In dispersion engineering, stable quality cannot be achieved solely based on the performance of the equipment. What is important is the overall design of the process, taking into account material properties and process conditions. This is referred to as dispersion process design. Dispersion quality is determined not only by the strength of shear but also by multiple factors such as flow state, residence time, and method of input. If these conditions are not properly designed, localized agglomeration or variation can occur, making it difficult to maintain stable quality. For example, poor wetting during powder input or the occurrence of stagnant areas due to flow bias can lead to clumping or dispersion issues. Additionally, even if the shear energy is sufficient, if it does not act uniformly on all particles, differences in dispersion state will arise. Therefore, in dispersion processes, it is crucial to design "flow," "shear," and "processing time" as an integrated system. This allows for all particles to receive the same dispersion history, achieving uniform and highly reproducible dispersion quality. In particular, inline continuous processing has the advantage of maintaining consistent conditions within the flow, making it easier to ensure reproducibility in process design. Dispersion process design is a key concept for stabilizing quality and successfully scaling up.

In dispersion engineering, issues such as unresolved agglomeration, sedimentation, and unstable particle size distribution occur frequently at many sites. These problems are caused not only by the performance of the equipment but also by inconsistencies in particle characteristics, dispersion conditions, and process design. For example, when there is insufficient dispersion energy, particles do not break down to primary particles, and agglomeration remains. Additionally, if the shear conditions or flow state are not appropriate, uniform dispersion cannot be achieved, leading to sedimentation and variations in quality. Particularly in high-viscosity systems or high solid content slurries, even slight differences in conditions can significantly impact the results. Furthermore, in batch processing, variations in mixing uniformity and residence time make it difficult to ensure reproducibility. To resolve these dispersion issues, it is important to optimize the entire process, including particle characteristics, dispersion energy, and flow design, rather than simply changing the equipment. By maintaining consistent conditions, as in inline continuous processing, stable dispersion quality and reproducibility can be achieved.

In dispersion processes, issues such as unstable particle size distribution and quality variation between batches occur in many settings. These quality variations are caused not only by equipment performance but also by variations in dispersion conditions, flow states, and process design. For example, when shear energy is uneven, differences arise in the disintegration state of particles, leading to a wider particle size distribution and residual agglomeration. Additionally, in batch processing, variations in mixing uniformity and residence time can cause fluctuations in dispersion state between batches, making it difficult to ensure reproducibility. Particularly in high-viscosity systems or high solid content slurries, even slight variations in conditions can significantly impact quality. To suppress quality variations, it is crucial to design processes that maintain consistent dispersion energy and flow conditions. By stabilizing conditions, as in inline continuous processing, it becomes possible to reduce inter-batch differences and achieve stable dispersion quality. Furthermore, in dispersion processes, not only the performance of the equipment itself but also operating conditions such as input order, residence time, and flow control greatly affect quality. Inline continuous processing makes it easier to maintain these conditions consistently, ensuring stable dispersion even in high-viscosity slurries. By designing the entire process, it is possible to fundamentally suppress quality variations.

Despite obtaining good dispersion results in the lab, the challenge of unstable quality upon mass production occurs in many settings. The main cause of this is that the dispersion conditions are not replicated due to differences in scale. In lab equipment, the smaller size leads to higher energy density, making shear and flow more uniform, while in mass production equipment, the larger scale often results in insufficient dispersion energy at the same rotational speed and processing time. Additionally, differences in equipment structure and flow patterns can cause variations in the shear history and residence time experienced by particles, leading to differences in the dispersion state. Furthermore, simple scale-up does not ensure that critical parameters such as flow rate, residence time, and shear intensity match, making it difficult to reproduce the same results as in the lab. To address these challenges, it is essential to focus on process design based on dispersion energy density and flow conditions rather than merely increasing equipment size. By designing the system so that particles pass through the processing area under consistent conditions, it is possible to achieve reproducible dispersion quality even when the scale changes, as seen in inline continuous processing.

In dispersion processes, the variation in quality is one of the significant challenges. Even when processing under the same equipment and conditions, it is not uncommon for the dispersion state to differ from batch to batch. The main factor behind this is the variability in the dispersion history experienced by the particles. In batch processing, the shear and residence time experienced by each particle differ depending on their position and flow state within the tank. As a result, there is a mixture of sufficiently dispersed particles and undispersed particles, leading to variations in quality. This tendency becomes particularly pronounced under high viscosity or high solid content conditions. On the other hand, in continuous processing, particles pass through a consistent processing area, receiving nearly the same dispersion conditions. Because shear energy and residence time can be controlled consistently, the variability in dispersion history is minimized, resulting in a uniform and highly reproducible dispersion state. Moreover, continuous processing is advantageous during scale-up. By adjusting the flow rate, it becomes easier to replicate similar dispersion quality from the lab to mass production. This helps reduce the risk of quality fluctuations during the transition from development to mass production. What is crucial in dispersion processes is to provide the same processing history to all particles. Continuous processing easily meets this condition and is an effective method for stabilizing quality and ensuring reproducibility.

In dispersion engineering, there are many cases where, although the appearance seems mixed, the particles are not actually uniformly dispersed. One of the causes of this is that the aggregation between particles has not been sufficiently resolved. When there is insufficient dispersion energy, the particles do not break down to primary particles, and aggregates remain. Additionally, if the shear conditions or flow state are uneven, the dispersion state can vary locally, resulting in variations in particle size distribution. This is particularly true in high-viscosity systems or high solid content slurries, where low flowability makes it difficult for energy to be transmitted uniformly, leading to dispersion inconsistencies. Furthermore, in batch processing, variations in mixing uniformity and residence time tend to make it difficult to maintain a uniform dispersion state throughout the process. To achieve uniform dispersion, it is important to design dispersion energy according to particle characteristics and to maintain uniform flow conditions in the process design. By maintaining consistent shear conditions, as in inline continuous processing, it is possible to achieve a uniform dispersion state and reproducible quality. The order of input, the wettability of the powder, and the initial mixing state of the dispersion also have a significant impact on uniformity. In particular, if local clumps or uneven distribution occur during powder input, it becomes difficult to resolve them in subsequent dispersion processes, leading to dispersion inconsistencies.

In dispersion processes, the occurrence of agglomerates (clumps) during powder addition, which cannot be resolved in subsequent dispersion stages, is a common issue in many settings. The cause of this is that the powder does not wet uniformly in the liquid, leading to the formation of localized high-concentration areas. These agglomerates are also referred to as "fisheyes," and due to their internal unwetted structure, they are difficult to break apart. Once an agglomerate forms during powder addition, liquid has difficulty penetrating its interior, resulting in only the outer layer being wetted, which makes it hard for the internal particles to be disintegrated. Additionally, depending on the addition position and speed, the powder may float on the liquid surface or remain stagnant without following the flow within the equipment, promoting the formation of agglomerates. Particularly under conditions of high viscosity or high solid content, the low fluidity makes it challenging to achieve uniformity in the initial dispersion stage, leading to a higher likelihood of agglomerates remaining. Such agglomerates may not be completely resolved even with strong shear in subsequent processes, causing variations in the quality of the final product and introducing foreign substances. To prevent the formation of agglomerates, it is crucial to improve wettability during powder addition, ensure appropriate addition positions and flow design, and optimize the initial dispersion. By performing shear and mixing simultaneously right after addition, as in inline powder addition and simultaneous dispersion, it is possible to suppress the formation of agglomerates and achieve stable dispersion quality.

In low bulk density powders and fine powders, issues such as "unstable supply," "pulsation," and "bridging without falling" frequently occur. Particularly with CNTs, carbon black, and flake powders, the particles tend to entangle easily and have low flowability, making stable quantitative supply difficult with conventional powder feeding methods. When powder supply becomes unstable, instantaneous concentration fluctuations occur, significantly affecting the dispersion quality, viscosity, and conductivity in subsequent processes. In practice, even problems that appear to be "poor dispersion" often have their causes on the powder supply side. Moreover, in low bulk density powders, bridging, rat-holing, and supply pulsations due to air entrapment are likely to occur within the hopper, and simply relying on feeder capacity may not resolve these issues. To achieve stable supply, it is crucial to design the entire process, including hopper design, supply methods, transport conditions, and feeding methods, according to the characteristics of the powder. Our company offers a solid-liquid mixing process that includes quantitative supply using loss-in-weight feeders and integration with inline dispersion devices. By designing the entire process from powder supply to dispersion as a cohesive unit, we support the establishment of stable manufacturing conditions even for high-performance materials.

In dispersion processes, viscosity is an important factor that significantly affects dispersion efficiency. Generally, as viscosity increases, fluidity decreases, making it more difficult for dispersion energy to be transmitted to the particles. When viscosity is low, liquids flow easily, and shear energy is widely transmitted throughout the system, making it relatively easy to break apart particle agglomerates. On the other hand, as viscosity increases, flow becomes localized, and shear tends to be concentrated near the equipment. As a result, there is a mixture of particles that receive sufficient energy and those that do not, leading to variability in the dispersion state. Additionally, under high viscosity conditions, the movement of particles is also restricted, making collisions and breakdowns between agglomerates less likely. Consequently, even if the mixture appears homogeneous, there may be undispersed regions remaining internally. To enhance dispersion efficiency, it is crucial to implement appropriate shear conditions and flow designs according to viscosity. Particularly in inline continuous processing, it is possible to provide uniform shear to the particles within the flow, allowing for efficient transmission of dispersion energy even under high viscosity conditions. In dispersion processes, optimizing flow, shear, and processing time while considering the effects of viscosity is key to achieving stable dispersion quality.

In the dispersion process of high solid content slurries, problems such as "too high viscosity to mix" and "unable to break down agglomerates" occur. The main cause of these issues is the increased frequency of particle contact, which strengthens the cohesive forces. As the solid content concentration increases, the distance between particles decreases, leading to interference between particles that reduces fluidity and prevents sufficient dispersion energy from being transmitted. Additionally, the crowding of particles restricts flow and makes shear localized, resulting in the persistence of undispersed areas and agglomerates. Furthermore, in a high solid content state, the increase in viscosity also leads to poor circulation and stagnation, causing variability in the dispersion state within the process. Particularly in batch processing, mixing inconsistencies and differences in processing history directly translate into quality differences, making it difficult to ensure reproducibility. To achieve stable dispersion under high solid content conditions, it is important not only to increase shear force but also to consider dispersion design that takes into account inter-particle interactions, as well as process design that simultaneously controls flow and shear. By establishing a mechanism like inline continuous processing, where particles pass through the processing area under constant conditions, uniform and highly reproducible dispersion can be achieved even at high solid contents.

In the dispersion of high solid content slurries, viscosity increases and fluidity decreases, making it prone to poor dispersion and variability. The movement of particles is restricted, making it difficult for aggregates to break apart, and it is not uncommon for undispersed areas to remain. Additionally, poor wetting during powder addition and the formation of localized high concentration areas can lead to the occurrence of clumps, which is another challenge. These issues may not be completely resolved even with strong shear applied in subsequent processes. What is important under such high solid content conditions is to efficiently transmit dispersion energy and standardize the processing conditions for each particle. However, in batch processing, variations in flow and residence time can lead to differences in the dispersion state. On the other hand, in inline continuous processing, uniform shear can be applied to particles within the flow, allowing for efficient transmission of dispersion energy even under high viscosity and high solid content conditions. This results in a uniform dispersion state for each particle, achieving stable quality. In the dispersion of high solid content slurries, it is crucial not only to apply strong shear but also to design the process considering flow and processing conditions. Inline processing is one effective method to address these challenges.

In the dispersion process of high-viscosity slurries, issues such as "not being dispersed despite being mixed" and "remaining clumps" occur. The main cause of these problems is that the increase in viscosity reduces fluidity, preventing dispersion energy from being evenly transmitted throughout the system. Generally, dispersion breaks apart agglomerated particles through shear force, but in a high-viscosity state, the flow becomes localized, leading to differences between areas experiencing shear and those that do not. As a result, undispersed areas and agglomerates remain, causing variations in particle size distribution and quality issues. Furthermore, the higher the viscosity, the weaker the circulation within the equipment, making it difficult for particles to pass uniformly through the processing area, which also decreases reproducibility. In batch processing, variations in residence time and mixing state become particularly pronounced, making it easier for lot differences to occur. To achieve stable dispersion in high-viscosity systems, not only shear enhancement but also flow design and ensuring circulation are important. By simultaneously controlling flow and shear, as in inline continuous processing, uniform and highly reproducible dispersion can be achieved. Additionally, the wettability of the powder and the method of introduction during the initial dispersion are also crucial; if the initial dispersion is insufficient, the subsequent breaking efficiency decreases.

In the manufacturing process of battery material slurry, it is important to uniformly disperse multiple materials such as conductive materials, active substances, and binders. However, on-site challenges arise, including the residual aggregation of conductive materials, variations in particle size distribution, and instability in coating properties. These issues stem from differences in dispersion behavior due to material characteristics. In particular, carbon-based conductive materials are prone to aggregation and can form a network structure if insufficient shear is applied, leading to poor dispersion. Additionally, battery material slurries often have high solid content and high viscosity, which can lead to reduced fluidity and make it difficult for dispersion energy to be transmitted uniformly. Furthermore, poor wetting during powder addition and differences in mixing order can also affect the dispersion state and final quality. Even if dispersion can be achieved without issues in the lab, variations in flow conditions and shear history during mass production may prevent the reproduction of similar quality. To resolve these challenges, it is crucial to design dispersion conditions tailored to the characteristics of the materials and to optimize the entire process, including flow, shear, and residence time. In inline continuous processing, particles are treated under consistent conditions, which helps to minimize variations in dispersion history and achieve uniform and reproducible quality. The design of the dispersion process plays a vital role in stabilizing battery performance.

In dispersion engineering, challenges such as "clumps persist regardless of how many times conditions are changed" and "variability in particle size distribution does not improve" occur in many settings. In one case, the cause of poor dispersion was attributed to equipment performance, leading to responses such as increasing rotation speed and extending processing time. However, the persistence of clumps and variability in quality were not resolved, and rather, new problems arose, such as particle fragmentation due to excessive shear. Behind such failures lies the misconception that "dispersion = just apply strong shear." In reality, if clumps are formed in the initial stage due to poor wetting or uneven flow when the powder is introduced, it is difficult to completely resolve them by applying strong shear in subsequent processes. Additionally, in batch processing, variations in flow and residence time lead to different dispersion histories for each particle, making it impossible to ensure reproducibility of quality. To address this issue, it is crucial to review the entire process, including not just changes in equipment conditions but also the steps from powder introduction to dispersion. By adopting configurations that apply shear simultaneously with powder introduction and implementing inline continuous processing that maintains consistent flow and dispersion conditions, it is possible to suppress initial clumps and achieve stable dispersion quality. Improving poor dispersion requires optimization of the entire process, not just the equipment alone.

In the dispersion process, it is not "how much to mix" but "how much energy to provide" that determines the quality of dispersion. The key factor here is dispersion energy. Dispersion energy refers to the amount of energy applied to break down the agglomeration of particles and achieve a uniform state. When dispersion is insufficient, it is often due to a lack of energy. Even if it appears to be mixed, the agglomeration between particles may not be resolved, leading to variations in quality and performance degradation. Dispersion energy is determined not only by the strength of the shear force but also by the duration of its application. In other words, it is important to consider it as "strength × time." In batch processing, this energy can vary for each particle, making it easier for differences in dispersion states to occur. On the other hand, in inline continuous processing, particles are subjected to the same shear conditions within a consistent flow, allowing for uniform application of dispersion energy. This results in a consistent dispersion state for each particle, achieving stable quality. In the dispersion process, it is crucial to provide the necessary dispersion energy to all particles without excess or deficiency. Therefore, process design that includes flow, shear, and processing time is essential.

Maintaining uniformity of quality in dispersion engineering has become an important issue in many manufacturing sites. Variations in particle size distribution and differences between batches are caused not only by equipment performance but also by differences in dispersion conditions and process design. In particular, uneven shear energy and variations in flow state can lead to differences in the disintegration state of particles, becoming a factor for quality instability. Additionally, in batch processing, variations in residence time and mixing conditions can easily occur, making it difficult to ensure reproducibility even under the same conditions. To achieve uniform dispersion quality, it is important to design the process as a whole rather than optimizing elements such as shear energy, flow state, and residence time individually. For example, by controlling the flow so that particles pass through the processing area under certain conditions, it becomes possible to suppress variations in dispersion history. Furthermore, adopting process designs that can maintain constant conditions, such as inline continuous processing, can reduce differences between batches and lead to the realization of stable dispersion quality. Uniformity is not just a result but a quality that should be built through process design, and for that, optimization from an engineering perspective is essential.

While dispersion was successful in the lab, transitioning to mass production leads to sedimentation and aggregation, resulting in unstable quality. Such challenges occur in many settings. One cause is that simple scale-up does not reproduce the flow conditions and shear conditions. Merely increasing the size of the stirrer significantly changes the forces acting on the particles and the dispersion state, making it impossible to achieve the same results as in the lab. This is particularly true for high-viscosity systems and nanoparticle dispersions, where even slight differences in conditions can greatly affect dispersion quality. Additionally, batch processing is susceptible to the effects of residence time and mixing uniformity, making it difficult to ensure reproducibility. To address these challenges, it is crucial to review the entire process, including shear history and flow design, rather than just scaling up the equipment. Approaches that maintain consistent conditions, such as inline continuous processing, are needed to reduce variability in dispersion state and replicate lab results in mass production. Furthermore, during scale-up, indicators such as energy density and circulation frequency become important, necessitating designs that maintain the amount of shear applied per unit volume. From this perspective, ensuring reproducibility throughout the entire process is key to stable production.

Even slurries that appear uniform after dispersion often face challenges of instability in quality due to sedimentation and separation over time, which is commonly observed in many settings. This phenomenon is not merely a result of insufficient stirring; it is influenced by the aggregation state of the particles, a lack of dispersion energy, and complex inter-particle interactions in the liquid. Particularly in the case of nanoparticles or high solid content slurries, even slight dispersion issues can significantly affect sedimentation behavior, leading to variations in product performance. Additionally, batch processing is susceptible to changes in state over time, making it difficult to ensure reproducibility. To suppress sedimentation, it is crucial to not only mix but also to break down particles to the primary particle level and achieve uniform dispersion. Furthermore, maintaining consistent shear conditions, as in inline continuous processing, can help stabilize the dispersion state and ensure uniform quality. Designing the dispersion state throughout the entire process is key to producing stable slurries that do not sediment.

We will be exhibiting at the "Electronic Equipment Total Solution Exhibition 2024 JPCA Show" held at Tokyo Big Sight. This time, we will showcase the laser ablation processing machine [Model SLA2021] equipped with a telecentric lens that has a scanning processing range of 67mm x 67mm. Compared to the scanning processing range of 34.5mm x 34.5mm, this machine offers a processing range that is 3.7 times larger, allowing for a reduction in processing time. We kindly invite you to visit our booth and see the actual machine. ◆ Event Information - Dates: June 12 (Wednesday) to June 15 (Friday), 2024, 10:00 AM to 5:00 PM - Booth Number: East Hall 6, 6G-36 JPCA Show Area ◆ Exhibition Content Laser ablation processing machine [Model SLA2021] - Processing samples (cutting, engraving, marking, peeling) - Various laser processing samples - Precision gas laser processing samples - Fine fiber laser processing samples ◆ Exhibitor Seminar Presentation at the Venue - Date and Time: June 13 (Thursday) 11:40 AM to 12:00 PM - Location: NPI Seminar Room D - Content: Introduction of the laser ablation processing machine

Shibuya Kogyo Co., Ltd. will showcase fiber laser processing machines, welding machines, and more at MEX Kanazawa 2024, held from May 16 (Thursday) to May 18 (Saturday) at the Ishikawa Industrial Exhibition Hall. Additionally, a fiber laser processing machine with a two-pallet changer, which will be unveiled for the first time, will be displayed at Shibuya Kogyo's factory (Mechatronics). During the event, we will connect the factory and the venue via the web for demonstrations. Visitors can also tour the factory. We are planning a manufacturing experience using the following exhibited machines during the event. Participants will be able to create a pen holder that can hold a pen and a seal. [Exhibited Items] - 2D Fiber Laser Processing Machine (manufactured by Shibuya Kogyo) - Small Hydraulic Press (manufactured by Negami Shibuya) - Fiber Laser Welding Machine (manufactured by Shibuya Kogyo) - Tank Cleaning Machine (manufactured by Shibuya Kogyo) - Ultrasonic Cleaning Machine "Sonocleaner Plus" (manufactured by Kaijo) We will also prepare wonderful gifts (limited quantity) for visitors who participate in the manufacturing experience. Please feel free to stop by with your family and colleagues.

Shibuya Industrial Co., Ltd. will showcase its latest fiber processing machine at Mechatrotech Japan 2023, held at Port Messe Nagoya from October 18 (Wednesday) to October 21 (Saturday). This machine is a 2D fiber laser processing machine developed for the domestic general sheet metal market. It is equipped with a 2kW oscillator and can handle various materials. Additionally, it has been designed with consideration for space-saving, workability, and operability. [Exhibit Details] ■ 2D Fiber Laser Processing Machine FALCON-S 48 / Fiber laser cutting machine FALCON-S 48 We sincerely look forward to your visit.

Shibuya Industrial Co., Ltd. will debut our advanced 2D fiber laser processing machine at MF-TOKYO, held at Tokyo Big Sight from July 12 (Wednesday) to July 15 (Saturday), 2023. This ultra-compact device features a processing area of 1250×255mm and has a 2Kw oscillator built into the main body of the machine. During the event, we will conduct demonstrations with narration. [Exhibition Details] ■ 2D Fiber Laser Processing Machine "SPF4125/SFX2000D" We sincerely look forward to your visit.

Added a target substrate for SBM371.