日建塗装工業 Product Lineup

The selection of coatings in the hot riveting process directly impacts not only quality but also production efficiency. In one case, a customer faced issues with resin adhesion to the riveting jig and insufficient durability of the coating during the lens component fixing process. Previously, a non-stick coating was applied, but its performance deteriorated after about 2,000 shots, necessitating frequent jig replacements. This led to problems such as line stoppages and increased maintenance burdens. We proposed a high-durability type called "Thermo Pro Release." This coating maintains non-stick properties for an extended period due to its film that is difficult to peel off even in high-temperature environments. As a result, durability improved to approximately 20,000 shots, achieving about ten times the lifespan compared to the previous solution. Resin adhesion and thread pulling were also significantly improved, successfully balancing quality stability and increased production efficiency. Similar challenges occur in many workplaces. We are available for technical consultations and prototype testing, including possibilities for process improvements, so please feel free to contact us.

In the process of sliding films and similar materials (feeding mechanism), the guide part of the feeding mechanism is coated with fluororesin to enhance slip properties and prevent adhesion. However, during transport, the workpiece (such as film) may stick to the guide, temporarily halting the line. This is caused by static electricity generated from friction between the resins, which causes the workpiece to adhere to parts like the guide and stop sliding. When this happens, the production line stops, necessitating recovery work. If this occurs frequently, it can lead to increased time and costs. Standard fluororesin tends to accumulate static electricity, but our static-dissipative fluororesin coating (Pass-e Coat) can release generated static electricity, thereby preventing workpiece adhesion due to static electricity. If you are experiencing issues with line stoppages caused by workpiece adhesion due to static electricity, please feel free to consult us.

PTFE is a fluoropolymer with one of the top-class low friction coefficients among solid materials, making it very effective in reducing friction in sliding parts and conveying components. By reducing friction resistance, it helps to suppress wear and seizure of parts, contributing to the longevity of equipment and reducing maintenance frequency. Additionally, it has an anti-adhesion effect, allowing for stable conveying even in processes that handle powders and sticky materials. Our company designs optimal PTFE coating specifications according to usage conditions and counterpart materials, providing surface modifications that balance practicality and durability.

In packaging machines and conveyor equipment, issues may arise where workpieces such as films adhere to guide components, leading to line stoppages. The primary cause of this is static electricity generated by friction between resins. Charged workpieces can stick to the guide parts, causing poor sliding, wandering, and unstable transport. An effective solution to these challenges is our anti-static fluororesin coating, "Pass-e Coat." While typical fluororesin coatings tend to easily accumulate static electricity, Pass-e Coat is designed to dissipate static, thereby reducing adhesion caused by charging. By combining non-stick and slip properties with anti-static functionality, it contributes to stable transport and a reduction in the risk of line stoppages.

In packaging machines and conveyor lines, line stoppages caused by film adhesion significantly reduce production efficiency. The adhesion of workpieces due to static electricity occurs frequently, and the accumulation of recovery work often leads to substantial cost increases. Pass-e Coat is a fluororesin coating with an anti-static function that addresses these issues. By dissipating static electricity, it prevents workpiece adhesion and stabilizes transportation. It serves as an effective countermeasure against static electricity-related troubles that conventional fluororesins could not adequately address. This solution simultaneously improves equipment operating rates and reduces total costs.

In the transport process of films and sheets, adhesion to guide parts due to static electricity is a major cause of transport failures. Especially in processes where there is a lot of contact and friction between resins, charging is unavoidable, which can lead to slipping issues, misalignment, and line stoppages. Pass-e Coat is a fluororesin coating equipped with static electricity prevention features that suppresses the accumulation of static electricity while exhibiting excellent non-stickiness and slip properties. This prevents films from sticking and clinging, achieving stable transport. It can also be applied to existing guide components, allowing for improvement effects without the need for equipment modifications.

In manufacturing, coating technology is directly linked to quality improvement and maintenance efficiency. Traditionally, fluoropolymer coatings (PTFE, PFA, FEP) have been mainstream, but recent strengthening of PFAS regulations has led to a demand for environmentally friendly alternative technologies. Our PEEK coating offers high wear resistance and heat resistance, and is PFAS-free, complying with environmental regulations. Although its release properties do not match those of fluoropolymers, it excels in load-bearing and durability for sliding parts. Depending on the application, a focus on sliding properties can utilize fluoropolymers, while a focus on durability can use PEEK, and a hybrid design combining both is also possible. By selecting the coating that best fits the process conditions, production efficiency can be maximized.

PEEK coating has high hardness and is resistant to wear even in sliding parts and high-load environments, allowing for a longer lifespan. The continuous use temperature is approximately 260°C, and it also has high chemical resistance, withstanding acids, alkalis, and organic solvents. In processes where wear resistance is a challenge for conventional fluoropolymer coatings, PEEK demonstrates stable performance. Being PFAS-free, it complies with environmental regulations and helps avoid future regulatory risks. It is an optimal choice for process improvements under high loads and harsh conditions.

PEEK coating is not only an alternative to fluoropolymer but also a next-generation surface treatment that combines wear resistance, heat resistance, and chemical resistance. By organizing the required characteristics of the process, such as emphasis on release properties, load-bearing and high-temperature environments, and compliance with environmental regulations, optimal coating selection is possible. We offer specification proposals and prototype verification tailored to your applications. Please feel free to consult us regarding the applicability in your own processes and considerations for PFAS measures.

In the manufacturing process of semiconductors and electronic components, which requires a highly clean environment, the electrostatic and particle countermeasures for transport hands (robot hands, end effectors) that transfer silicon wafers and glass substrates are crucial issues that affect yield. Conventional "machined PEEK resin products" not only generate wear particles due to continuous operation but also attract wear particles and surrounding debris due to the inherent electrostatic properties of the resin, leading to defects in circuit patterns. ■ PEEK Coating with Anti-Static Function "PEEKCOAT N04blk" - Maintains the excellent mechanical properties and chemical resistance of PEEK resin while imparting anti-static functionality to the coating. - Minimizes the generation of frictional static electricity, creating a surface environment that repels fine particles from the surroundings. - Forms a smooth and even coating on the surface of components, preventing scratches even when in contact with delicate workpieces and suppressing dust generation in clean rooms.

In semiconductor and electronic component mass production lines that operate continuously for 24 hours, frequent replacement and maintenance of transport hands are a significant bottleneck that causes the entire production line to stagnate. ■Challenges of Resin Hands - Conventional resin hands wear out quickly, requiring complete shutdown of manufacturing equipment with each replacement (resulting in downtime). - Since the working environment is a "clean room," strict entry procedures for workers and pre-cleaning (cleaning and degassing) of replacement parts are essential, leading to significant waste of labor time and costs. ■Switching from Resin to "Metal + PEEK Coating" In response, we proposed "high-rigidity metal (such as SUS) hands + antistatic PEEK coating (PEEKCOAT N04blk)." As a result: - By using metal for the core material, the mechanical strength of the parts themselves is dramatically improved, preventing deformation and cracking due to repeated transport loads. - The PEEK surface layer exhibits excellent wear resistance, significantly extending the lifespan compared to resin hands. - Maintenance labor and equipment downtime in the clean room are dramatically reduced, contributing to improved overall equipment efficiency in the factory.

The "machined products made of PEEK resin" used in the transport process of semiconductors and electronic components are expensive in terms of both material and processing costs. However, when the tips wear out or break, there is a cost-related weakness in that they must be discarded entirely. ■Switching from molded products to "metal + PEEK coating" In response to such challenges, our company has improved procurement and cost issues by changing the structure to "high-rigidity metal (such as SUS) substrate + antistatic PEEK coating 'PEEKCOAT N04blk'." 【Repainting (recoating) even if the coating film deteriorates】 It is possible to regenerate the expensive metal hand body to like-new performance and reuse it multiple times without discarding it. This dramatically reduces long-term running costs. The antistatic PEEK coating also covers necessary functions for a clean environment, such as "static electricity suppression," "reduction of particle adhesion," and "scratch prevention of workpieces due to high smoothness." This achieves both sustainability (reduction of environmental impact) and total cost reduction simultaneously.

In the CMP (Chemical Mechanical Polishing) process of semiconductor manufacturing, major factors causing a decrease in wafer yield are "scratches due to the detachment of adhered slurry" and "ion contamination (metal contamination) caused by chemical corrosion." ■ Scratch Issues from Adhered Slurry When slurry that has splattered onto equipment parts dries and adheres, it can become trapped in the polishing surface and damage the delicate wafer surface. ■ Contamination from Chemical Corrosion Corrosion of the substrate by strong acids and strong alkalis can be a source of contaminating impurities that destroy circuit characteristics. ■ Preventing Slurry Adhesion and Improving Component Corrosion Resistance Our "Fluoropolymer PFA Coating" is a high-performance surface treatment solution that addresses these quality issues. With excellent "non-stick and water-repellent" properties, it prevents the adhesion of high-viscosity slurry. Even if it dries, it does not adhere and can be easily removed. Furthermore, it possesses high "chemical resistance and corrosion resistance" that is inert to chemicals, reducing the risk of metal leaching and ion contamination. The high purity and smooth coating also suppress particle generation, directly contributing to maximizing yield in the CMP process.

A major bottleneck hindering the stable operation of semiconductor manufacturing lines is the "cleaning and maintenance work of slurry that has adhered to equipment parts." ■ The problem of slurry adhesion troubling the site The polishing slurry that splashes during processes such as CMP (Chemical Mechanical Polishing) in semiconductor manufacturing strongly adheres to the surface of parts over time, consuming a significant amount of time and labor for cleaning in clean rooms. Regular line stoppages (downtime) associated with maintenance become a cause of reduced productivity for the entire factory. ■ Fluoropolymer PFA coating that drastically reduces maintenance labor and downtime By applying a PFA coating with extremely low surface energy (high non-stick properties), we can prevent the strong adhesion of slurry. This achieves excellent cleanability, allowing for easy removal even if it adheres. As scraping off the adhered material becomes unnecessary, it can be quickly removed by simply rinsing, dramatically shortening maintenance time. This increases the average time between failures (MTBF) of the equipment and contributes to improved continuous operation rates and reduced burden on operators.

In the design and development of advanced semiconductor manufacturing equipment, measures against chemical corrosion and the maintenance of cleanliness are the most critical design challenges that affect the reliability of the equipment. ■ Issues of slurry adhesion and corrosion resistance in the CMP process The head parts of CMP (Chemical Mechanical Polishing) equipment, which face the wafer at a close distance, are constantly exposed to splashes of slurry containing acids and alkalis, as well as intense corrosion stress, making it difficult to maintain long-term quality with simple water-repellent treatments. ■ PFA coating with fluoropolymer It possesses chemical stability that does not react with almost all chemical substances, completely preventing the leaching of impurities due to metal substrate corrosion. Additionally, due to its strong adhesion and uniform coating formation technology, it exhibits long-lasting corrosion resistance and non-stick properties even for complex-shaped parts. Its high reliability has been recognized, and it boasts a track record of being officially adopted as "standard specification parts" by equipment manufacturers. From head parts to surrounding covers and flow path components, it enhances the overall reliability of the equipment and enables differentiation.

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 semiconductor and liquid crystal (FPD) manufacturing and inspection equipment, where high cleanliness and micron-level precision are required, the surface treatment of stages and transport components that come into direct contact with the workpiece significantly affects the reliability of the equipment. Our company offers contract processing solutions for large precision components using high-performance PEEK coating "PEEKCOAT." [Our Strengths and Value Proposition] ■ Large Equipment Available We can perform bulk processing of large stages and long arms sized 1 to 2 meters. ■ "Thick Film + Post-Processing" Technology By baking a PEEK coating film of over 1mm and then finishing it with precision machining, we achieve both stringent dimensional accuracy and smooth surface protection performance. ■ Advanced Distortion Control We possess specialized jig technology that suppresses deformation and shrinkage stress of the substrate due to firing heat of approximately 400°C. [Horizontal Expansion and Abundant Processing Achievements] We have numerous surface treatment achievements for various components in semiconductor and liquid crystal equipment, including inspection stages, transport hands, CMP peripheral components, cleaning and etching tanks, piping, and chambers. Please feel free to consult us for test processing (prototyping) tailored to your challenges.

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.

The resin varnish used in processes such as motors, transformers, and semiconductor encapsulation has extremely high viscosity and adhesion, making stickiness and adhesion to the inner walls of processing tanks and receiving pans a significant maintenance challenge. Conventional fluoropolymer coatings lack sufficient non-stick properties, resulting in enormous time and effort spent on manual solvent wiping and scraping. ■ We propose the ceramic coating "Biceram 100" Biceram is a surface treatment technology that boasts extremely high release properties, hardness, and durability, surpassing fluoropolymers. ■ Non-stick and release properties that exceed fluoropolymers Due to its low surface energy, even resin varnishes with strong adhesion are less likely to stick to the surface, physically suppressing strong adhesion caused by stickiness. ■ High-hardness inorganic-based coating The hard coating reduces wear and peeling from cleaning tools such as scrapers, maintaining excellent release performance for an extended period. This significantly shortens cleaning time and contributes to reducing equipment downtime and improving productivity.

In recent years, with the tightening of global regulations on per- and polyfluoroalkyl substances (PFAS), manufacturing sites have rapidly shifted towards "environmentally friendly, non-stick treatments" as alternatives to fluoropolymer coatings. ■ Ceramic Coating "Biceram 100" This next-generation release and non-stick coating achieves complete PFAS-free status. It physically suppresses the strong adhesion and stickiness of high-viscosity paints, adhesives, and other strongly adhesive resin varnishes that traditional fluoropolymers could not prevent. ■ High Hardness Coating Unique to Ceramics It overcomes the weaknesses of soft and easily scratched fluoropolymers, achieving high wear and scratch resistance with a hard ceramic coating. To prevent wear and peeling of the coating from cleaning tools, it reduces the frequency of re-coating, contributing to lower running costs. It is an optimal "fluoropolymer alternative solution" that simultaneously achieves environmental regulation compliance and improves on-site productivity.

Generally, "fluororesin coating" is widely used for non-stick and release purposes, but due to the softness of the coating film, using scrapers or spatulas during cleaning can damage the film, leading to wear and peeling. ■Features of Biceram 100 It is a high-performance surface treatment technology that forms a dense and hard coating based on ceramic components, achieving excellent non-stick properties and high coating hardness that surpass fluororesins. ■Prevention of scratches with the high hardness surface unique to ceramics Not only does it physically reduce the strong adhesion of high-viscosity resin varnishes and adhesives to the tank inner walls and receiving pans, but the coating is also less prone to scratches during cleaning with tools, allowing the initial excellent release effect to last for a long time. Additionally, it excels in chemical resistance and heat resistance against cleaning solvents, strongly supporting the longevity of equipment and maintenance-free operation in harsh industrial environments.