Toray Industries, Inc., announced that it has decided to boost production capacity by 60% for “Lumirror” biaxially oriented polyester release films for manufacturing multilayer ceramic capacitors (MLCCs). The company will invest ¥8 billion in this upgrade at the Gifu Plant. The new facilities will go on line in 2025.MLCCs are chip-type capacitors incorporating multi-layered ceramic dielectrics and metal electrodes. All electrical devices employ them, including telecommunications equipment, appliances, and automobiles. The MLCC market should expand at least 10%, annually. Key drivers would be 5G/6G advances in telecommunications and unit installation growth from electrified vehicle uptakes.Toray leads the global MLCC mold release film market, producing these offerings at the Mishima and Gifu plants in Japan, Penfibre Sdn. Berhad in Malaysia, and Toray Advanced Materials Korea Inc. The domestic upgrade will enable Toray to capitalize swiftly on the MLCC market’s expansion, as Japan is the biggest consumer of release films.Lumirror is an incredibly smooth film which Toray has developed based on its decades of experience in film development. This film provides a thin finish for ceramic layers and is free of irregularities. Many MLCC manufacturers have adopted it, helping them to miniaturize and raise the capacity of MLCCs.Toray’s new line will have one of the largest MLCC film production capabilities in Japan, embodying the company’s quality enhancement capabilities with existing lines. This setup will enable Toray to cater to market demand in coming years for thinner and smoother films. The company looks for the facility to accommodate current efforts to collect and reuse films. Toray will manufacture a wide range of products, from general-purpose to high-value-added products and grades that lower environmental impact to meet varying customer requirements.The capacity boost at the Gifu Plant will enable Toray to reinforce and stabilize its supply structure and bolster global operations through its four production sites to match rising demand for MLCCs in telecommunications and automotive applications.with a bending diameter of 3 mm and a test frequency of 10000 times. If the barrier layer is brittle or if adhesion to the PET film is poor, cracking or peel-ing of the film may occur upon bend-ing, resulting in degradation of barrier properties. However, the developed product showed almost no degrada-tion of barrier properties before and af-ter the test, and was confirmed to have good bending resistance.The expected applications are var-ious flexible devices. Among them, it expects organic thin-film solar cells and perovskite solar cells, for which demand is expected to grow. Mr. Tokunaga predicts that "the global market for organic thin-film solar cells will grow at an annual rate of 67% after 2023, and that for perovskite solar cells will grow at 95% of the same rate. The Japanese market for flexible devices is expected to grow at an annual rate of about 20% after 2025. First of all, as a next-generation energy source, we hope to see thin-film solar cells used for encapsulation in lightweight aircraft and drones, which can fly on solar power alone."In addition, for healthcare and sensing applications, the material can be used to encapsulate organic semi-conductors used in film-type thin-film sensors that detect temperature, pres-sure, light, gas, etc., as well as organic EL and wavelength conversion element displays used in smart glasses, etc. In response to food loss, the company intends to take on the challenge of ap-plying this technology to food packag-ing applications, as there is a need to reduce package weight to extend shelf life and save energy for transportation.The company plans to solve the problems of broadening the width of the roll-to-roll process for mass pro-duction by the company's group in Ja-pan, with the aim of commercialization in 2023. 40
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