Papermaking and New Materials Technology

Highly functional materials made from paper.

ABOUT OUR
TECHNOLOGY

Utilizing FCC’s unique papermaking technology cultivated through the manufacturing of highly durable and highly heat-resistant friction materials, we provide highly functional paper substrates applicable to various products with raw material blending, structure control, and shape control technologies suitable to customer needs, contributing to higher functionality, lighter weight, and cost reduction of products.

Because FCC is a multidisciplinary manufacturer, we are able to handle the processes of folding, bonding, grooving, and forming into universal shapes in addition to paper processing.

The unique and porous structure of paper is highly applicable at a high level to various applications, such as heat insulation, insulation, radio wave absorption, filtration, and catalysts; in terms of thermal management, it can be applied to the development and manufacture of EVs and related products as well. 

Using the friction material manufacturing technologies, we develop new materials in-house that create value in a variety of fields and manufacture them in small lots. 

What can Papermaking and New Materials Technology Do?

Synthetic Fibers
Inorganic Powders

Small cutting tool allowing deep groove machining

FCC’s papermaking technology allows for filling highly functional materials at a high ratio. Filling of a large amount of highly functional ingredients expands the options for use in a variety of applications. In addition to powders, combinations with a wide variety of materials such as functional fibers, microparticles, metals, and natural materials are possible.

Custom Fiber Spacing Technology

Groove Formation Technology
High Porosity Paper

Total Control Paper Structure

Paper structure is controlled in the papermaking process. Various shapes are provided in response to the applications such as thickness, density, surface structure (grooves, unevenness), and internal structure control (porosity). 

Products with High Precision Control of Paper Structure

OUR ADVANTAGES

Formula designs tailored to the application

Our database and know-how of raw materials, papermaking, and coating conditions, based on our many years of experience in friction material development and manufacturing, allows us the formulation design tailored to a wide variety of applications.

Adjustable Paper Structure and Surface Condition control

Total control of specific paper surface conditions, such as forming honeycombs for purifying exhaust gas, pyramid structures for absorbing radio waves, etc. in addition to manufacturing paper with different pore diameters and porosities.

Develop/Manufacture Prototypes Well-Organized Production Environment

We have the technology and facilities in-house in place free from impacts by any conditions (temperature, humidity, etc.) for mass production of prototypes.

Analysis and Evaluation

We have an environment in place that allows material analysis (ingredients, composition, hardness, stress, surface analysis, CT), strength testing (tensile, blanking, functional evaluation testing) and product evaluation (function, strength, durability testing).

Combination of Casting Technology and Joining Technology Challenges in Uncharted Fields

Combination of various other technologies, such as casting and joining, enables flexible approach to EV, thermal management, radio wave, and electromagnetic wave control.

PRODUCT REALIZATION

A new ceramic forming method with a high degree of control

Paper Ceramics Technology

Ceramic material-soaked paper, blended with ceramic materials and made into paper, is burned at a high temperature, causing the organic ingredients in the paper to disappear and the formulated materials to be sintered, resulting in a ceramic product.

Forming Ceramics into Various Shapes

Forming in the Paper state provides the flexibility and ease of processing. 
Ceramics with complex shapes are achieved at low cost by sintering through heat treatment after forming.

Material Flexibility

Capability to soak various materials in the paper.

Porosity Control by Organic Content

The paper constituent contained in paper ceramics is burned off when heated. 
The porosity is controllable by manipulating the size and number of pores created with the organic material is burned away.

Realization of Thin-Wall Ceramics

Formed from thin paper, thin sheet shapes are easily formed. 

Manufacturing Process

Processing of Ceramics by Paper Folding

Formation of Processed Ceramics by Paper Lamination

Lamination Forming Technology

Easily create 3D structures by layering paper. Lamination of different materials and different porosity making it possible to create gradient materials not possible with existing 3D printing technology.

Multi-Layer Material

Flexibility in designing the composition and multi layered variable porosity features according to the required function.

Ceramic work pieces having customizable geometry structure is formed by laminating ceramic soaked paper with different porosities and material compositions.

Image of Composition Gradient Material

Image of controllable Porosity amounts within customizable geometries

Fiber Composite Materials

Ceramic fibers and ceramic materials are mixed during the paper making process to form the primary substrate for fiber composite materials. Forming → Sintering to create highly functional products

Paper structure + ceramic fibers create a light weight, high heat resistance and high elasticity.

Catalytic converter for general-purpose engines (honeycomb)

Catalytic unit for wood stove

VISION

Future Technology Vision

Research on Catalytic Reaction Control Technology

Aim of the Study

Paper structure + ceramic fibers create a light weight, high heat resistance and high elasticity.

Technology Overview

Conversion of barrier greenhouse gases (such as CO2) into harmless, beneficial, and renewable substances through adsorption and recovery in order to achieve carbon neutrality.

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