Development of ignition resistant thermo-plastic for meter design application

Giacomo Parisi, Dow Chemical

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

Who we are?

� Our VisionTo be the largest, most profitable and most respected chemical company in the world.

� Our MissionTo constantly improve what is essential to human progress bymastering 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

Dow Products in the market

Building Maintenance and Construction

Transportation

Furniture and Furnishings

Paper and Publishing

Home Care and Improvement, Personal and Household C are

Food, Health and Medicine, Water purification

Energy and Hydrocarbons

Dow in Energy market: innovation, solution and products

� Dow and GM Hydrogen Fuel Cell Project

� Incorporation of photovoltaic in residential buildi ng material

� Wire and Cable business providing innovative soluti on for Energy transmission

� Dow Building Solution business takes part in the w orld’s third largest solar power plant

� Engineering Thermoplastic business provides plastic for Smart meter housing

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 To ns 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 compan ies

� Deep knowledge : from early development (specification evaluation and design stage) to manufacturing

Dow in the meter market: Development of Emerge ® PC 8701

International standard

Utilities spec

Meter design/manufacturing company

Material requirements

Material choice

IEC 62052-11/53-23

Emerge PC 8701

Industrial design:esthetic, color, surface,

shape

Mechanical design:Strength, wall thickness,

mold configuration

ManufacturingWelding technology:

Laser/vibration weldingGlobal availability

Major ItalianEnergyDistributor

Development process

CACACSCS VV DD I I

Concept Shaping

Concept Analysis

Validation Development Implementation

Realization

Requirements for Success

Best Fit

Design Concept chosen

Detailed Design completed

All Issues resolved

Business Plan created

Implementation and Transition of the Business Plan to “operations”

Hypothesis of Business Opportunity

CSCS

Concept Shaping

CACACSCS VV DD I I

energy liberalisation & true billingHuge potential (all households needing a meter)

Around 250 ml customers all around Europe

Potential of 50000 Tons of thermoplastics

Dow can be present with Engineeringthermoplastic business comprising

Polycarbonate CALIBRE®

ABS MAGNUM®

Specialty compounds EMERGE®

CACA

Concept Analysis

Requirements for Success based on analysis of the international standard, utilities specification and design constrains

Housing material is specified by IEC 62052-11/53-23 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

CACACSCS VV DD I I

� Vertical Burn Test (UL94, IEC 707, DIN VDE 0304)

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

� Glow wire test (IEC 60695-2)

Concept Analysis

� Environmental Regulation

WEEE : Requirements for separate handling of Br- waste

RoHS : Ban of Penta-/Octa- BDPE as of 2006

VV

Validation

Analyze the possibilities.Best Fit Design Concept chosen.Critical Issues resolved.Draft Business Model.

CACACSCS VV DD I I

Optimized Mechanical, Flammability Properties and processability

•Halogen Free IR Technology•10% Glass Filled PC.•Glass Type•Mould Release Package•Colour Formulation

•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

Continuous Phase, G.P.

5500 3000

Yield

Impact Material

Rupture

Stress After Yield

Strain Energy

Plastic

% Elongation

Elastic

Initial Modulus

Strain %

Stress, PSI

1 2 3 4

DD

Development

Detailed Design completed.All Issues resolvedBusiness Plan createdDevelopment customer(s) is/are committed to buy.

CACACSCS VV DD I I

•Process optimization:Different Hot runner system evaluatedBest process condition identified

•Formulation optimization

•Scale up trial•Internal test•External Trials•Best process condition

I I

Implementation

Implementation and Transition of the Business Plan to “operations”.Customer affirm the offering, meets the requirements and purchases the offering.

CACACSCS VV DD I I

960°C IEC 60695-2-10

Glow Wire Temperature, 1.0-3.0 thickness

V-0UL94UL94 Classification @ 1.5 mm

Flammability

>130°CIEC 60335-1

Ball Indentation Temperature

155°CISO 306A120

Vicat Softening Point120°C/hr, 10N

133°CISO 75-A

Deflection Temperature Under Load1.8 MPa, unannealed

Thermal Properties

9 kJ/m2

ISO 180/A

Notched Izod Impact, 23°C

3950 MPa ISO 527-2

Tensile Modulus (1 mm/min)

9 %ISO 527-2

Tensile Elongation at Break (50 mm/min)

50 MPaISO 527-2

Tensile Strength at Break (50 mm/min)

65 MPa ISO 527-2

Tensile Strength at Yield (50 mm/min)

Mechanical Properties

8 g/10 min

ISO 1133

Melt Flow Rate, 300°C/1.2kg

EMERGE 8701

Test Method

Global Execution

� Dow presence along the value chain

Contractor

Design/Meter Development, EUROPE Manufacturing, EUROPE ASIA

Molders

AssemblingCompany

CalibrationCompany

MechDesignDept.

Indust.DesignDept.

Indust.Dept.

Material science

Fabricationtechnologies

Aesthetic

Market

Plastics

Market

Utilities

Legislation

Costs

Meter

manufacturing,

design companyInnovation

Commitment to new development and collaboration

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