Our Strengths

2006Research papers

Vol.16 No.1 Manufacturing Technology special number issue

Index

Introduction of Pioneer Group related R&D

Vol.16 No.2 Special Issue on AV and Recording Technology

Index

Introduction of Pioneer Group related R&D

1．Application of Reliability Simulation to Car Electronics Products

Toshiyuki Sakai

Summary

With the purpose of reducing production cost and length of the development period, reliability assessment simulation was carried out, which included mechanism analysis, solder thermal stress analysis, shock analysis and FPC flexing fatigue endurance analysis. As a result, it contributed to an improvement in the efficiency of design.

Click for Details (PDF 138 KB)
in Japanese

2．Development of technology for shooting minuscule droplets of liquid

Takashi Nagashima, Takeshi Ishida, Keiji Oda

Summary

The development of an inkjet head was done to shoot a high viscosity material used in the production process with high-speed in extremely fine droplets.
Although only liquid of low viscosity can be sprayed in this way, the efficiency of use of the material is high and ,"here is the advantage of having a low environmental burden.
So, we did an examination of the problems (fluid resistance is large, persistence of bubbles in the liquid ) which are characteristic of high viscosity liquids.
It was confirmed that such liquids could be sprayed by improvement of the structural components such as nozzle and head, and optimizing the conditions of application.
The examination of the dispersion of the spray and of issues relating to mass production technology, such as maintenance, will be done from here on.

Click for Details (PDF 146 KB)
in Japanese

3．Analysis for warp mechanism at reflow soldering PCB Assembly

Youichi Enomoto, Hisashi Mamizuka

Summary

We analyzed the generation mechanism of PCB warping, which is a cause of SMT defects in reflow soldering We developed equipment for three-dimensional(3D) direct observation and measured the displacement which is generated in reflow soldering of a PCB Assembly using this. We used the area of the copper foil on the PCB, the directionality of wiring and the mounting part patterns as parameters, and observed the influence of each parameter on PCB warp. As a result, it has been understood that the state of the copper foil has an important influence on the occurrence of warping in the PCB. In addition we are attempting to decrease the warping of PCB assembly mounted BGA.

Click for Details (PDF 554 KB)
in Japanese

4．Laser weld sealing equipment for electronic device

Hiroyoshi Hirota, Yoshikazu Sakaguchi

Summary

We developed an airtight sealing system for ceramic packages of electric devices.
Also, we realized higher speed and high accuracy using laser welding for sealing, using a positioning compensation image processor with the combination of galvano -scanner and X-Y table.
Also, we achieved zero gas in the ceramic package by means of welding in the vacuum chamber, which provides high reliability for the electric devices.

Click for Details (PDF 330 KB)
in Japanese

5．Examining a characteristic of plastic derived from plant and existing difficult problem for applying it

Morio Mutou

Summary

We examined the characteristics of polylactic acid resin which is a type of plastic derived from plants, and examined the existing difficulties in applying it.
The polylactic acid is biodegradable and the amount of CO2 exhaust emited when manufacturing and burning is less than that of petroleum-based plastics. However, it is necessary to raise the heat and impact resistance of the polylactic acid because of its low values for these currently.
We understood that to raise the temperature resistance of the polylactic acid it is effective to heat it after molding it. Moreover, high impact resistance of the material has been achieved, by mixing proper quantity of rubber system material or acrylonitrile system with polylactic acid to suit the performance requested from it for each applied purpose
In addition, it was confirmed that it was effective to mix the electroconductive filler with the polylactic acid to create an electroconductive material.

Click for Details (PDF 86 KB)
in Japanese

6．The latest technology of PCB unit test

Kenichi Ogawa

Summary

We developed inspection technology which can examine PCB units with high mounting density, and find the causes of defective units. Introduction of a multi purpose tester platform (PucWin) that can execute "Compound Multi-function Testing", and an algorithm developed for specifying defective locations on a PCB, and a program for controlling this, enabled the use of an ICE (In Circuit Emulator).
As a result, the inspection technology is able to test the state of connection of ROM/RAM which is installed with the PCB unit and to specify the cause of any defects. Moreover the inspection technology achieved shorter inspection time of PCB units.

Click for Details (PDF 122 KB)
in Japanese

7．Establishment of lubricant spreading technology

Hirokazu Takeda, Toshirou Yamashita

Summary

In recent times, there is a tendency to spread lubricant on sliding surfaces of operation button in car navigation and car audio systems to achieve good feeling and muffling of operation noise.
It is important for spreading lubricant with stability to determine an accurate position on which to spread that and to maintain a constant amount over the entire surface.
In order to achieve the above-mentioned, it is necessary to introduce an automatic spreading machine because it is difficult to do the application by hand.
When the automatic spreading machine was introduced, we examined spreading methods, the characteristics of the lubricant, and the overall performance.
As a result, we adopted a spreading method in which lubricant is directly dispensed, which is able to maintain constancy in the amount of spreading lubricant, We selected "DRYSURF" which is a lubricant that has liquidity at low temperatures, and an automatic spreading machine, which is based on an orthogonalized three-axis robot, can control the amount of expelled lubricant with stability by using that method.
As a result of introducing this method into the production system, we observed that it gave accurate position of spreading and a constant amount of lubricant, and it required one third of the spreading time required of the hand painted case.

Click for Details (PDF 186 KB)
in Japanese

8．Report of activity for raising solder quality

Takashi Fukuyama, Kazuhiro Sato

Summary

In order to realize high performance and increased functionality of products, increases in mounting density and the miniaturization of parts are ongoing. Given these circumstances, finding new ways of improving soldering quality is an important subject. W e are taking various measures to investigate how improvement of soldering quality can be advanced beyond the present methods.
We measured various parameters such as the amount of solder printing and component loading accuracy which have a big influence on quality in the reflow process, and established two management methods which reduced the number of soldering defects in the process.
One is "Management of the volume of solder printings" which controls the amount of solder at the reflow process, with "Absolute management of the amount" and "Management of the relative amount".
"Absolute management of the amount" uses a reference of constant value regardless of product, and "Management of a relative amount" uses a reference value varied corresponding to each product.
The other is "management of part loading accuracy" using the reference which is decided by the installing accuracy of each part installed in the product, depending on the performance of the mounter.
It has been understood that we will be able to reduce solder defects at the reflow process by the established management.

Click for Details (PDF 494 KB)
in Japanese

[Introduction of Pioneer Group related R&D]
An Introduction of Production Engineering Department, MEC

Yuji Takahashi

Summary

Production Engineering Department belongs to the Mobile Entertainment Company, which develops and produces car electronics products as typified by GPS navigation systems. Production Engineering Department carries on a variety of activities such as responses to the production needs of multifunction and high-density products, improvement of the quality in the market, cost reduction, and establishment of production systems across the world. This article introduces the department through the explanation of a summary of the recent developments in core technologies.

Click for Details (PDF 262 KB)
in Japanese

1．Nano-pattern profile control technology using reactive ion etching

Megumi Fujimura, Yasuo Hosoda, Masahiro Katsumura, Masaki Kobayashi, Hiroaki Kitahara, Kazunobu Hashimoto, Osamu Kasono, Tetsuya Iida, Kazumi Kuriyama and Fumihiko Yokogawa

Summary

We have developed an electron beam recorder (Ebr) and studied a process technology for high-density optical disc mastering. In this study, we aimed at controlling a nano-pattern profile by adopting inductively coupled plasma reactive ion etching (ICP-RIE) under simple conditions for good productivity. To control the pattern inclination angle, we introduced an etching power ratio of antenna power to bias power and investigated the relationship. From the results of our investigation, it was confirmed that inclination angle depended on etching power ratio linearly. Furthermore, in the case of a 100 GB read-only memory (ROM) equivalent pattern, we formed two kinds of inclined pattern by adopting ICP-RIE. We evaluated line edge roughness (LER) to determine the difference in pit profile accurately. As a result, it was confirmed that LER was improved at a steep inclination angle. In addition, we applied ICP-RIE to a 300 GB ROM pattern.

Click for Details (PDF 1.2 MB)
in Japanese

2．Electron Beam Recorder for Next-Generation Superhigh-Density Disk Media

Hiroaki Kitahara, Yoshiaki Kojima, Masaki Kobayashi, Yasumitsu Wada
Masahiro Katsumura, Tetsuya Iida, Kazumi Kuriyama, Fumihiko Yokogawa

Summary

Electron beam mastering is expected to be a key technology indispensable to realize the next-generation optical disc for post Blu-ray discs and patterned magnetic disk media. We developed a high-resolution electron beam recorder (Ebr) to realize such next-generation high-density disk media. From experimental results, a superhigh-density patterning of capacity equivalent to 510 GB was achieved using the Ebr. The recording stability was proven by fabricating 100-GB-capacity stampers with good pattern size uniformity. This technology is introduced into the commercial Ebrs of Pioneer FA corporation.

Click for Details (PDF 2.6 MB)
in Japanese

3．Organic Write-Once Disk with In-Groove Structure for Blu-ray Disc System

Hiroyuki Nakajima, Hiroshi Nishiwaki, Kazutoshi Kitano, Eiji Muramatsu, Shoji Taniguchi, Fumihiko Yokogawa, Michikazu Horie, Kenjirou Kiyono

Summary

We developed a new write-once disk for Blu-ray disc system, which could be made by using a conventional spin-coat process.
A finite element method-based simulation and our sample disk with an organic dye layer, which was optimized for blue laser recording, showed that recording onto an in-groove structure was more suitable than recording onto an on-groove structure. It was also shown that this structure gives good results for single and double speed recording.

Click for Details (PDF 1.9 MB)
in Japanese

4．Inorganic Write-Once Disk by Complete DC Sputtering Process for Blue-violet Laser System

Nobuhiko Kato, Masataka Yamaguchi, Toshihiko Takishita

Summary

An inorganic write-once disk using an objective lens with a numerical aperture of 0.85 and a 405nm blue-violet laser diode has been reported.[1] [2] [3] We confirmed that the reflectivity of the disk was controllable by adjusting the nitrogen flow rate during sputtering of the Bi-Ge nitride recording layer and disk structure. The disk that had been adjusted to high reflectivity showed a large modulated amplitude. We also studied the depositing process of recording stacks. We confirmed that it is a practicable process to make inorganic recording stacks completely using the DC sputtering process. This means that the structure of the equipment for the production of such disks will be made simpler. [4]

Click for Details (PDF 1.4 MB)
in Japanese

5．Outline of Physical Format of DVD-R for Dual Layer

Tohru Kanegae, Eisaku Kawano, Masahiro Miura, Kyusho Omori, Masahiro Kato

Summary

When the second layer (Layer 1) of a DVD-R for Dual Layer disc is recorded, the LASER beam passes through the first layer (Layer 0). In this case, the transparency difference of Layer 0 which comes from its recording status (recorded or unrecorded) considerably affects to the signal reliability of the recorded signal on Layer 1. To avoid this, we have developed and introduced the new technical regulation that is called "Relative deviation" to the specification. The Relative deviation specifies the possible allocation range of the corresponding physical address on each layer.
The Relative deviation is applied to design a disc so that the recorder can record data easily without complicated operation. We have also developed the verification method of the Relative deviation with simple measurement. It has been also adopted in the "DVD-R for Dual Layer book version 3.0 part 1 (physical specification)" book.

Click for Details (PDF 3.7 MB)
in Japanese

6．Technologies for Full HD PDPs and Their Image Performance

Masataka Uchidoi, Yoichi Sato

Summary

PDPs have obtained the highest device quality in the field of large area displays by the recent progress of their technology, and show high image quality and low power consumption. In the progress of PDP technology, Pioneer has been acting in a leading role and has introduced many basic technologies, i.e. "world first technologies by Pioneer", as shown by the following examples;
high luminous efficacy technology of T-shape electrode and WAFFLE rib structure with high xenon content gas, and high image quality and power reduction technology of CLEAR driving method and Direct color filter.
The newly introduced Crystal Emissive Layer (CEL) technology, which has opened up new aspects in PDP technology, has been introduced to the 6th generation PDPs and newly introduced full HD (1080p) 50-inch PDPs with its excellent characteristics of stable weak discharge and high speed discharge.
Comparing the device performance of PDP to that of other display devices, e.g. LCD, SED, rear projection display, etc., PDPs show excellent picture quality, simple structure of self light emitting device and high productivity while retaining a large potential for improvement. PDPs will continue to be the main device of large area display in this just-started HD-TV era.

Click for Details (PDF 9.1 MB)
in Japanese

7．Development of "floating interface"

Masaru Ishikawa, Katsumi Unehara, Isao Tomisawa

Summary

Aiming at a new feeling for the user interface of future, we developed the "floating interface" that applied 3D imaging to a user interface.
"Floating interface" evolved from a glasses-free 3D image system "3D floating vision" which our company developed. On this trial production, the image size is enlarged, and it combines a sensor and real-time CG. Interactive operation is realized by touching 3D image displayed in the air, such as drawing characters and pictures in the air, or operating the window of a computer(PC) which floats in the air.
When many visitors experienced this technology in several exhibitions, the visibility and the operation feeling of 3D image were popular and we were able to confirm the possibilities of our "floating interface"

Click for Details (PDF 5.3 MB)
in Japanese

8．Knowledge Database and Its Application for Consumer Electronic Products

Masayo Kaji, Naoaki Horiuchi, Shinichi Gayama

Summary

We developed a "Knowledge Database" which is highly suited to consumer electronic products and we also proposed an information retrieval system as a practical use of its architecture. The Knowledge Database we defined has a well-organized data structure which comprises a set of product-specific information generated based on the analysis of a great deal of text data related to the product.
It was expected that the database would enable the information retrieval system to provide appropriate results that reflected some product-specific knowledge. As a result of applying the method to the "Drive Planner" functionality on the car navigation system, we succeeded in retrieving a variety of spots for sight seeing that could meet specified requirements such as region, purpose of trip and the presence of passengers.

Click for Details (PDF 540 KB)
in Japanese

9．Analysis of Listener's Favorite Music by Music Features

Katsunori Arakawa, Satoshi Odagawa, Fumio Matsushita, Yasuteru Kodama, Takehiko Shioda

Summary

Our purpose is to easily retrieve a listener's favorite music from a large number of musical pieces. The relationship between the musical features of music and the impression which these features give the listener is analyzed and reported.
Listeners listen to the given musical piece and evaluate their impression. Then, the musical piece was classified according to the degree of positive impression, and the relationship between the degree of impression and the musical feature was analyzed. It was confirmed that the variance of certain musical features of favorite musical pieces is smaller than the variance of all musical pieces. In other words, it was confirmed that favorite musical pieces were concentrated along certain musical feature axes.

Click for Details (PDF 480 KB)
in Japanese

10．Trend of the home network technology

Masao Higuchi, Hidemi Usub

Summary

The appearance of DLNA and DTCP-IP have had a strong impact on the popularization of home AV network for digital AV devices. This report introduces trends in home AV networks and the vision of home entertainment that DLNA presents.

Click for Details (PDF 1.7 MB)
in Japanese

11．An Overview of the History and Technologies of Surround Sound

Shinji Koyano

Summary

Today many surround sound contents are provided through movie, digital broadcast, DVD media and so on. In this article the author overviews the history of surround sound since 1940, and describes the topics of this technology and the issues to increase the popularity of surround sound.

Click for Details (PDF 2.1 MB)
in Japanese

12．Development of S-1EX speaker system

Hiroyuki Shirakawa, Shunich Takahashi

Summary

This text presents the speaker system "S-1EX" developed as a flagship
model of the pioneer brand.
This describes the background technology of each element.

Click for Details (PDF 1.9 MB)
in Japanese

13．Surround sound productions on Digital Broadcasting Today and Tomorrow

Masaki Sawaguchi

Summary

One of the advantages of Digital Broadcasting, which will take over from analogue by the end of 2011 is that it will enable the provision of 5.1ch surround sound audio to viewers in Japan. This paper will describe current production techniques and pending issues from the production side. Also, it will point out the key details of how it will expand into home environments.

Click for Details (PDF 1.9 MB)
in Japanese

14．A Roadscape Analysis System of Vehicle Mounted Camera-image

Ryujiro Fujita

Summary

A Roadscape Analysis System was developed that can analyze images captured by a camera mounted on a vehicle. The system divides images into cells, calculates five features of each cell, and distinguishes between "town," "forest," and "plain" automatically. This system can judge a road landscape image to be "Town," "Forest," or "Plain" with more than 75% accuracy.

Click for Details (PDF 832 KB)
in Japanese

[Introduction of Pioneer Group related R&D]
Promotional Activities of DVD-RW/DVD-R by the RW Coordination Center

Masami Morishita

Summary

The mission of RWPPI (RW Products Promotion Initiative) is to promote products related to the DVD-RW / DVD-R recording formats proposed by Pioneer. Day-to-day operations are handled by the staff in the HBG, RW Coordination Center (referred to as "RWCC" hereunder). RWPPI has undertaken over 100 activities, exhibiting at worldwide exhibition shows, holding press conferences, conducting Round Robin Tests, and arranging General Meetings periodically. Such activities are internally beneficial to Pioneer as well, where RWCC acts as a window to gather and offer various information within the industry, coordinating to resolve common problems with RWPPI member companies, etc... all to serve in establishing DVD-RW / DVD-R as a defacto standard. Detailed activities of the RWCC are introduced herewith.

Click for Details (PDF 976 KB)
in Japanese

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