Development of Environmentally Conscious Products
Sony Chemical & Information Device Corporation has been introducing solventless methods and alternative solvents into our manufacturing designs and production processes in order to reduce possibly hazardous chemical substances in its products manufactured with the use of specific solvents and chemicals for raw materials.
Typical environmentally conscious products
1. Halogen-free products
Halogen-free build-up and Flex-Rigid printed circuit board
High-density build-up and Flex-Rigid printed circuit board were made halogen-free by improvements in materials and pigments for solder resist. The preflux needed in soldering was switched from the conventional, possibly hazardous organic solvent-based type to water-soluble, heat-resistant type that generates less gases.
Halogen-Free Self Control Protector (SCP)
In 2008 we commercialized halogen-free type self control protector (SCP), a surface mounted type fuse that interrupts overcharge or overcurrent in Li-ion rechargeable batteries.
2. Products with UV curable manufacturing method
Double coated tape G9000
Adhesive tape with lower environmental impact with UV curable manufacturing method, was first marketed in 1997 as Green Tape G9000 series. Since then new types with improved resilience to curved surfaces, impact resistant and recyclability were launched, which have widely been used in electrical appliances and industrial machines.
*Green Tape won the Minister of Economy, Trade and Industry Prize in the 2009 Awards for Circular Resource Techniques and Systems from the Ministry of Economy, Trade and Industry of Japan.
3. Solar Cell Conductive Film
“SP 100 Series,” Solar Cell Conductive Film for Photovoltaic Modules that requires no Soldering
In recent years, photovoltaic modules have become the focus of attention as a form of reusable energy and implementation is progressing at a rapid pace. At the present time, although soldering is used to connect the metal ribbon in photovoltaic cell modules that collects electricity, in anticipation of the fully-fledged spread of photovoltaic modules in the near future, in addition to performance and cost aspects, photovoltaic module material and components manufacturers are beginning to see the emergence of requirements for environmental compatibility.
There is a strong demand for materials and components that feature lower environmental impact, no matter how small, with no loss of performance and good cost balance.
Mass production of the “SP100 Series,” a solar cell conductive film for photovoltaic modules developed by Sony Chemical & Information Device Corporation that makes use of Anisotropic Conductive Film (ACF) and can be used for solder-free connection was launched in April 2010.
“SP100 Series” solar cell conductive film for photovoltaic modules realizes conduction by heating and pressurization of conductive particles distributed evenly in an epoxy-type thermosetting resin binder and, at the same time, this process heat-cures the resin to enable unfailing conduction equivalent to that provided by soldering.
Low-temperature bonding that puts no stress on photovoltaic modules
While, to suppress costs without lowering electrical conversion efficiency, manufacturers are reducing the volume of structural material used and producing progressively thinner, more lightweight products, solder needs to be heated to at least 200℃ before it will melt and this facilitates the occurrence of residual stress due differences in the thermal and mechanical characteristics of the silicon used in cells and metal ribbon (generally solder-coated copper wire), leading to problems such as fracturing of cells after bonding. The “SP100 Series” is capable of low temperature bonding at 180℃, resulting in a sizeable reduction in residual stress in cells caused by heating, thereby enabling metal ribbon bonding of thin cells (approximately 150 μm), a process normally held to be difficult.
Sony Chemical & Information Device Corporation are engaged in the development of products in which substances that impact on the environment are either replaced or eliminated and proactively promotes the manufacturing of products with no impact on the environment through measures such as reduction in the amount of energy used in production processes and waste and reduction of impact on the environment caused by products after disposal.
Approach that promotes circulation of resource
Product environment initiatives are underway with Sony recording media products manufactured at the Tagajo Plant with the focus on reduction and recycling.
[ Recycling of packaging materials and external cases ]
1.Polycarbonate Recycling (Reuse in Processes and Reprocessing into High-quality Resource Circulation Materials)
Rather than being disposed of, approximately 10% of polycarbonates discharged from optical film manufacturing processes at the Tagajo Plant is pulverized by in-house processes as raw material and reintroduced to manufacturing processes together with virgin materials.
In addition, approximately 30% of polycarbonates controlled as waste are processed in-house into high-quality resource circulation materials using technology and equipment unique to the Tome Plant Toyosato Site and is used for part of the exterior of products such as 3.5MO and 5.25MO professional Blue-ray discs and LTO* cartridges. Although previously, the remaining 70% was pulverized and recycled by an external contractor as valuable material, since FY2010, part of this material has been used as raw material for Sony Recycled Plastic “SoRPlas,” marking the beginning of an initiative that contributes to resource recycling and waste reduction within the group. (Achievement in FY2010: 380 tons: All discharged material scheduled to be targeted from FY2011 onward).
SoRPlas (Sony Recycled Plastic) is an original flame-retardant polycarbonate resin developed by Sony and used in the body of Sony’s “BRAVIA” LCD televisions.
* LTO (Linear tape-Open): magnetic tape large-capacity storage device)
2. Coloring of consumer Blu-ray disk cases was discontinued, while prioritizing ease of recycling and implementing display of materials used in displayable plastic components.
3. Use of highly recyclable cardboard as packing material and use of recycled paper for cards used with products to realize resources recycling.
[ Reducing use of packaging materials and product cases ]
1. Reduction of plastic used in existing Blu-ray disk cases for business use by approximately 5% and of plastic used in LTO cases by approximately 17%.
2. Discontinuation of use of individual packaging cases in a cartridge containing ten LTOs and change to a packaging format that eliminates the need to unpack disks, realizing improved convenience for the customer at the same time.
3. Design review of cardboard cushioning material for consumer Blu-ray disks, achieving further reduction in consumption.
4. Changing cushioning material for products from urethane to cardboard.
