Appliance Design May 2011

May 2011 REACHING OEM DESIGN ENGINEERS ACROSS CONSUMER AND COMMERCIAL MARKETS WORLDWIDE INTERFACE DESIGN EVOLVES p. 1...

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May 2011

REACHING OEM DESIGN ENGINEERS ACROSS CONSUMER AND COMMERCIAL MARKETS WORLDWIDE

INTERFACE

DESIGN EVOLVES p. 13

INSIDE 10 Elastomers 13 Displays & Interfaces 20 Noise & Vibration 23 Quality & Standards

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N OW I T H I N K I N 3 D. AND MY DESIGNS JUST KEEP GET TING BET TER. With our Dimension ® 3D Printer, I know my model will represent my idea exactly. And that makes it easier to improve my design with each iteration. Our Dimension is right here in the ofﬁce, and that helps us get our products to o market faster. The Dimension models we create are made in ABS, S, so they’re tough and durable. Leases start at only $275 a month, or you can n buy a printer for under $15,000, so they’re also really affordable. Overall, ll, Dimension gives me an amazing sense of freedom—and creativity. Find out more at dimensionprinting.com/ad4

Prices applicable in the United States. Additional options, shipping, applicable taxes and/or duties not included. ©2011 Stratasys, Inc.

One Testing Program. Less Time. Lower Cost.

We Make ENERGY STAR® and Safety Testing a Single, Seamlessly Efﬁcient Process Third-party certiﬁcation and veriﬁcation are now &/&3(:45"3SFRVJSFNFOUT$4"*OUFSOBUJPOBMIBT FBSOFE&1"SFDPHOJUJPOBTBO&/&3(:45"35FTUJOH 'BDJMJUZBOE$FSUJmDBUJPO#PEZ5IBUNFBOTUPEBZXF DBONFFUBMMPGZPVSQSPEVDUTBGFUZBOEFOFSHZFGmDJFODZ UFTUJOHOFFETXJUIBTJOHMF TFBNMFTTMZFGmDJFOUUFTUJOH QSPHSBNUIBUTBWFTZPVUJNFBOENPOFZ -PPLUP$4"*OUFSOBUJPOBMUPNFFU&/&3(:45"3 SFRVJSFNFOUTGPSBXJEFSBOHFPGQSPEVDUTJODMVEJOH

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CONTENTS MAY 2011 volume 59, no. 5 REACHING OEM DESIGN ENGINEERS ACROSS CONSUMER AND COMMERCIAL MARKETS WORLDWIDE

DEPARTMENTS

10

4 Editorial: There’s an App for That 6 Shipments/Forecasts 7 News Watch 29 New Products 32 Association Report: American Consumer Institute Center for Citizen Research

23

33 Advertiser’s Index

16

FEATURES ELASTOMERS 10 Thermoplastic elastomers can make it easier to accomplish a number of design objectives.

DISPLAYS & INTERFACES 13 Ultra-thin LED-based light guides provide an ideal illumination solution for touch-enabled display graphics. 16 Interface design, button design and increasing connectivity options allow for an easier enduser experience, and help eliminate the need to change product design based on region.

appliance DESIGN ONLINE WEB EXTRAS WEB EXTRAS

Quieting the Home Leveraging Active Noise Control (ANC) technology can allow for quieter and more efficient appliances. Persistent Serial Memory Eases Burden in Repetitive Event Systems A new type of non-volatile memory was designed with repetitive event systems in mind. Case Study: LCP Provides Critical Heat Resistance in Electrolux Ovens AEG-Electrolux implemented a low-warpage grade of liquid crystalline polymer (LCP) to an easy-to-clean interior door panel for critical heat resistance.

NOISE & VIBRATION 20 Correcting for noise is best done by acquiring accurate and useful data followed by in-depth analysis.

QUALITY & STANDARDS 23 Take a look at regulations and objectives set for manufacturers and how OEMs can obtain conformity to sell products within the EU market.

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

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

The soft buttons on this concept refrigerator/freezer enable a simple interface. Image: Microchip Technology Inc.

SOCIAL MEDIA

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Real parts. Really fast. Simply upload your 3D CAD model, and choose the best option for your needs.

CNC Machining in 1–3 days. Best for 1–10 parts. Priced from $95.

Injection Molding in 1–15 days. Best for 10–10,000+ parts. Priced from $1495. Choose from hundreds of engineeringgrade resins, including HDPE, Polypropylene, ABS/PC, Acetal, PBT, Polycarbonate, Nylon 66, Polyamide and LPDE.

Choose from 30 different materials including ABS, Nylon, PC, Delrin, PEEK, ULTEM, aluminum and brass.

It’s easy to work with Proto Labs. Choose CNC machining or injection molding, whichever is best for your project. Upload your CAD model and receive an automated, interactive quote in hours. Once approved, our cluster computing technology and automated manufacturing systems will deliver real parts using real materials in as little as one day. And that’s the real story. ©2011 Proto Labs, Inc.

Have a smartphone? Download a case study.

Get Tips for Better Plastic Parts! The Protomold Design Cube is an indispensible aid that illustrates key aspects of designing parts for injection molding. Visit www.protolabs.com/appliance today and request your free Design Cube! Enter code AD11B.

Call 877.479.3680 or visit www.protolabs.com

ISO 9001:2008 Certiﬁed

EDITORIAL ®

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There’s an APP for That

H

ave you seen the commercials that introduce the OnStar MyLink Mobile App allowing car owners of most 2011 GM models to use their iPhone or Android smartphone to remotely start a vehicle, as well as lock/ unlock the car doors and activate the car horn and lights? The communication between the app and car is powered by OnStar—meaning you have to be an OnStar subscriber to use it. Subscribers can connect up to five mobile devices per vehicle and, to prevent unauthorized access, the company has implemented a number of safeguards as part of the application, such as a registration, login and PIN verification process. Is this the future of modern appliances? Absolutely. We saw LG and Kenmore both make announcements at CES 2011, unveiling technology that will allow consumers to control their appliances via a smart network or smartphone—and the possibilities are downright exciting. LG is calling its technology Thinq, and appliances in the mix include ovens, refrigerators, washing machines and vacuum cleaners. The technology requires owners to have a Thinq-compatible appliance and a compatible smartphone. The appliance connects via WiFi to an access point or router and then connects to a smartphone or tablet. Communication between the appliance and smartphone is two-way. The appliance can send updates to a smartphone as well as receive incoming commands. Ideally, consumers will be able to monitor the usage of their appliances and turn them on or off like the OnStar MyLink Mobile App—taking full advantage of

publishing staff Darrell Dal Pozzo Group Publisher

smart grid technology and energy efficient features. Do you want to set your dishwasher to turn on at noon while you’re out of the house? Done! LG said that with the Thinq technology, its refrigerators will be temperature adjustable, and even keep track of food inventory as a convenience feature. Kenmore gave viewers an early look of its “enhanced” appliances at CES 2011 as well. The company said it will start rolling out its line of washers, dryers, stoves and refrigerators—which will be able to be controlled via a smartphone or smart tablet—in 2012. All of this technology sounds promising, but the real question is whether manufacturers will be able to deliver on all the promises. Implementing these technologies takes a lot of research, planning and investment on the part of the OEM—and consumers expect a finished, functional product and not just a BETA test. Other manufacturers continue to keep their eyes peeled and their ears to the floor to find out what works and what consumers want, before delving into this new world of remote control homes. Come next year around this time, we should all have a better perspective on where the technology is going. By then, I’m hoping for an app that will let me cook a meal, open a bottle of wine, and feed my dog—all of which I can do on sitting in traffic on my way home from work.

Maggie McFadden Shein Editor

(847) 405-4066 [email protected]

Daryl Delano Economics Editor

(508) 746-7986 [email protected]

Paul Roggema Kevin Henry New Media Contributors

[email protected]

Lindsay Nagy Production Manager

(248) 244-6438 [email protected]

MaTT Britcher Art Director

(480) 334-0286 [email protected]

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

Kevin Collopy List Manager

(800) 223-2194 x684 [email protected]

Shawn Kingston

(800) 409-4443 x828 [email protected]

marketing Michele Raska Marketing Coordinator

(248) 786-1694 [email protected]

Deana Weber Trade Show Coordinator

(248) 244-6249 [email protected]

editorial advisory board Bob Brown Vice President, Marketing & Sales, North America, Emerson Industrial Automation John Davis

Business Development Manager, Traulsen

Kevin Henry

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

(847) 405-4044 [email protected]

President, Group42

Joseph McGuire

President, Association of Home Appliance Manufacturers (AHAM)

Richard Watson

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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25+ OF

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Rosemont, IL s Donald E. Stephens Convention Center

CE

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Pre-Conference: June 6, 2011 Conference & Expo: June 7-8, 2011

YEARS

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Gain the knowledge you need from leading experts and peers in the sensors industry. This year’s Conference Program includes more Technical Sessions in Tracks covering the topics that are most important to you and your business, including: s-%-3 s%NERGY(ARVESTING s7IRELESS3ENSOR.ETWORKING s.OVEL!PPROACHESTO-EASUREMENT$ETECTION

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Identify speciﬁc solutions to your most difﬁcult sensing, detection and control-related challenges on the expo ﬂoor. 3ENSORS%XPOBRINGSTOGETHERTHELARGESTANDBEST IN CLASSSHOWCASEOFSENSINGTECHNOLOGIESANDSYSTEMSFOR attendees to evaluate and make informed decisions.

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SHIPMENTS Product

FORECASTS Feb-11

Feb-10

%Chg 2 Mo. 2011 2 Mo. 2010

%Chg

MAJOR APPLIANCES (Thousands of Units) TOTAL

4,752.1

4,461.3

6.5%

8,309.0

8,167.3

1.7%

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

1,244.5 325.4 251.8 41.9 31.7 202.9 176.5 3.0 23.4 716.1

1,220.3 326.1 253.8 46.5 25.7 193.6 167.5 3.3 22.8 700.7

2.0% -0.2% -0.8% -9.9% 23.1% 4.8% 5.4% -9.4% 2.6% 2.2%

2,303.0 605.0 467.2 82.4 55.3 370.8 320.4 6.3 44.1 1,327.2

2,345.1 627.4 488.1 89.3 50.0 377.3 325.9 7.3 44.2 1,340.3

-1.8% -3.6% -4.3% -7.7% 10.6% -1.7% -1.7% -13.5% -0.1% -1.0%

Home Laundry - Total Automatic Washers Dryers - Total Electric Gas

1,135.7 630.8 504.8 408.0 96.8

1,145.1 619.6 525.4 430.7 94.8

-0.8% 1.8% -3.9% -5.3% 2.1%

1,886.6 1,046.1 840.5 676.2 164.3

2,125.1 1,147.5 977.6 795.5 182.0

-11.2% -8.8% -14.0% -15.0% -9.7%

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

877.5 421.8 452.8 446.1 6.7 2.9

828.4 413.2 412.2 405.8 6.5 3.0

5.9% 2.1% 9.8% 9.9% 4.0% -1.9%

1,622.3 814.8 801.5 790.4 11.1 6.0

1,635.5 861 768.4 757.5 10.8 6.1

-0.8% -5.4% 4.3% 4.3% 2.6% -2.1%

Food Preservation - Total Refrigerators Freezers - Total Chest Upright

694.5 571.1 123.4 72.8 50.6

687.3 562.8 124.6 74 50.6

1.0% 1.5% -1.0% -1.6% 0.0%

1,253.9 1,024.7 229.3 136.8 92.5

1,274.6 1,043.2 231.3 136.1 95.2

-1.6% -1.8% -0.9% 0.5% -2.9%

Home Comfort - Total Room Air Conditioners Dehumidifiers

800.0 747.7 52.2

580.1 511.2 69.0

37.9% 46.3% -24.3%

1,243.2 1,048.5 194.7

787.1 571.8 215.3

57.9% 83.4% -9.6%

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.

36>*6:;=HYPHISL:WLLK*VU[YVSZ -VY-HUZ)SV^LYZ/\TPKPÄLYZ:[V]LZ/LH[LYZ >OVSL/V\ZL=LU[PSH[VYZ9HUNL/VVKZ3HTWZ DIAL-A-TEMP Plug-In 2.5 Amps-120VAC.

Qtr: 1 2 3 4

2010 2040.7 2023.4 1902.5 2038.6

2011 1981.5 2067.9 1976.7 2150.7

2012 2124.2 2173.4 2059.7 2232.5

For 2011, a 2.1% increase to 8.177 million units For 2012, a 5.0% increase to 8.590 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 1720.8

2011 1567.5 1682.7 1541.9 1834.4

2012 1685.1 1760.1 1603.6 1894.9

For 2011, a 1.2% increase to 6.627 million units For 2012, a 4.8% increase to 6.944 million units Data Source: AHAM Forecast Source: Delano Data Insights

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

2010 434.2 516.0 526.9 480.4

2011 436.4 520.1 553.8 507.3

2012 455.6 539.9 577.0 523.0

For 2011, a 3.1% increase to 2.018 million units For 2012, a 3.9% increase to 2.096 million units Data Source: AHAM Forecast Source: Delano Data Insights

GAS RANGES and OVENS – Shipments (Thousands of Units) Qtr: 1 2 3 4

2010 656.2 694.4 673.1 766.1

2011 652.3 697.2 701.4 802.1

2012 677.7 736.2 742.8 838.2

For 2011, a 2.3% increase to 2.853 million units For 2012, a 5.0% increase to 2.995 million units Data Source: AHAM Forecast Source: Delano Data Insights

KBWC-Wall Box Mount 2.5, 5.0, 6.0, 8.0, 10.0, 12.0 & 15.0 Amp models, 120 & 240VAC, 50/60Hz.

KBMC-Panel Mount 2.5, 3.0 & 4.0 Amp models, 120 & 240VAC, 50/60Hz.

Designed for Shaded Pole, AC/DC and Permanent Split Capacitor (PSC) Motors. Send for complete literature. If it’s not in our catalog, let KB engineers design a custom control for your application.

2),SLJ[YVUPJZ0UJ

AUTOMATIC WASHERS – Shipments (Thousands of Units)

5> [O:[YLL[*VYHS:WYPUNZ-3 -H_! 6\[ZPKL-3 ^^^RILSLJ[YVUPJZJVT,THPS!PUMV'RILSLJ[YVUPJZJVT

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

2010 506.9 552.6 646.6 747.2

2011 551.5 588.6 665.4 758.4

2012 568.0 612.7 700.6 803.9

For 2011, a 4.5% increase to 2.564 million units For 2012, a 4.7% increase to 2.685 million units Data Source: AHRI Forecast Source: Delano Data Insights

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

2010 551.2 668.4 250.6 82.0

2011 520.9 678.4 267.1 89.2

2012 547.4 705.6 276.0 91.7

For 2011, a 0.2% increase to 1.556 million units For 2012, a 4.2% increase to 1.621 million units Data Source: AHAM Forecast Source: Delano Data Insights Note: All forecasts begin in Q1/2011

6 applianceDESIGN May 2011

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NEWS WATCH

AHAM President Testifies Before Senate oseph M. McGuire, AHAM president, testified before the Senate Energy and Natural Resources Committee in support of legislation to enact the appliance efficiency standards portion of a consensus agreement among appliance manufacturers, efficiency and consumer advocates and state energy officials. The bill, Implementation of National Consensus Appliance Agreements Act of 2011 would amend the Energy Policy and Conservation Act to improve energy efficiency of refrigerators, freezers, clothes washers, clothes dryers, dishwashers and room air conditioners. In his testimony, McGuire stated that the agreement, including the standards contained in the legislation, “saves energy and increases our energy independence. It would lead to improved product energy efficiency saving more than 9 quads of energy over 30 years and save consumers billions of dollars in reduced energy bills. Further, it requires and incentivizes clothes washers and dishwashers to use nearly 5 trillion less gallons of water over 30 years. Overall, it will result in greenhouse gas emission reduction by approximately 550 million metric tons of CO2.” The other two components of the agreement are an extension of manufacturer tax incentives for production of super-efficient appliances, which are even more efficient than those in the Energy Star program and recognition by Energy Star of the benefits of smart appliances.

J

TFT LCD MAKERS TARGETING 53% LED BACKLIGHT PENETRATION FOR TV PANELS

Global shipments of LCD TV panels with LED backlights reached a high of 16.6 million units in the fourth quarter of 2010, with strong growth in edge-lit configurations, according to the DisplaySearch’s Quarterly Large-Area TFT LCD Shipment–Advanced LED Report. Panel makers are targeting rapid penetration increases for LED backlights in LCD TV panels, growing from 36% in the first quarter of 2011 to 62% in the fourth quarter for an overall penetration of 53% for 2011. For the year 2010, penetration reached 21%, up from 2% in the previous year, according to the report. “Despite some buildup of LEDbacklit TV panel inventories in the second half of 2010, the industry has recognized that LED backlighting is an irreversible trend, with benefits such as lower power consumption and slimness,” noted David Hsieh, DisplaySearch vice president and research leader for large-area panels. “This has encouraged LCD TV panel makers to reduce LED backlighting costs continuously in order to increase shipments.” Hsieh added, “This does not mean that www.applianceDESIGN.com

CCFL will no longer be in demand, as there are still many end users and emerging markets that are very price sensitive. It’s important for the industry to maintain support for CCFL panels.”

into commercial production within five years by adding image and voice recognition functions. The prototype is slightly bigger than the size of a palm and features an outer coating that feels like human skin, according to ATR officials. A speaker is installed in the head of the doll-like gadget and a light-emitting diode in its chest turns blue when the phone is in use and red when it is in stand-by mode.

VIRTUAL REALITY CAN IMPROVE DESIGN SKILLS RESEARCHERS DEVELOP HUMANSHAPED MOBILE PHONE

Japanese researchers said they have developed a human-shaped mobile phone with a skin-like outer layer that enables users to feel closer to those on the other end. “The mobile phone may feel like the person you are talking to,” according to the Advanced Telecommunications Research Institute International (ATR), which described the gadget as a “revolutionary telecom medium.” The project is a collaboration between Osaka University, the mobile telephone operator NTT DoCoMo and other institutes. The parties hope to put the phone

Constant technology adaption isn’t an adjustment for consumers in the “Generation Y” category—but rather, it is a way of life. A University of Missouri researcher says a widening gap is occurring between educators and students due to the difference in how older and younger generations approach evolving technologies. Newton D’Souza, an assistant professor of architectural studies at the University of Missouri, is looking for ways to move beyond traditional teaching methods and to bridge the technology gap between teachers and students. Researchers at the University of MisapplianceDESIGN

May 2011 7

NEWS WATCH souri are studying ways to integrate technology into design learning, specifically how to teach design basics. In an effort to study how children who have grown up in a wired, video game culture use technology, D’Souza engaged young students using a 3-D virtual reality platform to teach design. Using a popular existing virtual reality platform called 2nd Life, researchers directed students to design a small zoo. The 2nd Life platform provided a realistic 3-D spatial simulation for students to explore. They were given instructions on certain design specifics and then allowed to work within the simulation. D’Souza found that students working within the 3-D virtual reality environment tended to improve spatial skills, including kinesthetic and logical abilities. However, verbal and intrapersonal skills seemed to suffer. “Because they are wired in media, the kids entered into the system much faster than we expected,” D’Souza said. “Today’s students already exist in a 3-D environment; we need to find a way to teach them where they already are.”

GE MARKETS WASHERS TO MOMMY BLOGGERS

GE’s frontload steam washer’s “Overnight Ready” cycle washes clothes, then removes enough moisture so that the clothes are comfortable to wear without transferring to the dryer. To introduce this feature, GE displayed the products at Nashville’s Opryland Hotel for the Blissdom 2011 conference. The company sponsored a

“me-time” spa exhibit, which gave bloggers the chance to see what they could be doing instead of waiting on laundry watching a short video about the Overnight Ready feature. “This is the first time GE Appliances participated in an event like this and it was a perfect space for us since moms use these products. We wanted to develop and build relationships, inform moms about the product, and alert moms about the Overnight Ready feature,” said Allison Gatta, public relations product manager for GE Appliances & Lighting. GE also held a sweepstakes with one winner receiving their choice of one of four laundry pairs.

Tawanna Browne Smith, right, won a new GE Profile Frontload Washer with Overnight Ready and matching dryer at the 2011 Blissdom Conference in Nashville. At left is Jennifer Schoenegge, product manager with GE Appliances.

GROWTH SEEN IN MATURING PATIENT MONITORS MARKET

The aging population has led to a larger proportion of patients requiring longterm care. According to the World Health Organisation (WHO) cardiovascular disease was estimated to be the highest cause of death in 2004, killing an esti-

mated 17.1 million people that year; this is expected to increase to 23.6 million in 2030. With an increasing number of patients admitted to hospital for treatment for disease of this kind, demand for patient monitoring devices is expected to increase, according to InMedica, IMS Research’s medical research group. “With an increasing number of patients admitted, hospitals are trying to improve healthcare facilities in the most cost-effective way. In order to reduce financial burden on healthcare resource, patients are being transferred to low-acuity wards sooner. As a result, increased demand for products that monitor low-acuity parameters is projected,” said Kelly Barritt, market research analyst at InMedica. “Furthermore, in an attempt to reduce the number of preventable medical errors occurring and to improve patient care, the Centers of Medicare and Medicaid Services (CMS) in the U.S., has now stopped providing reimbursement coverage for associated treatment, if a patient suffers from an event that should never have happened. This has prompted hospitals to ensure all patients have some form of monitoring during hospital treatment,” added Barritt. This is expected to directly affect the patient monitor device market, with increased demand for products to ensure susceptible patients are monitored. As the weight of the economic recession starts to lift, demand for low acuity products such as low-end patient monitors, vital signs monitors and patient-worn telemetry monitors increased in 2010, with demand projected to remain strong in 2011.

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NEWS WATCH

CHEMICALLY RESISTANT EPOXY WITHSTANDS A YEAR IN ACID

For applications demanding chemical resistance, especially to acids, fuels and oils, Master Bond developed its EP21AR. The two-component epoxy can withstand harsh, acidic environments, including prolonged immersion in 96 to 98% sulfuric acid and 36% hydrochloric acid for over a year, whether coating, lining, bonding or sealing, according to the company. With a dielectric strength of 400 volts/ mil, EP21AR is a durable and stable epoxy that is also a superb electrical insulator. Its coefficient of thermal expansion is 45 to 55 ppm/deg. C, and it is serviceable from -60-deg. F to +275-deg. F. It produces high strength, abrasion resistant bonds with a tensile strength more than 10,000 psi, a shear strength exceeding 2,700 psi, and a compressive strength greater than 14,000 psi at 75-deg. F. The epoxy has a working life of 45 to 55 minutes at ambient temperature for a 200 gram batch, an d cures at room temperature or faster at elevated temperatures. It bonds well to a variety of substrates, including metals, glass, ceramics, cements, vulcanized rubbers, wood and many plastics.

OWENS CORNING OPENS NEW CHINA FACILITY

Owens Corning, a producer of glass fiber reinforcements, held an official opening ceremony of its production facility in the Yuhang Economic and Development Zone, Hangzhou, China. The plant significantly expands the company’s capacity in China. “Building a new facility in China is part of our global business strategy to supply our customers locally in growing regions of the world,” said Mike Thaman, chairman and chief executive officer at the

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company. Capacity from the new Yuhang plant, currently in its first phase of operation, will augment output from an existing facility nearby, and will supply rovings to the Asia Pacific market which are currently being imported from Europe and the Americas. The new facility employs approximately 280 people and brings the number of composite production sites in Asia to eight.

MAPPING FOOD DESERTS

Maps are great for showing where things are. They’re also good for showing where things aren’t. Two Michigan State University professors have developed interactive maps that offer a visual perspective of urban food deserts. By using GIS (geographic information systems) technology, they are showing, rather than simply telling, how urban residents are losing access to fresh produce and balanced nutrition. Phil Howard, assistant professor of community, agriculture, recreation and resource studies, and Kirk Goldsberry, assistant professor of geography, conducted their research in Lansing, Mich. They found that many supermarkets have closed their stores that serve urban areas and have moved to the suburbs. They also showed that Michigan’s state capital is a model for what’s happening to food environments around the country. One aspect on which the study focused was store locations. It showed that less than 4% of the population lived within a 10-minute walk of a supermarket. The researchers

also looked at the cost in reaching those stores as well as the availability of produce at each retail location. They took into account everything from urban party stores, which may offer lemons and limes, to suburban box stores, which offer nearly 250 different produce items. By taking actual food inventories and pairing that data with geospatial inputs, the team was able to precisely measure geographic access to produce sections. What was revealed was a tale of two food environments. First, people with cars can overcome many geographical obstacles to obtain fresh produce while pedestrians’ ability to obtain fresh produce is becoming increasingly challenging, Goldsberry said. The maps give residents, city officials and community organizations an outreach tool to visualize their food environment. Having a highly detailed method to examine each city’s food environment provides a graphic illustration of areas where produce is abundant and where it’s lacking, Howard said.

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May 2011 9

ELASTOMERS

DESIGNING GREENER AND MORE ERGONOMIC APPLIANCES WITH TPES Thermoplastic elastomers can make it easier to accomplish a number of design objectives.

by joe kutka Joe Kutka is global market manager, appliances, at PolyOne GLS Thermoplastic Elastomers, McHenry, Ill. 10 applianceDESIGN May 2011

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everal trends are strongly influencing appliance design today, and though diverse, these trends share something in common: they can be leveraged using thermoplastic elastomers (TPEs). These versatile elastomeric materials combine the functionality and performance of thermoset rubber with the processability and design freedom of thermoplastics. TPEs are being used to solve a range of design challenges thanks to their colorability, soft-touch feel, broad range of hardnesses, ability to be overmolded (bonded) to other materials, processing versatility, and the ability to be formulated using “green” components. Today’s appliance designers must create new products that are more environmentally responsible, that meet the needs of an aging and fragile population, and that provide new color and aesthetic choices. TPEs can make it easier to accomplish all of these design objectives.

Environmental Mandates One of the major environmental challenges for appliances is end-of-life disposal—in particular, keeping these items out of over-

taxed landfills. While recycling appliances is a desirable solution, the practical aspects can be daunting due to the wide variety of materials used and disparities in their recyclability. Disassembly can be cost-prohibitive and complicated. TPEs can help solve this problem. For applications requiring bonding or overmolding of a TPE onto an engineering resin, elastomeric grades can be developed with exceptional compatibility to the engineering resin. As a result, the two materials do not have to be separated prior to being recycled or repurposed. This can simplify the disposal process by lowering the need to disassemble or remove the TPE from the engineering resin. Often, TPEs can replace thermoset materials that cannot be recycled, helping to make an appliance more sustainable. For example, a wet-vacuum cleaner made by Vacman Internacional in Mexico uses five different seals made from a recyclable styrenic block copolymer (TPE-S) instead of vulcanized neoprene rubber, which is not recyclable. The elastomer also delivers excellent sealing properties www.applianceDESIGN.com

Household appliances are suitable applications for thermoplastics elastomers.

ELASTOMERS

Elastomer materials are used for the hosing components of vacuum cleaners.

and mechanical strength, ease of processing and greater design freedom. Another important environmental benefit of select TPEs is the ability to be formulated without the use of hazardous substances, such as halogens that are restricted by current legislation, including the European Union Restriction of Hazardous Substances (RoHS) directive. Gaskets, seals, wiring and other appliance parts made from these TPEs also are easier to recycle than components made from traditional materials because they do not require special handling at end of life. For example, halogen-free, flame-retardant TPEs based on styrene-ethylene butylenestyrene (SEBS) technology can help appliance makers meet current and upcoming environmental regulations. They can replace traditional halogen-containing vinyl materials used in cable jacketing and insulation to support regulatory compliance and promote recyclability. There are even new halogen-free TPE grades formulated without phthalates that

address an increasing concern among consumers and environmentalists. Applications capable of utilizing these elastomers include internal power distribution and electrical cords.

Ergonomic Design for an Aging Population It is no secret that the U.S. population is aging and that demographic is having a profound impact on all types of consumer goods. Designers are rushing to modify products or create new ones that meet the needs of older people—many with chronic conditions such as arthritis or osteoporosis. Ease of use, comfort and safety—which are so important to older or disabled individuals—are key benefits of designing appliances with TPEs. Ergonomic designs for handles, knobs and buttons can benefit significantly from the use of TPEs. These soft, tactile materials offer a high coefficient of friction that creates a confident, “grippy” feel when overmolded onto appliance handles, controls and other parts that must be grasped firmly by the user. People with arthritis and other conditions benefit in two ways:

Thermoplastic elastomers have been increasingly used in feet and grommets of small appliances. Photos: PolyOne GLS www.applianceDESIGN.com

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May 2011 11

ELASTOMERS

Thermoplastic elastomers are finding increasing usage for refrigerator seal applications. Photo: PolyOne GLS

Washer/dryer wheels and feet Pump grommets Ice cube dispenser components Handles and grips And buttons and knobs.

less force is required to manipulate a part covered with these materials and greater comfort is provided from its soft cushioning. TPEs can be overmolded onto critical surfaces with a wide variety of geometries and configurations to provide this combination of grip and softness. There are highflow, low-viscosity grades available that support overmolding of thin, yet durable layers. For example, closures for over-the-counter medications are currently using a layer of TPE to make it easier for seniors to open and securely reclose the bottle. Importantly, TPEs retain their grip, feel, and other desirable properties even after repeated exposure to hot water and detergents. Overall, TPEs can deliver long service life without performance degradation.

New Aesthetics for Consumer Appeal The days of white-only washers, ranges and refrigerators are long gone. Consumers enjoy a wide choice of colors, textures and effects in both large and small appliances. In today’s market, where aesthetics are now a critical differentiator, TPEs can add significant value to design, thanks to their ability to be easily colored and molded with different textures. For example, elastomers can provide unique surfaces ranging from silky to ribbed to gel-soft to meet different usage needs. Special color effects can include metallics, pearlescents, thermochromics (heatactivated effects) and geometric metamerism, an effect that changes depending upon the viewing angle. 12 applianceDESIGN May 2011

TPEs can be injection molded, overmolded (two-component injection molding), extruded, coextruded, blow molded and thermoformed. The ability to be overmolded or coextruded with an underlying rigid product provides a secure bonded interface between the elastomer and the rigid substrate. Eliminating a mechanical interlock design can help ensure final product consistency and enhance product quality as a result. Applications that can benefit from this quality are door seals, drawer stops and handle grips. TPEs can be formulated to have waterwhite clarity that makes special effects and tints stand out. For example, a clear TPE overmolded onto a patterned or colored substrate can create visual depth. TPEs also deliver outstanding color consistency. Designers can use elastomers to match or contrast with substrate materials on grips and handles, creating unique effects for product differentiation and helping consumers to see functional parts more easily.

TPEs for Appliances Because TPEs are available in a wide range of formulations and hardnesses, they are appropriate for a variety of appliance components, including: Gaskets and seals Corrugated hoses

Design Implications Appliance designers need to be more knowledgeable than ever about the materials that are selected for their products—particularly about how they can support and enhance sustainability. It’s important to look beyond product creation and everyday use to the full life cycle of the appliance. Materials that provide longer useful life, avoid hazardous substances and are easily recycled, can make a significant environmental impact. TPEs can play a key role in a sustainability strategy, while also giving designers greater flexibility to innovate and provide aesthetic differentiation. For more information, visit: www.glscorporation.com www.applianceDESIGN.com

DISPLAYS & INTERFACES

The common trend with buttons today is to use universal symbols on them, so that the products can be sold in many different locations without the need to produce different buttons. Image: Microchip Technology Inc.

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or anyone who designs user interfaces, if you see a typical television set from the mid 50s, the first thing that’s likely to catch your attention is just how much real estate was occupied by its user interface. There were two large knobs, one for volume control and the other for channel selection, along with a large area of what looked like unused space below the small screen that housed the mono speaker. This was nothing less than state of the art in its day. Today, there are products that allow manufacturers to have simulated surround sound and high-quality video in the palm of a hand. One of the best areas to see this change is in the new appliance products produced in today’s marketplace. This article will take a look at the available options for selecting the best appliance user-interface technology; guidelines for how to decide between different types of user-interface buttons; and the use of touch screens and graphics. Today’s appliances are a balance of form and function. The demand from users to include complex cooking, cooling or even reheating algorithms might help sell a product, but these features will always be trumped by “love at first sight,” based on how the product looks and how the user interacts with it. www.applianceDESIGN.com

Simple, clean and powerful are the guidelines that product designers use today. Think of the television of yesteryear and how simple that interface was: a knob for tuning and one for volume. Compare that to a microwave of just a couple of years ago, and you will see that there are buttons for making popcorn, melting butter or even reheating pizza. Some recent microwaves added buttons that bring up submenus driven by the hard-to-read alphanumeric displays, which tend to lead to confusion on what results you might get.

Interface Trends The common trend with buttons is to use universal symbols on them, so that the products can be sold in many different locations without the need to produce different buttons with different languages or localization. For example, at the 2011 Consumer Electronic Show (CES), a visitor did not see many buttons on the washers and dryers being displayed, nor labels like “start” and “stop.” However, many had single buttons with the symbol for “play” and “pause” on it. Another button that is being seen more frequently is the symbol for “power.” These symbols have become synonymous

Interface design, button design and increasing connectivity options allow for an easier end-user experience, and help eliminate the need to change product design based on different regions.

by stephen porter Stephen Porter is applications manager, Home Appliance Solutions Group at Microchip Technology Inc., Chandler, Ariz. applianceDESIGN

May 2011 13

DISPLAYS & INTERFACES with the electronic products produced today, and they are finding their way outside this market to all consumer products, as more electronics are designed into the products we buy.

Soft Buttons There is, however, one other thing that using symbols in place of words cannot do for the user interface, and that is to make the buttons soft buttons. A “soft” button makes use of the display on the product to label the button’s functionality. Therefore, the button can have many different functions—or the same functions but displayed in a different language—reducing the need to produce products for different areas. The concept of soft buttons also helps to make the user interface crisp. For example, think of a side-by-side refrigerator with an ice/water dispenser built into the front of it. Not so long ago, it would have had a mechanical button for crushed ice, one for cubes and one for the light in the ice/water dispenser area. In this case, inside each door is a rotating knob that sets the temperature of the freezer and refrigerator sides of the unit, respectively. Such refrigerators do not have any feedback as to the current temperatures inside the unit, nor the ability to customize how the lighting looked on the inside of the unit. There is a circuit board for each of the button/knob locations, and labels on or around each of these printed in a given language. Today, we can take that same design and move the entire interface to just above the ice/water-dispenser area on the outside of the refrigerator—a user interface that consists of no more than two fixed buttons and a graphical display. Users can see what the temperatures are in both the freezer and refrigerator, change them if desired, check the status of the water filter and more—without opening the door.

Interface Design Two questions that come up from time to time are how much information is too much, and what is the best way to display the information? If all of the information possible were displayed at the same time, then the details would be lost to the user. The goal with today’s user interfaces is to provide the high-level information that most users will likely want to see most often, along with intuitive drill-down menus that will quickly get the user the additional information that they desire. The manufacturer must also provide a clean and easy way 14 applianceDESIGN May 2011

The soft buttons on this concept refrigerator/freezer enable a simple interface. Additionally, two fixed buttons switch between dispensing water and ice, and a USB port is available for uploading pictures to customize the display. Image: Microchip Technology Inc.

back the home screen. For example, a water-filter soft button might show green if it is OK and has about 30% life. It could then change to yellow or even red when its life falls below 30%. In this case, the user is given a simple visual status of the filter. However, if they see green and want to know just what the life of the filter may be, all they have to do is touch the button and the display will show more detailed information about it. There are also some underlying reasons that a designer might want to use display technology with one or two simple buttons, over fixed displays or several buttons. The foremost reason is that, as time goes on, the information can be upgraded or changed as needed. Today’s embedded microcontrollers, which drive much of the technology talked about in this article, have provisions for connectivity. Manufacturers can utilize this connectivity to update the firmware in the product. This could be as simple as providing the end user with a USB port that allows them to download updates from the manufacturers’ Web site, or it might use connected wired or wireless paths and automatically send the updates to the appliance. For example, washing-machine manu-

facturers spend countless hours developing how to keep the little balls of lint from building up on clothes when washed. Imagine that just after a consumer bought a new washer and dryer there was a discovery of a new algorithm that prevented this lint buildup. Ideally, this wouldn’t be an issue, as the manufacturer would send an email to all owners explaining how to push a few buttons on the washer and dryer to receive the updated software. Because of the new program, the consumer could also receive an updated display menu, which could not have been done if the machine was made with an older, fixed display.

Button Design There are several different technologies that can be used for either the display or outside buttons. First, the displays that are in use today are getting larger and have higher resolutions (or pixels per inch). In the past, resistive touch screens were used over the display, but their typical polyester film surfaces were prone to scratches and had lower levels of light, making the displays look dull. Newer technology is making use of projected-capacitive sensors that are sputtered on the back of the glass and mounted in front of the display. The technology that is www.applianceDESIGN.com

DISPLAYS & INTERFACES www.applianceDESIGN.com

A single Microchip PIC24DA microcontroller can drive an entire user interface while enabling multiple connectivity options. Image: Microchip Technology Inc.

used to manufacture projected-capacitive sensors allows for greater light transmission, which in turns allows the display to appear brighter. Projected-capacitive technology also allows for multi-touch inputs on the display, if needed. As for the buttons outside of the display, there are several technologies that can be used. There are standard capacitive-touch buttons that have some covering plate over them that is not conductive, such as glass or plastic. These types of buttons can be found on almost every type of product. With capacitive buttons, one does not have to apply force to depress them, but physical contact must be made to change the capacitance and register a touch—so there are some tradeoffs. First, gloves or the end of a wooden spoon will not activate them, so using them on the backsplash of a stove, for example, can be tricky. Second, there are people who want tactile feedback from their buttons. To solve this issue, many designers have either stayed with mechanical buttons or used metal over cap technology. Metal over cap measures the deflection of the front service panel through a capacitive sensor and a target mounted above it. This allows the user to use a gloved hand or the end of a wooden spoon to activate a button. The one thing that people always notice about this type of technology is the fact that it does take a bit of force on the button, which is unlike standard capacitivetouch technology.

The Future

and the smart grid projects will definitely have an impact on what information will be displayed and where it will be displayed on appliances. Standards are being developed that will allow for the interoperation of appliances. This will not just allow a refrigerator and oven to talk to each other and the meter base at a house, but also to a thermostat, hot water heater, washer and dryer, and other appliances. There are locations around the world that now have tiered prices for power, based on average use and demand. Therefore, using the dishwasher right after dinner might not be the most cost-effective time. It would be nice if, after dinner, when a consumer goes to start the dishwasher, that its display would provide feedback comparing the cost of running it right away versus four hours later. This real-time information would allow consumers to make the best choices for their situation. The state of user interfaces is ever evolving to provide users with more information and cleaner designs, along with the ability to customize the information displayed to their needs. All of this allows for more consistent manufacturing processes and eliminates the need to produce products for specific regions. Additionally, the same microcontrollers used in these displays can provide connectivity. Such integration can enable manufacturers to diagnose and upgrade products without having to visit the homeowner; saving both the manufacturer and the homeowner time and money.

Where is the future of user interfaces going within the appliance market? Smart energy

For more information, visit: www.microchip.com

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May 2011 15

DISPLAYS & INTERFACES

ADDING THE RIGHT TOUCH

Edge-lit, super-thin light guides use LED technology to provide a backlighting solution for all kinds of touch-enabled display interfaces using fewer LEDs. Image: Global Lighting Technologies

Ultra-thin LED-based light guides provide an ideal illumination solution for touchenabled display graphics.

L

ED-based lighting technology continues to transform the appliance industry as designers take advantage of the new opportunities it offers for brightness, color, sensing and control. Another trend among today’s designers is the increasing incorporation of touch technology into the displays and front panel graphic interfaces of kitchen appliances, printers, laptop PCs, home entertainment devices and an array of other products to enhance functionality, ease of use, aesthetic appeal and brand recognition. Touch technology also extends the useful lifetime of control interfaces versus traditional mechanical buttons, switches and membrane-actuated devices.

Why Touch?

by tim bixler Tim Bixler is sales manager for Global Lighting Technologies (GLT) Inc., Brecksville, Ohio. 16 applianceDESIGN May 2011

Touch screen monitors on PCs have become more commonplace as their price has steadily dropped over the past decade, and the technology has rapidly spread from backlit LCD panels to the various graphic interfaces used to control appliances. These include on/off and function buttons, menus, keypads, directional symbols, rotary switch-

es, sliders, company logos and any other graphic icons that provide information to the user and enable the user to get information or send commands to the appliance. Touch technology can also enhance the styling of a product and its perceived value to the consumer. It enables “dead front” capability where, when the device is not in use, the graphic icon backlights go out and the overlay “fades to black” until it is powered up again. This makes for a less intrusive and more pleasing appearance that is more in harmony with the overall aesthetic of a room. There are three basic systems that are used to recognize a person’s touch: resistive, capacitive and surface acoustic wave. While each system has its merits, capacitive touch technology has become the most frequent design-in for touch-enabled appliances. With capacitive touch, a layer that stores an electrical charge is placed on the overlay containing the graphic icons of the appliance or device. When a user touches the icon, some of the charge is transferred to his or her finger, so the charge on the capacitive www.applianceDESIGN.com

DISPLAYS & INTERFACES Capacitive touch technology is increasingly being designed into touch-enabled graphic applications. Image: Global Lighting Technologies

Edge Lighting is Key

layer decreases. This decrease is measured in circuits located on the PC board behind the overlay. The relative difference in charge is calculated to identify exactly where the touch event took place and this information is relayed to the driver software. One advantage that the capacitive technology has over resistive technology is that it transmits almost 90% of the light from the backlight compared to only 75% for resistive; resulting in a brighter, clearer image.

Illuminating the Interfaces These graphic interfaces need to be backlit. Until recently, designers have had to dedicate an individual LED to illuminate each icon, button or symbol, and it has been difficult to achieve perfect uniformity among all of the backlights. An enabling technology that would solve the uniformity problem while reducing the number of LEDs required to backlight multiple graphic interfaces has been desirable. The backlight that illuminates the graphic interfaces is placed between the overlay and the PC board/circuit sensor. This determines the appearance, brightness, clarity, color and overall aesthetic of the display interface. It also presents a design challenge to the appliance manufacturer. So, what makes for the optimum backlight? There are several factors to consider: Brightness Uniformity – Dispersion of Light Discrete Area Illumination Capability Thickness Sensitivity Number of LEDs Required / BOM Power Consumption Manufacturability www.applianceDESIGN.com

The use of low-profile, side-firing, white LEDs placed along the edge of an extremely thin light guide in concert with a light extraction technology called Microlens is the basis of the solution discussed here. Microlens is a light extraction technology that harnesses and controls the LED light sources by spreading their light uniformly across the area to be illuminated, with no dark areas or hot spots. Hundreds of thousands of micro-optical elements (miniature reflective and refractive surfaces) are molded directly into the top and bottom of the light guide and the angle of the emitted light is optimized to maximize the efficiency of the LED backlight. The light guides can be custom designed in a range of sizes with uniformities of greater than 90% and brightness ranging from hundreds of cd/m2 to thousands, depending on the application requirements. The light can be directed to wherever it is desired, such as illuminating only selected areas of an appliance overlay. The LEDs are strategically placed along the edge of the light guide to disperse their light efficiently. In previous designs, manufacturers had to dedicate an individual LED to each icon, button or symbol that needed illumination. Now, one LED can be used to effectively backlight multiple graphic icons, eliminating the need to use individual LEDs for each

graphic interface or multiple LEDs for larger areas such as company logos. This keeps the number of LEDs required (and the bill of materials) to a minimum.

Assembly In touch-enabled graphics applications, what the user sees is the front panel, which is an overlay (usually plastic) that contains the application-specific graphics. Behind this is an ultra-thin (< 0.6 mm thick) light guide with discrete optical areas molded into it for the most efficient and uniform dispersion of the light from the LEDs located on the PC board, into which are embedded the LEDs and touch-sensor electronics. When assembled together the OEM has an exceptionally thin overall stack, with bright, uniform graphics and fewer LEDs. The user can touch right through it with no loss of sensitivity. Depending on the application, these light guides can be designed as thin as 0.2 mm. The operating current of the LEDs, along with the brightness desired and the number of LEDs used, will affect power consumption. The fewer the LEDs, the lower the overall power consumption. The side-firing LEDs typically used in appliance applications are low-current devices that operate at 25 to 30 mA to as low as 12 mA, and, with the aid of an edge-lit light guide, can reduce the LED count from 3, 4 or more to 1 or 2, proportionately reducing the power consumption, increasing the “green” component of the

Microlens is a light extraction technology that harnesses and controls the LED light sources by spreading their light uniformly across the area to be illuminated. Image: Global Lighting Technologies applianceDESIGN

May 2011 17

DISPLAYS & INTERFACES In touch-enabled graphics applications, what the user sees is the front panel, which is an overlay that contains applicationspecific graphics, followed by an ultra-thin light guide with discrete optical areas molded into it for the most efficient and uniform dispersion of the light from the LEDs located on the PC board, into which are embedded the LEDs and touch-sensor electronics. Image: Global Lighting Technologies

appliance and helping it to achieve a coveted Energy Star rating.

Benefits for the OEM A graphic overlay can be glass, polycarbonate, polyester, acrylic or possibly some other non-conductive material. It is essential for the backlighting material to be compatible with the range of materials used in the overlays. Also, the thinner the backlight, the

slimmer the assembly. In addition, a thinner edge-lit light guide of compatible material that requires fewer LEDs and can be injection molded at high speeds simplifies the manufacturing process, lowers the BOM, and makes for a more costefficient assembly. Touch technology is becoming increasingly ubiquitous as designers seek to enhance the performance, styling and visual appeal of a

wide range of appliances as well as their company brand. As LEDs have established themselves as the lighting technology of choice for graphical user interfaces, ultra-slim edge-lit light guides that provide uniform illumination with fewer LEDs offer a cost-effective and more easily manufactured alternative to previous backlighting approaches. For more information, visit: www.glthome.com

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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

NOISE & VIBRATION CONTROL This G.R.A.S. Kemar mannequin is an advanced example of simulating human hearing. Photo: National Instruments

Finding and Testing for Noise Correcting for noise is best done by acquiring accurate and useful data followed by in-depth analysis in the case of design or comparison to a baseline for manufacturing test purposes.

he marketplace for white goods is changing and noise detection and identification is critical during both the design and manufacturing stages of these products. Noise is becoming crucial in evaluating product quality. Correcting for noise is best done by acquiring accurate and useful data followed by in-depth analysis in the case of design or comparison to a baseline for manufacturing test purposes. Acquiring and defining a noise, however, is no simple task. This article will discuss case studies and examples of how noise should be acquired to most accurately reproduce a human experience; analysis techniques to determine what noises are most significant to human users; and how manufacturing and design based on analysis can alter the human perception of how a product sounds.

T

Pleasing Noise

by michael denton Michael Denton is a sound and vibration manager at National Instruments, Austin, Texas. 20 applianceDESIGN May 2011

White goods, including washing machines, microwaves, refrigerators and dryers, continue to evolve and change. Most simply, many of these appliances are no longer white. An important differentiator for white goods moving forward is the type or amount of noise they make or create. Common marketing terms such as silent or quiet have been used for many years now. In the near future, terms like pleasing and soft will become common as well. With modern white good designs packing ever more performance into smaller packages, it will not be possible to eliminate all noise.

However, understanding the nature of the sound will make it possible to modify it into a more pleasing sound. Adjusting the sound of a noisy and annoying refrigerator into a pleasant one requires sound-quality engineering. Sound-quality engineers analyze the acoustic data recorded from a product and make recommendations on how the design could be modified to change the nature of the sound. Sound is not simply the physical phenomena of sound waves passing through the air, though this has an impact and is important. Rather, it is also the physical process of sound being sensed in the ear. The design of the human ear results in some sounds being acquired at much higher levels and transmitted to our internal sensors with greater relative magnitude. Finally, sound is also a psychological phenomenon. Our brains must interpret the physical occurrences for us to decide if a sound is good or bad, annoying or pleasant. Properly performed sound-quality engineering accounts for all of these factors.

Challenges The first factor to take into account is how sound waves physically pass through the air. In a sense, it is important to see how a human will experience the sound. If a person is standing directly in front of an object, then often the sound will hit both ears. This is frequently the case, but in the example of a HVAC system people are often off to one side based on the layout of the house or building. www.applianceDESIGN.com

Jury testing is a technique often used for product refinement. In the case of a dryer barrel noise testing, an acoustic array is used while taking the physical measurement to help the sound quality engineer locate the source of the sound at a certain frequency. The sounds are then recorded and played back for a jury of listeners. Photo: National Instruments

There is no hard and fast rule, but when undertaking a sound-quality investigation the special physical arrangement of microphones should be evaluated. The purpose of acoustic data acquisition is to simulate human perception. Often this requires the use of a bi-aural microphone setup, preferably with a human head simulator. A second factor to be aware of is the physical characteristics of the inner ear canal. The result is that certain frequencies are amplified in human hearing perception. A general rule of thumb is that human hearing, which has a range of 20 Hz to 20 kHz, interprets the loudness of sound in the 1 kHz to 5 kHz range—about double that of the other frequencies. Avoiding these frequencies results in a quieter product and alternatively moving one sound into this frequency range could mask other sounds. Depending on the device, the sound could be deemed pleasant or expected. The last challenge is to properly account for how the human brain interprets sound. This is often the most challenging as it is more unique from person to person. That being said, there are well-documented standards that take into account the most basic of human hearing issues. A good start to imitate human hearing is to calculate the zwicker loudness and aures sharpness spectrums of the acquired sound. These algorithms demonstrate the difference between human hearing and microphone recordings and are often used on recorded data from controlled environments. They can be implemented in production tests as well. In general, sound quality algorithms make assumptions about the physical relationship between the microphone and sound sources. It is important to make sure those assumptions are valid for the data being analyzed. www.applianceDESIGN.com

Some of the largest noise pollution sources are four wheelers, golf carts and other smaller engine lower power designs, such as lawn mowers. Photo: National Instruments

Applications & Trends Jury testing is a technique often used for product refinement. Physical data can be taken and acquired based on the expected physical hearing situation. Multiple product revisions and operation modes are recorded and then analyzed. The sounds are filtered and modified to acquire the noise content that the sound quality engineer feels is most significant. In the case of a dryer barrel, this can often be a noise created by rubbing that yields a higher frequency sound. Often, an acoustic array is used while taking the physical measurement to help the sound quality engineer locate the source of the sound at a certain frequency. These sounds are then recorded and played back for a jury of listeners. Each listener evaluates and grades the sounds for different criteria supplied by the sound quality engineer. For example, “How annoying is this sound on a scale of 1 to 5?” Jury testing creates not only product suggestions, but also can be used in production tests to identify absolute max tolerances that can be accepted for sound pressure at certain frequencies. This approach provides a tremendous amount of information, but does require intensive review. It is appropriate for design testing and a quality check on some finished products, but not as an analysis to be run on every manufactured white good. In the case of a computer laptop it can be just as critical to make good design decisions. Laptop speakers are usually tested as an audio device, which is a different measurement approach than this paper discusses. Due to their small nature, laptops have other sound sources that can create sharp and annoying noises. The hard drive on a laptop

in particular can be analyzed for two different purposes. Acoustic analysis can reveal if a hard drive sounds bad or sharp, but it is also possible to measure a hard drive disk spinning and decide if it is beginning to fail. Sharpness is the most common measurement to process laptop drives with. Loudness should also be processed, but is not crucial, as laptop users are often very close to the noise source. The most common place for sound quality to be applied is in the automotive space. Traditionally, this was only performed on the highest end vehicles. With easier to use and more affordable data acquisition tools, sound quality analysis is starting to move into all automotive vehicle design and production testing. Additionally, some of the largest noise pollution sources are not necessarily automotive products; these include four wheelers, golf carts and other smaller engine lower power designs. This idea has already been applied to some of these products and will be a major differentiator for future products. In the future, creating a pleasant sounding lawn mower or suppressing the most annoying frequencies from one will make differentiation possible. In many white goods, from coffee pots to dryers, noise is the most continual experience for the user, which constantly impacts the perception of products. In the white goods industry, premium products have begun to adapt the idea of quietness as a positive differentiator. Moving forward, as data acquisition technology becomes more readily available, it should be expected that white goods vendors will place more importance on striving to improve sound quality. For more information, visit: www.ni.com applianceDESIGN

May 2011 21

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QUALITY & STANDARDS

ECODESIGN: A Sustainable Approach

Energy efficiency standards reduce energy consumption worldwide.

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s countries compete to trade, more shoppers consume evergreater numbers of products. With that, the production and the use of natural resources continue to spiral upward. In many cases, resources are being used up faster than they can be replenished. A different, more sustainable approach is needed; one that considers the environmental impact of a product, throughout its whole lifetime. In recent years, manufacturers have increasingly found themselves obligated to meet a whole new set of standards—environmentally friendly ones. Ecodesign aims at reducing the environmental impact of products, including their energy consumption throughout the entire life cycle. A framework within which compulsory ecodesign requirements are set, enables a coherent and integrated approach from the design of a product through an assessment of its natural resources and raw materials requirements, ending with an assessment of manufacturing, packaging and transportation costs—both environmental and economic. www.applianceDESIGN.com

Since 2006, for example, Europeanbased producers or importers of electrical and electronic equipment have been responsible for collecting and recycling their used products according to the Waste Electrical and Electronic Equipment Directive (WEEE). In addition, they must implement ecodesign processes to satisfy Energy related Products (ErP) regulations. Further directives, End of Life Vehicles (ELV) and Reuse Recycle Recover (RRR), require that manufacturers prove and improve the recyclability of their products. The packaging industry also is affected, and most industries where chemicals are involved in the process are affected by REACH. Such measures appear all over the world. The U.S.A. Environmental Protection Agency (EPA) promotes a product stewardship program to focus on end-of-life considerations as one means of encouraging more environmentally conscious design and greater resource conservation. More and more states in the U.S. are developing take back mandates for selected products (especially for electronics) and several states have passed

Take a look at regulations and objectives set for manufacturers and how OEMs can obtain conformity to sell products within the EU market.

by ke yang, ph.d. Ke Yang holds the title of global sustainability services at SGS - North America Inc. applianceDESIGN

May 2011 23

QUALITY & STANDARDS legislation to reduce mercury in waste. In this way, battery manufacturers and retailers have increased the collection and recycling of used rechargeable batteries and automotive manufacturers are working to reduce toxic and hazardous materials in their vehicles.

U.S. Legislation on Ecodesign The Consumer Product Safety Act (CPSA) is the basis for legislation on product safety and was enacted in 1972 by the U.S. Congress. The Act established an agency, which provides a safety standard to evade any risks associated with consumer products. It also prohibits products of a substandard nature, and products can be recalled if they are found to be hazardous. Although in December 2010 the U.S. Department of Labor’s Occupational Safety and Health Administration (OHSA) decided not to implement the EU approach of ensuring manufacturers declare product safety before products enter the market, known as Supplier’s Declaration of Conformity (SDoC), measures are in place to protect American workers. OSHA requires employers to use electrical devices tested and certified by independent testing companies recognized by OSHA. These companies, known as nationally recognized testing laboratories, conduct tests to determine whether products are safe before manufacturers or distributors place them on the market and employers use them in the workplace. It is to be noted that OSHA also currently lacks explicit legislative authority to implement the enforcement powers required for an effective SDoC system, including issuing product recalls and bans, assessing fines and imposing criminal penalties. Furthermore, a variety of voluntary programs engage in reducing the environmental impact of electrical products, including energy consumption. The Energy Efficiency Standards (EES) group aims to improve efficiency across all energy sectors in the U.S. Key aspects of electrical goods come under this group’s remit, including regulations on standby mode and the amount of water used in dishwashers and washing machines, for example. In addition, by working closely with private industry, the government and consumers established the voluntary U.S. Energy Star program in 1992 in order to 24 applianceDESIGN May 2011

Ecodesign considers a product’s environmental impact.

identify energy efficient products and reduce carbon emissions. At the state level, California was the first to adopt appliance and equipment efficiency standards. The authority to adopt efficiency standards was bestowed upon the California Energy Commission as stipulated under the Warren-Alquist Act, which was enacted in 1974. California’s 2006 Appliance Efficiency Regulations became effective on December 30, 2005, replacing all previous versions. The regulations create standards for 21 categories of appliances, including standards for both federally-regulated and non-federally regulated appliances. The current version became effective January 1, 2011 and will be updated in 2013.

EU Directive Comes into Force The European Union has introduced a new energy directive that has a wider scope than its predecessor. Toward the end of 2009, the EuP Directive, 2005/32/EC, was replaced with a new energy-related directive, 2009/125/EC. The new directive covers products that utilize energy, and also products that influence the consumption of energy. So, in addition to affecting manufacturers of light fittings, microwave ovens, washing machines and so on, the directive also covers manufacturers of windows, taps, shower heads, detergents and even

insulation materials, for example. The Ecodesign Directive provides a coherent and integrated framework for compulsory ecodesign requirements for key products. For example, electrical and electronic standby requirements now dictate that on standby, such products must not utilize more than 1 Watt in off mode until 2013, where the wattage is to be reduced to 0.5 W. The directive has been stringent in ensuring that such measures do not affect safety, affordability or consumer health. Implementing Measures (IMs) have been mandatory since the original directive, but what is new, however, is that all EU products must now comply with applicable and original IMs as well as continuing to qualify for CE conformity. This is so as to ensure full compliance with Ecodesign Directive of ErP—otherwise, the manufacturer may find it is illegal to sell the product. All references to the repealed Directive 2005/32/EC (EuP) are to be taken as references to the new Directive 2009/125/EC (ErP). Therefore, manufacturers of consumer goods will now have to update their declaration of conformity to include references to the new Energy-related Products Directive as well as maintain full compliance with implementing measures in the manufacturing process as per the old directive.

Reasons for Change Reasons for change include concern for the environment and the drive for the harmonization of standards with regard to products across the EU. To that end, policymakers have deemed the ecodesign of products crucial in the strategy for an integrated product policy. The directive aims to instill a preventative approach with regard to ecodesign, in order to ensure the optimization of environmental performance of products while making no sacrifices with regard to functionality. Another reason for the EU directive has been the increasing demand for electrical energy—the fastest growing energy end use category in the EU. The projected increase in demand over the next two to three decades further motivated the drive to reduce energy consumption, particularly as suggested by the European Climate Change Programme (ECCP). The saving of energy is the most cost-effective means for the increase of security of supply and the reduction of import dependency. www.applianceDESIGN.com

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QUALITY & STANDARDS Aside from the environmental benefits, implementing an ecodesign approach will bring other substantial benefits including competitive advantage, cost savings and optimized materials consumption.

Thus, the decision to adopt substantial demand-side measures was made.

Solutions for Compliance The eco-directive can appear to be a daunting hurdle for overseas manufacturers. It is, however, navigable if the entire range of product-specific requirements is considered carefully, prior to market launch. Many manufacturers will prefer to employ a third-party accredited organization for the purpose of ensuring their product meets the stringent EU requirements of both observing the strictures of the directive and declaring CE Conformity. A third-party accredited organization can help OEMs achieve conformity by both ensuring that products comply with the requirements of future and proposed directives and by verifying that products comply with the implementation measures. This can help an OEM obtain the Declaration of CE Conformity essential for the sale of products within the EU market. A third-party accredited organization should also be able to inform the manufacturer, in a timely fashion, of how to ensure compliance with other relevant EU Directives, such as the Low Voltage Directive or the EMC Directive. In addition, to ensure a trauma-free implementation of the eco-directives, an ecological profile of the manufactured product must be performed and the product’s lifespan as well as its environmental impact in the manufacturing process must be analyzed. All testing, manufacturing and planning must be implemented without contravention of the ErP Directive.

New Duties for Manufacturers and Importers The Ecodesign Directive affects both energy-using products (EuPs) and other energy related products (ERPs). Although the EU has sought to reduce the negative administrative impact on manufacturers, new duties apply to manufacturers. The first of these duties entail that the energy consumption of a product be as low as 26 applianceDESIGN May 2011

possible. Secondly, information will be required with regard to best practice in use of the product. Thirdly, the manufacturer may well be required to perform a lifecycle analysis of the product in order to identify alternative design options and solutions for improvement.

A Decision-Making Approach Ecodesign is an approach to the design of a product with particular thought for the environmental impacts of the product during its entire existence including raw materials, manufacturing process, retail, usage, waste and recycling. As consideration for the use of the product during its lifecycle is grabbing more importance, so the first steps of the product’s conception have taken on more significance. This is driven by ecodesign. The meaning of ecodesign is to integrate environmental constraints in the design of a product or a service in order to decrease the negative environmental impacts. It is not only about extending the life of a product; the fundamental objective is to ensure that the product has an eco-friendly existence throughout its life or life cycle. Ecodesign and life-cycle assessment (LCA) provide a strong stimulus for companies to adopt a more sustainable agenda, where the focus is on all the good that companies can do for the environment, society and economic growth. To succeed requires the highest level of management support as well as a high level of involvement by both the company’s employees and all partners in the value chain. Aside from the environmental benefits, implementing an ecodesign approach will bring other substantial benefits including competitive advantage, cost savings through increased efficiency with regard to raw materials, resources and energy consumption, as well as optimized materials consumption, especially with reference to renewable materials and recycled materials. Incorporating an ecodesign approach also can bring energy savings, packaging and logistics optimization, an increase of

quality with increased product lifespan as well as innovation and the possibility of new markets. As the advantages are reasonably balanced between both environmental and economical benefits, there are high expectations that ecodesign will be adopted as the benchmark standard by which more manufacturers operate.

What’s Next for ErP? Within the European Union, a working plan is due for release in October 2011 and will seek to establish an indicative list of product groups for 2012 to 2014. By 2012, the effectiveness of the directive will be under scrutiny, particularly with regard to non-energy related products, i.e. those products that do not directly utilize energy but affect its consumption. The EU hopes for ErP to complement the Energy Star regulation in place in the United States. For the state of California, the ecodesign approach is part of a clear and coherent strategy to implement energy savings, increase the safety of products and reduce environmental impact. The California Energy Commission’s 2010 Appliance Efficiency Regulations include standards for both federally regulated appliances and non-federally regulated appliances and 23 categories of appliances. The standards within these regulations apply to appliances that are sold or offered for sale in California, except those sold wholesale in California for final retail sale outside the state. Products that are covered by the Appliance Efficiency Regulations include commercial and noncommercial refrigerators, walk-in coolers and freezers, air-conditioning units, ceiling fans, gas wall furnaces, floor furnaces, room heaters, water heaters, fluorescent lamps, incandescent lamps, dishwashers, clothes washers, clothes dryers, electric motors, audio and video equipment, and televisions. For all manufacturers, the amount of legislation in place can be risky if not managed properly. For more information, visit: www.sgs.com/ee www.applianceDESIGN.com

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NEW PRODUCTS envelopes without requiring equipment redesigns. They can be specified for electric motors up to 37kW (50hp) with shaft diameters up to 60mm. Custom solutions can be developed to satisfy particular application needs. For more information, visit www.skfusa.com

continuous operation even under low battery voltage conditions. For more information, visit www.austriamicrosystems.com

E+E Elektronik The EE892 is a CO2 sensor module that includes an adjustable measuring interval enabling optimum adaptation to specific applications while maintaining an average current consumption of less than 60μA. The module was specially developed for OEM applications and high-volume production. A digital interface and compact design facilitate clear-cut integration in mobile and energy-sensitive applications such as data loggers or demand-controlled ventilation. The CO2 load cell is based on infrared technology (NDIR) and, with an autocalibration process, it is maintenance free, according to the company. For more information, visit www.epluse.com

Vision Numeric

Maxon EC 22 motors are equipped with preloaded ball bearings and latest generation Neodymium permanent magnets. The motors feature low vibration and low noise levels at high speeds. Nominal torque of up to 44 mNm and an efficiency of more than 90% and a 25% reduced speed/torque gradient are achieved according to the company. For more information, visit www.maxonmotorusa.com

An add-in for CATIA: Type3 CAAV5 Based V5.10 allows CATIA users to integrate design needs earlier in the PLM. Users are able to quickly integrate text, company logos, model and serial numbers, graphic elements, symbols or part identification earlier in the design process for simulation, validation and production purposes. The engraving add-on provides a sustainable solution improving not only the data management in the PLM process, but also the communication process between designers and engineers. For more information, visit www.type3.us

Austriamicrosystems SKF USA Energy-efficient ball bearings for electric motors are alternatives to standard bearings by generating significantly less friction and reducing energy consumption. These deep groove ball bearings are engineered for a wide range of applications. The bearings exhibit 30% to 50% lower friction compared with conventional types and benefit from an optimized design balance between highly engineered internal geometries, grease, and bearing cages, according to the company. They perform in combination with an energy-efficient grease developed by the company. The bearings comply dimensionally with ISO 15:1998 in a range of selected sizes off-the-shelf to allow for interchangeability within existing design www.applianceDESIGN.com

The AS1119 LED dot-matrix driver (channels vs. PCB space) drives 144 LEDs, requires 9 mm² PCB space, reduces external component count, reduces connector pin count and requires fewer PCB layers, according to the company. Benefits include up to 80% longer battery lifetime, more colorful effects and smoother running animations. The product is targeted for dot matrix displays in personal electronics and other items. An 8-bit analog current control allows tuning of each matrix to compensate for different brightness of different colors, or to adjust the white balance on RGB LEDs. The AS1119 incorporates six frames of memory for small animations or for use as a buffer to reduce host processor load. An on-chip 320 mA charge pump, which is required when LEDs require a higher voltage than the battery can supply, allows for

Swissbit The 2GB DDR2 Chip-On-Board (COB) SODIMM is suited for industrial small form factor (SFF) PCs and other spaceconstrained applications. The COB technology directly attaches and wire-bonds the DRAM dies to the substrate and fully covers the dies and bond wires with a protective Epoxy encapsulating material. With this process, the module becomes mechanically robust against shock and vibration, along with an overall reduction of electrical interapplianceDESIGN May 2011 29

NEW PRODUCTS connections. Due to the direct die attachment, the heat dissipation is enhanced via the substrate and socket and by the extended surface. The glob top encapsulation also provides a platform for conformal coating, which can be added as an additional protection against environmental conditions. For more information, visit www.swissbit.com

output, compact linear actuator ideal for precision motion applications requiring a small footprint. Technical enhancements over previous generations, include optimized stator tooth geometry, high-energy neodymium magnets, custom-engineered plastics, and larger ball bearings for greater rotor support for maintaining accuracy and repeatability over a long life. The line provides high force-to-size ratios and is ideal for a variety of applications including precision medical equipment, scanning and printing equipment and other mechanisms requiring high force in a small package size. For more information, visit www.haydonkerk.com

Flexaust A full line of lightweight, reinforced PVC high-stretch hose can be customized for upright, canister or central vacuum cleaners. Dayflex lightweight stretch hoses feature PVC construction reinforced with a vinyl coated spring steel wire helix and come in a flat top style providing a >5:1 high stretch ratio or full block style with a 4:1 ratio. Supplied with custom engineered end fittings, hose assemblies can be designed to match functional, aesthetic and economic requirements. The line is offered in 3/4-inch to 2-inch diameter sizes and standard lengths ranging from 2 to 36 feet, depending upon style. Suitable for virtually all vacuum cleaner applications, these hoses resist most chemicals, detergents, and abrasion and come in standard gray or can be custom color matched. For more information, visit www.flexaust.com

Performance Coatings International Vueguard 941 anti-static coating is meant for plastic products required to dissipate a static charge. The product is a crystal clear, solvent-based UV curable coating that maintains optical clarity on molded plastics. It is designed for applications where a permanent, clear coating is required to dissipate or prevent a static charge. A typical use would be to prevent static build-up on a personal electronic display. Vueguard 941 can be applied via spray, dip, spin, roll or flow coating. For more information, visit www.vueguard.com

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Haydon Kerk The high-resolution 19000 series captive linear actuator is a 20 mm diameter canstack with a 7.5 degree step angle resulting in smaller move increments and finer positioning ability. The 19000 Series is a high 30 applianceDESIGN May 2011

sures up to 90 psi, or flow rates up to 100 ml/min. The pump can achieve the high pressures due to its precision machined components, and spring loaded track to maintain occlusion of the tubing under high pressure. All fluid being pumped is completely contained within the tubing. The pump has a cover/loading lever that lifts the track when opened facilitating loading of the disposable tubing. The cover comes with an integrated switch that can be wired to turn the pump off when the cover is opened. The pump accepts tube sizes from 1/6-inch to 3/16inch in diameter, and has 4 stainless steel rollers for low pulsation of the flow stream. The pump is available as a panel mount OEM unit. Drive options for the 400/RX includes brushless, or stepper motors both with built-in drives. For more information, visit www.watson-marlow.com

Watson-Marlow The 400RX is suited for catheter washing and cooling applications requiring pres-

Multi-Seals Inc. Wash-Away dissolvable spacers are designed to provide consistent spacing between printed circuit boards and PCB components. These organic polymer spacers locate PCB components during soldering operations. After soldering, Wash-Aways dissolve in water or alcohol solvent baths. This leaves uniform spacing between components and boards, which provides free circulation of air, mechanical protection, optimum filleting, and greater accessibility for inspection, cleaning and conformal coating. Wash-Aways are available in a wide range of sizes and shapes to accommodate a variety of PCB components, including resistors, capacitors, transistors, potentiometers, and integrated circuits. The products contain no ionizable material, salts, sugars, metals, or soaps, and they are non-corrosive, non-conductive and non-toxic. For more information, visit www.multi-seals.com

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NEW PRODUCTS

DESIGN MART Crystek The 190 Series CCK26.5 and CCSMA26.5 cable assemblies are additions to the company’s line of low-loss RF coaxial cables. Designed to operate up to 26.5GHz, the 190 Series CCK26.5 and CCSMA26.5 cable assemblies offer a minimum bend radius of 1.1 inches and are available in-stock with 2.92 mm (K) and high frequency SMA connectors, featuring rugged stainless-steel solder-clamp construction and heavy-duty strain reliefs. The cables provide an attenuation value of 0.50 dB/ft at 26.5 GHz and offer shielding effectiveness of greater than -90 dB with an operating temperature range of -55 to +85-deg. C. An extended range of -55 to +125-deg. C is available through special order. For more information, visit www.crystek.com

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TDK-EPC The EPCOS MotorCap DM (direct mold) series of highly compact motor run capacitors is a space-saving version of the product implemented in a new housing technology in which the capacitor windings are directly molded in plastic. The product boasts a reduction in capacitor dimensions to between 24 by 43 mm and 29 by 43 mm (diameter by length). This corresponds to a volume reduction of up to 44% compared with conventional capacitors, according to the company. The capacitors are designed for 250 VAC with capacitances of 10 to 15 μF and for 450 VAC with capacitances of 1.2 to 6 μF. Their operating life is specified as 10,000 hours over the entire temperature range from -25 to +85-deg. C. For more information, visit www.epcos.com/motorrun

This appliance DESIGN Design Mart section brings you information on new products and services available through print and online. To receive more information about the the products and services in this section, visit appliance DESIGN online at www.applianceDESIGN.com.

Want to see YOUR Product here? appliance DESIGN’s Design Engineering readers are interested, active and always looking for information to help them design and specify products and services to use in the creation of their appliances.*

Contact Jennifer Nagel at 248-244-1729 or [email protected] for more information. *AM Editorial Readership Study, August 2004

Loctite Structural Adhesives Loctite Structural Adhesives are strong as welds, 2x stronger than bolts, & easier on the bottom line. Costs are reduced vs. mechanical methods by decreased cycle time & welding labor - no buffing/grinding of welded joints. Better aesthetics vs. screws/rivets. Free info. & engineering seminars available Henkel Corporation One Henkel Way Rocky Hill, CT 06067 USA Phone: (800) LOCTITE Web: www.henkelna.com/loctitestructurals

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applianceDESIGN May 2011 31

ASSOCIATION REPORT: AMERICAN CONSUMER INSTITUTE CENTER FOR CITIZEN RESEARCH

Clean Up the Vacuum Industry Stephen B. Pociask President of American Consumer Institute Center for Citizen Research

32 applianceDESIGN

ccording to the U.S. Census Bureau, annual spending on vacuum cleaners totals approximately $1.4 billion in shipments value and $1.9 billion in consumer expenditures per year. For the ordinary household, choosing among competing brands and models is both a complex and potentially costly undertaking. Vacuum cleaner models offer different degrees of quality, styling, suctioning and warranty coverage, and they cover a wide range of prices—from less than $50 to $1,200 per vacuum. Consumer choice among vacuum cleaners has expanded to embrace wide ranges in price, functionality, quality and assorted minor and major product differentiating characteristics. Models vary by type: upright, canister, robotic and handheld. Some are bagless and others provide sealed HEPA filtering and other features. A sizable portion of consumer spending is not on the upfront price of the vacuum itself, but the service maintenance and accessories needed for operation, such as bags, belts and filters. In fact, the upfront price does not, in most cases, reflect what we call the total vacuum cost of ownership (VCO). In other words, while vacuum prices are apparent to consumers at the checkout register, the longer term cost of owning and operating these vacuums is not obvious. Without fully understanding the VCO, consumers may be misled into purchasing inferior vacuums and vacuums with higher ownership costs. A study conducted by TeleNomic Research and released by the American Consumer Institute (www. theamericanconsumer.org) found that the long-term expense of operating and maintaining a vacuum cleaner usually costs consumers much more than the vacuum’s purchase price. In fact, the cost of maintenance and required replacement accessories are usually not explicitly identified on the retail box, so knowing the prices and longer term costs before purchase requires a lot of research time—making comparisons across brands and models nearly impossible for most consumers. The fact is that manufacturers generally do not want their customers to know these costs, because manufacturers benefit from hiding these costs. The TeleNomic Research study, “Are Manufacturers Cleaning Up?” compares the most popular brands and

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models and calculates a long-term cost or VCO measured as the sum of the retail price of the vacuum plus the cost of all of its accessories and maintenance over a 5-year period. In finding that the cost of operating and maintaining vacuums is most often greater than the upfront price of the vacuum, the study uncovered a number of examples, including one in which the 5-year VCO for one vacuum was seven times the original price of the vacuum. For example, among lower-priced vacuums and those vacuums rated lower in performance and quality by a survey of repair shops, the Shark Navigator, while the most expensive model in its class, had no variable costs and provided the lowest cost-of-ownership over a five-year period. Similarly, among the moderate and higher-priced vacuums and those rated highest among repair shops in terms of quality and performance, Dyson and its divergence from the razor-and-blades business model had no variable costs and provided the lowest cost-of-ownership over a five-year period. It is difficult for consumers to identify these hidden costs and that is to the advantage of manufacturers. The lack of information leads many bargain shoppers to buy cheaper and lower-quality brands and models, only to pay much more by using vacuums with higher operational costs. The answer to the problem is simple: manufacturers should disclose these hidden costs in order to give consumers better information to compare brands and models. This can be accomplished by developing an industry standard, like the VCO. If consumers could find the VCO on the box, on fact tags at the point-of-purchase, or on manufacturers’ websites, they would be able to make informed decisions to save them money and suit their needs. In turn, this would encourage competition in the market for vacuums with lower variable costs. Better informed consumers and increased competition is a recipe for maximizing consumer benefits and savings. For consumers, the current system of hidden costs provides neither. The firms with the most cost transparency will likely win in the end. www.applianceDESIGN.com

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Tough, yet inspiring.

Corning is cooking up new possibilities for tomorrow’s kitchens with Gorilla® Glass. Elegant, lightweight, and incredibly damage resistant, Corning Gorilla Glass enables sleek, seamless designs. And touch-screen compatibility means surfaces can be as smart as they are beautiful. Corning Gorilla Glass already enhances the beauty and durability of today’s coolest electronic devices— and we haven’t even scratched the surface of its potential. Start innovating at CorningGorillaGlass.com

©2011 Corning Incorporated. All rights reserved.