Appliance Design March 2011

March 2011

REACHING OEM DESIGN ENGINEERS ACROSS CONSUMER AND COMMERCIAL MARKETS WORLDWIDE

i l O s l a r u Nat

GET RIGID P. 14

INSIDE 18 Power 20 Metals See our ad on page 17

24 Switches & Relays 28 Displays & Interfaces

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CONTENTS MARCH 2011 volume 59, no. 3 REACHING OEM DESIGN ENGINEERS ACROSS CONSUMER AND COMMERCIAL MARKETS WORLDWIDE

DEPARTMENTS 4 Editorial: Las Vegas Showdown 6 Shipments/Forecasts 8 News Watch 30 New Products

18

28

32 Association Report: AHAM 33 Advertiser’s Index

FEATURES INSULATION 14 Biobased polyols made from vegetable oils overcome obstacles.

POWER 18 If a high-potential test is not performed, a product with poor insulation or incorrect internal conductor spacing may fail under the influence of environmental factors.

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METALS 20 Learn the differences between metal and plastic ultrasonic welding through this question and answer session with a leading expert in the field of high power ultrasonics.

WEB EXTRAS WEB EXTRAS

Case Study: Cooking with Gas Italian domestic appliance manufacturer Merloni Elettrodomestici installs a new system to handle the manufacture of its gas and electric cooker hobs.

An Interesting Application: Polycarbonate Sheets Used for Train Windows Polycarbonate sheets from a plastics manufacturer are being used to thermoform European passenger train window frames to be used in Norwegian State Railways train cabins.

BLOGS Kevin Henry's The Essential Kitchen AD's Remix Blog Paul's European Perspective

SWITCHES & RELAYS 24 Switches and relays choices abound to fit the needs of today’s OEM. See the latest product offerings in this category.

DISPLAYS & INTERFACES 28 The progression of touch screen technology in the domestic environment lends itself to considerations unique to the home appliance sector.

SOCIAL MEDIA Connect with appliance DESIGN on:

E-NEWSLETTERS Sign up for appliance DESIGN’s monthly e-newsletters at www.applianceDESIGN.com/enews

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COVER Soybean oil is one of the leading components found in natural-oil polyols. Photo: Bayer MaterialScience www.applianceDESIGN.com

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EDITORIAL ®

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publishing staff (630) 694-4342 [email protected]

Darrell Dal Pozzo Group Publisher

Las Vegas Showdown

I

had a lot of time to reflect on my visit to AHR this year as I waited in the Las Vegas airport after the show due to inclement weather in Chicago and much of the Midwest. With an estimated 30,000 visitors and 20,000 exhibitor personnel, it was a bustling event and one that many took as a sign of a stabilizing, if not growing, economy. I had the chance to visit many of the component manufacturers of heating and cooling technologies and was struck by several themes at this year’s show. Whether an OEM or aftermarket professional, many of the wants and needs I heard were the same—reducing noise, reducing costs and reducing your footprint at every point in the product lifecycle. Many exhibitors talked about ways to reduce the carbon footprint—whether it be by reducing weight, shipping costs, and in many instances, material costs. A few booths I visited that stood out included Silentium, an Israeli company that has introduced an active noise cancelling technology for appliance and HVAC applications. By implementing the chip technology during production, OEMs can cut down on the noise of fans and blowers—similar to the idea of noise cancelling headphones. At Protexic, a brand of Tegrant Corp., the company showcased molded foam products made of expanded polystyrene (EPS) and expanded polypropylene (EPP).

The material can be customized for a wide range of applications from water heaters for housing and insulation—replacing heavier metal components—to automotive and packaging solutions. Also, manufacturer Tecumseh announced the release of its AE2 compressor for commercial refrigeration applications. The new compressor supports traditional HFC refrigerants and also hydrocarbon refrigerants, including R290 (propane) and R600a (isobutene)—in anticipation of hydrocarbon refrigerants expecting to be authorized for U.S. applications by the EPA in the near future. The product boasts reduced energy consumption and wider capacity in a smaller package than its predecessor. Again, the name of the game here is smaller size, more power and a reduced footprint. Let me know what you saw at the show be emailing me at [email protected] or chat with your peers about the show via our LinkedIn Group at www.appliancedesig n.com/connect. Judging by what I saw at the Las Vegas Convention Center at this year’s AHR, OEMs are more equipped than ever to continue toward a route of greener technology and sustainability. 

Maggie McFadden Shein Editor

(630) 694-4388 [email protected]

Daryl Delano Economics Editor

(508) 746-7986 [email protected]

Paul Roggema Kevin Henry New Media Contributors

(248) 244-6438 [email protected] (248) 486-7800 [email protected]

MaTT Britcher Art Director

circulation Rita Foumia Corporate Strategy Director Christina Roth Audience Development Coordinator

(248) 786-1687 [email protected] (248) 244-6435 [email protected]

Alison Illes Multimedia Specialist

(248) 244-1730 [email protected]

Catherine M. Ronan Corporate Audience Audit Manager

[email protected]

(248) 244-8259

(800) 223-2194 x726 [email protected]

Robert Liska List Manager

(800) 409-4443 x828 [email protected]

Shawn Kingston

marketing (248) 786-1694 [email protected]

Michele Raska Marketing Coordinator Deana Weber Trade Show Coordinator

(248) 244-6249 [email protected]

editorial advisory board Bob Brown Vice President, Marketing & Sales, North America, Emerson Industrial Automation President and CEO, Proto Labs Inc.

Brad Cleveland John Davis

Business Development Manager, Traulsen President, Group42

Kevin Henry

President, Association of Home Appliance Manufacturers (AHAM)

Joseph McGuire

Maggie McFadden Shein, Editor E-mail: [email protected] Twitter: @aplncdsgn

[email protected]

Lindsay Nagy Production Manager

Andreas Schuessler Richard Watson

Product Designer, BSH Bosch and Siemens Founding Partner, Essential

Stephen Yurek, JD President, Air-Conditioning, Heating and Refrigeration Institute (AHRI)

| HVAC | Majors | Water Processing | Housewares | Commercial Appliances | Vending | Medical | Lab | | Test & Measurement | Lawn & Garden | Electronics | Computers | Communications | Business Equipment | APPLIANCE DESIGN (ISSN 1552-5938) is published 12 times annually, monthly, by BNP Media, 2401 W. Big Beaver Rd., Suite 700, Troy, MI 48084-3333. Telephone: (248) 362-3700, Fax: (248) 362-0317. No charge for subscriptions to qualified individuals. Annual rate for subscriptions to nonqualified individuals in the U.S.A.: $178.00 USD. Annual rate for subscriptions to nonqualified individuals in Canada: $216.00 USD (includes GST & postage); all other countries: $228.00 (int’l mail) payable in U.S. funds. Printed in the U.S.A. Copyright 2011, by BNP Media. All rights reserved. The contents of this publication may not be reproduced in whole or in part without the consent of the publisher. The publisher is not responsible for product claims and representations. Periodicals Postage Paid at Troy, MI and at additional mailing offices. POSTMASTER: Send address changes to: APPLIANCE DESIGN, P.O. Box 2148, Skokie, IL 60076. Canada Post: Publications Mail Agreement #40612608. GST account: 131263923. Send returns (Canada) to Pitney Bowes, P.O. Box 25542, London, ON, N6C 6B2. Change of address: Send old address label along with new address to APPLIANCE DESIGN, P.O. Box 2148, Skokie, IL 60076. For single copies or back issues: contact Ann Kalb at (248) 244-6499 or [email protected].

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SHIPMENTS Product

FORECASTS Dec-10

Dec-09

%Chg 12 Mos. '10 12 Mos. '09

%Chg

MAJOR APPLIANCES (Thousands of Units) TOTAL

4,932.4

4,626.8

6.6%

61,485.2

59,502.7

3.3%

Cooking-Total Electric Cooking - Total Electric Ranges Electric Ovens Surface Cooking Units Gas Cooking - Total Gas Ranges Gas Ovens Surface Cooking Units Microwave Ovens

1,555.3 428.9 340.9 57.3 30.7 279.8 249.2 4.9 25.7 846.6

1,411.7 389.9 304.8 55.1 29.9 261.3 229.6 4.6 27.1 760.5

10.2% 10.0% 11.8% 4.0% 2.6% 7.1% 8.5% 6.7% -5.2% 11.3%

16,570.8 4,447.8 3,508.9 603.9 335 2,789.8 2,432.5 43.6 313.7 9,333.1

16,557.3 4,333.4 3,448.1 549 336.2 2,598.1 2,263.9 43.7 290.5 9,625.8

0.1% 2.6% 1.8% 10.0% -0.4% 7.4% 7.5% -0.3% 8.0% -3.0%

Home Laundry - Total Automatic Washers Dryers - Total Electric Gas

1,289.9 725.1 564.7 453.4 111.3

1,324.5 720.7 603.9 480.4 123.5

-2.6% 0.6% -6.5% -5.6% -9.8%

14,546.0 7,998.9 6,547.1 5,260.9 1,286.1

14,348.8 7,864.6 6,484.2 5,201.0 1,283.2

1.4% 1.7% 1.0% 1.2% 0.2%

Kitchen Clean Up - Total Disposers Dishwashers - Total Built-In Portable Compactors

1,038.8 488.8 545.8 538 7.8 4.2

929.6 458.3 466.6 459.4 7.2 4.6

11.8% 6.7% 17.0% 17.1% 8.1% -9.5%

11,071.5 5,320.3 5,707.6 5,642.0 65.5 43.6

10,670.7 5,219.8 5,403.7 5,333.4 70.3 47.2

3.8% 1.9% 5.6% 5.8% -6.7% -7.5%

Food Preservation - Total Refrigerators Freezers - Total Chest Upright

875.8 705.8 170 100 70

835.1 672.9 162.2 93.1 69.1

4.9% 4.9% 4.8% 7.5% 1.2%

11,326.6 9,368.7 1,957.9 1,137.2 820.7

10,440.8 8,397.4 2,043.3 1,218.3 825

8.5% 11.6% -4.2% -6.7% -0.5%

Home Comfort - Total Room Air Conditioners Dehumidifiers

172.6 137.5 35.1

126 73.9 52.1

37.0% 86.2% -32.7%

7,970.2 6,418.0 1,552.2

7,485.2 5,785.6 1,699.6

6.5% 10.9% -8.7%

Note: Figures (in units) include shipments for the U.S. market whether imported or domestically produced. Export shipments are not included. Source: Association of Home Appliance Manufacturers (AHAM).

HVAC - Shipment figures for unitary air conditioners, heat pumps, furnaces, and water heaters can be found at www.ahrinet.org.

MAJOR HOME APPLIANCES – Shipments (Thousands of Units) Qtr: 1 2 3 4

2010 15291.7 18309.3 14169.4 13714.8

2011 15964.5 19023.4 15147.1 14702.3

2012 16970.3 20297.9 16010.5 15452.1

For 2011, a 5.5% increase to 64.837 million units For 2012, a 6.0% increase to 68.731 million units Data Source: AHAM Forecast Source: Delano Data Insights

DIGITAL TELEVISIONS – Shipments (Thousands of Units) Qtr: 1 2 3 4

2010 5497.2 6441.1 6557.8 14840.0

2011 5997.4 7226.9 7108.7 15656.2

2012 6399.3 7588.3 7435.7 16517.3

For 2011, an 8.0% increase to 36.989 million units For 2012, a 5.4% increase to 37.940 million units Data Source: CEA Forecast Source: Delano Data Insights

MICROWAVE OVENS – Shipments (Thousands of Units) Qtr: 1 2 3 4

2010 2220.7 2355.9 2370.5 2386.0

2011 2311.7 2464.3 2460.6 2517.2

2012 2395.0 2585.0 2591.0 2668.3

For 2011, a 4.5% increase to 9.754 million units For 2012, a 5.0% increase to 10.239 million units Data Source: AHAM Forecast Source: Delano Data Insights

RESIDENTIAL ELECTRIC WATER HEATERS – Shipments (Thousands of Units) Qtr: 1 2 3 4

2010 1006.3 984.1 864.0 918.3

2011 1001.3 1016.5 901.2 949.5

2012 1028.3 1047.0 930.9 990.3

For 2011, a 2.5% increase to 3.869 million units For 2012, a 3.3% increase to 3.997 million units Data Source: AHRI Forecast Source: Delano Data Insights

DISHWASHERS – Shipments (Thousands of Units) Qtr: 1 2 3 4

2010 1408.8 1508.4 1355.7 1434.7

2011 1442.6 1559.7 1475.0 1529.4

2012 1474.3 1606.5 1556.1 1634.9

For 2011, a 5.2% increase to 6.007 million units For 2012, a 4.4% increase to 6.272 million units Data Source: AHAM Forecast Source: Delano Data Insights

ROOM AIR CONDITIONERS – Shipments (Thousands of Units) Qtr: 1 2 3 4

2010 1916.5 3621.1 612.8 267.6

2011 2213.6 3762.3 551.5 279.6

2012 2432.7 4183.7 565.3 296.4

For 2011, a 6.1% increase to 6.807 million units For 2012, a 9.9% increase to 7.478 million units Data Source: AHAM Forecast Source: Delano Data Insights Note: Forecasts begin in Q1/2011

6 applianceDESIGN March 2011

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Asking a couple guys in suits to rate your new LED TV, not very efficient. Getting 24-hour turnaround on ENERGY STAR® certification, very efficient. You can’t simply waddle into the market. You have to get there fast and make them melt. That’s why Intertek’s Energy Efficiency solutions address your success. For starters, we have the size and speed to save you both time and money. Our 18 Energy Efficiency testing laboratories across the globe have the capacity to slide you into market, faster. What’s more, with our unflappable core of energy expert reviewers ready, you’ll get ENERGY STAR certification in 24 hours after testing is complete. Now is not the time to wing it. Built with 50 years of Energy Efficiency testing experience, from the innovators who brought you 15-day ETL testing, we help products prepare for today’s harsh climate. So, see the big picture. Get Intertek and get to market first. We’ll help you move up the pecking order, faster. 1-800-WORLDLAB

w w w. i n t e r t e k . c o m / e n e r g y s t a r

NEWS WATCH

DCS Shows Off Indoor Kitchen Collection he 2011 DCS by Fisher & Paykel indoor kitchen collection, which is set to debut in April 2011, focuses on authenticity, performance, functionality and substance, according to the company. “This is the most exciting launch for DCS to date. The newly styled collection follows our tradition of combining advanced cooking power and technology to deliver cooking accuracy and performance in a distinctive professional appliance,” said Scott Davies, Fisher & Paykel marketing manager. The line’s dual-fuel range offers convection cooking, a full extension telescopic racking system and illuminated halo for the home chef. Multiple configurations include a commercial grade griddle and the company’s patented grease management

T

system. The new cooktop has patented dual-flow burners, which create extreme heat and precision for the lowest constant simmer temperature to cook delicate sauces and simmer chili or stew on an ultra low flame for hours without scorching. The DishDrawer is a 24-inch, Energy Star rated appliance with ultra quiet operation, all while using as little as 1.95 gallons of water per drawer. The top drawer can accommodate 13-inch plates. The dishwasher also has a fully adjustable racking system with independently movable racks. Finally, the wall oven comes complete with 10 cooking modes ranging from bake to roast. The DCS oven has 4.0 cu ft of space and full extension DCS has debuted a new line of indoor kitchen appliances for racks.  residential customers, available in April 2011. Photos: Fisher & Paykel

MANUFACTURERS ANNOUNCE USE OF DOE MEASUREMENT FOR CLOTHES WASHER CAPACITY

Manufacturers of clothes washers have independently determined that, beginning on or before April 30, 2011, they will voluntarily communicate capacity to consumers using only the U.S. Department of Energy (DOE) clothes washer test procedure for drum volume calculations, including the most recent guidance on measuring drum volume, released by DOE during the summer of 2010. The manufacturers who are choosing to communicate drum volume for non-energy purposes solely based on the DOE procedure, will not reference an “IEC equivalent” volume. This change will be applicable to all 8 applianceDESIGN

March 2011

clothes washers sold as of that date regardless of when manufactured. The participating manufacturers will communicate these capacities to retailers of washers and will encourage retailers to communicate washer capacities calculated in accordance with the DOE test procedure following the April 30, 2011 date. The DOE procedure is currently used by all manufacturers to report energy and water consumption to DOE, and will be used in AHAM’s new energy verification program for clothes washers. The DOE procedure provides an accurate, uniform and repeatable measurement of drum volume for the purpose of calculating energy and water consumption for all clothes washer types, said AHAM.

Because of advances in clothes washer design, technology and efficiency, AHAM is also continuing development of a test procedure that may enhance the communication of useable washer capacity information, beyond volume, to the consumer when making a purchase decision among a wide variety of product choices. The enhanced test procedure would provide more information to consumers regarding the quantity of clothes that can be effectively washed and rinsed in a single load. When completed, the test procedure would be voluntary; however, AHAM may present the test procedure to the Department of Energy (DOE) for proposed incorporation into the DOE’s test procedure for clothes washers. www.applianceDESIGN.com

NEWS WATCH

DYMAX EXPANDS WEB REACH

Dymax Corp., manufacturer of adhesives and light-curing equipment in Torrington, Conn., launched a new website for its Korean location. For ease of use, the site (http://www.dymax.co.kr) has been configured to match the design and style of the corporate website, www.dymax.com. Browsers can find the newest product information and events featured in a rotating slideshow on the home page. Visitors will also find detailed Web pages containing product information, downloadable selector guides and technical bulletins available in English, and even some application videos. Designed with expansion in mind, the site will broaden as the company continues to grow in the coming years, according to Dymax.

Scientists at OSRAM Opto Semiconductors received the Beckurts Prize for development work on the direct green laser diode.

SCIENTISTS AWARDED BECKURTS PRIZE FOR DIRECT GREEN-EMITTING LASER

Representing the entire research team, Désirée Queren, Stephan Lutgen and Adrian Avramescu from OSRAM Opto Semiconductors received the Beckurts Prize for their work in researching direct, green semiconductor lasers. The laser has the potential to open up opportunities in many applications such as in ultrawww.applianceDESIGN.com

compact mobile RGB laser projectors, said the company. The Karl Heinz Beckurts Foundation grants the award annually to honor outstanding scientific and technical achievements that give rise to discernible impetus for industrial innovations in Germany. The availability of small and low-cost red, blue and green semiconductor lasers is crucial for large-scale diffusion of RGB laser projection. The laser diodes enable production of low-cost, compact and efficient pico-projectors, which can be incorporated into mobile devices such as smartphones or digital cameras. Due to the particular beam properties of lasers, these projectors have unlimited depth of sharpness and extremely high resolution, which go even beyond that of LED solutions. The low spectral bandwidth of semiconductor lasers enables lifelike display of colors. OSRAM Opto Semiconductors started developing direct blue laser diodes for RGB laser projection in 2006. Based on the findings for the blue laser in the InGaN material system, the company’s research team managed to break through the barrier to green from a wavelength of 500 nm. In 2009, they took over the technological leadership in direct green laser diodes of >515nm with optical outputs of more than 50 mW. The basic development of blue and green laser diodes and research into miniaturization of systems in mobile laser projection are supported by project Molas—technologies for ultra-compact and mobile laser projection systems—as part of the “Optical components and systems for volume markets” funding initiative of the German Federal Ministry of Education and Research. OSRAM also is working together with several German universities and research institutes in the innovative research field of nitride lasers.

to provide a more effective and efficient service to customers with production sites in those countries, and also in neighboring ones, said the company. The new openings, approved by the board, will guarantee commercial and technical assistance not just to local manufacturers, but also to those multinational companies with manufacturing plants in the two countries. The decision is part of Sabaf’s wider strategic policy, aimed at increasing and developing the market in areas of strong potential.

SABAF OPENS TWO REP OFFICES ABROAD

A. LYONS ANNOUNCES FASTENER DIVISION

Sabaf, a producer of components for domestic appliances, announced two new representation offices in Poland and Turkey. The offices will be located respectively in Lodz and Izmir. Sabaf takes this step

A. Lyons & Co. announced the formation of its Fastener division headed by Rick Fine, vice president of industrial products. A worldwide provider of various components for more than 75 years, A.

HAIER INTRODUCES UNDERCOUNTER, DUAL-DRAWER FRIDGES

Haier introduced a line of built-in, dualdrawer refrigerators in stainless steel, white and black. The DDE400R dualdrawer, under-counter refrigerator is stainless steel inside and out, with 5.4 cu. ft. capacity, two refrigeration drawers and electronic temperature controls. The touch control panel allows for temperature adjustment while the top-drawer divider system adjusts with one hand to securely hold items of different sizes such as fruits and vegetables, cheeses and liquids. The dual-drawer series can be installed without having to drill into stone or solidsurface countertops. The units have side installation brackets that allow them to be secured to the sides of kitchen cabinets.

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March 2011 9

NEWS WATCH

PEOPLE NEWS EMERSON NAMES PRESIDENT – MIDDLE EAST AND AFRICA Emerson Climate Technologies Inc. – Asia, appointed of Pratap Chavan as president of Emerson Climate Technologies Inc. – Middle East and Africa. In his new role, Chavan will focus on expanding the engineering, production and customer synergies that exist between the Middle East, India and China organizations of Emerson Chavan Climate Technologies Inc. Chavan joined Copeland in 1981 and assumed a number of positions in engineering, product planning, international marketing and sales. In 1996, he became the vice president of marketing and sales – Europe, and then was promoted to vice president and managing director – Middle East and Africa.

A.T. WALL APPOINTS STAMPING MANAGER A.T. Wall Co., a supplier of precision tubing and fabricated metal components, appointed Lisardo (Lee) Garcia as stamping department manager. He will coordinate A.T. Wall’s manufacturing employees to produce a quality, cost competitive product that meets all customers’ specifications, said the company. Garcia has more than 35 years of experience in the tool and die making industry. MACTAC DEVELOPMENT DIRECTOR NAMED TO PSTC BOD Kurt Schramer, strategic business development director at MACtac North America, was elected to the board of directors of the Pressure Sensitive Tape Council (PSTC). PSTC’s committee nominated Schramer based upon his experience in the PSA tape industry. PSTC is a not-for-profit trade association representing North America’s pressure-sensitive tape manufacturers and suppliers. Schramer will serve a three-year term and is responsible for upholding the PSTC mission, directing and monitoring key strategies, and assigning resources for volunteer and staff to achieve PSTC goals. Schramer has more than 30 years experience serving MACtac’s roll label, graphics and technical commercial areas in a variety of managerial roles. In his current role, Schramer is responsible for the growth of products within the specialty commercial area and works with sales on technical, operational and business assessments of new opportunities.

Schramer

AHAM NAMES DIRECTOR OF GOVERNMENT AFFAIRS Kevin Washington joined the Association of Home Appliance Manufacturers (AHAM) as director of government affairs. In this position, Washington will lead AHAM’s advocacy in the states and Canada. He will also support AHAM’s advocacy of the home appliance industry before Congress. Washington will report to Kevin Messner, AHAM’s vice president of government relations. In his most recent government service, Washington served at the Federal Communications Commission as director of the Office of Legislative Affairs. Prior experience includes senior roles in the Executive branch and several years in the U.S. House of Representatives’ leadership.

Shaner

Rupp

DU-CO CERAMICS ADDS TWO Du-Co Ceramics Co., a supplier of extruded and dry-pressed technical ceramics, has promoted Jim Shaner to the position of ceramic process engineer at its Saxonburg, Pa. facility. His experience will be utilized in production, R & D, product improvement, cost reduction and material management. In addition, the company named Josh Rupp to the newly created position of process engineer. Rupp attended Penn State Behrend University with a degree in Mechanical Engineering and will assist to develop and design automation systems and improving overall efficiencies.

PURAFIL ADDS DIRECTOR OF DEVELOPMENT Purafil has added Thomas Ramsey to its executive team. Ramsey joins the company as the director of business development. He has more than 30 years of global experience in marketing, sales and business development of high technology filtration and separations products to industrial, healthcare, consumer and laboratory markets. In his new role at Purafil, he will focus on the development of strategic business relationships and commercializing Purafil products and services within a newly formed business unit identified as Purafil Scientific, and across the company. Purafil designs, engineers and manufactures gas-phase air filtration systems, air monitors and UL classified granular media.  Ramsey

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NEWS WATCH Lyons specializes in importing and supplying fasteners, nails and other industrial components to customers.

TAOS EARNS DALLAS 100 AWARD

Texas Advanced Optoelectronic Solutions Inc. (TAOS) received a Dallas 100 Award as one of the top 100 fastest-growing, private companies in the Dallas Metroplex for the third consecutive year. TAOS ranked 22nd among the 2010 Dallas 100 companies and has advanced 67 place rankings since 2008. Approximately 43% of the 2010 Dallas 100 winners are hightechnology companies. TAOS is the only semiconductor company selected to receive a 2010 Dallas 100 award. The company manufacturers its ambient light sensor, proximity detection and color sensor products for smartphones, 3D/LED HDTVs, tablets, desktop computers and laptops. The company said it has also seen growth in the industrial, medical, health fitness, commercial lighting and automotive markets with its light sensing solutions.

advanced manufacturing control has allowed the product to be engineered to maximize the fiber content. As a result, it has up to 20% lower thermal conductivity than competitive insulations, claims Morgan Thermal Ceramics. With its smaller footprint, customers can use less insulation, resulting in weight and cost savings. A thinner insulation blanket, such as the Superwool Plus 6 pcf (pound-force per cubic foot), can provide the same insulation as a typical 8 pcf blanket. The insulation fiber blanket has high tensile strength with good handling ability. It is currently available in blanket, modules, Pyro-Bloc modules, paper and bulk (chopped and unchopped). Felt, vacuum formed products, and board varieties are expected to be available in early 2011.

WATERPROOF INSTRUMENTATION PANELS IDEAL FOR HARSH CONDITIONS

SUPERWOOL PLUS CLAIMS TO BE MORE ENERGY EFFICIENT THAN TRADITIONAL INSULATION

Superwool Plus, a high-temperature insulation wool product from Morgan Thermal Ceramics, is 17% more energy efficient than traditional refractory ceramic fiber (RCF) and alkaline earth silicate (AES) insulations, according to the company. Superwool Plus is designed for furnace linings in the iron and steel and aluminium industries and applications requiring high-temperature processing. The material provides insulation in high temperature environments with a classification temperature of 2,192-deg. F (1,200deg. C). A breakthrough in the company’s www.applianceDESIGN.com

CTI Electronics released a switch function control device for extreme conditions. There are three devices that are similar in form, but offer different functionality. Two offer mouse cursor control and the third offers switch function control. All have the Syn-Proof coated elastomer, which protects against harsh chemicals and synthetic oils. When combined with an intelligent serial or USB interface PCB, the six-button function switch pad can be programmed to provide six individual function codes to a host computer. Illumination is an option with either constant or toggled backlighting, or no backlight. Applications include automotive, outdoor test equipment, medical devices and ultrasound equipment, and utility and energy plant console panels.

have launched ZnCoat, a new finish that offers effective solutions for the problems that have been encountered by users of zinc plating for fasteners and small parts. ZnCoat, a zinc-rich coating for ferrous metals, offers several major advantages for high-strength fasteners when compared to electroplated zinc. The finish is chromium-free (no hexavalent or trivalent chromium), and provides corrosion resistance with a thin film, without risk of hydrogen embrittlement. ZnCoat is applicable for construction, appliance, and marine applications, offering an alternative to conventional zinc-plated finishes. The zinc in the ZnCoat is passivated without the use of toxic materials. ZnCoat is free of chromium, nickel, cadmium, lead, barium and mercury and meets RoHS, REACH & WEEE environmental regulations. By comparison, conventional zinc plating is passivated by the use of hexavalent or trivalent chromates. Chromates provide a thin-film passivation layer, but only on the surface of the zinc plating. Subsequently, during installation or inuse, the fragile film can be damaged and lead to premature zinc oxidation. ZnCoat uses environmentally friendly passivation agents and corrosion inhibitors throughout the film, and so the coating is less susceptible to early failure, according to the company. Compared to conventional zinc plating, ZnCoat consistently achieves over 240 hours of ASTM-B117 salt spray corrosion protection, as well as higher cyclical corrosion performance and real-world outdoor weathering resistance, said the company. For threaded fastener applications, ZnCoat has a tight, consistent friction coefficient (CoF). Lower CoF can be achieved with conventional wax-type topcoats, as is common with electroplated fasteners. ZnCoat is compatible with microencapsulated, anaerobic and nylon type thread adhesive and sealant patches.

COMPANY UNVEILS FIBER-OPTIC CHANDELIERS COMPANY DEBUTS ALTERNATIVE TO ZINC COATING

NOF Metal Coatings North America Inc. and Curtis Metal Finishing Company

TLSANLI develop new products with cutting-edge LED technology, and recently unveiled its line of fiber-optic chandeliers. All designs strictly follow the UL applianceDESIGN

March 2011 11

NEWS WATCH and EU electrical safety standards. The company uses Cree LED chips and Edison LED chips for assembly, to ensure quality. All the products are CE certified and RoHs compliant. Made of fiber cables and stainless steel, the chandeliers are available in an array of colors, sizes and eight designs. Custom options also are available.

JOHNSON CONTROLS INTRODUCES YVAA AIR-COOLED VARIABLE-SPEED SCREW CHILLER

Johnson Controls recently introduced its York YVAA air-cooled variable-speed screw chiller, which can be tailored and tuned to offer efficiency, reduced sound and sustainability. On replacement projects, YVAA energy performance can exceed that of older chillers by as much as 50%, according to the company, while performance on new projects can exceed competitors’ chillers by up to 25%. In addition, the chiller’s performance can be tailored and tuned to hit specific targets for state, municipal or utility rebates, where available. The chiller also offers flexible energy consumption, with design efficiencies up to 11.6 EER. The unit can be configured

to deliver an integrated part load value (IPLV) up to 19.8 EER. In addition to a variety of sound-attenuation options, the YVAA offers its SilentNight feature which works with a BAS (or programmable control) to load-limit the chiller when noise reduction is a priority. When optimized for sound performance, the YVAA chiller can reduce ambient noise by as much as 16 dBA at off-design conditions, said the company. The YVAA chiller uses HFC-134a refrigerant, which has no phase-out date and an ozone-depletion potential of zero. Fewer joints and potential leak points keep the refrigerant inside the system, while a proprietary falling-film evaporator and advanced microchannel condenser coils reduce the refrigerant charge by as much as 15%. No cooling tower is required, and because power generation is a major water consumer, the high efficiency of the YVAA chiller conserves water.

PANASONIC INTRODUCES WHISPERWELCOME VENT FAN

Panasonic Home & Environment Co. introduced two new ventilation fans, designed to address the lodging industry’s

need for a quiet, energy efficient bath fans to improve indoor air quality and guest experience. The Energy Star rated, ceiling mounted WhisperWelcome ventilation fans aim to reduce operating and maintenance costs. In the past, there were only two options for ventilation operation - connect the fan to the same switch as the light or install a separate switch for fan operation only. When the fan was connected to the light switch, it would be left on for hours, consuming energy and ultimately resulting in burnt out motors. When a separate switch was installed for the fan, guests would not turn it on and therefore moisture was not removed, potentially resulting in mold and mildew damage. With quiet noise levels as low as 0.3 sones, the WhisperWelcome is the only Energy Star rated ventilation fan with a motion sensor available for the lodging market, according to the company. The motion sensor with delay-off timer activates the fan when a person enters the bathroom and automatically shuts the fan off 20 minutes after the occupant has left. This function helps reduce operating costs. The vent fans fit in a 2 inch by 6 inch joist cavity and is available with a dual duct rating of 4 or 3 inches. The fan is powered by an enclosed AC motor rate for continuous run, increasing the life of the motor. They also are UL listed for tub/shower enclosure and ASHRAE 62.1, LEED, California Title 24, and Washington State Ventilation and Indoor Air Quality Code compliant. 

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Hungry For Change? Your Customers Are. They want great features offered in the refrigerated products they buy, like environmentally friendly and GRAS (Generally Regarded As Safe) materials.

ecomate by Foam Supplies, Inc. | © 2011 All rights reserved

SUS TAINABLE | ENVIRONMENTALLY BENIGN | ENERGY EFFICIENT | H YGIENIC ALLY SAFE

Foam Supplies’ innovative product Ecomate provides GRAS approved foam insulation for various types of refrigerated products, like walk-in freezers, refrigerated cases and residential refrigerators. It’s also green – and a competitive replacement for all blowing agents. Ecomate meets all current and future regulatory requirements, being both U.S. EPA and SNAP approved to replace HFCs and SMOG producing hydrocarbons. In fact, FSI customers in 2009 alone reduced potential greenhouse gas emissions by 1.2 billion pounds of CO2e, which is 3x more than any competitor.* So, be kind to the environment and your customers. Make the change to Ecomate. * The 284 member companies of EPA’s Climate Leaders Partners, some of the largest and most competitive companies in major sectors of the economy and the US leaders in ghg reductions, on average reduced their emissions by 176,056 mt or the equivalent of 31,960 cars a piece. FSI customers reduced emissions by 549,817 mt or the equivalent of 90,000 cars.

Better Products. Better for the Environment. 1.800.325.4875 or +1 314.344.3330 www.ecomatesystems.com

INSULATION Soybean oil is one of the leading components found in natural-oil polyols. Photo: Bayer MaterialScience

i l O s l a r u Nat

GET RIGID

Understanding the welding process can help streamline an intricate task.

by larry adams Larry Adams is a contributing writer to appliance DESIGN. 14 applianceDESIGN March 2011

I

n the past several years, designers have faced a whirlwind of changes when it comes to insulation options. From materials that have zero ozone depletion potential (ODP) to the push for materials with lower global warming potential (GWP), designers have had the challenge of adapting as material migrated from one environmentally acceptable product to the next. Driven by economic and market forces, that evolution is not over. New and ever greener, insulation options are coming down the garden path. For instance, suppliers are incorporating vegetable oils into their insulation mix. Natural-oil polyols, or NOPs, are polyols derived from vegetable oils— particularly soybeans—by several different techniques. The primary use for these materials is in the production of polyurethanes, a product that traditionally used petroleum material in its polyols. In addition to the market demand for “green” products, the rise in petroleum prices has also given rise to the interest in natural-oil polyols. For their part, NOPs are not new, nor are they are unknown. Today, natural-oil poly-

ols are used in urethane coatings, elastomers and sealants. Commercial and residential insulation made with NOPs, whether sprayin, panel, or even insulation-in-a-can, are becoming readily available to contractors and consumers alike at the local hardware or do-it-yourself store. Flexible foams made with NOPs are also become more en vogue. Companies such as BASF, Bayer MaterialScience, BioBased Technologies, Urethane Soy Systems, Cargill, Dow Polyurethanes and others, are producing flexible polyurethane foams for a range of industries including automotive and furniture. Simmons, the bedding manufacturer, announced that it is using Renuva, a flexible foam made by Dow with a soy-based NOP as part of its Natural Care Collection. Seats, headrests, and armrests in the 2010 Hyundai Santa Fe, the Sonata Sedan and the 2009 Kia Amati Sedan are cushioned with NOP-based foam. One of the most vocal supporters of these polyurethanes made using natural oil polyols is the Ford Motor Company, which used polyurethane foam made using natuwww.applianceDESIGN.com

INSULATION

ral oil polyols in the seats of its 2008 Ford Mustang.

Insulating Foams

Bayer MaterialScience developed a technology to produce rigid polyurethane foams based on renewable raw materials. By combining two processes, the company was able to achieve a high content of vegetable oil components and deliver the same range of properties and the structural diversity of conventional polyols.

Household refrigerators such as this one from Liebherr are a suitable application for rigid polyurethane insulation foams made with natural-oil polyols. The energy efficiency of such appliances depends largely on rigid polyurethane foams. Photo: Bayer MaterialScience

www.applianceDESIGN.com

Natural-oil polyols used in rigid polyurethane foam, however, is a different matter. For this product, suppliers have found NOPs to be a challenge. Polyurethane rigid foams are widely used as insulation materials for appliances such as refrigerators and freezers, and these foams account for almost one-third of the polyurethane market. Polyols are a key ingredient in the manufacture of these foams. Out of the annual 2.8 billion lbs. of North American polyol market, approximately 1.3 billion lbs. of polyols are used for manufacturing polyurethane rigid foams. The lion’s share of this amount has been made with mineral oil derived from petroleum. Cellular insulation materials are made by reacting polyols with polyisocyanates and other catalysts, additives, and blowing agents according to the white paper, Natural Oil Polyol of High Reactivity for Rigid Polyurethanes, by BioBased Technologies. As a cross-linked material, the rigidity of polyurethane foams is closely associated with the formation of cross-linked structures and urea linkages. A highly crosslinked polyurethane material requires a reactive polyol that has a relatively high hydroxyl number ranging from 200 to 800 mg KOH/g and high functionality, typically in the range of 3 to 5. Traditionally, the problem with NOPs is that they had low hydroxyl functionalities and relatively high equivalent weight, which made them more suitable for solid urethanes and flexible foam, not rigid urethane foam. They lacked solubility for blowing agents, as most NOP technology is based on fatty-acid triglycerides, which have different solubility characteristics than polyether or polyester polyols. That is changing, however, as suppliers such as Bayer MaterialScience, a Germanbased company with U.S. headquarters in Pittsburgh, and BioBased Technologies, Fayetteville, Ark., have developed ways to overcome NOPs challenges. Dr. Geza Avar, head of Innovation in the polyurethane business unit at Bayer MaterialScience, said applianceDESIGN

March 2011 15

INSULATION Agrol from BioBased Technologies is available in five functionalities, including 2.0, 3.6, 4.3, 5.6, and 7.0. It features a color range from 5 to 8 on the Gardner Index depending on the functionality, low acidity and hydrolytic stability.

that in the past, the relationship between solubility, reactivity and attainable density has been “less than satisfactory” for NOPs, and they could only be used to a limited extent as a replacement for conventional polyols. Bayer’s method is a one-step process that incorporates fatty acid residues and glycerin into functional polyols giving them higher renewable content and a wide range of possible properties. The company’s process merges two different chemical reactions in a single step. They combine the process of alkoxylation, the reaction between a hydroxyl and a propylene- or ethylene-oxide, and transesterification, to provide polyols with a high content of vegetable oil components that can deliver the same properties. The polyols can be used with various popular blowing agents and are compatible with conventional polyols. They have a hydroxyl weight of up to 280. BioBased Technologies has two products, Agrol and Agrol Diamond, which is its rigid foam product. The company’s tri-functional polyol derived from natural soy oil has a biobased content of up to 96%, and is compatible with both conventional and other natural oil polyols. It is completely miscible (mixable) with hydrocarbon blowing agents. The Agrol product, which is used more in spray and flexible foam applications, did

16 applianceDESIGN March 2011

undergo an interesting study sponsored by the United Soybean Board. The study compared production data of Agrol polyol to five petroleum-based polyols. According to Jennifer Wilson, brand manager for BioBased Technologies, the study documented that the production of Agrol has a lower GWP than petroleum-based polyols -310 gm C02 eq/kg compared to petroleum polyols resulting in 4100 gm C02 eq/kq. She added that it also helps manufacturers reduce their carbon footprint. As much as 5.5 lbs. of carbon dioxide equivalents are removed or prevented from entering the atmosphere for every pound of Agrol that replaces petroleum-based polyether polyol, she says.

Improved Marketing Capability Both Bayer MaterialScience’s polyols and BioBased Technologies’ polyols qualify as biobased products, as defined by the United States Secretary of Agriculture, meaning that they can qualify for the USDA’s procurement guidelines, which accord preferential treatment to products made from renewable materials. However, most NOPs do meet this threshold. The trick is to meet the threshold after the NOP has been mixed with other ingre-

dients to create the rigid polyurethane foam. In the past, materials such as sugar and glycerin were used in the production of polyols. In fact, polyether polyols based on sugar may contain up to 30% renewable raw materials, but may not meet the threshold. Compare this to Bayer’s NOP that can contain between 40 and 70% renewable material, and when rigid foam is made, it can still hit about 10 to 15% total biobased content, which is a candidate for a biopreferred stamp. While NOPs use in appliances are still limited, at least one manufacturer has successfully used NOP-containing Baytherm rigid polyurethane foam from Bayer MaterialScience. Liebherr, German manufacturer of refrigerators and other appliances, used rigid foam made with natural-oil polyols as the insulation layer to insulate a refrigerator in Europe. As new formulations for rigid natural-oil polyols come to market, it is likely that more companies will look to improve their green credentials by insulating their appliances with materials made from high content, biobased polyols. 

www.applianceDESIGN.com

POWER

High-Voltage GDTs Help Protect Appliance Circuitry During Hi-Pot Testing If a high-potential test is not performed, a product with poor insulation or incorrect internal conductor spacing may fail under the influence of environmental factors.

by faraz hasan Faraz Hasan is global global marketing manager and business development manager, appliance/industrial/lighting for Tyco Electronics’ Circuit Protection Device Business Unit, Menlo Park, Calif. 18 applianceDESIGN March 2011

T

he hi-pot (short for “high potential”) test is commonly used by manufacturers to determine whether appliances and other electronic products will remain safe when subjected to high-voltage conditions. During routine use of an appliance, a high-voltage condition may occur when transients are present on the power supply. This test—also known as flash, highvoltage, or dielectric strength test—is not an actual measurement, but a process for determining if a product is electrically safe. If this test is not performed a product with poor insulation or incorrect internal conductor spacing may fail under the influence of environmental factors such as the ingress of moisture, dirt, or the effect of vibration. These defects cannot be consistently detected by any other electrical safety tests. Designed to detect insufficient gaps or clearances between conductive parts and earth/chassis, the hi-pot test helps identify damage to the product’s insulation or defects in the product construction and internal wiring, and ensure that conductor spacing is correct and electrically safe. The test applies high voltage to the product to check the insulation between the live conductors and exposed metal surfaces. For Class I equipment, high voltage is applied between conductors and earth. For Class II equipment, high voltage is applied between

the conductors and the outer surface of the product.

Safety Agency Requirements Manufacturers have a legal responsibility to provide safe products. Product safety evaluation is conducted by organizations around the world and acceptable performance can be expressed in the form of a symbol. In the United States, the Underwriters Laboratories (UL) mark is required. The Conformite European approval, symbolized by the CE Marking, is the European assurance of safety as well as the product passport allowing equipment into the 18-nation European marketplace. Other organizations, including Canadian Standards Association (CSA), International Electrotechnical Commission (IEC), British Standards Institute (BSI), German Electrical Engineers Association (VDE), Technische Uberwachungs Verein (TUV) and the Japanese Standards Institute (JIS), also have similar product safety requirements and standards. Much of the safety-test emphasis culminates in the right to use the UL and CE marks on retail products. Qualification tests for each design and production records for each product manufactured must be maintained in order to retain the qualification symbols. www.applianceDESIGN.com

POWER

A GDT helps control discharge of voltage surges that may exceed the type test rating. Source: Tyco Electronics

Test Procedures and Requirements Before testing, it is important to differentiate between the two distinct test requirements: type testing and routine, or production line, testing. Type testing levels vary according to the relevant product specific standard.

Type Testing For Class I metal-clad earthed/grounded products, the test voltage ranges from 1000 to 1500 V. For Class II double insulated products with no earth/ground connection, the test voltage ranges from 2500 to 4200 V. The usual practice is to use an AC voltage, as it is representative of the supply, but DC voltage can be substituted where high leakage is experienced due to the inclusion of line filtering capacitors within the design. If a DC test is to be applied, the test voltage will be the AC value multiplied by 1.414. As type testing is used to destructively test the product to the design standard, a leakage capability of 100 mA is common. Due to potential high levels of leakage, these tests must be conducted in a safe environment (laboratory) and by competent test operators who are aware of the hazards associated with test equipment capable of delivering a potentially lethal 100 mA of current from a high voltage source.

Routine Testing Routine testing must take into consideration the requirements of the production environment. These generally comprise the overall test time burden and safety implications of installing a high voltage test area within the production environment. Here, the need to have faster but equally rigorous tests is achieved by applying a 10% higher www.applianceDESIGN.com

Potential discharge paths and equipment components may be damaged due to voltage surges exceeding the type test rating. Source: Tyco Electronics

voltage to the type test level, but with a reduced test time of a few seconds. To maximize operator safety, it is recommended that the leakage current limit is reduced to 5 mA.

Overvoltage Protection Considerations Many appliance manufacturers find that they can improve product safety and reduce warranty exposure through prudent planning and designing equipment that can withstand overvoltage events that may exceed the base levels required to obtain industry safety agency approvals. One approach to designing equipment so that it will remain safe and withstand voltage surges that exceed the production hi-pot test is to include a gas discharge tube (GDT) in the input power circuit. GDTs help protect personnel, equipment and circuitry from abnormally high voltages caused by lightning or electrical transients. These devices have well-defined surgelimiting characteristics enabling them to spark over (or breakdown) when the abnormal voltage on a line reaches a specific level. When sparkover occurs in the GDT, the surge is redirected to earth. Available in a variety of form factors, high-voltage GDTs are suitable for power supply applications where hi-pot testing is required. In the following example of an appliance that must meet a 1500 VAC (2121 VDC) hipot test to meet safety agency requirements, the engineer could begin by designing the electrical clearance, creepage and insulation system to withstand 3000 VDC. Next, the design can be verified by type testing. Now production test levels must be set; in this example 2250 VDC is used. This test is performed on 100% of the production lot and is a pass/fail test, with the criteria being that if

over 5 μA of current flows through the system it is unsafe. By installing a 2500 VDC-rated GDT with a 10% tolerance between the live circuit and the safety ground wire, the results of the hipot test will not be affected. This addition allows the design engineer to localize the current flow during an overvoltage event at the power entry location. This design technique provides two distinct advantages. The first is that the current path to ground will occur prior to reaching any sensitive electronic controls, sensors or motors that may be damaged by high surge currents. The second is that the return current path can be located as far from the user as possible, reducing safety hazards during a high voltage surge or fault condition.

Summary Appliance manufacturers are increasingly using GDTs as overvoltage protection components in their designs. GDTs help protect against damage from voltage surges caused by lightning or AC power faults that can affect sensitive electronics. They help improve operator safety by shunting surge currents to ground and by limiting transient voltages to a safe level. As hermetically sealed devices, GDT discharge regions are shielded against environmental influences and can operate from -40-deg. to 100-deg. C without any parametric deratings. Moreover, GDTs are not susceptible to unusually high rates of current rise and have very low capacitance. The GDT device can help manufactures meet stringent product safety requirements, improve product reliability and reduce warranty costs.  For more information, visit: www.tycoelectronics.com or e-mail [email protected] applianceDESIGN

March 2011 19

METALS

METAL PLASTIC U LTR A S O N I C W E L D I N G Learn the differences between metal and plastic ultrasonic welding.

Senior Editor Austin Weber asked Karl Graff, Ph.D., to explain the differences between metal and plastic ultrasonic welding. What follows, is part of the pair’s question and answer session. Dr. Graff is a leading expert in the field of high power ultrasonics, including transducers, applications and systems. He previously served as the Edison Welding Institute’s executive director in Columbus, Ohio, and also is the former head of the Sonic Power Laboratory at Ohio State University.

Is the process of joining aluminum parts with ultrasonics any different than it is with other materials, such as thermoplastics?

by austin weber Austin Weber is senior editor at Assembly magazine, Deerfield, Ill.

20 applianceDESIGN March 2011

Dr. Karl Graff: The ultrasonic metal welding process (whether aluminum or other metals) is fundamentally different from welding plastics in how the ultrasonic energy (or vibrations) is delivered to the weld, and in how the actual weld is created. First, ultrasonic metal welding delivers vibrations to the zone via transverse vibrations that are parallel to the weld surfaces. Ultrasonic plastic welding delivers vibrations to the zone via longitudinal vibrations that are normal (i.e., at right angles) to the weld surfaces. Second, ultrasonic metal welding creates the weld via a frictional action of the surfaces that creates a solid-state bond without any melting of the material. Ultrasonic plastic welding is based on melting and fusion of the material (in a sense, like many metal welding processes, such as arc, resistance or laser), but at much, much lower temperatures than experienced in metal fusion processes. There are two slightly different ways of delivering the ultrasonic vibrations to the weld zone: “lateral drive” and “wedge-reed.” While each has selected special advantages, they both end up getting the vibrations to the weld zone in a transverse vibration action. With this fundamental distinction between ultrasonic metal and plastic welding in mind, then one has ultrasonic welding of all metals done in the same way. Weld arial in all cases are very fast— on the order of 0.2 to 0.5 seconds.

www.applianceDESIGN.com

METALS

Is there a difference in the tooling used to ultrasonically weld metal and plastic components? KG: The shape of the horns that transmit the ultrasonic vibrations into metal and plastic welds are quite different, although they are designed from the same principles of acoustics. The fundamental driving transducers for both ultrasonic metal and plastic welding are quite similar, as are some of the coupling horns (often called boosters) between the transducer and welding tool. Most ultrasonic metal welding companies are in both plastic and metal welding, since much of the underlying technology is similar, including power supplies. Nevertheless, as ultrasonic metal welding tries to meet new challenges, especially in welding thicker materials, there will be increasing differentiation between metal and plastic welding apparatus.

Are high or low frequency levels typically used for metal and plastic welding applications? KG: Most ultrasonic metal welders work at 20 kilohertz, similar to plastic welders (40 kilohertz metal welders are available as well). In moving to higher power, it would not be surprising to see some drop in frequency, to say 15 kilohertz, as has occurred in plastic welders.

What is the biggest mistake end users make when using ultrasonics to weld parts? KG: Ultrasonic welding is based on acoustic and solid-state phenomena, and not fusion phenomena, so users may not make sufficient effort to acquaint themselves with this “animal.” Ensuring set-up of a good, robust

www.applianceDESIGN.com

applianceDESIGN

March 2011 21

METALS

METAL

PLASTIC

set of welding procedures is very important. This becomes especially so for first-time users, since they may not have a backlog of past experience to guide them in setting up the process. Static or clamping force happens to be a very important ultrasonic metal welding parameter. One must be aware of overall part vibrations induced by the ultrasonic welding action. Control of these matters lies in clamping and placement of welds so that resonant conditions are not encountered. A user may set up a process that works at as low a force as possible (maybe to avoid material deformation), not realizing the process is at the “ragged edge” of that parameter. Then, a slight variation of incoming material in surface finish, hardness or cleanliness may throw it “over the edge” resulting in no, or poor welds. When that happens, the user is faced with a new process that was never used before (and that was not trusted too much to begin with) that isn’t working. This, however, is not untypical of many other processes. 

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SWITCHES AND RELAYS

Choose Switches and Relays A broad range of switches and relays are available to fit the needs of today’s OEM.

by appliance DESIGN staff

The metal head on this switch can prevent damage and also can be rotated eight different ways based on actuator entry, providing mounting flexibility. Photo: IDEC Corp.

24 applianceDESIGN March 2011

A

s technology progresses, components in electronic equipment must continue to perform multiple functions with the smallest footprint possible. With today’s advanced products, design engineers need to pay attention to choosing switches and relays as they affect the overall operation of the product, and all devices connected. For example, minimum operating voltage, ambient temperature, shock and vibration to be applied, and sizing of the power supply and transformer must all be taken into consideration. Luckily, there are a range of component choices for OEMs when it comes to switches and relays—a broad category to suit the needs of almost any control engineer of an electronic product. Read on to learn more about the latest products on the market.

HS5D safety switches from IDEC Corp. allow a user to see if the head is separated or improperly mounted on the body. The HS5D has a contact that will allow easy identification of incorrect head installation, providing an extra safety measure, according to the company. The switch is 30 by 30 by 91 mm, and is available with up to three contacts. Metal or plastic heads are available. The metal head can prevent damage, says the company, and can also be rotated eight different ways based on actuator entry, providing mounting flexibility. Allegro MicroSystems Inc. recently introduced a line of two-wire, unipolar, Hall-effect switches. These devices include improved high voltage transient protection, which is a feature that is critical for applications that do not allow protection circuits to be located close to the sensor, such as in automotive applications. The company’s A1152/3/5/6 devices are factory trimmed to optimize the accuracy of the magnetic switch points and employ a patented, high frequency, four-phase, chopper-stabilization technique to achieve magnetic stability over temperature and to eliminate offset inherent in single-element devices, when exposed to harsh environments, according to Allegro. Additionally, the company says its chopping technique provides significantly reduced jitter and faster poweron time. Two-wire, unipolar switches require one less wire for operation versus the more traditional open-collector output switches. Carling Technologies offers its Contura Series and L-Series families of illuminated and non-illuminated, sealed rocker. They are designed to protect against dust and prolonged effects of spray and immersion under pressure, www.applianceDESIGN.com

The company says its Ethernet switch streamlines costs and system footprint by facilitating a line topology for fieldbus wiring, eliminating additional switches and hubs. Photo: WAGO Corp.

and are sealed to an ingress protection rating of IP66 and IP68. The company’s rocker, toggle, push button, and rotary style switches come with a variety of aesthetic and functional options, including circuit configurations, AC & DC ratings, insulated and water shedding constructions, termination options, mounting options, custom colors and imprinting. WAGO Corp.’s high-speed 750-881 Ethernet 2.0 Programmable Fieldbus Controller processes 1000 instructions/235 μS and has an integrated dualport Ethernet switch. The product line provides significant amounts of memory for PLC programs and Web applications. Independent Ethernet ports respond in 1ms, transmitting real-time information to production and enterprise management. The company says its Ethernet switch streamlines costs and system footprint by facilitating a line topology for fieldbus wiring, eliminating additional switches and hubs. An onboard DIP switch configures the last octet of IP address/assignment, expediting commissioning. The slotted housing optimizes heat dissipation while maintaining a 0-deg. C to +55-deg. C operating temperature range and IP20 rating. The CG and the CL series from C&K Components are UL- and CSA-approved www.applianceDESIGN.com

TOWER OFFERING UL/CSA ON MOST PRODUCTS PRO AND EUROPEAN APPROVALS ON CERTAIN SNAP-ACTION THERMOSTATS AND SWITCHES

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www.towermfg.com applianceDESIGN

March 2011 25

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SWITCHES AND RELAYS

The CG and CL series switches have a snap-in installation design for quick, high-volume product assembly. Photo: C&K Components

single pole power rocker switches for household appliances, instrument panels, industrial controls and computers/peripherals with two-tone and multi-colored illuminated actuators. The CG and CL series have a snap-in installation design for quick, high-volume product assembly. The CG switch has contact ratings of 16A at 125VAC or 10A at 250VAC and an electrical life of 10,000 make-and-break cycles at full load. The operating temperature for the CG series is -20deg. C to +85-deg. C. The CL series single pole power rocker switch features a positive detent with several models available with illuminated actuators in red, amber and green color options. The contact ratings for the rocker switches are 16A at 125VAC, 1/3HP or 10A at 250VAC, 1/2 HP. Operating temperatures are -20-deg. C to 80-deg. C.  For more information, visit: www.idec.com/usa www.wago.us www.allegromicro.com www.ck-components.com www.carlingtech.com

Look for the winners of the 24th Annual Excellence in Design Awards in appliance DESIGN's June 2011 issue!

Don't miss the showcase of some of the most successful, innovative products on the market.

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March 2011 27

DISPLAYS & INTERFACES

On the Home Front

When interactive, touch-enabled “smart mirrors” are networked with other domestic systems, they enable the user to control air conditioning, lighting and security, in addition to browsing web pages or reading emails. When not in use, the display disappears behind the mirror. Photo: Zytronic

The progression of touch screen technology in the domestic environment lends itself to considerations unique to the home appliance sector.

by ian crosby Ian Crosby is sales and marketing director, Zytronic, Blaydon on Tyne, U.K. 28 applianceDESIGN March 2011

H

uman machine interfaces (HMIs) that rely on some form of touch screen are commonplace in everyday applications ranging from mobile communication devices and public information kiosks to ATMs and digital signage systems. A new era is approaching where touch control enters the home appliance sector. OEMs must factor in some main considerations in this particular market when deploying a touch screen-based HMI. Various technology decisions need to be made, so that engineers can create HMIs that are fully optimized for the challenges faced around the home. With the huge success of touch-enabled control in the portable electronics space over the last few years (in devices such as MP3 players and smartphones), touch screens have gained great exposure amongst the general public. Inevitably, consumers are demanding similar levels of style and functionality to be applied to other everyday products and, as a result, white goods are increasingly likely to witness a similar transition from mechanical switches and dials to touch interactive displays presenting sophisticated graphical user interfaces (GUIs). The appeal of touch screen control is easy to understand. It bestows more direct and intuitive functionality than keypad/keyboard alternatives and, when coupled with bright displays and high definition graphics, provides user experiences that are both quick and compelling. At the same time, by com-

bining the functionality of several peripheral controls into a single user interface (UI), touch screens provide design engineering teams with the potential to lower the system’s bill-of-materials, introduce new features, potentially reduce the unit’s footprint, and in many cases enhance its aesthetics. In a fiercely competitive market, they can provide the means for OEMs to create products that are differentiated from those offered by rival manufacturers. For home appliance OEMs to benefit from incorporating touch-enabled HMIs into their products, in addition to the basic considerations of accuracy and touch response time, they must be aware of the specific operational challenges that can come into play in environments where the products will be used. Among the issues to address are: 1. Mechanical wear and tear (particularly for appliances employed within kitchen environments). 2. Extremes of temperature (both in kitchen and bathroom environments). 3. Resilience of the sensor’s operation to build up of dust, grease or food matter. 4. Exposure to high levels of humidity (mainly in bathroom environments). 5. Importance of a smooth work surface (so the unit is easier to clean, but also more attractive in conception). 6. Resistance to harsh chemicals (such as cleaning fluids, etc.). www.applianceDESIGN.com

DISPLAYS & INTERFACES 7. Reliable, stable operation, minimizing costly service calls or product returns. There is a broad range of different touch sensing technologies currently on the market. Before an engineering team specifies a touch screen for a particular product, they should ensure the sensor technology is up to the job. If factors such as those described in the list shown above are not taken into account, the product’s success is likely to be jeopardized. An in-depth investigation of the types of sensors available is thus called for. Touch screens using front-face-active sensor technologies have been used for several decades, proving particularly popular in personal consumer electronic device applications, such as hand-held games, GPS and PDAs. Based on either resistive or surface capacitive sensing techniques, these may be acceptable in less demanding environments, but, in the often uncompromising locations being discussed here, have considerable shortcomings. As their sensing elements are located on the screen’s outer surface, they are left vulnerable to all manner of damage. Hot water splashes in bathrooms or spillages from cooking pots in kitchens, as well as scratches for knives or other culinary implements, will all impair touch performance. Sensors based on either infrared (IR) or surface acoustic wave (SAW) technologies also have major disadvantages here. Their design requires bezels or frames to house the active sensing elements, and as a result they are difficult to clean. Dirt, grease and other substances will inevitably accumulate around the sensor over time and will affect the operation. In an era where the iPhone has defined the look of contemporary touch displays, the obvious drawback with these types of screens is their bulky bezels, which detract from the appliance’s visual appeal. On a more practical level, most front surface touch technologies are also prone to sensor drift over time, which require recalibration to be periodically carried out to maintain accuracy. This results in inconvenience and potential expense for manufacturer and consumer alike. With costly product warranties and valuable reputation on the line, OEMs need to have total confidence in the abilities of the specified touch technology. The stability and longevity of the touch sensor must at least match that of the appliance into which it is incorporated. White goods such as cookers, dishwashers and refrigerators, are in regular daily use and are relatively high value items, which consumers rightly expect to use for several years after purchase. This further underpins the fact that specifying a lowcost, less reliable touch sensor would prove to be false economy when considering the total cost of www.applianceDESIGN.com

Touch screens based on projected capacitance sensing technology can be designed for white goods and home appliances to deliver satisfying, reliable performance year after year. Photo: Zytronic

ownership over the lifetime of the product. An intriguing touch sensing technology which has rapidly emerged in recent years is projected capacitance. These screens have a conductive sensing array positioned on the rear-face, and touch is detected at a distance when the user’s finger creates a small change in either the charge or frequency carried within the array as it approaches the screen’s surface. As the rear mounted array effectively breaks the screen into an XY grid, the touch is pinpointed by calculating the position of greatest change within the matrix. With the active element of the sensor situated on the rear of the screen and away from damage and the surrounding environment, it is perhaps more suited for demanding, high use, domestic settings than most alternative touch solutions. All projected capacitive sensors are capable of being designed for use in flush, bezel-free designs, and generally have pure glass fronts capable of harsh cleaning and unaffected by the build up of grease or dirt. This furnishes design teams with far greater flexibility than the majority of alternate touch technologies, and may avoid compromising the look and feel of the appliance—a crucial marketing consideration. Proprietary technology from Zytronic

allows projected capacitive sensors to be applied to large display formats and customized designs. As a result, patented projected capacitive technology is beginning to be integrated into an increasing range of appliances and white goods. The PCT sensor structure comprises an array of micro-fine copper electrodes (10μm in diameter), arranged in an XY grid and embedded into a laminated substrate. This substrate can even be placed behind a thick protective glass or plastic overlay providing designers with the ability to seamlessly embed the touch screen display within the overall product design. Furthermore, PCT is not susceptible to scratches, mechanical shock, water ingress, harsh chemicals or heat and can be completely sealed into a unit, capable of complying with IP67 or NEMA 4x standards. Finally, PCT is highly scalable, being applied to an almost limitless range of form factors between 5 and 82 inches. Whatever the technology used, the OEM must factor in considerations particular to the appliance market including operating environment and reliable operation with little or no maintenance.  For more information, visit: www.zytronic.co.uk applianceDESIGN

March 2011 29

NEW PRODUCTS

Aremco Aremcolox 502-1400-96 is a high density, full-fired, red alumina ceramic used to machine and mold components used in applications to 3000-deg. F (1650-deg. C). The ceramic is a high density, fullfired, 96% pure, red alumina ceramic that provides exceptional abrasion and corrosion resistance as well as high mechanical strength and electrical resistance for continuous operating temperatures to 3000-deg. F. Properties include a compressive strength of 340,000 psi, flexural strength of 46,000 psi and dielectric strength of 225 volts/mil. Aremcolox 502-1400-94 experiences no weight loss when exposed to high concentrations of sulphuric acid for extended periods of time and demonstrates a very low index of volume loss upon extensive impingement and erosion tests. Parts are fabricated to close tolerances through injection molding, isostatic pressing and diamond machining processes. Lapped, polished and metallized surface finishes are also available. For more information, visit www.aremco.com

Ametek Technical Products Pittman 22 mm brush-commutated DC gear motors integrate planetary gearboxes to meet speed and torque requirements in applications with tight design envelopes. These 22 mm DC gear motors 30 applianceDESIGN March 2011

(Series 6000) are available in three standard motor lengths. Sturdy gearbox construction incorporates either metal gearing to promote high torque capacity or economical plastic gearing to reduce audible noise. Both gearbox versions offer the capability of bi-directional rotation. Maximum load capabilities range from 7 oz-in / 0.05 Nm to 99 oz-in / 0.70 Nm and continuous torque up to 0.70 Nm can be achieved. For more information, visit www.ametektechnicalproducts.com

Dontech Therma Klear transparent heaters provide the warmth necessary to extend the operating temperature of liquid crystal displays (LCDs) in cold environments (e.g., from 0 to below -40-deg. C) for the anti-fog, anti-icing, and de-icing of optics and optical camera, sensor and display assemblies. The heaters are composed of electrically conductive thinfilm coatings on a visually transparent substrate. When current flows across the coating, it generates heat. The company manufactures heaters using different types of crystalline materials (e.g., zinc sulfide or germanium), glass, acrylic and polycarbonate substrates. Custom shapes are available in sizes up to 24 inches in diameter. The company can optically match the properties of a Therma Klear conductive coating through dielectric enhancement (index-matching) to improve reflection and transmission properties in the desired optical performance band (e.g., visible spectrum, near IR). By index-matching, reflection losses are converted to transmitted light. For more information, visit www.dontech.com

LCR Electronics Two digital electronic temperature controls are available in an open-board style that incorporates solid state digital circuitry. The EC112 and EC114 controls are ideal for use in various heating and chilling applications such as convection ovens, conveyor ovens and toasters, buffet lines and refrigerating products or any process application where temperature regulation is important. The EC114 was made by combining the low-cost EC112 with an easily integrated ‘snap-on’ board to provide a digital interface. Because both boards utilize the same base architecture, OEMs can incorporate both versions into their product lines, while benefitting from economies of scale by purchasing larger quantities of the EC112 to use alone or with the supplementary digital interface board for EC114 applications. For more information, visit www.lcr-inc.com

OSD Displays Optical Bonding Technology is a technology option that attaches to cover lenses, anti-reflective glass, plastic or touch sensors on the company’s range of high brightness flat panel displays. This technology allows for the elimination of the air gap between the cover plate or touch sensor and the TFT panel. By using an adhesive that closely matches the index of refraction of the panel and the cover plate, the total reflectance of the module can be reduced to as low as 0.2% according to the company, dramatiwww.applianceDESIGN.com

NEW PRODUCTS cally increasing the contrast ratio in a high ambient light environment. Other benefits of this process include improved impact and shock resistance. For more information, visit www.osddisplays.com

such as cool white (6000K), neutral white (4000K) and warm white (3000K). The device comprises moisture sensitivity level (MSL) rating of 2a with longer floor time of 4 weeks, enabling flexibility during the assembly process. For more information, visit www.kingbrightusa.com

PennEngineering The family of Atlas Plus+Tite blind threaded steel inserts has expanded with a straight shank design. This fastener joins Plus+Tite pre-bulbed inserts in offering pullout resistance when installed permanently in plastics or thin sheet metal. Both types provide reliable and reusable threads for “blind” attachment applications, including tubing and extrusions, where only one side is accessible for fastener installation and component assembly. A single mating screw completes the final attachment process. Atlas Plus+Tite inserts can install permanently into single, variable, or multiple-thickness materials as thin as 0.020-inch / 0.50 mm. The straight shank design accommodates a small mounting hole and the pre-bulbed inserts require less installation load. For more information, visit www.pemnet.com

die cast aluminum. Other features include a baked polyester power coat paint finish, TEFC industrial duty motor and no belts and pulleys for simple maintenance. For more information, visit www.continentalfan.com

Nameplates for Industry Inc. Selco Products Co. These hot capillary thermostats are designed to provide the ideal temperature control solution for a wide variety of commercial and consumer heating applications. Available in manual or automatic reset models, the hot capillary thermostats are UL, C-UL, VDE, EC and RoHS compliant, and are available in a wide selection of preset temperature ranges and differentials. The CAP series of thermostats are compact, constructed of ceramic bodies, and feature temperature ranges of 32-deg. F to 752-deg. F (0-deg. C to 400-deg. C. The liquid within the thermostat bulb expands as the temperature rises, transmitting pressure through the capillary tube to an expandable diaphragm. When the thermostat set point is reached, an electrical switch is activated, shutting off the thermal current. For more information, visit www.selcoproducts.com

The NFi Prototype Program for custom product labels and other applied graphic products features fast delivery and a flat fee for 10 pieces. The program aims to provide product designers with a finished label, decal, nameplate, overlay or keypad from standard graphic software files within 3 to 5 days, depending upon part complexity. Digitally printed on a selection of substrates with textures, windows and various adhesive types, they are laser cut and can include custom shapes. The finished label or applied graphic product must fit within 18” x 24” and can also include serial numbers and barcodes. For more information, visit www.nfi.name

Piher

Kingbright Corp. Cost-efficient 3.5 x 3.5mm 0.5W SMD LEDs (AA3535 series) are available in an industrystandard PLCC4 package. Despite its compact design with a wide 120-deg. viewing angle, the ultra-bright LED achieves high intensity illumination up to 35 lm @ 150 mA, optimizing advantages for designers of various appliance, backlighting and consumer applications. Furthermore, the product extends aesthetic benefits with its assorted color selections including blue, green, yellow, red and white in various color temperature www.applianceDESIGN.com

Continental Fan The APW Panel Fan requires little or no maintenance. The direct drive APW offers aerodynamically efficient performance within a heavy duty welded steel panel and motor base. The fan is available in diameters from 14 through 60 inches, with capacities ranging up to 60,000 cfm. The APW Panel Fan has a factory set, adjustable pitch impeller for precise performance matching. The airfoil axial impeller is constructed of spark-resistant,

An SMD version of the company’s PT15 Potentiometer is available. The PS15 rotary position sensor features configurable capabilities for maximum design flexibility in a small 15mm package. The sensor offers a surface mountable solution for detecting changes in angle and position and converting them into a highly reliable voltage output. It can be processed by standard automated placement equipment and reflow (or lead-free reflow) soldered. For applications where rotor angle is critical, locating pins are available. The series is available with seven different rotor designs and 15 shaft styles with choice of nine colors in standard or UL94 compatible plastic. For more information, visit www.piher.net  applianceDESIGN March 2011 31

ASSOCIATION REPORT: AHAM

Smart Grid Opportunities

D

A smart appliance has the capability to receive, interpret and act on a signal received from a home energy management system, utility or third-party energy service provider, and automatically adjust its operation depending on the signal’s contents and settings from the owner. The smart grid system will produce energy and financial savings to both the grid and individual consumers. It is critical, however, that the implementation costs of the grid infrastructure and smart appliances themselves results in benefits that far outweigh the costs. To ensure that the implementation costs are minimized for smart appliances, national communication standards are needed to allow manufactures to develop mass produced products suitable for nationwide distribution. National standards are needed to ensure an appliance has the capability to function anywhere in the U.S. where the smart grid infrastructure is available. These national standards also will promote interoperability between appliances and enhance consumer choice. National standard communications and application protocols will make it possible for consumers to move from one area of the country to another while continuing to benefit from smart grid technologies without having to replace, modify or upgrade their appliances. The assessment includes only open technologies, which were evaluated through a requirements-driven scoring system, to rank the ability of the studied communications technology to meet the unique needs of appliance consumers. According to the assessment results, the most relevant communications technologies were clearly separated from their peers for use in smart grid appliance applications. For the application layer, SEP 2.0 and OpenADR scored the highest. Across the media and network layers evaluated, Wi-Fi, ZigBee and HomePlug Green PHY scored the highest. Although there could be other viable architectures, the assessment reflects a clear preference by the home appliance industry that the best communications architecture at this time features a hub or gateway that can communicate using common protocols and serve as the adapter or bridge to other devices on the home area network (HAN). There is still much work to be done to bring the next generation power grid online. However, AHAM members are staying on top of the developments and working to develop the public policies and the technical foundation for successful adoption of smart appliances. 

March 2011

www.applianceDESIGN.com

Joseph M. McGuire President Association of Home Appliance Manufacturers

32 applianceDESIGN

uring the past 18 months, it seems as though AHAM has been thrust forward into a technology wind tunnel. The association has gone from an organization that monitored the nascent developments of the smart grid to the go-to resource for the technical and public policy requirements for the effective integration of smart appliances with the smart grid. A key objective of the smart grid is to provide technology and systems integrated into appliances and consumer devices that will allow consumers to automatically control their energy use and costs. AHAM’s goal is to engage with government, utilities, the technology sector and other stakeholders to advocate for a regulatory environment that offers manufacturing and consumer incentives to hasten the deployment of smart grid enabled appliances. In mid January of this year, AHAM partnered with environmental and energy efficiency organizations to submit a petition to the U.S. EPA’s Energy Star program to recognize the benefits of smart appliances. The petition urges the Energy Star program to incorporate a 5% credit to the energy performance level required to meet Energy Star eligibility criteria for smart-grid-enabled appliances as soon as possible. AHAM and efficiency organizations agree that the incorporation of this incentive for smart-grid-enabled appliances will save consumers energy and money and contribute significantly to a more efficient electrical grid. In late 2010, AHAM published the study, “Assessment of Communication Standards for Smart Appliances: The Home Appliance Industry’s Technical Evaluation of Communication Protocols,” developed by AHAM’s smart grid task force. It provides an assessment of existing communication standards, and an assessment based on their application with home appliances, for standards bodies and government agencies to consider. AHAM’s position, as outlined in its smart gird white paper, “The Home Appliance Industry’s Principles & Requirements for Achieving a Widely Accepted Smart Grid” published in December 2009, called for open, flexible and secure communication standards that are limited in number. The development of standardized and interoperable communications and application protocols for smart appliances will benefit consumers and utilities, allowing customers to manage their energy use and demand, thus reducing peak loads on the electric grid as well as enabling consumers to save money on their electric bills.

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March 2011 33

33% Electricity. 100% Cold.

The cold facts: energy savings of 67% - the result of high-efficiency EC technology and sophisticated aerodynamics! In our specially developed ESM series for refrigeration technology, the motor and impeller are optimally matched. Compared to conventional shaded-pole motors with separately attached impellers, the overall efficiency is substantially increased. This advantage makes a particularly great difference in refrigeration systems with a high duty cycle. By the way: our highly successful W1G200 model is now available in the 172, 230, 250, and 300 mm sizes and with an easy-to-clean surface. Learn more at: www.ebmpapst.us

The engineer’s choice