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Easy Guide of Products

Carbon Black

Carbon black is widely used around the world as a strengthening agent for rubber products such as tires, tubes, belts and hoses. When combined with natural or synthetic rubber, carbon black strengthens the rubber product.

As the name suggests, carbon black is black in color. For example, tires are black because it contains carbon black. A tire for a regular passenger car normally weighs around 10 kg and carbon black accounts for about one-third of that weight. See if you can find any black rubber products other than tires around you. Most black rubber products contain carbon black. As you can see, carbon black is indispensable for manufacturing rubber products including tires. Carbon black is also used as a colorant for plastics and as pigment for various inks, and also as the conductivity imparting filler for cable cladding. Furthermore, the minute nanometer-level particles of carbon black have prompted active studies on its applications in various advanced materials.

At Tokai Carbon, we have developed new products called Aqua-Black by imparting hydrophilic property to the carbon black surface. Its unique characteristics have led to its application as a pigment for inks used in inkjet printers.

Carbon black is thus a very important, yet behind-the-scenes raw material that supports our lifestyle.

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Graphite Electrode

Iron is considered as the bread and butter of heavy industry and ever since its mass production began across the world, it has been significantly improving people's lifestyle. It's hard to imagine our present lifestyle and industrial development without iron. There are primarily two ways of producing iron. One is the blast furnace method where iron ore is reduced using coke to produce pure liquid iron (pig iron). The other is the electric furnace method, where iron scrap (for example, scrap from automobiles or old iron rods from demolished buildings) is melted and recycled into new iron. Graphite electrodes are used in these electric furnaces to pass electricity and generate heat to melt the iron scrap. The word electrode may remind you of the few centimeters-long ones commonly found inside dry batteries. Though similarly cylindrical in shape, the electrodes used in electric furnaces, are on an entirely different scale. The most commonly used size for electric furnaces nowadays has a diameter of 60 cm and a length of 2.4 m. Also, with the capacity of the transformers used in electric furnaces increasing, demand for electrodes with 80 cm diameter and 2.7 m length is also growing. When the graphite electrode is in use, its tips become red hot and the temperature exceeds 1,000 degrees Celsius. Therefore, the material used for the electrodes is required to have high quality and the strength to handle the large diameters, withstand high-power operations and resist thermal shock. And “graphite electrode” is something that meets all those requirements.

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Fine Carbon Products

We go about our daily lives casually, without realizing the fact that a wide range of fine carbon products actually supports our modern life where convenience has become the norm. The following list, by category, shows how some of our products are contributing to facilitate this taken-for-granted convenient lifestyle.

(1)Electronics

In manufacturing processes where impurities are the primary problems, our highly pure graphite materials and SiC coated products play an active role. Solid SiC and Glassy Carbon are used under specific ambient gas, while TOKAREC is used for heat shielding. Thus our major fine carbon products provide crucial support to the semiconductor industry.

(2)Opto-electronics

Our fine carbon products led by isostatic graphite play an important role as manufacturing parts in various areas such as the compound semiconductor used in cellular phones, LEDs used in traffic signals, semiconductor lasers used to read signals of DVDs, and in the metallurgical tools used for manufacturing the optical fibers that connect all over the world.

(3)Molding - in the automobile and aviation industries

Isostatic graphite is used as the electrode for manufacturing various molds starting from injection molds for plastic products sold at 100-yen shops to those used to make engine parts, exteriors and interiors of premium automobiles. It is an indispensable star player for the molding industry.

(4)Environment and new energy

In the environmental and new energy fields, which are currently attracting a lot of attention, our graphite products and heat resistant products such as TOKAREC as well as chemical-resistant products such as impervious graphite TOKABATE are being used in fuel cells that generate electricity from water and air, condensers for hybrid vehicles and semiconductor devices for solar power generation. (Both TOKAREC and TOKABATE are brand names proprietary to Tokai Carbon.)

(5)Heat resistance and heat treatment

Our isostatic graphite materials are used in continuous casting to shape non-ferrous metals into rods, pipes or plates. In heat treatment, our extruded graphite materials are used in vacuum furnaces and heat-treating furnaces, while our extruded graphite products and TOKAREC are used as insulating boards for furnace walls as well as jig tables.

(6)Chemical engineering

With their excellent thermal conductivity and remarkable chemical resistance, products from our fine carbon family are often used in equipment that removes heat from acidic and alkaline corrosive solutions in chemical engineering. The life of such products ranges from several years to longer than 10 years and you can surely rely on our products to do a good job over a long term.

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Friction materials

Friction materials, which are used in automobiles, motorcycles and construction equipment - as brakes for stopping the motion or as clutches that transmit movements -, are considered to be the backbone of engine control devices. The quality of these parts could literally be the difference between life and death, making them even more important. As engines become more powerful than ever and engine control devices get more sophisticated, superior performance has been required of friction materials. Since embarking on the development of sintered metal friction materials in 1949 and starting production of paper-based friction materials in 1977, we have built our current No. 1 position in the industry through a series of technological innovations. With the addition of Tokai Material Co., Ltd., which makes resin-based friction materials, to our group in 2003, Tokai Carbon became a one-of-a-kind integrated friction materials manufacturer with a product lineup ranging from sintered metal-based and paper-based to resin-based friction materials. We enjoy a high reputation both domestically and abroad for meeting the needs of our customers with a wide range of products.

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Industrial furnace and related products

One of the main products in this category is EREMA (electric resistance material) heating elements, which are used in various applications such as baking ceramic condensers and IC substrates, sintering in powder metallurgy and quenching and tempering of steel parts. They are also used in glass melting and retention, fabrication of ceramic fibers and firing of pottery and porcelain. Industrial furnaces such as electric furnace and gas furnace are used for heat treatment of metals and ceramics. We have an established track record in the design and manufacturing of a wide-range of heating devices for such heat treatment and, with the help of our integrated advanced technologies, we are making significant contributions to the industrial world as a manufacturer of heating elements and refractory products essential to such industrial furnaces.

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Easy Guide of Products