Developed through proprietary Kuraray technologies, GENESTAR is a polyamide resin that demonstrates superior heat resistance. Since its commercialization in 1999, the application of GENESTAR has steadily expanded, growing mainly in the electric and electronic fields. Based on this success, and leveraging GENESTAR's unique characteristics, Kuraray now seeks to expand its adoption into the auto components field and other new sectors.
In order to meet increased future demand, Kuraray has made the decision to substantially enhance its manufacturing structure, expanding the current production facilities of GENESTAR resin and nonanediamine, a major raw material monomer of GENESTAR.
GENESTAR is a new polyamide resin (PA9T) that uses the world's first industrialized nonanediamine (diamine with a carbon number of nine), made possible by Kuraray. Owing to its unique aromatic ring and aliphatic chemical structure GENESTAR is characterized as a semi-aromatic polyamide that exhibits superior heat resistance, low water absorbency, low traction and chemical resistance properties.
In recent years with the strengthening of environmental regulations such as the European RoHS Directive, the advancement toward lead-free processes in the electric and electronic fields has accelerated. Correspondingly, demand for GENESTAR as a highly heat-resistant material for use in surface mounting technology (SMT), which is applied in the production of connectors for mobile telephones, personal computers and smart media, has grown dramatically. In addition, Kuraray looks forward to the adoption of GENESTAR based on its highly sought-after heat resistance and tractionless properties for application in bearing retainers, fuel piping and radiator components in the automotive field.
As Kuraray prepares for this increase in demand, it is taking steps toward streamlining its current resin manufacturing facilities, affecting an increase in annual production capacity from 4,500 tons to 5,500 tons by August 2007. Furthermore, in anticipation of significant market growth, Kuraray has invested in the expansion of resin and raw material monomer facilities to achieve an overall annual production capacity of 12,500 tons by 2010.
|After streamlining |
|Expansion (Stage 1) |
August 2008 operation
|Expansion (Stage 2) |
|Resin PA9T||Kuraray Saijo||4,500||5,500||5,500||5,500|
|Monomer nonane- |
|Kashima Plant||3,000||3,000||(Pause in production)|
Approximately ¥10 billion (monomer ¥8 billion/resin ¥2 billion)
|Connector applications||Increased adoption of GENESTAR for its thermal stability (260℃ and over) in reflow processing, in line with the spread of SMT (surface mounting technology: soldering technology used to mount electronic components to the surface of printed circuit boards) and the development of lead-free soldering|
|LED reflectors||Expanded adoption as side view LED (light emitting diode) reflectors used in light sources for mobile telephone displays. Promoting development for future adoption in top-view LEDs.|
|Electric auto components||Advancing application development by making the most of superior anti-tracking properties (insulation capabilities) for use in electronic components contained in automotive ECUs (electronic control units).|
|Slide components||Development of applications targeting bearing retainers and various types of gears by making the most of GENESTAR's low traction, heat resistance and dimensional stability.|
|Fuel-related components||Development of applications targeting fuel rotation piping, leveraging heat resistance and fuel barrier properties.|
|Radiator components||Application development for radiator hoses employing heat and chemical resistance properties.|