Development of ignition resistant thermo-plastic for meter design application. Giacomo Parisi, Dow Chemical

Transcription

1 Development of ignition resistant thermo-plastic for meter design application Giacomo Parisi, Dow Chemical

2 Topics: Dow in few words Sustainability and energy market Commitment to the meter market Development of Emerge PC 8701 Commitment to new developments Trademark of The Dow Chemical Company

3 Who we are? Our Vision To be the largest, most profitable and most respected chemical company in the world. Our Mission To constantly improve what is essential to human progress by mastering science and technology. A science and technology leader with annual sales of $49 billion 156 manufacturing sites in 37 countries Employs 43,000 people globally

4 Dow Products in the market Building Maintenance and Construction Transportation Furniture and Furnishings Paper and Publishing Home Care and Improvement, Personal and Household Care Food, Health and Medicine, Water purification Energy and Hydrocarbons

5 Dow in Energy market: innovation, solution and products Dow and GM Hydrogen Fuel Cell Project Incorporation of photovoltaic in residential building material Wire and Cable business providing innovative solution for Energy transmission Dow Building Solution business takes part in the world s third largest solar power plant Engineering Thermoplastic business provides plastic for Smart meter housing

6 Dow in the meter market: facts Successful story: Since 2001 in the smart meter market with the implementation of 30 ml meters in Italy,8000 Tons of Emerge PC 8701 sold Global presence: Emerge PC 8701 developed for the application and available globally Focus on the future: Collaboration in other projects for smart meter implementation all around the world, strong relation with all Meter manufacturing companies Deep knowledge: from early development (specification evaluation and design stage) to manufacturing

7 Dow in the meter market: Development of Emerge PC 8701 IEC International /53-23 standard Major Italian Energy Distributor Utilities spec Meter design/manufacturing company Material requirements Emerge Material PC choice 8701 Industrial design: esthetic, color, surface, shape Mechanical design: Strength, wall thickness, mold configuration Manufacturing Welding technology: Laser/vibration welding Global availability

8 Development process R ea CSCS CACA VV DD I I l i z a ti Concept Shaping Concept Analysis Validation Development Implementation o n Hypothesis of Business Opportunity Requirements for Success Best Fit Design Concept chosen Detailed Design completed All Issues resolved Implementation and Transition of the Business Plan to operations Business Plan created

9 Concept Shaping CSCS CACA VV DD I I CSCS Around 250 ml customers all around Europe Potential of Tons of thermoplastics Dow can be present with Engineering thermoplastic business comprising energy liberalisation & true billing Huge potential (all households needing a meter) Polycarbonate CALIBRE ABS MAGNUM Specialty compounds EMERGE

10 Concept Analysis CSCS CACA VV DD I I Requirements for Success based on analysis of the international standard, utilities specification and design constrains CACA Housing material is specified by IEC /53-23 standards for High heat resistance High flammability resistance ( UL94, GWT) High mechanical resistance Utilities/Design requirements: Halogen free due to (WEEE Waste E&E equipments) Rohs (Restriction of Hazardous Substances) Compatible with vibration/laser welding

11 Concept Analysis Vertical Burn Test (UL94, IEC 707, DIN VDE 0304) Glow wire test (IEC ) V-0 V-1 V-2 Flame time (t1, t2) 10s 30s 30s Total flame time (t1+t2)* 50s 250s 250s Glow time 30s 60s 60s Particles ignite cotton? no no yes Environmental Regulation WEEE : Requirements for separate handling of Br- waste RoHS : Ban of Penta-/Octa- BDPE as of 2006

12 Validation CSCS CACA VV DD I I Analyze the possibilities. Best Fit Design Concept chosen. Critical Issues resolved. Draft Business Model. VV DOE Different technologies Lab samples Cost analysis S t r e s s - S t r a i n C u r v e f o r P o l y s t y r e n e Optimized Mechanical, Flammability Properties and processability Halogen Free IR Technology 10% Glass Filled PC. Glass Type Mould Release Package Colour Formulation 5500 Continuous Phase, G.P Stress, PSI Yield Stress After Yield Impact Material Rupture Strain Energy % Elongat Elastic Plastic Initial Modulus Strain %

13 Development CSCS CACA VV DD I I Detailed Design completed. All Issues resolved Business Plan created Development customer(s) is/are committed to buy. DD Scale up trial Internal test External Trials Best process condition Process optimization: Different Hot runner system evaluated Best process condition identified Formulation optimization

14 Implementation CSCS CACA VV DD I I Implementation and Transition of the Business Plan to operations. Customer affirm the offering, meets the requirements and purchases the offering. I I Melt Flow Rate, 300 C/1.2kg Mechanical Properties Tensile Strength at Yield (50 mm/min) Tensile Strength at Break (50 mm/min) Tensile Elongation at Break (50 mm/min) Test Method ISO 1133 ISO ISO ISO EMERGE g/10 min 65 MPa 50 MPa 9 % Tensile Modulus (1 mm/min) ISO MPa Notched Izod Impact, 23 C ISO 180/A 9 kj/m 2 Thermal Properties Deflection Temperature Under Load 1.8 MPa, unannealed ISO 75- A 133 C Vicat Softening Point 120 C/hr, 10N ISO 306A C Ball Indentation Temperature IEC >130 C Flammability UL mm UL94 V-0 Glow Wire Temperature, thickness IEC C

15 Global Execution Dow presence along the value chain Indust. Design Dept. Mech Design Dept. Indust. Dept. Contractor Assembling Company Molders Calibration Company Design/Meter Development, EUROPE Manufacturing, EUROPE ASIA

16 Commitment to new development and collaboration Plastics Aesthetic Material Costs Innovation science Meter manufacturing, design company Utilities Market Market Fabrication technologies Legislation

17 Conclusion Commitment to the meter market: Development of EMERGE PC 8701 able to fulfill International standard requirements Translate standard in material solution, Understanding of International Standard and different utilities specifications Ability to develop different resins according new specifications and standards, exploration of new applications Participation in other smart meter implementation projects all around the world Provide cost effective resin solution for your industry