to 2 meters involved significant labor and costs due to "high-precision positioning," "drilling for fixing holes," "screwing," and "micron-level precision adjustments," which posed a major challenge. ■ Elimination of Attachment Work through PEEK Coating Our thick-film PEEK coating "PEEKCOAT N" directly forms a coating of over 1mm on metal substrates and provides a solution for high-precision mechanical cutting and finishing of the surface. 【Main Benefits of Implementation】 ■ Complete Elimination of Labor Hours Manual tasks such as attaching, drilling, screwing, and positioning are no longer necessary. ■ Reduced Lead Time The assembly and adjustment processes are simplified, dramatically shortening the production period. ■ Over 30% Cost Reduction Significant cuts in material costs, processing costs, and labor costs for molded products. We propose overwhelming rationalization to equipment manufacturers struggling with manufacturing costs and labor hours due to the attachment of molded products.

In laser inspection devices that perform precise measurements of LCD panels and silicon wafers, the "surface smoothness" and "high dimensional accuracy" of the metal stage that holds the workpiece directly influence measurement accuracy. In conventional hand-applied PEEK molded products, the presence of seams and screw fastening areas posed a risk of snagging and scratching the workpiece. Additionally, common coatings faced challenges with warping and distortion of the substrate due to "approximately 400°C firing heat." Our thick-film PEEK coating technology is a solution for designers that balances high precision and surface quality. 【Technical Approach】 ■ Distortion-free Construction Using our proprietary "deformation prevention fixture," we eliminate warping of the substrate caused by thermal shrinkage stress. High precision is maintained even for large substrates (1-2m). ■ Seamless Integrated Flat Surface Machining can be performed after applying a thick coating of over 1mm. A smooth flat surface is formed without screw holes or seams. ■ Scratch Prevention for Workpieces Eliminating metal exposure and unevenness reduces the risk of damage to delicate products. This technology is ideal for large precision components that require high dimensional accuracy and clean surface quality.

In the manufacturing and inspection processes of semiconductor wafers and glass substrates, minute contact scratches and the adhesion of metallic microparticles (contamination) can lead to critical product defects. Traditionally, measures such as processing resin blocks or attaching resin plates to metal parts were mainstream, but there were many challenges, including "a huge amount of labor required for fine adjustments during assembly," "foreign substances accumulating at joints," and "the need for regular replacement due to peeling and wear." Our "functional coating" fundamentally resolves these issues by directly forming a high-performance resin (PEEK or fluororesin) as a single integrated film on metal parts. ■ Advantages of this technology - Elimination of the risk of foreign substance accumulation and peeling due to a seamless integrated coating - Simultaneous achievement of high-precision dimensional control and excellent scratch prevention and resistance to metal contamination - Complete elimination of the processes of attaching resin molded products or using screws, significantly reducing manufacturing costs We can flexibly respond to prototype construction and test processing from a single piece.

In the inspection equipment stage for the LCD and semiconductor fields (1-2m class), structures that attach or screw PEEK molded parts onto metal surfaces are commonly used to prevent scratches on the workpieces. However, this method has posed challenges in manufacturing costs and quality control due to "the hassle of positioning and drilling," "the enormous labor involved in achieving high-precision leveling adjustments," and "the accumulation of foreign substances at the joints." We propose a solution that eliminates the need for this protective part attachment process by using "thick-film PEEK coating + machining." ■ Solution Approach For large stages, we directly apply a thick coating of PEEK resin that exceeds the specified values. Subsequently, we perform high-precision machining on the surface to create a completely flat coating surface without any seams. This approach completely eliminates the labor involved in manual attachment and adjustment, significantly supporting the reduction of manufacturing lead times and total costs. We can also respond quickly to evaluation samples and prototype construction from a single unit.

In the manufacturing lines of semiconductors and precision electronic components, wear of transport hands and deterioration or detachment of protective rubber and resin parts can lead to catastrophic line stoppages in clean rooms. Additionally, in CMP processes and chemical treatment areas, corrosion of metal parts and contamination from strong acids and strong alkalis are significant challenges. Our company achieves the long lifespan of equipment parts through "high-performance resin coating," which forms a coating of fluororesin or PEEK resin tailored to harsh operating environments. ■ Features and Effects - Transport Hands: PEEK coating prevents chipping of wafers due to metal contact, completely eliminating the risk of "peeling and detachment" associated with attached parts. - Chemical Area Parts: Fluororesin coating prevents corrosion of the substrate and provides cleanability and insulation. This reduces the frequency of regular part replacements, contributing to lower maintenance costs and improved equipment operating rates.