ZEON's polymer molding technologies have attained a stage of high-level precision based on the company's extensive accumulated expertise. Currently, these technologies are systematically developed in the RIM Laboratory, the Physical Properties Processing Laboratory, the Zeon Kasei Co., Ltd. Laboratory and the Zeon Medical Laboratory.

RIM Laboratory

The RIM Laboratory develops RIM molding (reaction injection molding) technologies using DCPD (dicyclopentadiene) as a raw material extracted from C5 fraction. RIM molding is a special technology in which molding and a non-solvent metathesis ring-opening polymerization reaction caused with a transition metal catalyst are simultaneously implemented within a metallic mold. RIM molding is especially suitable for large molding products due to its material strength and support for low pressure molding. PENTAM, now used in such products as domestic waste water purifiers, is becoming increasingly well known around the world.

 

Physical Properties Processing Laboratory

ZEON founded the current Physical Properties Processing Laboratory as a company total research institute in 1997 by reorganizing the Physical Properties Research Division, focused on the characterization of particle structure and research into the physical properties of synthetic rubber materials. In addition, the Processing Research Division was founded for the vinyl chloride resin business, the company's key business at the time of its establishment. The laboratory is composed of the Physical Properties Laboratory, the Processing Technology Laboratory, and the Processing and Trial Manufacturing Laboratory. Work at the Physical Properties Processing Laboratory contributes to a wide range of technology development from basic technologies to applied technologies related to macromolecular materials that ZEON handles through a wide variety of studies including macromolecular analysis, physical property technologies and material manufacturing technologies.

The Physical Properties Laboratory conducts research into the following:

1. The particle design of specialty chemicals, monomers, polymers and catalysts through computer chemistry.
2. Polymer characterization and physical property performance using various analyzing devices, including electron microscopes, viscosity and elasticity analyzing devices, NMRs, atomic force microscopes (AFX), and X-ray analyzing devices.

ZEON focuses special effort on research into new analytic technologies, recognizing the vital role of improved analyzing capability in the development of unique company technologies.

Sample of computer chemistry: Model of CPK's DCPD endo-body (van der Waals molecule)

Sample of atomic force microscope (AFM) analysis: Surface condition of cast film in blending polystyrene and polybutadiene

Sample of product designed and developed: Lenses and other products produced by cyclo-olefin polymer (ZEONEX)

The Manufacturing Technology Laboratory is responsible for the flow analysis of materials in metallic molds when molding polymers, research and development into CAE technology that implements structure analysis of polymer molding products utilizing computers; and the application of CAE technology, as well as research and development of molding technologies related to various polymers. The laboratory explores a wide range of areas, from mold design and improved moldability to the development of molding products. These technologies, in turn, are applied to injection molding, RIM molding, extrusion molding, and sheet and film processing. The results include a wide range of products, including DCPD-RIM (PENTAM) molding products, cyclo-olefin polymer (ZEONEX) molding products, medical equipment, and easy-to-burn olefin sheet molding product, handled by Zeon Kasei Co., Ltd.

Sample of Structure Analysis

Engine hood for construction equipment

Waste water purifier

Housing for arcade game machines

 

The Processing and Trial Manufacturing Laboratory is responsible for the evaluation of the physical properties of polymer molding products and the development of trial products in cooperation with the Manufacturing Technology Laboratory. The laboratory pursues product development and research on manufacturing technologies for environmental materials, building materials and park materials which are handled by the Civil Engineering Product Division, and also focuses on the improvement and R&D of vinyl chloride compounds handled by Zeon Kasei Co., Ltd.

Zeon Kasei Co., Ltd. Laboratory

This laboratory, directly controlled by Zeon Kasei Co., Ltd., is engaged in the compound design of resin materials, processing and physical properties research, design and development of manufacturing products (CAD/CAM/CAE) and functional materials research (sound-proofing, deodorization, delustering). Zeon Kasei Co., Ltd., a member of the ZEON Group, mainly handles secondary manufacturing products and goods. Originally span-off from ZEON's Product Processing Laboratory, the Zeon Kasei Co., Ltd. Laboratory is currently responsible for the research and development of materials and manufacturing technologies, along with product design support for customers, related to Zeon Kasei's molding materials, building materials, packing materials, distribution materials and high functional products.

(1) Highly functional building materials

The laboratory develops the latest well-designed, wood-like resin materials, produced by kneading powdered wood from waste wood and macromolecular materials, primarily using vinyl chloride resin to conserve environmental resources.

(2) Powder molding materials

The laboratory develops resin powder materials for detailed automobile interior materials and toys. The powder is applied with a special molding technology known as powder molding, in which the powder is processed at high temperatures on the mold surface, resulting in a product with a high-grade appearance at low cost.

(3) Sheet materials for vacuum molding

Taking into consideration cost reduction, the environment and processability, the laboratory develops functional sheets for vacuum molding and conducts research into molding technologies.

(4) Design technology

The laboratory is engaged in R&D in a wide range of processes, from effective design and product evaluation to manufacturing technologies for resin molding products, including packing materials, utilizing advanced CAD/CAM/CAE.

(5) Sound-proofing technologies

The laboratory conducts research into sound-proofing materials for industrial use, such as those used in the construction business, utilizing material design technology and measurement technology, including sound insulation/damping, in order to contribute to improved housing environments.

(6) Deodorization technologies

The laboratory targets the creation of various products based on the technology of evaluating diverse deodorization with deodorants that exhibit excellent chemical reactions against everyday odors.

(7) Optical catalyst technologies

The laboratory promotes the development of devices for maintaining the freshness of fruits, vegetables and flowers and the development of air cleaners, utilizing ZEON's unique optical catalysts.

Woody-like resin molding products	Machining center
Vacuum molding products	Freshness-maintaining device
Sheet molding machine

Zeon Medical Laboratory

ZEON's medical equipment research started around 1975 with the development of an artificial kidney. With the establishment of a full-scale research system in the 1980s, ZEON took on the challenge of developing the world's first ventricular-assist device through the applied study of precision molding technologies and living body conformity materials required for medical equipment, based on the ZEON's achievements as a leading high-polymer chemistry manufacturer in Japan.

In the course of developing the ventricular-assist device, the laboratory conducted a significant number of material design and performance tests in order to produce unprecedented, highly advanced medical equipment. As a result, the company developed new anti-thrombus materials and reliable pumps. Furthermore, through animal studies in the company's animals test facilities and approximately 60 clinical trials, the company developed in 1990 its first commercial products after acquiring an approval to manufacture a ventricular-assist device from the Ministry of Health and Welfare.

Since then, the laboratory has conducted research and development focused on the development of cardiovascular and digestive products utilizing materials technologies, precise molding technologies and animal evaluation technologies, which were acquired through the experience of developing the ventricular assist device.

In the area of cardiovascular products, the laboratory has developed a series of products, including a IABP catheter, which simultaneously exhibits the characteristics of a thin catheter with stability in blood vessels and anti-thrombus balloon with excellent abrasion resistance; a thermodilution catheter for measuring cardiac output with distinct characteristics in the catheter's outside diameter and balloon; and a Sheath Introducer Set, which is excellent for insertion into blood vessels due to the application of special fluorine resin and its unique design. The laboratory is especially focusing on technologies for manufacturing a small-diameter multi-rumen catheter.

IABP balloon		Thermodilution catheter
Sheath introducer
Regarding digestive products, the laboratory developed Japan's first bipolar snare, considered much safer than conventional products.
Bipolar snare

In the medical equipment business, Zeon Medical Inc., established in 1989, released the XEMEX line.

Furthermore, ZEON's Medical Equipment Material Laboratory was transferred to Zeon Medical in 1996 as the Zeon Medical Laboratory, which is responsible for the complete process from research to sales as a entire medical equipment manufacturer.

Looking toward the future, the laboratory plans to focus on the design and development of medical equipment that is clearly differentiated from competing products, by taking full advantage of ZEON's unique polymer technologies.