Appliance Design February 2011

February 2011

REACHING OEM DESIGN ENGINEERS ACROSS CONSUMER AND COMMERCIAL MARKETS WORLDWIDE

Plastic Compounds Perform EMI Shielding p. 22

INSIDE 12 Electronics 14 Controls & Sensors 16 Joining 26 Connectors & Cords

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CONTENTS FEBRUARY 2011 volume 59, no. 2 REACHING OEM DESIGN ENGINEERS ACROSS CONSUMER AND COMMERCIAL MARKETS WORLDWIDE

DEPARTMENTS 4 Editorial: Of a Philosophical Variety 6 Shipments/Forecasts 8 News Watch 29 New Products

14

16

31 Design Mart’s 32 Association Report: AHRI 33 Advertiser’s Index

FEATURES ELECTRONICS 12 New MCU aims to offer increased efficiency and capabilities at a lower cost than ever before.

CONTROLS AND SENSORS

26

14 This commercial refrigerator controller can help OEMs save energy, reduce inventory and decrease installation time.

JOINING

appliance DESIGN ONLINE WEB EXTRAS WEB EXTRAS

Designing for Developing Countries This article offers three guidelines for developing products for those looking to break into new markets.

A More Efficient Path to Energy Star Changes to the Energy Star program have now gone into effect, leaving many questions about the updated specifications, requirements and regulations. Designing In and For Asia Sean Hughes, senior design director at Philips Design Hong Kong, discusses designing in and for the Asian market.

BLOGS

16 Understanding the welding process can help streamline an intricate task.

SHIELDING EMI/RFI 22 Recently, there has been increased use of plastic materials with metalized additives or coatings for EMI shielding.

CONNECTORS & CORDS 26 Medical equipment OEMS must choose interconnectivity options carefully, with an eye on open standards and future product road maps to meet the increasing functional and financial needs of such equipment.

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

SOCIAL MEDIA Connect with appliance DESIGN on:

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Traditionally, metals have been the material of choice for EMI shielding, but in recent years, there has been increased use of engineered plastic materials that incorporate metalized additives or coatings. Photo: RTP Co. www.applianceDESIGN.com

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EDITORIAL

Of a Philosophical Variety

O

ver the holidays, I spent some time in Taiwan. I’ve been to the country several times, so it wasn’t my first impression of the 13,900-square-mile island. This time, however, I paid particular attention to the technological differences between my life in the U.S. as a consumer, and my family members’ lives in Taiwan as consumers. When traveling, I always find it an interesting, if not a philosophical, exercise to take my observations of the small part of a culture I see and compare those similarities and differences to the life I’m used to. Who among us in the states, would not comment on a kitchen without a microwave when on the hunt to buy a new home? In Taiwan, as in other Asian countries, microwaves are not a typical household appliance. Refrigerators are small and clothes dryers are often a luxury item, as many people hang dry their laundry. Rice cookers are a popular appliance in Taiwan, and do much more than your standard white rice cooker in the states—think dumplings, soups, steamed vegetables, etc. Also individual air conditioning units and temperature control systems, rather than central systems, are often seen in homes and businesses. Shopping habits are different for the mainstream populations as well, which account for many of the everyday appliance differences I mention above. Most grocery stores are small in Taiwan and people tend to buy fresh food for the day’s meals from markets and street vendors, rather than stocking up on groceries twice a month as we often do in the states—save some of the larger urban areas. And what about the one car per person norm that many North Americans are used to? Forget it. Many families have one or no cars—choosing public transportation or scooters to make their way around town. In

®

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fact, I made a visit to a condo building in midconstruction and found that while motorcycle parking comes free with the purchase of a home, car parking would be an extra fee— standard, I was told, for the country. What you do see are many “middle class” homes by North American standards decked out with the latest large screen televisions, security systems and surround sound systems. In my experience, many Taiwanese homeowners have the latest in technologically advanced lighting and window treatments, all powered by remote—items that one might expect to see only in the elite households of the U.S. Other than for making great conversation, such cultural and lifestyle differences among countries create challenges for design engineers. How do smaller or midsized global component manufacturers and appliance manufacturers tailor their products to be accepted by the consumer? I don’t pretend to understand or know the reasons for differences in buying habits, product design and trends—rather, I will just ask the question: Why do buying habits and general lifestyle habits differ among cultures? How, for example, did we come to expect microwaves in our kitchens, when other cultures may not have? It is important for design engineers, manufacturers and global companies to not only know the differences among buying habits and trends for their customer base, but also understand why the differences exist. It’s another level of insight that can help global companies remain competitive in today’s marketplace. Share your comments and experiences with me at [email protected]. 

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

Darrell Dal Pozzo Group Publisher 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 Andreas Schuessler

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

[email protected]

Lindsay Nagy Production Manager

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 Nov-10

Nov-09

%Chg 11 Mos. '10 11 Mos. '09

%Chg

MAJOR APPLIANCES (Thousands of Units) TOTAL

4,491.9

4,331.8

3.7%

56,540.4

54,875.9

3.0%

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

1,435.6 372.7 296.3 50.7 25.7 248.8 219.8 4.7 24.3 814.1

1,338.4 377.8 302.9 48.1 26.8 223.2 196.2 4.2 22.9 737.3

7.3% -1.4% -2.2% 5.4% -4.3% 11.5% 12.1% 11.8% 6.4% 10.4%

15,015.9 4,019.3 3,168.1 546.6 304.7 2,510.0 2,183.4 38.7 288 8,486.5

15,145.6 3,943.5 3,143.3 493.9 306.3 2,336.8 2,034.2 39.1 263.4 8,865.4

-0.9% 1.9% 0.8% 10.7% -0.5% 7.4% 7.3% -1.1% 9.3% -4.3%

Home Laundry - Total Automatic Washers Dryers - Total Electric Gas

1,317.3 692.9 624.4 502.8 121.6

1,327.3 706.7 620.6 497.7 122.9

-0.7% -1.9% 0.6% 1.0% -1.0%

13,254.8 7,273.1 5,981.7 4,807.0 1,174.7

13,024.2 7,143.9 5,880.3 4,720.6 1,159.7

1.8% 1.8% 1.7% 1.8% 1.3%

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

812.9 361.8 447.7 442.8 4.9 3.4

864.9 416.8 445 440.3 4.6 3.2

-6.0% -13.2% 0.6% 0.6% 6.5% 7.7%

10,032.7 4,831.5 5,161.8 5,104.0 57.7 39.5

9,741.1 4,761.5 4,937.0 4,874.0 63.1 42.6

3.0% 1.5% 4.6% 4.7% -8.4% -7.3%

Food Preservation - Total Refrigerators Freezers - Total Chest Upright

851.3 686.4 165 91.5 73.5

775.3 616.2 159.2 88.7 70.4

9.8% 11.4% 3.7% 3.2% 4.3%

10,439.3 8,651.5 1,787.9 1,037.1 750.7

9,605.7 7,724.5 1,881.1 1,125.3 755.9

8.7% 12.0% -5.0% -7.8% -0.7%

Home Comfort - Total Room Air Conditioners Dehumidifiers

74.8 56 18.7

25.9 -19.3 45.3

188.1% N/A -58.6%

7,797.6 6,280.5 1,517.1

7,359.2 5,711.7 1,647.5

6.0% 10.0% -7.9%

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.

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

2010 2040.7 2023.4 1902.5 2063.1

2011 2106.0 2108.4 2007.1 2199.2

2012 2251.3 2234.9 2107.5 2293.8

For 2010, a 2.1% increase to 8.030 million units For 2011, a 4.9% increase to 8.421 million units Data Source: AHAM Forecast Source: Delano Data Insights

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

2010 1702.0 1659.5 1468.5 1769.4

2011 1739.4 1719.2 1540.5 1877.3

2012 1856.0 1820.7 1614.4 1950.5

For 2010, a 1.8% increase to 6.599 million units For 2011, a 4.2% increase to 6.876 million units Data Source: AHAM Forecast Source: Delano Data Insights

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

2010 434.2 516.0 526.9 468.4

2011 435.5 521.7 551.1 491.8

2012 456.0 549.3 572.1 509.6

For 2010, a 4.8% decline to 1.946 million units For 2011, a 2.8% increase to 2.000 million units Data Source: AHAM Forecast Source: Delano Data Insights

GAS RANGES and OVENS – Shipments (Thousands of Units)

NEED

? S T N I R P E R

Qtr: 1 2 3 4

2010 656.2 694.4 673.1 758.8

2011 672.6 701.3 698.0 788.4

2012 701.5 736.4 725.9 821.5

For 2010, a 7.1% increase to 2.783 million units For 2011, a 2.8% increase to 2.860 million units Data Source: AHAM Forecast Source: Delano Data Insights

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

2010 506.9 552.6 646.6 699.5

2011 494.2 554.9 674.4 744.2

2012 512.5 578.2 714.2 785.2

For 2010, a 10.6% increase to 2.406 million units For 2011, a 2.6% increase to 2.468 million units Data Source: AHRI Forecast Source: Delano Data Insights

DEHUMIDIFIERS – Shipments (Thousands of Units)

Have you or your company been featured in a recent issue of Appliance Design? Reprints can be a single sheet or multiple pages. They are available in color or black and white in quantities of 500 or more.

Contact Jennifer Nagel for a price quote at (248) 244-1729 or Email: [email protected]

Qtr: 1 2 3 4

2010 551.2 668.4 250.6 125.8

2011 554.0 690.5 267.6 136.9

2012 596.6 729.1 280.2 141.4

For 2010, a 6.1% decline to 1.596 million units For 2011, a 3.3% increase to 1.649 million units Data Source: AHAM Forecast Source: Delano Data Insights Note: All forecasts begin in Q4/2010

6 applianceDESIGN February 2011

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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 314.344.3330 www.ecomatesystems.com

NEWS WATCH

Energy Efficiency, Sustainability Advances in Polyurethane Foam Reported he standards for energy efficiency are constantly rising, and at the same time the polyurethane foam market faces ever increasing pressure to address climate change by focusing on substances with lower global warming potential,” said Joseph Costa of Arkema Inc., at the Polyurethanes 2010 Technical Conference. “Blowing agents are a vital component of rigid polyurethane foams, providing the outstanding thermal performance needed to improve energy efficiency.” Costa’s presentation focused on Arkema’s progress in developing a new low global warming potential (GWP) blowing agent for use in rigid polyurethane (PU) insulation foams. DuPont also reported on further development of its low-GWP foam expansion agent, while Bayer MaterialScience presented results of a comparison study of gaseous and liquid low-GWP blowing agents. Honeywell described its preliminary plan for a high energy efficiency household refrigerator that also uses ultra low-GWP

“T

LOW-PROFILE HOT WATER UNIT HEATER: FIRST OF ITS KIND IN NORTH AMERICA

Modine Manufacturing Co. announced its newest unit heater, the Hot Dawg H2O. An extension of the company’s Hot Dawg line, the Hot Dawg H2O hot water unit heater features the power needed to deliver heating for commercial applications and and an unobtrusive, low-profile design for residential use. The company said that this is the first water heater of its kind in North America. The unit has no outside moving parts, making it suitable for garages, attics and basement areas, as well as workshops, mechanical rooms, vestibules and rooms with low ceiling heights. 8 applianceDESIGN

February 2011

The 2010 Polyurethanes Technical Conference covered sustainability advances in polyurethane foam.

materials, and Huntsman presented a longterm study of the energy consumption performance of appliance cabinets. During the second Renewable Content Polyols session, Composite Technical Services LLC described a group of polyols derived from naturally occurring moieties “We listened to our customers and took great strides to ensure the Hot Dawg H2O would work as well in residential spaces as it would in commercial spaces,” said Matt McBurney, director, Modine Commercial Products Group North America. The unit’s twin centrifugal blowers keep all moving parts inside the unit, making it safe for high-traffic living or working spaces. The cabinet’s return air inlets, located on the side of its casing, combined with its low profile, allow the cabinet to be rotated for either horizontal or vertical air discharge. Two models exist: the standard HHD30 – operating at a range of 23,700 to 39,200 BTU/hour and the high-capacity HHD45 – operating at a range of 23,900 to 56,800

with an alkyl-phenolic structure, making them the only commercially available natural-content polyols with an aromatic or aromatic-amine structure and a biobased content of more than 73%. At a sustainability session, Caleb Management Services addressed legacy issues related to ozone depleting substances (ODS) in PU foams. The session also included a review of the Federal Trade Commission’s proposed revisions to the Green Guides, as well as a comprehensive look at projects in the U.S. using carbon credit programs to address the problem of CFC refrigerant and blowing agent from retired refrigeration and air conditioning equipment and appliances. “Clearly, polyurethane foam remains a vital material for insulation, and the polyurethane industry continues to improve both the environmental and technical performance of this product,” said the American Chemistry Council’s Steve Russell, vice president, Plastics Division.  BTU/hour at 180 degrees of entering water temperature.

TAIWAN COMPANY INTRODUCES MATERIAL TECHNOLOGY THAT REDUCES FIRE RISKS

Industrial Technology Research Institute (ITRI), a high-tech research and development institution in Taiwan, introduced Reddex, a non-toxic, fire-resistant composite material technology that offers simultaneous ignition resistance and fire protection in one system. Reddex introduced its new family of polymer inorganic composites, which provide ignition resistance and effectively slow down the rate at which fire burns. The mawww.applianceDESIGN.com

NEWS WATCH terial can be prepared as a paint, paste or foam, and is offered in mechanical properties ranging from flexible to rigid. It is ideal for buildings, hospitals, schools and residences, as well as for interiors of transportation and other products. Reddex can be used in applications such as films, tapes, hoses, tubes, electrical cables and wires. The material can be coated onto the surface of substrates, polymeric foams, woods, silicate boards and metals for the construction of fireresistant layered structures. The polymer component chars and burns at a slower rate than any other fire retardant, according to the company. The Reddex material eventually converts into a bound inorganic porous structure, which effectively becomes a structure that has low thermal conductivity to insulate heat and good mechanical rigidity to maintain structural integrity. In addition, the formulation does not use conventional ignition resistant additives that contain halogen, sulfur or phosphor components. As a result, no toxic gas is generated when exposed to fire, said the company. By using polymers such as PU as the organic component, which is turned into water vapor and carbon dioxide when burned, much less smoke is produced.

PRE-COLORED STAINLESS STEEL PROMISES TO BOOST PRODUCTIVITY

Sandvik Decorex, from Benton Harbor, Mich.-based supplier Sandvik Materials Technology, combines a color range and various surface textures with the excellent processing properties and technical benefits of stainless steel strips. Currently available in thicknesses up to 0.8 mm and in widths up to 350 mm, the pre-colored stainless steel can be produced from different standard stainless steel grades depending on the application. Coiled strips have excellent adhesion between the base material and the surface layer. The product is made with a rollto-roll process where the color can be applied to one side of the strip. Most bending and forming processes do not affect the color, according to the company. Compared to post-operation colors, www.applianceDESIGN.com

these materials removes manufacturing steps, which may shorten production time, with less material tied up in production and stock, said the company. The color stability of the material improves production yields and green practices, as it doesn’t require any wet operations during the coloration process. The material is 100% recyclable and has complete color consistency along the whole strip length and from batch to batch. Components can be optimally designed enabling producers to take advantage of economical, reliable and repeatable processing. Surface finishes are scratch and fingerprint resistant.

A.S. TRUST AND HOLDINGS PRODUCES ALL-NATURAL, ENERGYEFFICIENT REFRIGERANT

A.S. Trust and Holdings has developed a green household refrigerator, which runs on an all-natural, climate-friendly and energy-efficient refrigerant. The company will produce the product in limited quantities in the United States. The “188” refrigerator uses cooling technology offered by the climate-friendly hydrocarbon refrigerant HCR188C1, developed by Hawaii businessman and inventor, Richard Maruya, of A.S. Trust and Holdings. The refrigerant, a unique blend of pure hydrocarbons, has been certified by thirdparty testing laboratory, Intertek, to have zero global warming potential (GWP) as well as a zero ozone depletion potential, and is approved by the U.S. Environmental Protection Agency (EPA) for sale in the USA. A.S. Trust and Holdings is finalizing energy reduction efforts on the “188,” a standard 21-cubic-foot home refrigerator/freezer, and will be submitting it for Department of Energy (DOE) Energy Star ratings. Current results show that the required refrigerant-charge amount of HCR188C1 is approximately 25% the amount of R-134 by volume, just 37 grams, according to the company. Future products bearing the new Climate Friendly 188 energy-savings label will include household window air-conditioning units.

LEDs are arranged to configure a combination block and light guide plate to backlight the S-LED.

HITACHI USES GLOBAL LIGHTING TECHNOLOGIES’ LEDS FOR LCD TVS

Hitachi recently demonstrated its latest LCD TV lineup with S-LED (slim-block LED) backlight technology developed in conjunction with Global Lighting Technologies (GLT). The brightness of each backlight is independently controlled by a small block of LEDs, producing sharp contrasts with clear colors and true deep blacks. Scaling back brightness in black pixels also allows for less power consumption— approximately 27% for the L42, and 21% for the L37, said the company.

One of four configurations, the Tippmatic Timer for filter-type coffee machines is an auto power-off switch with integrated electronics.

JOHNSON ELECTRIC LAUNCHES ENERGY-SAVING SWITCHES FOR COFFEE MACHINES

Johnson Electric’s Tippmatic product line of intelligent auto shut-off switches for coffee machines complies with Europe’s eco-design directive for energy using products (EuP). The Tippmatic product line is designed to improve the energy efficiency of a wide range of coffee machines from the basic filter type to fully automatic espresso maapplianceDESIGN

February 2011 9

NEWS WATCH

PEOPLE NEWS IPS CEO NAMED COLORADO’S CLEANTECH ENTREPRENEUR OF THE YEAR

Infinite Power Solutions Inc. (IPS) announced that its president and chief executive officer, Ray Johnson, has been named Colorado’s Cleantech Entrepreneur of the Year by the Colorado Cleantech Industry Association (CCIA). Under Johnson’s guidance, IPS has grown the business of its Johnson solid-state rechargeable batteries that are changing the way micro-electronic products are designed, powered and recharged. During his tenure, Johnson has grown the company’s workforce from five employees to more than 45; helped launch the company’s award-winning energy storage products into the global marketplace; raised more than $60 million in venture capital investment; formed strategic partnerships with Fortune 100 companies; and, completed the build-out of a manufacturing facility for solid state, thin-film battery technology—achieving ISO 9001 certification in 2010. AHAM NAMES DIRECTOR OF PRODUCT CERTIFICATION AND VERIFICATION

The Association of Home Appliance Manufacturers (AHAM) appointed Ralph Hudnall as the director of product certification and verification. In this position, Hudnall will oversee AHAM’s ongoing and new appliance rating certification and verification programs. AHAM currently administers performance certification and verification programs for room air cleaners, room air conditioners, dehumidifiers and refrigerators and freezers. The association also is developing verification programs for clothes washers and dish washers.

EMERSON APPOINTS NEW VP

Emerson Climate Technologies Inc. appointed Ed Blittschau to vice president of sales and marketing for the Flow Controls business, where he will have responsibility for all North America, Latin America and Asia sales and marketing. In this role, Blittschau will be responsible for sales plans, Blittschau forecasting and demand management, marketing, customer service, application engineering, and price plans for all flow control products.

NEWAGE APPOINTS SALES MANAGER

Plastic tubing manufacturer NewAge Industries appointed Michael Allard as its global distribution sales manager. Allard brings many years of sales and management experience in the industrial, biopharmaceutical and semiconductor sectors to this position. In addition to overseeing the company’s worldwide distribution network for plastic tubing and high purity, single use products, Allard will manage the New England sales region.  Allard

chines for domestic or commercial use. It is made to simplify coffee machine design and assembly. The product line comprises four configurations to address the functional requirements of different coffee machine designs.

OBJET GEOMETRIES GAINS ISO 13485:2003 CERTIFICATION

Objet Geometries Ltd., a provider of 3-D printing for rapid prototyping and additive manufacturing, has achieved ISO13485:2003 certification for medical devices. ISO 13485 specifies requirements for a comprehensive quality management system for the design and development, 10 applianceDESIGN

February 2011

production, installation and servicing of medical devices. The international standard confirms Objet’s ability to provide the medical industry with 3-D printers and related services that meet the regulatory requirements applicable to medical devices. “We are very committed to the medical industry and to meeting our medical and dental customers’ expectations while adhering to strict regulatory compliance regulations,” said Gilad Gans, executive vice president at Objet Geometries. “This ISO 13485 medical certification validates our consistent obligation to high-quality 3-D printing systems and processes and provides independent confirmation that our quality

management system is in full compliance with industry and regulatory standards.”

A. O. SMITH INTRODUCES NEW LINE OF TANKLESS GAS WATER HEATERS

A. O. Smith released its new line of tankless gas water heaters. The new line of tankless water heaters offers a range of

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NEWS WATCH products, including condensing models with higher efficiencies and heavy-duty commercial models. All models offer improved flow rates for increased hot water delivery. The tankless units also offer optional remote temperature controllers and a full line of accessories. All residential tankless models are Energy Star qualified and come with a 12-year limited warranty.

MEETINGS February NAFEM SHOW Feb. 10-12, Orlando, Florida Website: www.nafem.org/events PRODUCT SAFETY & PRODUCT LIABILITY PREVENTION SEMINAR Feb.10-11, Milwaukee, Wisconsin Website: http://randallgoodden.com

A. SCHULMAN PURCHASES BRAZILBASED MASTERBATCH AND ENGINEERED PLASTICS PRODUCER

A. Schulman, Inc. has agreed to purchase Mash Compostos Plasticos, a masterbatch additive producer and engineered plastics compounder based in Sao Paulo, Brazil. “Brazil is a highly attractive market for A. Schulman and is very important to our growth strategy,” said Joseph M. Gingo, chairman, president and chief executive officer of A. Schulman. “It is a large, diversified market with strong macroeconomic fundamentals. The Brazilian plastics industry holds significant growth potential because per-capita consumption of plastic is still much lower than in other countries. With this acquisition, and with our April 30, 2010 acquisition of ICO, Inc., which included two facilities in Brazil, we are aggressively expanding our presence in that market and enhancing our ability to serve customers.”

POWERTEST 2011 - ELECTRICAL MAINTENANCE AND SAFETY CONFERENCE Feb. 21- 24, Washington, D.C. Website: www.powertest.org/ conference SPE - INTERNATIONAL POLYOLEFINS CONFERENCE 2011 Feb. 27-March 2, Houston, Texas Website: www.4spe.org

March EXPO MANUFACTURA 2011 March 1-3, Monterrey, Mexico Website: www.expomanufactura.com.mx ISH CHINA March 1-3, Beijing, China Website: http://cnccchina.com/ 6TH ANNUAL METAL MATTERS THE FABRICATOR’S LEADERSHIP SUMMIT March 2-4, Lake Buena Vista, Florida Website: www.fmanet.org/training/ MetalMatters/metal-matters.cfm IHHS 2011 - INTERNATIONAL HOME AND HOUSEWARES SHOW March 6-8, 2011, Chicago, Illinois Website: www.housewares.org/ ISH 2011 March 15-19, Frankfurt, Germany Website: http://ish.messefrankfurt. com/frankfurt/en/besucher/ willkommen.html 

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FRIEDRICH MOVES HEADQUARTERS

Friedrich Air Conditioning has moved its headquarters into 22,000 square feet of space at the Union Square II Building at 10001 Reunion Place in San Antonio, Texas, after almost 40 years at a different location in the city. The move included about 90 employees engaged in management, accounting, marketing and sales, product management, engineering, information systems, credit, customer service, human resources and production management. Closer proximity to San Antonio International Airport was one factor in the move, making visits to Friedrich’s headquarters easier for customers and vendors, as well as being able to consolidate staff onto a single floor.

QUICKPARTS OFFERS LARGER CNC CAPABILITIES FOR BIGGER DESIGNS Umesh Anand, managing director of HPL (on the left) and Jongho Park, chairman and CEO of Songwon Group sign a letter of intent to form Songwon HPL Additives PVT Ltd.

SONGWON AND HPL FORM JOINT VENTURE

Songwon Industrial Co. and HPL Additives Ltd. announced the formation of Songwon HPL Additives PVT LTD. HPL will transfer all its business and assets related to polymer stabilizers to the new entity, which will be owned 40% by HPL and 60% by Songwon. The parties expect the new company to be operational by Q2 2011, subject to completion of all necessary formalities. The new company will capitalize on Songwon’s and HPL’s respective strengths to serve the global market. Songwon is a producer of plasticizers for the plastics industry, as well as lubricants, surface coating agents, polyurethane, alkyl phenols, biphenol, flocculants and other chemicals. HPL Additves Ltd. is a producer of polymer stabilizers and modifiers.

Quickparts added new capabilities, which allow for the CNC Machining of larger part designs than its previous capabilities. The company now has the ability to CNC mill designs up to 157 by 78 inches on the X and Y axis, with a Z height up to 59 inches. The capabilities for turned parts requiring a CNC lathe are up to 30 inches in diameter and 107 inches in length. Customers still have the flexibility to select from any commercially available material available to be machined. These expanded services give designers looking to prototype much larger designs an alternative, who have found traditional prototyping methods to be cost prohibitive for large parts. “When designers are faced with manufacturing parts that are 6 or 8 feet long, for example, their options become limited very quickly. We are proud to be able to serve this niche market for our customers,” said Patrick Hunter, VP of sales and marketing for Quickparts.  applianceDESIGN

February 2011 11

ELECTRONICS

Optimize Performance and Reduce Costs M

New MCU aims to offer

increased efficiency and capabilities at a lower cost than ever before.

by maggie m. shein Maggie M. Shein is editor in chief of appliance DESIGN.

anufacturers know that by implementing a microcontroller (MCU) embedded into a product, they can not only reduce the final size of the product, but the cost as well, when compared to a design with a separate microprocessor, memory, and input and output devices. But while that choice may be an easy one for any engineer, choosing an appropriate MCU for a particular application, takes a bit more research. Selecting the appropriate speed and memory options also can help save money down the line as having to implement external, expandable memory at a later date not only can be costly, but may not be an option. For developers looking to cut costs and achieve maximum efficiency and functionality (and who isn’t?), Texas Instruments (TI) has recently unveiled a new line of floatingpoint MCUs ideal for energy-efficient applications and applications involving power line communications. TI’s previous MCUs included those of its lower-cost Piccolo line, which debuted in 2008, and its higher-performing Delfino floating-point models. With the new F2806x Piccolo floatingpoint MCU, the company hopes to target engineers looking for a performance boost whether in high or low-production manufacturing—though with an initial cost of $4.95 for 1K unit volumes, high-production manufacturers may find the product particularly enticing. Engineers are able to receive the benefit of faster development times and increased performance that come along with native floating-points, without the cost of higher-end models.

The new MCUs have an enhanced math engine specifically designed to simplify programming and optimize performance in real-time control applications that may require integrated communications, said Michael Wei, C2000 MCU marketing manager at TI. The chips have an 80 MHz floating-point C28x core, a Viterbi complex math unit (VCU) and control law accelerator (CLA) options. “The control law accelerator adds an extra 80 MIPs of performance,” Wei said. And, of course, the floating-point core adds a performance boost and more efficient coding capability, while the VCU increases the product’s complex math efficiency compared with other Piccolo versions. “The VCU complex math unit provides 75 tailored math instructions to accelerate processing of communications algorithms and complex math code, such as those for PLC, by a factor of up to 7X,” according to TI. Ideal applications would be energy efficient motor control and renewable energy applications such as air conditioning blowers and compressors, washing machines, refrigerators and solar inverters. Developers have the ability to use a single F2806x MCU to execute control loops as well as power line communications (PLC) protocols and modulation schemes—reducing complexity and cost of a project. In addition, now added USB 2.0 capability can help make any design engineer’s life a little simpler. “We’re seeing this as increasingly important to our customers for field firmware upgrades and data logging,” said Wei. 

The above diagram illustrates the enhanced math capabilities of a Viterbi complex math unit in a power line modem application. Source: TI 12 applianceDESIGN February 2011

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CONTROLS & SENSORS

ELECTRONIC REFRIGERATOR CONTROLLER SAVES ENERGY AND REDUCES COSTS

This electronic refrigerator controller for GDMs, and commercial refrigerators and freezer, reduces energy consumption, is globally compatible, and can help reduce inventory, installation and operation time. Photo: Danfoss

New commercial refrigerator controller can help OEMs save energy, reduce inventory and decrease installation time.

by appliance DESIGN staff 14 applianceDESIGN February 2011

B

ehind every perfectly chilled beverage or frozen product stored in glass door merchandisers (GDMs) or commercial refrigerators and freezers is a small device—an electronic controller that manages a complex range of functions, from compressor operating times and canopy/ cabinet lighting schedules to evaporator/ condenser fan control and variable temperature control. Until recently, manufacturers of GDMs, and commercial refrigerators and freezers had two options when selecting a controller: a mechanical thermostat that offered no intelligence or an electronic controller with limited capabilities. Neither option could be applied globally to any modern commercial refrigerator or freezer, and few offered energy savings significant enough to meet efficiency thresholds for Energy Star ratings sought by original equipment manufacturers (OEMs). “As their customers search for ways to reduce energy consumption in the face of rising energy costs, OEMs are under increasing pressure to provide energyefficient solutions, including equipment

that is Energy Star rated,” said Ebbe Hassl, product manager – commercial refrigeration, at Danfoss, Baltimore, Md. “There is an obvious trend for more electronic controls. At the same time, many of these customers operate facilities around the world, so finding a universal controller is a priority for them.”

Saving Energy To address the needs of OEMs for a cost-effective, energy-efficient electronic controller that can be applied globally, Danfoss, manufacturers of electronic and mechanical components and control systems for refrigeration and air conditioning, heating and motion controls, developed the first in a series of globally approved, energyefficient electronic refrigeration controllers, called the ERC 102. Designed to operate between 50 and 300 V at 50 to 60 Hz, the 0.5 W controller is an energy saver. The mini-computer uses four inputs and four outputs, powerful algorithms and input from multiple sensors to deliver energy-saving compressor, defrost, fan and lighting control in a small, lightweight box. www.applianceDESIGN.com

CONTROLS & SENSORS

The ERC 102 can be applied globally to control a variety of functions in glass door merchandisers. Photo: Danfoss

When fitted on a standard one-door refrigerator with a mechanical thermostat, a fan and a 0.5 HP compressor, the controller can reduce the refrigerator’s energy consumption by up to 52%. Extending the calculation to the seven-year life expectancy of such a merchandiser, savings of 4.5 kWh per day will result in a total energy reduction of approximately 11,500 kWh throughout the refrigerator’s lifetime, according to the company. In addition, the controller’s electronics consume 70% less power than standard electronics, said Hassl. For example, the unit’s energy-saving design allows the use of a light level sensor to control the economy mode, which takes the cabinet into night set-back by increasing the control set point. “As a result, OEMs are better positioned to secure an Energy Star rating for their equipment,” said Hassl. “At the same time, end-users reap the benefits of an Energy Star product, including reduced energy consumption and lower utility bills.” Because the control features a globally compatible, switch-mode power supply, the ERC can be connected from 100 up to 240 VAC powers, which allows one model to be used globally despite differences in voltage supply from country to country. The controller is tested and approved according to UL, NSF, IEC/EN, CQC and GOST standards, including use with hydrocarbon

(HC) refrigerants. “This means that the same controller can operate in the freezing temperatures of a sub-arctic winter or the sweltering heat of the tropics,” Hassl said. “IP65 protection from the front and IP31 from the rear provides resistance to dust, water and condensation. The unit also features patented silicone coating used in the marine sector to protect the power board from moisture and humidity, so no extra enclosure is necessary.”

Global Compatibility The global compatibility of the unit, along with its ability to function in a variety of operating conditions and control a variety of functions in a single box, can help reduce inventory requirements for OEMs. Fully configurable, the ERC’s control parameters can be set by OEMs and end-users to suit individual operating needs. The product features more than 200 individually programmable parameters. To avoid accidentally resetting important parameters, the ERC features a three-level password protection function, which gives OEMs and end-users different access levels. “This feature allows the customer to select which parameters users will see and have access to—up to three levels, e.g. end user, service technician and OEM level—ensuring that unauthorized people cannot tamper with control settings,” Hassl explained.

The ERC can be reconfigured to meet new or refurbished refrigerator or freezer control parameters. A computer with Danfoss “KoolProg” software connected to the ERC or a USB-based memory tool allows the OEM or end-user to configure and make parameter changes quickly and effectively.

Customizability According to Hassl, installation of the control is just as easy. “It only takes five seconds to mount the ERC on the front or back of the refrigerator. Drawing on the Japanese poka-yoke error-proof assembly principle, color-coded wires, sensors and connectors can be attached in less than 20 seconds. As a fail-safe to ensure the temperature sensors are attached properly, an internal test sequence can be performed to make sure the controller is ready for installation,” he said. The unit can be branded and company logos can be applied to the front cover. The four push-buttons are also customizable. “And customers can select from among five colors in the LED display to best suit their application,” said Hassl. “Blue displays, for example, have proven to increase sale of cold beverages.” Danfoss expects to make the ERC 102 available for broad distribution in 2011.  For more information, visit: www.danfoss.com

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February 2011 15

JOINING

SemiAutomation of Ultrasonic Welding Assembly Understanding the welding process can help streamline an intricate task.

Twin sonotrodes allow for a significant increase in the weld area. One generator drives two converters and they expand and contract in sequence like a single sonotrode. Photo: Herrmann Ultrasonics

U

ltrasonic welding is a commonly used assembly method in the appliance industry. It efficiently addresses the demands for hermetic, high strength welds with superior cosmetic appearance. The growing acceptance of ultrasonic welding is due, in part, to fast weld times (milliseconds) and no post weld curing or cooling. This technology is used for several applications within the appliance industry, including parts in the control panel such as status display windows, control panel buttons, chrome accent rings, and electrical and electronic components throughout the machine. Door assemblies and sound dampening insulation also are feasible applications for ultrasonic welding.

The Basics by uwe peregi Uwe Peregi is the executive vice president and general manager at Herrmann Ultrasonics, Bartlett, Ill. 16 applianceDESIGN February 2011

Ultrasonic welding of plastics is an intricate task. Each application is unique and places different requirements on the complex interplay of factors. Acoustic waves, or ultrasound, are converted into mechanical vibrations to generate molecular heat. Welded parts are immediately available

and do not require cool down or curing time. The weld process is controlled by sophisticated control software and must be adapted to the geometry and condition of the welded parts, which are made from amorphous or semi-crystalline polymers. Each welding tool, the sonotrode, is custom to each application, as it is adapted to the application at hand. Ultrasonic welding uses 75% less energy than other thermal joining processes, because the welding tools remain cold and has a low energy requirement. The ultrasonic vibrations are specifically applied to the joint area for only milliseconds during welding. New digital ultrasonic generators, with a power output of up to 8,000 Watts, work with an extremely high degree of efficiency of over 80% when powered. The most commonly used frequencies are 20 kHz for larger parts and 35 kHz for smaller parts. For parts with continuous weld beads that exceed the scope of a single sonotrode, multiple rigid ultrasonic stacks can be mounted in close proximity to each other for an uninterrupted seam. With the correct energy director design, www.applianceDESIGN.com

JOINING

In case of a hard coating, such as chrome or paint, the stud should be masked. Photo: Herrmann Ultrasonics

Loctite® Structural Adhesives: • Improve product performance • Reduce manufacturing costs • Improve product aesthetics

Contact us for a free engineering seminar! www.henkelna.com/loctitestructurals 1.800.LOCTITE (562.8483)

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February 2011 17

JOINING

An increasingly popular option for manual load machines is the use of high frequency switching. Photo: Herrmann Ultrasonics

a continuous weld line can be created for large parts. Newer technologies such as twin sonotrodes, allow for a significant increase in the weld area. One generator is driving two converters and they expand and contract in sequence a single sonotrode with a length up to 16 inches.

Joining The most commonly used joining geometries for appliances are direct welding of two compatible plastic parts using an energy director or mechanical fastening of dissimilar components using staking of a solid or hollow post. When welding two injection molded parts together, they should be molded of compatible thermoplastic materials, and one of the parts should be designed with an energy director. For amorphous resins, the angle of the energy director should be between 60 to 90 degrees with a height of 0.3 to 0.4 mm for smaller parts and 0.5 to 0.7 mm for larger parts. Semi-crystalline resins require an angle of 90 degrees with a height of 0.5 to 0.7 mm for smaller parts and 0.7 to 1.0 mm for larger parts. During the vibration, the energy director will start to melt and create a molecular bond between the two parts. Strength between the parts typically exhibits 80% of the original material strength. Therefore, the cross section of the weld area should be

18 applianceDESIGN February 2011

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JOINING Table top machines were commonly used for parts that could be loaded manually. New developments have helped to increase the throughput of these types of machines. Photo: Herrmann Ultrasonics

1.5 times nominal wall thickness, to avoid failure of the parts at the weld interface. Ultrasonic staking allows quick and clean assembling by melting and reforming a thermoplastic stud. It mechanically locks dissimilar material in place. Strong, gap-free joints overcome the elasticity behavior of the plastic in order to eliminate the “memory” of the plastic. Concentrating the ultrasonic energy to small areas, eliminates thermal overstressing of the material. Furthermore, the heat generated during the staking process is dissipated by the sonotrode. Low weld force, high amplitude and a specifically designed sonotrode is generally used. When post diameter is greater than 2/3 of the wall thickness, a hollow post design should be considered to avoid sink marks. Simple staking can be accomplished with sonotrodes made of titanium. In case of a hard coating, such as chrome or paint, the stud should be masked. If a glass-filled material is chosen, a coated titanium or hardened steel sonotrode should be utilized. Air cooling of the sonotrode might be required in situations of longer weld times.

Strength and Cost

Except as otherwise noted, all marks used are trademarks and/or registered trademarks of Henkel and/or its affiliates in the U.S. and elsewhere. ® = registered in the

Loctite® Structural Adhesives: • Improve product performance • Reduce manufacturing costs • Improve product aesthetics

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applianceDESIGN

February 2011 19

JOINING The use of hydraulic dampening devices has proved excellent for these applications. This ensures a constant weld travel permitting the plastified material to form to the sonotrode face detail. As a result, cold forming is avoided. Radii or recesses help prevent cracks on the base of the staking post. The ratio between the post diameter and its length should not exceed 1:2. In addition to the ultrasonic joining technologies discussed above, other technologies also can be found in the appliance industry, including inserting, spot welding and slitting.

Manual Workstation Traditionally, table top machines have been commonly used for parts that could be loaded manually. New developments have helped to increase the throughput of these types of machines. Newer features include fully automated start functions, freely programmable Z axis to start the weld closer to the part, and velocity-controlled Z drive with sophisticated soft impact. Multiple built in I/O in the ultrasonic welding machine allow for easy integration of additional features such as barcode scanners, laser markers, shuttle tables, automatic product selection from the user interface, data acquisition, leak testing and quality control.

Semi-Automation Due to product variants and ever-changing volume size, semiautomated work cells are becoming commonplace within the appliance industry. Handling of delicate or sophisticated parts and efficient production schedules, require increased productivity by

Rotary tables are a convenient way to enhance manual loading of semi-automated assembly machines. Photo: Herrmann Ultrasonics

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JOINING When post diameter is greater than 2/3 of the wall thickness, a hollow post design should be considered to avoid sink marks. Photo: Herrmann Ultrasonics

allowing people to perform tasks, which cannot be performed by a machine. An increasingly popular option for manual load machines, is the use of high frequency switching. The work station can, as seen in other industries, weld several weld points within a single cycle. The most common practice includes actuation of all the ultrasonic stacks and then sequential switching of the high frequency signal from one ultrasonic generator to multiple stacks. For example, an application with 30 stacks (or weld points) requires significantly fewer generators. The tradeoff of a modest increase in cycle time is offset by a significant cost savings by reducing the number of generators required. Switching 10 generators three times would increase the overall cycle time by only 4 seconds. Shuttle tables allow for a safe and ergonomic loading of large

parts into an ultrasonic welding machine with multiple weld points. For a fast change over, a complete tool set can be stored inside the machine and, with a quick tool change, the complete machine can run with a new product in less than 5 minutes. Lastly, rotary tables are a convenient way to enhance manual loading of semi-automated assembly machines. The main advantage here, is that progressive assemblies can be built on a single machine with multiple stations. The fast welding time allows for a high throughput with only a single welder installed on a rotary table. Cycle times, depend on size, but 50 or more per minute are common in the industry. Rotary tables can easily add additional process station and/or automated quality controls.  For more information, visit: www.herrmannultrasonics.com

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February 2011 21

SHIELDING & EMI/RFI

Plastic Compounds Shield

Electronics from EMI In recent years, there has been increased use of engineered plastic materials that incorporate metalized coatings for EMI shielding.

M

anaging electromagnetic interference (EMI) is an important consideration when manufacturing electronics and has historically challenged product designers and OEMs. Electronic circuits in many devices not only emit electromagnetic fields that might interfere with other systems, but such circuits also are susceptible to stray fields affecting their performance. As a result, devices must be shielded to ensure proper operation. Metals have traditionally been the material of choice for EMI shielding, because they are inherently conductive. Even though plastics are inherently transparent to electromagnetic radiation, in recent years, there has been increased use of engineered plastic materials that incorporate metalized additives or coatings as a replacement material because of their lighter weight, enhanced design freedom, and cost effectiveness.

Higher Frequencies Pose Greater Challenges

by ned bryant Ned Bryant is a senior product development engineer for RTP Company, Winona, Minn. 22 applianceDESIGN February 2011

The most common type of EMI occurs in the radio frequency range of the electromagnetic spectrum from 104 to 1012 Hz. Energy in that range can be radiated by electronic circuits, radio transmitters, fluorescent lamps, electric motors, overhead power lines and many other sources.

Device failures caused by interference from electromagnetic energy, or noise, are increasing due to the growing number of products that contain sensitive electronic components. Additionally, the smaller size and faster operating speeds of electronic components make managing EMI noise increasingly more challenging. For example, computer processors now operate in excess of 250 MHz and some new mobile phones operate at 900 MHz. Higher device frequencies—some over 10 GHz— result in proportionately shorter wavelengths that can easily penetrate very small openings in housings or enclosures. Proper shielding incorporates the use of conductive materials to reduce EMI by reflection or absorption. EMI needs be considered at the design phase of any electronic system so that potential interference problems can be minimized. Since interference can occur anywhere within a system, shielding consideration often needs to be given to the whole assembly. Shielding can be applied to an entire system in the form of a housing or enclosure, or to individual elements that may be highly susceptible, such as circuit boards. Shielding requirements for commercial electronics generally range from 35 to 70 dB. Establishing a system’s shielding requirewww.applianceDESIGN.com

SHIELDING & EMI/RFI

A portable telemetry device manufactured by Apogee Labs took advantage of a polycarbonate compound incorporating stainless steel fiber from RTP Company to provide EMI shielding. The material lightened the weight of the portable instrument and allowed for design changes. Photo: RTP Co.

ments involves determining the radiated frequencies and government emission regulations the unit must meet.

Plastics Fill Larger Role Over the past several years, plastics have grabbed a larger share of the EMI shielding market because of their many advantages. Industry reports show that plastic shielding materials account for more than one-third of the half billion dollar U.S. EMI shielding market. The European market is substantially larger due to more stringent regulatory standards. Much of plastic’s growth is in new applications. Uses for EMI shielding abound in computers, medical devices, telecommunications, transportation and other types of electronic equipment. Commonly, this type of equipment contains micro-circuitry that switches at high speed. Each switching event results in a short duration electrical pulse, which has a characteristic frequency inversely proportional to its time length. FCC regulations define specific field strength limits between 30 MHz and 2 GHz. Placing a Faraday Cage around an electrical device is a fundamental technique for shielding against EMI. Faraday Cages can be www.applianceDESIGN.com

constructed using metal, plastics with metalized coatings, or plastic compounds that incorporate metalized additives. Plastics can deliver significant performance advantages over metals in EMI shielding applications. Among their key benefits are reduced weight—particularly in portable systems—and enhanced design freedom, which allow for greater use of complex shapes, part consolidation and fastening options. The material also provides physical properties such as corrosion resistance, high strength-to-weight ratios, along with manufacturing efficiencies for high-volume parts produced via injection molding. A common test method for comparing the shielding effectiveness of plastic materials is ASTM D 4935 which uses a plane-wave, far-field EM wave. The test method is valid for a frequency range of 30 MHz to 1.5 GHz. Varied thicknesses and types of materials can be tested to acquire a relative ranking of their shielding effectiveness.

Compounds vs. Coatings Electromagnetic compatibility can be achieved in two ways using plastics. First, plastic compound suppliers, such as RTP Company, offer EMI shielding compounds that combine metalized fibers, which are melt

An internal shield within a multimeter from John Fluke Manufacturing is made of polycarbonate combined with stainless steel fibers to obtain EMI shielding capabilities. The material was selected over metal because of the plastic’s ability to be easily formed into a complex geometric design. Photo: RTP Co.

compounded into a thermoplastic matrix to provide shielding capabilities. Plastics are normally electrically insulative and transparent to EMI. Incorporating high aspect ratio conductive fibers creates a conductive network within the plastic compound rendering it electrically conductive and opaque to EMI. Customized plastic compounds also can incorporate flame retardant, wear reducing, reinforcing and color additives, along with EMI shielding properties, into a single material. Alternate methods for giving plastics EMI shielding properties is through applying conductive coatings of various types. Three different metalized coating processes can shield electronics through a reflective mechanism: Vacuum metallization use is increasing due to its process control. It’s a multi-stage process whereby a layer of aluminum is deposited on plastic in the absence of air. Electroless plating consists of a thin layer of copper being deposited and then overplated with nickel for corrosion inhibition. Conductive paints are the most common method of applying a conductive surface coating to molded plastic parts. Conductive paints contain particles of silver, copper or nickel dispersed in an acrylic, vinyl, epoxy or urethane binder. applianceDESIGN

February 2011 23

SHIELDING & EMI/RFI

Optical encoders from Quantum Devices Inc. replaced aluminum with a polycarbonate compound containing carbon fiber to provide EMI shielding. Photo: RTP Co.

An advantage that EMI shielding plastic compounds have over coating methods is their integral shielding performance. Coatings can be susceptible to adhesion problems, like de-lamination during thermal cycling, or scratching. Additionally, EMI shielding compounds are capable of more complex designs and shorter production times, because no secondary operations are required. Conductive coated parts must be kept free of contamination and undergo masking and coating steps. A cost analysis done by RTP Company indicated that EMI shielding plastic compounds on a cost per part basis are price competitive with conductive coatings for both low- and high-volume applications. Coatings do have an advantage in larger parts or those that require a very heavy wall thickness.

Products and Applications EMI shielding compounds are available with additive loadings ranging from 5 to 20%. Additive options include carbon fiber, stainless steel fiber, nickel-coated carbon fiber and nickel-coated graphite. Compounds can be created using any ther-

24 applianceDESIGN February 2011

moplastic matrix including those popular for housings and enclosures such as polycarbonate, PC/ABS, nylon, polyester, and even hightemperature resins like polyetherimide (PEI) and polyetheretherketone (PEEK). The shielding performance of plastic compounds is very design dependent. Wall thickness of the plastic part as well as additive choice and loading percentage all factor into shielding effectiveness; with the latter aspects being customizable within the compound formulation to meet performance requirements. A portable telemetry device demonstrates how EMI shielding compounds deliver not only shielding protection but also light weight and cost efficiency. For example, Apogee Labs in San Diego used a polycarbonate compound containing stainless steel fiber as an alternative to metal for the enclosure of the company’s first-ever portable device.

The compound not only ensured EMI compatibility, but also allowed weight reduction and provided the design freedom to decrease the device’s size, with a corresponding cost reduction that Apogee passed onto its customers—resulting in increased sales. Other key properties included impact resistance, which became a necessity with portability, and a flammability rating of V-0 to obtain UL certification. Going forward, EMI shielding compounds can be expected to offer the same type of solution in increasingly more demanding electronics applications as manufacturers seek to maximize performance by achieving electromagnetic compatibility while also gaining additional value-added benefits by using plastic materials.  For more information, email: [email protected] or visit: www.rtpcompany.com

BLOGS

VISIT

For general shielding, nickel/acrylic paints have captured the most market share. Automated spraying systems apply the coatings consistently and repeatably.

A point-of-sale printer produced by Axiohm Transaction Solutions contains a base plate made from a polycarbonate compound combined with stainless steel fibers. The plate provides protection from EMI emitted by nearby equipment and dissipates static charges. Photo: RTP Co.

WWW.APPLIANCEDESIGN.COM AND CLICK ON BLOGS. www.applianceDESIGN.com

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CONNECTORS AND CORDS

CONNECTORS BOOST PERFORMANCE Components that provide increased performance, such as connectors that are ideal for highspeed applications, can help bring down the overall cost of medical imaging systems. Photo: FCI

Medical equipment OEMS must choose interconnectivity options with an eye on open standards and future product road maps to meet the increasing functional and financial needs of such equipment.

by gijs werner Gijs Werner is global market manager at FCI in Versailles, France. 26 applianceDESIGN February 2011

W

hile many high-tech industries now require increasing levels of functionality and flexibility, this is particularly true of the medical industry, where applications are critical to the successful care and safety of patients. Continuous improvements in the medical imaging segment have resulted in more accurate and easier-to-use technologies that benefit an aging population, both in hospitals and at home. The increasing demands on new medical imaging equipment are driven mainly by investments in scanning systems by hospitals, replacement of older outpatient facilities, replacement of conventional analog machines by digital X-ray systems, growth in diagnostic ultrasound equipment, and the trend to combine different technologies within the same equipment, such as CT and MRI. As medical testing and procedures become more advanced, the electronic components designed into the equipment must be more than just reliable in critical applications. Connectors utilized in today’s medical applications must function at higher speeds, provide higher density, require smaller footprints and lower profiles, and comply to strict industry standards. These trends are most evident in medi-

cal imaging applications, but they are just as prevalent in data storage devices, communication systems, image archiving and online manipulation of images in the medical industry.

Speed Higher speed requirements are a result of the desire for real-time diagnoses, increased accuracy and faster imaging—to ensure patient safety and to make diagnostics more effective. There also is a need for improved functionality for machines that combine previously separate systems, such as positron emission tomography (PET) and computed tomography (CT). Combined imaging techniques allow doctors to more readily identify and diagnose cancer, heart problems and brain disorders. Speed is a fundamental design parameter that has system-wide implications, from board-level to PCI bus. It is important that OEMs choose component suppliers that understand these end-product requirements, because choosing the right connector can save time during the design and testing process that can be spent on other aspects of the system. In addition, components that provide increased performance, such as connectors www.applianceDESIGN.com

CONNECTORS AND CORDS

Connectors for medical applications must function at high speeds and high densities, and require smaller footprints and lower profiles. Photo: FCI

that are ideal for high-speed applications, can help bring down the overall cost of medical imaging systems, because as the performance of an individual connector increases, fewer are required for the overall design. Part of this drop in end-product prices is due to the shrinking of overall system size. To meet that need, connector manufacturers have significantly increased the density of their products, packing more speed and performance into less space. Product engineers try to prevent complete system redesigns by making system upgradeable to keep pace with market trends, making scalability an important feature, not just in systems but in the electronic components as well. For example, there are high-speed backplane connectors that offer design versatility, because signal connectors can be scaled by varying the number of columns of contacts, the number of contacts per column and the column spacing. They also allow for mixed pin assignments (differential or single-ended signals or power), to provide additional flexibility to system designers. Data rates can scale from 2.5Gb/s to beyond 12Gb/s without requiring re-design of a basic platform. Medical equipment continually requires more performance, but it helps if the architectural design remains intact. www.applianceDESIGN.com

Size The miniaturization of connectors in the medical industry is being driven by equipment such as mobile monitoring stations and handheld equipment such as field-operable CT scans, as well as a trend toward outpatient treatment over in-hospital stays, which requires components with lower profiles in addition to smaller footprints. One of the best connector solutions for these machines are flex cable connectors. In the past, utilization of these types of connectors may have meant a lower level of electrical performance. Currently, however, connector manufacturers have developed more advanced solutions, employing flex foil for less demanding applications. Among the most recognized solutions for the scanning applications is a highdensity mezzanine connector system, which stands out for many of the leading medical digital imaging equipment manufacturers, in both hospital systems and portable scans. It provides the features needed for MRI, CT and other imaging applications to achieve real-time, higher resolution imaging. Used to connect the photo diode within the scanner, the system’s higher density allows a greater number of slices, resulting in more accurate imaging. Additionally, it delivers outstand-

ing mechanical and electrical performance, achieving data rates of up to 10 Gb/s.

Standards Other changes in this segment, include new industry standards (such as USB, PCI, RJ45, DVI, MicroTCA and PCI Express), which are being incorporated in new equipment designs. Today, leading connector manufacturers are developing products specifically for these markets. The growing implementation of such standards can be attributed to their facilitation of shorter design cycles and faster system introductions, and the fact that open standards technology offers ready-made solutions to expanding connectivity requirements—all of which can give OEMs an edge in a competitive marketplace. OEMs are often pushed to “experiment” with new architectural options, making even the latest electronic components quickly obsolete. Because of this, many OEMs prefer to avoid proprietary systems, because they result in higher costs and longer development cycles—typically 5 to 7 years for a new generation of MRI scan to be introduced, for example. Components that do not readily work with a specified architecture can create additional lag time and affect overall design. applianceDESIGN

February 2011 27

CONNECTORS AND CORDS Connector manufacturers are developing products specifically for medical imaging equipment and medical device markets to address the particular needs of the industry. Photo: FCI

It is crucial that design engineers choose the right connector: interconnects are essential elements of overall system reliability. The product lifetime of medical equipment is relatively long so the ability to scale up and upgrade via open standards, as well as a high level of reliability, are essential elements of an equipment’s performance, especially for complex and expensive combined-modality systems, such as MRI, which require constant use to provide proper payback. If the interconnectivity selection has been carefully made with an eye on open standards and future product road maps, increasing functional and financial needs of medical equipment will be met. One example of this was the introduction of PCI Express, which is now the connector standard of choice for PC-based systems, and found its way into medical equipment as well. Instead of proprietary systems, the open PCIe standard is being applied more and more, particularly in ultrasound systems. Traditionally, ultrasound systems have used standards-based architectures like CompactPCI bus or VMEbus. However, with the backplane performance hitting the limitations of standard architectures, there is a

clear need for connector technologies that offer higher performance and higher reliability at a reasonable cost. Card-edge technology, in addition, is a logical choice for these backplane connections, combining highspeed performance and reliability at low applied cost. To meet a growing demand for highperforming medical systems, OEMs need to find reliable component suppliers that can meet the needs of highly advanced, highspeed, small-sized, portable medical diagnostics equipment. Connector manufacturers who develop products specifically for imaging and other medical applications that incorporate open standards, provide reliable and durable connections, yet still offer high-speed and top-quality electrical performance, will be the leaders in this industry due to their ability to facilitate the evolution of end-product development. For more information, email: [email protected] or visit: www.fci.com

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28 applianceDESIGN February 2011

www.applianceDESIGN.com

NEW PRODUCTS mm (1.97 to 19.69 inches). The high temperature resistance of APTIV film enables the MMP to operate in a temperature range of -40-deg. C (40-deg. F) up to 125deg. C (257-deg. F). For more information, visit: www.victrex.com

Morrill Motors The Arktic SSC motor is an electrically commutated (ECM) unit bearing motor available for commercial refrigeration applications. The product features both a two-speed and reversing option, as well as a patent-pending application that kicks the motor into a timed third speed when the cooler door closes to remove fog from the glass. This feature can save costs by eliminating the need for anti-fog glass, says the company. The unit bearing motors are primarily used in commercial refrigeration evaporator fan applications, but can be used in many applications demanding high efficiency and dependability with output ratings between 2 to 38 W. For more information, visit: www.morrillmotors.com

Victrex Victrex APTIV film is featured in this Metapot (MMP) sensor as a spacer film and was chosen for its ability to withstand the highly exacting demands of the sensor application. Made from Victrex Peek polymer, the film delivers friction and wear properties combined with high heat resistance, chemical and radiation resistance, purity and electric insulation. The APTIV film-based MMP is used as a linear and angular sensor based on Metallux’s MetaPot foil potentiometer technology, which combines all the advantages of this proven technology with a contact free function, making a long life time of more than 100 million cycles possible. It can operate in measurements from 50 to 500 www.applianceDESIGN.com

Akron Coating and Adhesives Developed specifically for use with Santoprene and other thermoplastic elastomers (TPEs), this family of waterbased, heat-activated adhesives eliminate the need for costly surface treatments or primers, says the company. The adhesives are designed to reduce the time and cost of manufacturing over-molded products used in appliance, medical, automotive, packaging and construction applications. The ACA 30-101, 102, and 103 adhesives can eliminate the need for primers and surface treatments altogether. This family of adhesives is designed to cover the entire spectrum of TPE grades from soft to very hard. They provide excellent adhesion, with peel values of up to and exceeding 25 lbs. per linear inch (including substrate tear). Because they are water based, they also simplify EPA and OSHA compliance. For more information, visit: www.akroncoating.com

C&K Components The CG and the CL series, the UL- and CSA-approved single pole power rocker switches for household appliances, instru-

ment panels, industrial controls and computers/peripherals have 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 -20-deg. 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.ck-components.com

Sensor Products Inc. Routine use of Pressurex during the set up of ultrasonic welders provides an economical method to ensure proper contact pressure and alignment between the horn and the anvil. This results in welds of greater bond strength, lower rejected product, and lower base factory cost, according to the company. Pressurex is a tool that reveals the distribution and magnitude of pressure between any two contacting surfaces. When placed between the horn and the anvil of the ultrasonic bonder, the film instantaneously and permanently changes color directly proportional to the actual pressure applied. The precise pressure magnitude (PSI or kg/cm2) is determined by comparing color variation results to a color correlation chart (conceptually similar to interpreting Litmus paper). The tool is thin (4 to 8 mils) and flexible, which enables it to conform to curved surfaces. For more information, visit: www.sensorprod.com applianceDESIGN February 2011 29

NEW PRODUCTS

Crystek

EAO Switch Corp.

The CVCO55CXT-5800-5800 coaxial resonator oscillator (CRO) employs frequency doubling, 2X fundamental technology to reach new performance levels of low phase noise and harmonics, while minimizing current consumption in the process. The oscillator operates at 5800 MHz with a tuning voltage range of 0.5 Vdc to 4.5 Vdc. This coaxial VCO features a typical phase noise of -100 dBc/Hz at 10KHz offset and has excellent linearity. The product exhibits an output power of +3 dBm typ. into a 50 ohm load with a supply of +8.0 Vdc and a typical current consumption of 35 mA. Pulling and Pushing are both minimized to 1.0 MHz and 3.0 MHz/V, respectively. For more information, visit: www.crystek.com

M Series and S Series keypads are vandalresistant and ideal for indoor or outdoor use in applications including banking kiosks and ticketing machines. The M Series offers easy panel configurations and adaptable layouts to accommodate a wide range of customer designs. Users can specify any number of keys, as well as standard 4, 12, or 16 key layouts. Features include LED illumination in blue, red, yellow, green or white, multiple button shapes and colors within one keypad, and blank spaces for separation between keys in one unit. The S Series Lite simulates the look and durability of metal, but is made from Polycarbonate (PC) plastic. Standard illumination is produced by either blue or yellow LEDs, and is visible either through or

30 applianceDESIGN February 2011

AVX Corp. Designated the RM Series, the lead free SMPS stacked capacitors provide high capacitance values with low ESR ratings in a small footprint for high current/ripple applications. The SMPS stacked capacitors are uniquely suited for filtering capacitors on the input and output of power supplies or as snubber capacitors, according to the company. The addition of the RM Series stacked capacitors allow customers to choose between a tin/lead termination (SM Series) or a RoHS compliant product, depending on the application specifications. For more information, visit: www.avx.com

www.applianceDESIGN.com

NEW PRODUCTS around the legend. Other colors (red, green, orange and white) are optional. When mounted, both M Series and S Series Lite keypads are protected to IP 67 requirements against the ingress of water, oil, and dirt and are impact resistant to an IK09 (10 joule) rating. For more information, visit: www.eao.com

DESIGN MART This appliance DESIGN Design Mart section brings you information on new products and services available through

Genteq The Evergreen CM is a universal electrically commutated motor (ECM) for light commercial heating and cooling applications. Using up to 50% fewer watts than a standard indoor permanent split capacitor (PSC) blower motor, Evergreen CM upgrades the efficiency of most light commercial heating and cooling equipment, reports the company. The replacement motor upgrades the HVAC system while using up to 50% fewer watts than a standard indoor blower motor. The ultra-high-efficiency ECM features flexible control methods to help the installer balance airflow in HVAC systems such as VAV, Variable Air Volume, Series Boxes or Package Heat Pumps. The Evergreen CM motor is available for 277V systems, counter clockwise or clockwise rotation, and outputs of 1/3, 1/2, and 3/4. For more information, visit: www.thedealertoolbox.com

print and online. To receive more information about the the products and services in this section, visit appliance DESIGN online at www.applianceDESIGN.com. TEMPERATURE SENSOR EXPERTS

IP68 WATERPROOF TEMPERATURE SENSORS thermistor.com QUALITY THERMISTOR, INC WWW.THERMISTOR.COM 800-554-4784

Aimtec This ultra-wide input, low profile, 40-watt DC/DC converter provides input voltage ranges of 9~36 VDC and 18~75 VDC and a tight line/load regulation of ±0.5%. The AM40UW-Z series also features a remote on/off function, output voltage adjustment (trim) and load voltage sensing. Wide industrial operating temperature range of -40-deg. C to +85-deg. C supports integration in a variety of indoor and outdoor applications. Output voltage adjustment and load voltage sensing specifically help to compensate for wire or track voltage losses due to the high current output, maintaining consistently high load voltage accuracy, while the converter can to be controlled remotely from a microprocessor through the on/off function, allowing the load circuit to be indirectly controlled. Models are available with single output voltages of 3.3, 5, 12, 15 VDC, and dual output voltages of ±12 and ±15VDC while sourcing maximum output currents as high as 10A and efficiency rates as high as 92%. For more information, visit: www.aimtec.com  www.applianceDESIGN.com

TEMPERATURE ISSUES?

Precision Thermistors RTDs, Probes & Assemblies for Temperature Measurement and Control

www.ussensor.com

‡[email protected] 1832 W. Collins Ave, Orange, CA 92867

applianceDESIGN February 2011 31

ASSOCIATION REPORT: AHRI

Morrison Carter Chairman, AirConditioning, Heating, and Refrigeration Institute

A Note on Credibility redibility makes our organization the solid, reliable, dynamic association it is. If we are complacent, we risk making AHRI less relevant than it must be for the good of our industry, for the nation and for the world. Nearly three years ago, we came together to form AHRI from two similar, and yet different, organizations. During these three years, those on the so-called “cooling side” and those on the so-called “heating side,” have learned a lot from each other. We have all learned, for example, that listening and putting ourselves in each other’s shoes can help break down barriers of mistrust. We’ve learned that making an effort to understand the issues inherent in each area of our industry helps to address those issues and make our whole industry stronger.

C

Without quality standards, we cannot have credible, successful industry certification programs.

But what perhaps we’ve learned most from each other is that doing all those things helps increase our credibility—with the membership, with policy makers both here and abroad, with regulators, with the trade press and mainstream media, with contractors and distributors, and with the public. When we speak of AHRI, we often refer to the three pillars of the association: standards, certification and advocacy. I want to briefly examine how credibility enhances those three areas, and how any breakdown in credibility can harm any or all of them, to the detriment of the association. Take standards, for example. Our industry standards and guidelines are the linchpin of the credibility of AHRI. Without credible industry standards, 32 applianceDESIGN

February 2011

we would have nothing to base our certification programs on. And without the credibility that comes from certification, we would not have such a positive story to tell when dealing with regulators, legislators and mediators. AHRI’s standards are, for the most part, not only designated as American National Standards, but are also duplicated and harmonized in countries and regions around the world because of the credible science and engineering on which they are based. Organizations in places such as the Middle East, South America and Asia ask to either adopt our standards or work together to harmonize them for use in their countries and regions. In just the past four years, we have signed memoranda of understanding with organizations in China, Korea, India, United Arab Emirates, Mexico and Brazil to ensure that our standards in one form or another become their standards. That is credibility. And without quality standards, we cannot have credible, successful industry certification programs. When we participate in trade shows or visit with sister associations around the world, AHRI certification programs are always high on the agenda. Why? Because they are credible. People the world over, whether they are industry insiders, government officials, or contractors, specifiers, architects or building owners, know that if a product is certified by any of the association’s 36 certification programs, it will perform as advertised. That is credibility you can’t buy. That credibility came in handy this year, when the Department of Energy began to take a closer look at enforcement of federal minimum efficiency standards. The fact that we have a respected, established program made it easier for AHRI to work with DOE officials to ensure requirements were met. It was not easy, but it did help to open some doors and enable us to get to the right people to ensure our members’ interests were protected. AHRI will continue to work on behalf of its membership and program participants to enhance and promote the integrity of its certification programs.  www.applianceDESIGN.com

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0211MAG

This index is for the convenience of our readers. Every care is taken to make it accurate. appliance DESIGN assumes no responsibility for errors or omissions.

sales team Dawn LeRoux [email protected] Phone: (248) 633-4818 Fax: (248) 283-6558 AK, AZ, HI, IA, IL, KS, MI, MN, MO, NE, ND, NM, NV, OK, SD, TX, UT, WI. Western Canada Brad Glazer [email protected] Phone: (216) 233-6943 Fax: (216) 803-6151 AL, AR, CT, DC, DE, FL, GA, IN, KY, LA, MA, MD, ME, MS, NC, NH, NJ, NY, OH, PA, RI, SC, TN, VA, VT, WV. Eastern Canada Jennifer Nagel [email protected] CA, CO, ID, MT, OR, WA, WY. Design Marts, Reprints & Buyers Guide Phone: (248) 244-1729 Fax: (248) 244-2040 international Dawn LeRoux [email protected] Europe & U.K. Phone: 1-248-633-4818 Arlen LUO [email protected] China & Hong Kong, Japan, Korea, Taiwan Phone: 0086-10-88579899 Fax: 0086-10-82160061 applianceDESIGN

February 2011 33

Holding Power Inside and Out

From permanent bonding to temporary holding, tesa tapes have the holding power you need!

QGlobal partner QConsistent performance QProducts you can trust QAvailable when you need them QTechnical support Q

Solutions for pre-foam, assembly, and packaging Call or email Todd Powers at 704-553-4689 / [email protected]

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