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INSIDE20 Connectors & Cords

24 Quality & Standards

27 Prototyping

32 Excellence In Design

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CONTENTS JUNE 2015 volume 63, no. 06

DEPARTMENTS

4 Editorial: Emergence Theory 5 Shipments/Forecasts 6 Making It: Forging 8 News Watch 47 New Products 54 MUST SEE products & services 56 Association Report: CEA 57 Advertisers’ Index

FEATURES

CONNECTORS & CORDS20 Connector Evolution

Impacts Appliance Designs Connectors are frequently an

underappreciated aspect of an appliance design.

QUALITY & STANDARDS24 Energy Star Launches

Standard for Dryers New Energy Star certified clothes dryers

must be at least 20 percent more efficient.

PROTOTYPING27 How to Leverage Additive

Manufacturing to Build Better Products 3-D printing technologies for prototyping

and production.

EXCELLENCE IN DESIGN32 And The Winners Are… The results of appliance DESIGN’s 28th

annual Excellence in Design Awards.

WEB EXTRASOvercoming Thermal Cycling with Distinct AdhesivesBe specific about materials being joined. Adhesives for thermal cycling aim at stress-sensitive devices, ensure joint and bond strength while bonding metal and fiber-reinforced composites.

See photo galleries from the floors of the latest trade shows!

appliance DESIGN ONLINE



E-NEWSLETTERSSign up for appliance DESIGN’s semi-monthly e-newsletter, “Plugged In” at www.applianceDESIGN.com/enews

SOCIAL MEDIAConnect with appliance DESIGN on:

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BLOGS

White Goods in Russia—as depressing as the country itself?

WEB EXTRAS

BLOGS

COVER

Excellence in Design Awards. The voting is done and the winners have been selected for the 2015 Excellence in Design Awards. Source: appliance DESIGN archives

20 24

31

28TH ANNUAL

AWARDS

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The most romantic way I have ever heard Chaos Theory described is, “there are patterns, and even great

beauty, in seemingly chaotic events.” Formally, Chaos Theory is defined as a sub-discipline of mathematics that studies complex, or dynamic, systems.

These complex systems contain so many moving parts that it takes computers to calculate and model all of the movements of the system. In fact, it has been said that the emergence of this theory could not have happened without the invention and proliferation of the computer.

Up until what is called the Quantum Mechanical Revolution, “people believed that things were directly caused by other things.” In Latin it is referred to as post hoc ergo propter hoc, or after, therefore, because of it. In essence, if one thing follows another, it must have been caused by it.

It is the basis of Freudian psychoanalysis, “a belief that malfunctions in the mind are the results of traumas suffered in the past” and that Regression Therapy—pinpointing when and how these traumas occurred—would allow us to heal. It is called linear cause and effect.

Chaos Theory, however, tells us that it is less about linear effect and more the existence and production of patterns caused by many different forces, the most important of which are initial conditions, popularly referred to as The Butterfly Effect.

The Butterfly Effect posits that the flapping of a butterfly’s wings in South America could affect the weather in Texas, meaning that the smallest, seemingly inconsequential part of a system can have a huge effect on all the other parts. Simply

said, “Unless all factors can be accounted for, large systems would be impossible to predict with total accuracy because there are too many unknown variables to track.”

From the study of Chaos Theory comes Emergence Theory, described by Karen Tesson for Inclusion Research as “systems, which are fundamentally chaotic, or complex, [that] have the capacity to produce patterns that are seemingly non-chaotic and predictable in behavior.” These theories have helped us understand simple, or everyday, phenomena such as water boiling on a stove and complex events such as how birds migrate, how vegetation spreads and the structure of stars in the night sky, but its origins stem from the study of weather systems.

For the appliance industry and others the phenomena is the electron. When first discovered, the electron was considered inconsequential because no one seemed to know what to do with it or what its discovery meant or could do for us. In studying the patterns of the chaos of its interactions, we now have an entire world that is run by electronics. And it will only get grander.

This month’s appliance DESIGN Association Report by Shawn DuBravac, chief economist of the Consumer Electronics Association (CEA), describes our “digital destiny” and the arrival of The Internet of Things. And take a cue from Emergence Theory and do not overlook the seemingly simple in your designs, such as connectors and cords for ever-growingly sophisticated interfaces and complex systems with David Erickson’s article, “Connector Evolution Impacts Appliance Designs.”

Enjoy and thanks for reading!

EDITORIAL

Emergence TheoryFrom the simple comes the complex;

from the chaotic, great understanding.

volume 63, no. 06

by Darryl Seland, Editorial Director


publishing staffDarrell Dal Pozzo (847) 405-4044Group Publisher [email protected]

Darryl Seland (610) 436-4220 x8532Editorial Director [email protected]

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Editorial Advisory Board 2014-2015Joe McGuire . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AHAMPresident

Jill Notini . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AHAMVice President, Communications & Marketing

Francis Dietz . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AHRIVice President, Public Affairs

Bob Brown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Branson UltrasonicsVP Marketing & Sales North America

Bill Romick . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .DNA Group, Inc.VP, Business Development

Richard Watson . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Essential-Design

Steven J. Vaccaro . . . . . . . . . . . . . . . . . . . . . . . . . .Henkel CorporationFocus Segment Marketing Manager Derek Silva . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IntertekDirector, Marketing Communications

Pat Blanc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Lydall

John Davis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Traulsen

Brian Ferriol . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ULGlobal HVAC/R Business Development Manager

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www.applianceDESIGN.com applianceDESIGN June 2015 5

Product April-15 April-14 %Chg YTD 2015 YTD 2014 %ChgMAJOR APPLIANCES (Thousand of Units)All Major Appliances 7,361.30 7,608.70 -3.30% 17,551.30 17,324.10 1.30%Cooking-Total 1,907.60 1,675.60 13.80% 4,652.50 4,196.40 10.90%Electric Cooking - Total 548.7 500.7 9.60% 1,252.80 1,192.50 5.10% Electric Ranges 442 395.1 11.90% 983 929.9 5.70% Electric Ovens 72.7 72.9 -0.20% 182.6 178.2 2.40% Surface Cooking Units 33.9 32.7 3.90% 87.3 84.4 3.40%Gas Cooking - Total 307.1 290 5.90% 727.4 708.7 2.60% Gas Ranges 265.2 250.8 5.80% 619 606.4 2.10% Gas Ovens 2.7 3.2 -14.90% 7.1 8.1 -12.60% Surface Cooking Units 39.1 36 8.60% 101.2 94.2 7.40% Microwave Ovens 1,051.90 884.9 18.90% 2,672.30 2,295.20 16.40%Home Laundry - Total 1,606.00 1,606.30 0.00% 3,628.20 3,697.00 -1.90% Automatic Washers 884.5 883.4 0.10% 2,032.40 2,059.80 -1.30% Dryers - Total 721.6 722.9 -0.20% 1,595.80 1,637.20 -2.50% Electric 597.3 597.7 -0.10% 1,311.70 1,339.40 -2.10% Gas 124.3 125.2 -0.70% 284.1 297.8 -4.60%Kitchen Clean Up - Total 1,325.90 1,322.80 0.20% 3,440.10 3,470.80 -0.90% Disposers 639 646.9 -1.20% 1,781.40 1,825.20 -2.40% Dishwashers - Total 683.7 672.2 1.70% 1,649.90 1,636.20 0.80% Built-In 678.1 666.8 1.70% 1,635.20 1,623.40 0.70% Portable 5.6 5.4 3.90% 14.8 12.8 15.10% Compactors 3.2 3.7 -12.10% 8.7 9.4 -7.20%Food Preservation - Total 1,057.90 1,072.90 -1.40% 2,492.10 2,426.10 2.70% Refrigerators 6.5 & Over 882.7 885.8 -0.40% 2,067.00 1,997.50 3.50% Freezers - Total 175.2 187.1 -6.40% 425.1 428.7 -0.80% Chest 119 124.7 -4.50% 275.1 279.1 -1.40% Upright 56.2 62.4 -10.00% 150 149.6 0.30%Home Comfort - Total 1,463.90 1,931.20 -24.20% 3,338.40 3,533.70 -5.50% Room Air Conditioners 1,200.30 1,735.90 -30.90% 2,895.90 3,143.00 -7.90% Dehumidifiers 263.6 195.3 35.00% 442.5 390.6 13.30%

SHIPMENTS

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

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).FORECASTS

MAJOR HOME APPLIANCES – Shipments(Thousands of Units)

Qtr: 2014 2015 20161 15986.6 17551.3 18235.82 18763.5 19082.4 19864.93 16531.8 17077.3 18136.14 16199.3 16976.9 18182.2For 2014, a 5.5% increase to 67.481 million unitsFor 2015, a 4.8% increase to 70.688 million unitsFor 2016, a 5.3% increase to 74.419 million unitsData Source: AHAM Forecast Source: Delano Data Insights

DIGITAL TELEVISIONS – Shipments(Thousands of Units)

Qtr: 2014 2015 20161 5597.3 5496.6 5424.12 5708.9 5657.6 5561.43 5440.0 5075.5 4928.34 19546.3 18158.2 17341.1For 2014, a 7.4% decline to 36.292 million unitsFor 2015, a 5.2% decline to 34.388 million unitsFor 2016, a 3.0% decline to 33.355 million unitsData Source: CEA Forecast Source: Delano Data Insights

MICROWAVE OVENS – Shipments(Thousands of Units)

Qtr: 2014 2015 20161 2118.4 2672.3 2685.72 2432.6 2508.0 2590.83 2673.1 2731.9 2783.84 2658.6 2698.5 2819.9For 2014, an 8.0% increase to 9.883 million unitsFor 2015, a 7.4% increase to 10.611 million unitsFor 2016, a 2.5% increase to 10.880 million unitsData Source: AHAM Forecast Source: Delano Data Insights

RESIDENTIAL ELECTRIC WATER HEATERS – Shipments (Thousands of Units)

Qtr: 2014 2015 20161 1097.7 1205.2 1251.02 1063.0 1134.2 1198.83 970.0 1005.9 1069.34 1146.7 1186.8 1253.3For 2014, a 6.7% increase to 4.277 million unitsFor 2015, a 6.0% increase to 4.532 million unitsFor 2016, a 5.3% increase to 4.772 million unitsData Source: AHRI Forecast Source: Delano Data Insights

DISHWASHERS – Shipments(Thousands of Units)

Qtr: 2014 2015 20161 1511.1 1649.9 1715.92 1757.3 1862.7 1955.93 1819.7 1907.0 2010.04 1877.2 1965.4 2093.2For 2014, a 9.6% increase to 6.965 million unitsFor 2015, a 6.0% increase to 7.385 million unitsFor 2016, a 5.3% increase to 7.775 million unitsData Source: AHAM Forecast Source: Delano Data Insights

ROOM AIR CONDITIONERS – Shipments(Thousands of Units)

Qtr: 2014 2015 20161 2924.9 2895.9 3032.02 2793.3 2907.8 3053.23 228.4 263.8 272.54 66.1 73.4 76.7For 2014, an 11.2% decline to 6.013 million unitsFor 2015, a 2.1% increase to 6.140 million unitsFor 2016, a 4.8% increase to 6.434 million unitsData Source: AHAM Forecast Source: Delano Data Insights

Note: Forecasts begin in Q2/2015 for all data series except for ‘Residential Electric Water Heaters’ which begin in Q1/2015.

For the most up-to-date information, visit www.applianceDESIGN.com.

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MAKING IT

Forging is a major process in metal forming, sometimes utilizing archi-tectural-scale machines for pound-

ing metals into shape. It is not only a method of forming metal, it also produces a change in its physical properties, result-ing in enhanced strength and ductility. In its simplest manual form—open-die forg-ing—it involves a chunk of metal being heated to just above its recrystallization temperature and then being formed into shape by repeated blows with a hammer, as performed by a traditional blacksmith.

Movement of the work piece is the key to this method. In its more industrial incar-nation, it incorporates several variations, including hot and cold forgings.

Closed-die (or drop) forging involves a very similar process to that of the open-die method described above. In this instance, however, the shaped hammer is held in a machine and repeatedly dropped onto the metal, which sits in a shaped die. The shape of the two parts determines the formed shape. Drop forging can be either hot or cold. The hot form involves the blank metal being heated, and results in stronger components due to the realign-ment of the grain.

Press forging involves a heated bar being slowly squeezed between two rollers, which form the metal as it is fed through. Upset forging is used for shaping the ends of the rods by compressing them as they are held in the die. Typical products produced by

upset forging are nails or bolts. <

by chris lefteri

POSITIVES:One of the main reasons for choosing forging is

for the control it gives over the grain structure in the metal. It allows for the grain flow to be aligned to specific shapes, making the part stronger and more ductile.

No gaps or voids occur in the metal, as they can in die casting and sand casting.

Less waste than with runners and sprues.

NEGATIVES:Forged parts often require machining to remove

the excess metal that is left when the two halves of the die are brought together.

QUICK GUIDEVolume of productionFrom simple hand forgings up to about 10,000 units.

Unit price vs. capital investmentIn hot open-die forging, done by hand, the cost is based on the skilled manual labor. In automated methods, tooling costs can be very high.

SpeedQuite slow, which is partly due to the fact that 90 percent of all forging processes are hot processes, so that the work pieces need to be heated before forming.

SurfaceForged parts will generally need to be machined in order to achieve a good, smooth surface and to remove flash, which is the result of metal being squeezed out into a flat web around the outside of the part.

Types/complexity of shapeThe type of forging process will dictate the complexity and type of shape that is possible. In drop forging, draft angles are generally required, and parting lines need to be designed in order for complex shapes to be formed. Draft angles vary and are dependent on the type of metal used.

ScaleForging can be used for parts that weigh from just an ounce or so to those reaching half a ton.

TolerancesHigh tolerances are difficult to achieve, partly due to the wearing of the die. Different metals offer a range of tolerances.

Relevant materialsWith hot forging, most metal and alloys can be formed. However, the ease with which they can be forged varies enormously.

Typical productsBecause of the increased strength of forged components (compared with cast metals), a large number are used in aircraft engines and structures. Other applications include hand tools such as hammers, wrenches and spanners, and swords—notably Samurai swords.

Similar methodsPowder forging. Impact extrusion and rotary swaging are both forms of forging.

Sustainability issuesThe increased strength the material acquires during forging can increase the durability and lifespan of the final product.

However, the heated forging techniques consume high amounts of energy, which increases emissions and subsequent effects on the environment. In addition, a significant amount of excess metal is produced, and secondary machining and further energy use is required to trim it. Fortunately this excess can be recycled.

Further informationwww.forging.orgwww.iiftec.co.ukwww.key-to-steel.comwww.kingdicktools.co.ukwww.britishmetalforming.com

This bi-monthly series features entries from the well-known designer’s handbook, Making It: Manufacturing Techniques for Product Design, 2nd Edition, published by Laurence King Publishing at www.laurenceking.com. Each column describes a material used in design and/or the processes for its use.

FORGINGWITH OPEN- AND CLOSED-DIE (DROP),

PRESS, AND UPSET FORGING.

Chris Lefteri is an internationally recognized authority on materials and their application in design.

He has published eight books on design and material innovation, and his design firm has worked with Fortune 100 companies and major design studios across the Northern Hemisphere. Visit www.chrislefteri.com

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NEWS WATCH

ARLINGTON, VA — A House of Representative’s subcommittee hearing, “Patent Reform: Protecting America’s Innovators and Job Creators from Abusive Patent Litigation,” presented an urgent and powerful case for fixing our broken patent system, the Consumer Electronics Association said in a press release.

One entrepreneur, TMSOFT CEO and CEA member Todd Moore, described how a patent troll almost ruined his business with a frivolous lawsuit.

“The patent troll business is low risk and high reward. The trolls are destroying small businesses while offering society absolutely no benefit,” said Moore.

Moore went on to dismiss the patent troll lobby’s claim that reform would hurt small businesses, stating, “This is nonsense. What harms me is that litigation opportunists are exploiting the patent system. The only way to protect real inventors is for Congress to reform the patent system so it works as intended.”

Gary Shapiro, president and CEO of CEA, reaffirmed his support for patent reform and the Innovation Act saying, “One reason people innovate in America is because we have

taken such a strong stand in fighting bribery and extortion.

Yet extortion is exactly what businesses across the county

face from patent trolls. These trolls use threats of lawsuits

to demand money from job-creating small businesses — an

abuse of our patent system that costs our economy $80 billion

a year, and prevents our innovators from hiring workers and

developing new products. Our nation is better than this — we

can’t simply allow patent abusers to cripple job creators with

their legal extortion racket.

“Some say comprehensive reform isn’t needed and will

weaken the patent system. The truth is trolls are harming

small and large businesses across our nation, handcuffing

innovation through extortion. The only ones who claim

reform isn’t needed are those who benefit from the current

unbalanced system. I commend Chairman Goodlatte,

Chairman Issa, Ranking Member Nadler and the members of

the subcommittee who support this overdue and common-

sense reform. I urge that it be brought to the House floor and

passed as soon as possible.” <

CEA Commends House IP Subcommittee for Taking on ‘Patent Trolls’

CEA, CEDIA AND INFOCOMM RELEASE JOINT ARCHITECTURAL DRAWING SYMBOLS STANDARD

INDIANAPOLIS — The Consumer Electronics Association, Custom Elec-tronic Design and Installation Associa-tion’s R10 Residential Systems committee and InfoComm International announced the publication of ANSI Standard J-STD-710 Audio, Video and Control Ar-chitectural Drawing Symbols.

This new standard defines a common set of blueprint icons that represents all facets of pre-wire and installation of elec-tronic systems, products and devices in residential and commercial environments.

“This is a milestone for the industry, since there has been a huge void in sym-bols representations for the low-voltage industry,” said Walt Zerbe, chairman of CEA’s R10 Residential Systems Com-mittee. “This was an important cross-industry/association effort among CEA, CEDIA and InfoComm that gives this standard even more weight and value. I’m excited it’s complete, released and ready for adoption.”

“Any integrator will tell you that a proj-

ect is easier when technology is part of the discussion from the start,” said Dave Tkachuk, an engineer at Symbol Logic and CEDIA volunteer. “The architectural blueprint icons will help foster the con-versations among integrators and indus-try partners including architects, build-ers and interior designers. These icons will help them make informed decisions about including technology, while they’re in the planning stages of a project.”

“AV floor-plan symbols simply repre-sent complex technology,” said Dr. Walter P Black, senior consultant, VidCAD LLC, and InfoComm International volunteer. “It’s as if a symbolic language can now be spoken between U.S. and international integrators, consultants, architects, engi-neers and owners — one that is endorsed by ANSI and U.S. National CAD Stan-dards V6.”

The recently-published standard is available free of charge through Tech-Street and the CEDIA Resource Library. CEA, CEDIA and InfoComm will also soon release icons that can be used in Mi-crosoft Visio, AutoCad, and other draw-ing programs.

AHAM URGES DOE TO PULL PLUG ON PROPOSED DISHWASHER ENERGY STANDARD

WASHINGTON, DC – The Association of Home Appliance Manufacturers urged the Department of Energy to suspend a dishwasher energy efficiency regulation from proceeding until adequate technical and economic analyses are complete.

“It is unprecedented that the U.S. De-partment of Energy would promulgate a major energy conservation standard without substantial technical and eco-nomic evidence and input from exter-nal groups including the manufacturing industry,” said AHAM President Joseph McGuire.

“The home appliance industry has been at the table alongside DOE and energy efficiency advocates for every appliance standards rulemaking since NAECA was signed in 1987. The energy conservation standard DOE has proposed, as it stands, will threaten the existence of popular and energy efficient models of dishwashers installed in millions of U.S. households today,” he added.

According to AHAM’s analysis, under

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NEWS WATCH NEWS WATCH

the new standard, it would take consum-ers twenty years to recover added product cost through electric utility savings, lon-ger than the estimated product life. It is possible that over 70 percent of consum-ers would actually experience a net finan-cial loss when purchasing a product that meets the proposed levels. For manufac-turers, DOE itself estimates the dishwash-er industry’s value to decrease up to 34.7 percent due to the increased investment costs. And AHAM’s analysis, based on data from manufacturers, estimates that the value could decrease by as much as 80 percent.

The benefit to the environment does not justify the additional cost to consum-ers and manufacturers. AHAM’s analysis shows that the proposed standard levels result in a national energy savings of less than 0.6 quads, the threshold for a prod-uct to even be eligible for a national ef-ficiency standard. According to AHAM’s analysis, DOE’s forecasting models show water usage would actually increase by some 63 billion gallons due to product impact and altered consumer behavior in pre-rinsing dishes.

McGuire stated, “As a result of DOE’s rush to judgment, the proposed dish-washer energy and water efficiency stan-dard is neither technically nor economi-cally justified. DOE chose not to obtain current economic or technical informa-tion from product manufacturers regard-ing their ability to produce products to meet the standard without jeopardizing product functionality. AHAM believes that it is vital that DOE reopen the rule-making process to undertake the type of data gathering from experts it normally conducts.” DOE has indicated that fur-ther review may be required.

DOE has relied on outdated and incor-rect product costs, energy consumption, product life cycles and performance char-acteristics. For example, one result of the rule will be to increase the length of the dishwashing cycle if dishwashing tem-peratures and mechanics are decreased to meet stringent energy conservation stan-dards.

At the proposed efficiency levels, AHAM believes that consumers, who expect optimum performance, may be

more likely to select cycles other than the “normal” cycle, which is the cycle used to rate a product’s energy and water use. The result would be more energy or wa-ter use and thus DOE’s projected energy and water savings would be lost. In addi-tion, consumers could choose to run the dishwasher more than once, or pre-wash dishes by hand to reach the desired level of cleanliness which would also negate DOE’s projected energy savings. More-over, AHAM believes that wash perfor-mance could well suffer at the proposed levels and has urged DOE to undertake more rigorous analysis to ensure that consumers will continue to receive the cleaning performance they expect.

WOHLERS ASSOCIATES PUBLISHES 20TH ANNIVERSARY EDITION OF ITS INDUSTRY REPORT

FORT COLLINS, CO — Wohlers As-sociates, Inc., a consulting firm and au-thority on additive manufacturing and 3D printing, announced the publication of the Wohlers Report 2015.

The annual publication has served as the undisputed industry-leading report on the subject for two decades. Over the 20 years of its publication, many have re-ferred to the report as the “bible” of ad-ditive manufacturing and 3D printing — terms that are used interchangeably.

The market for additive manufactur-ing, consisting of all AM products and services worldwide, grew at a compound annual growth rate of 35.2 percent to $4.1 billion in 2014, according to Wohlers Report 2015. The industry expanded by more than $1 billion in 2014, with 49 manufacturers producing and selling in-dustrial-grade AM machines. The CAGR over the past three years (2012–2014) was 33.8 percent.

Wohlers Report 2015 provides an in-depth review and analysis of the in-dustry worldwide. It includes growth, competitive products and services, and the future outlook for the industry. The comprehensive study covers all aspects of AM and 3D printing, including its his-tory, applications, processes, materials, and equipment manufacturers. It covers developments in R&D, investment and

collaborative activities in government, academia, and industry, and summarizes the state of the AM industry around the world.

Wohlers Associates reports that growth occurred in all segments of the diverse industry, including the low-cost desktop 3D printer segment. The use of indus-trial metal AM systems for demanding production applications in the aerospace and medical markets also grew strongly. The report thoroughly documents the increasingly rich range of technologies, markets, and business models that are emerging within the industry.

“The first Wohlers Report was pub-lished in April 1996,” said Terry Wohlers, principal consultant and president of Wohlers Associates. “It was 40 pages in length and represented the first-ever pub-lished analysis of the industry worldwide. The AM industry represented a mere $295 million in 1995. A lot has changed in 20 years, and we’ve worked hard to document this change. I am proud to say that no other publication comes close to matching the depth and breadth of data and market analysis that is found in our annual report.”

Wohlers Report 2015 is an informa-tion-rich 314 pages, and includes 39 charts and graphs, 63 tables, and 279 im-ages and illustrations. The report, which sells for $495, was developed with sup-port from 87 service providers, 40 system manufacturers, and the valuable contri-butions of 78 co-authors in 31 countries.

ABOUT 50 PERCENT OF BROADBAND HOUSEHOLDS HAVE SECURITY CONCERNS ABOUT SMART HOME DEVICES

SAN FRANCISCO — Research firm Parks Associates reported 47 percent of U.S. broadband households have privacy or security concerns about smart home devices. The connected home industries need to formalize strategies, such as con-sumer privacy rights, in order to push these markets forward, according to Parks Associates.

“Recent high-profile media reports of hacks into smart baby monitors and con-nected cars, whether valid or not, have


NEWS WATCH

heightened consumer concerns over pri-vacy and security for connected home systems,” said Tom Kerber, director of re-search, home controls and energy, Parks Associates. “Companies need to move quickly to reinforce the security of their solutions as well as ensure the consumer’s right to privacy.”

The consumer research finds that if firms offer a bill of rights to consumers, specifically the rights to be invisible, to ap-prove who uses the data, and to be erased, these efforts could ease concerns for nearly three-fourths of U.S. consumers.

“Finding the right balance between ease-of-use and security is a challenge in designing and deploying smart home products,” said Maia Hinkle, research analyst, Parks Associates. “Consumers do not want to have to enter a password just to turn on a light, so the market needs so-lutions that are cross-platform and user friendly. Consumers expect convenience and control both with their smart devices and the data that the devices produce.”

GE’S FIRSTBUILD MEGA HACKATHON ANNOUNCES WINNERS

LOUISVILLE, KY — FirstBuild, a glob-al co-creation community, announced the winners of its 33-hour Mega Hack-athon: Hack the Home challenge, the biggest hackathon related to home appli-ances ever.

Teams of more than 200 makers, de-signers and engineers converged at First-Build’s microfactory in Louisville, to hack and build major appliance innovation for the home of the future. More than $60,000 in cash and other prizes were awarded.

Ideas ranged from hands-free refrigera-tor doors to a kitchen cabinet greenhouse. Designs were judged by representatives from FirstBuild and the Mega Hack-athon’s more than 30 sponsors including Atmel, AT&T, Delta, Renesas, Texas In-struments and hackster.io.

With access to advanced manufactur-ing tools such as 3D printers, laser cutters, water jets, ShopBots and HandiBots, the

teams hacked GE appliances to conceive and create innovation. Fueled by music, food and caffeine, the teams’ ingenuity was evident in creations like a refrigera-tor inventory system, an automated pasta cooker controlled with an app, and a rug-ged microwave powered off a car battery.

FirstBuild is an online community of engineers, designers, makers and home enthusiasts dedicated to conceiving, co-creating, and building the next generation of major home appliances. Participants identify market needs, directly participate in the product development and watch via social media as ideas speed from mind to market.

First-place winners were Rob Lewis, Joshua Longenberger, Ali Faraji-Tajrishi, Nick Dillon and Rick Suel. The winners adapted a conventional GE wall oven to roast coffee precisely using an Arduino control. Their invention, House Roast, adjusts the oven temperature automati-cally to mimic the professional roasting of coffee beans.

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LG Electronics was recognized by the U.S. Environmental Protection Agency with the 2015 Energy Star Partner of the Year — Sustained Excellence Award for continued leadership in protecting the environment through energy efficient consumer electronics and home appli-ance products. LG also earned the 2015 Energy Star Partner of the Year — Cli-mate Communications Award for efforts to raise consumers’ awareness of the im-pact of climate change.

“LG values our partnership with Ener-gy Star, and it’s exciting to see the positive impact LG is making with American con-sumers,” said William Cho, president and CEO of LG Electronics USA. “We’re help-ing consumers experience innovation for a better life by creating products that deliver energy savings without sacrificing performance or style. We are committed, now more than ever, to continuing our work to help reduce greenhouse gas emis-sions and protect the environment.”

“Through their sustained participation with Energy Star, LG is helping Ameri-cans save money, save energy, and do their part to reduce our nation’s greenhouse gas emissions that fuel climate change,” EPA Administrator Gina McCarthy said. “I applaud LG for earning EPA’s highest Energy Star honor, the 2015 Partner of the Year — Sustained Excellence Award, demonstrating a strong commitment to energy efficiency and to preserving a healthy planet for future generations.”

ElectricFilm, LLC announced the launch of a line of proprietary light har-vesting technology solutions that opti-mizes the conversion of any light — from low indoor levels to full daylight — into reliable, sustainable power with better cost and system performance than alter-native methods.

The company’s solutions are capable of capturing extremely low levels of light and are not negatively impacted by shad-ing like other photovoltaic (PV) tech-nologies. Optimized to power a variety of wireless applications in the Internet of

Things, ElectricFilm technology can be tailored to satisfy a wide range of power needs, environments and product design requirements. It is ideally suited for smart building sensors — from thermostats to motion and smoke detectors to electronic locks — as well as motorized window shades and powered retail displays.

“ElectricFilm has optimized the con-version of indoor light to electricity with lower cost and better system perfor-mance than others, eliminating the need for costly hardwiring or battery replace-ment,” said Stuart Spitzer, president, Elec-tricFilm. “Our solutions harvest any light, from natural light through windows to artificial indoor light, to power a number of wireless applications that are all part of the Internet of Things.”

ElectricFilm light harvesting technolo-gy represents the culmination of 25 years of photovoltaic (PV) cell development and advancements. Signifying a break-through as a cost-effective, maintenance-free solution to power smart devices, ElectricFilm is a proprietary PV technol-ogy which harvests light from any direct, reflected, diffused or shaded source (in-cluding sunlight, fluorescent, incandes-cent and LED light) and converts it into a smart, convenient power alternative to hardwiring or disposable batteries. Elec-tricFilm captures low to medium light levels (25 to 50,000 lux) with high effi-ciency, making it ideally suited for indoor environments.

The current is tuned with smart elec-tronic controls to provide output for a wide variety of devices that need wireless power. The result is the ability to install devices anywhere with no wiring costs or maintenance calls, while reducing battery disposal.

EIS, Inc., a subsidiary of Genuine Parts Company, acquired Connect-Air Inter-national, Inc. from Wincove Capital.

Connect-Air is a leading North Ameri-can specialty distributor of low-voltage wire and cable used in critical building ap-plications, primarily HVAC, security and

fire alarm systems. Connect-Air services the United States from seven sales offices and warehouses across the country.

“We are very pleased to bring Connect-Air International into our Genuine Cable Group and the EIS family,” Bob Thomas, chief executive officer of EIS, said. “Con-nect-Air is one of the most successful distributors in the markets they serve and their team has built a tremendous business since 1978. This acquisition will open a new segment of business build-ing opportunity for the Genuine Cable Group and EIS.”

“All of us at Connect-Air International are excited by the opportunities that will be presented by our partnership with the Genuine Cable Group and the EIS family,” Sean McCarthy, president of Connect-Air Wire and Cable, said. “Connect-Air takes pride in our customer service and we be-lieve that the expertise, extensive product offerings and network of locations the Genuine Cable Group provides will greatly enhance our ability to meet or surpass our customers’ expectations. We’ve enjoyed an excellent partnership with Wincove Capi-tal for many years and are well positioned to capitalize on a substantial market op-portunity as part of EIS.”

Toshiba Corporation and United Technologies Corporation plan to establish engineering centers in India, North America and Europe to support global innovation for heating, ventilat-ing and air-conditioning products. This cooperation is the first to result from the companies’ recent agreement to further strengthen their strategic collaboration through their joint venture, Toshiba Car-rier Corporation.

The plan will leverage Carrier’s global footprint, with new engineering centers expected in India, North America and Europe within the next five years. The two companies also agreed on plans to local-ize manufacturing in the same regions in a similar time frame.

Toshiba Corporation is a world-lead-ing manufacturer and provider of electric

BUSINESS NEWS


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and electrical products and systems; and UTC, of which Carrier is a part, is the world’s largest provider of building tech-nologies. TCC was formed in 1999, when Toshiba and Carrier joined forces to bring leading Japanese technology to markets worldwide.

In October 2014, Toshiba and UTC signed an agreement to expand their strategic collaboration that included an outline for enhancing cooperation in HVAC through TCC, targeting to accel-erate growth and aiming to double the unit’s annual revenues in the next decade. The companies will also continue to ex-plore collaboration on smart cities and machine-to-machine solutions.

“I am delighted to see UTC and Toshi-ba proactively forwarding our strate-gic collaboration and shaping up plans in the HVAC field,” said Hisao Tanaka, CEO and president of Toshiba Corpora-tion. “The establishment of joint engi-neering centers and manufacturing will give Toshiba local product development,

manufacturing and sales in key regions, which will increase our global footprint while allowing us to provide customers with greater value through localized solu-tions. At Toshiba, our diverse capabilities range from devices to battery and inverter technologies, and I hope to see this col-laboration in HVAC become an engine that drives future cooperation between Toshiba and UTC and further strengthen ties between us.”

“This agreement is a milestone in the long and successful relationship between United Technologies and Toshiba,” said Geraud Darnis, president and CEO, UTC Building & Industrial Systems. “Through our expanded collaboration, our joint venture is positioned to pioneer new, in-novative and customized solutions for customers around the world.”

The SPI Bioplastics Division named Eastman Kodak the winner of the 2015 Innovation in Bioplastics Award for its

creation of a bio-toner, designed for the electro-photographic printing industry that contains greater than 90 percent bio-based and biodegradable materials. The announcement was made at NPE2015: The International Plastics Showcase, hosted at the Orange County Convention Center in Orlando, Fla.

“The term ‘bioplastics’ has quickly grown to become synonymous with in-novation, and Eastman Kodak’s creation of a bio-toner that is formulated with bio-based and biodegradable materials con-tinues that tradition,” said SPI President and CEO William R. Carteaux. “SPI con-gratulates Eastman Kodak for winning the 2015 Innovation in Bioplastics Award and thanks all of this year’s entrants for their continuing pursuit of new applica-tions for biobased and biodegradable materials and for supporting the expan-sion of choices that plastics manufactur-ers have when it comes to which materials they use in their products.”

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Rochester, N.Y., created its award-winning biobased and biodegradable bio-toner using low-carbon-footprint, naturally-advanced Ingeo resin, which is comprised of polylactic acid and derived from renewable and naturally abundant resources and natural waxes that only contain a small amount of inorganic ma-terial. Having such a high percentage of PLA makes the de-inking process for this material much simpler, and the result-ing waste material that’s leftover contains mostly lactic acid, which Eastman Kodak noted is a useful feedstock for other plas-tics products and stands in stark contrast to typical residue leftover after standard de-inking processes.

According to Eastman Kodak, toner resin worth approximately $1 billion is consumed each year in the printing in-dustry for electro-photographic toners. One third of that goes into chemical toner production of which color toner produc-tion accounts for 98 percent. Bioresins have limited impact in the industry, ac-counting for only 1 percent of color ton-ers and 10 percent of monochrome ton-ers, but developing economically-viable biotoners that can be used at 100 percent incorporation, as Eastman Kodak’s inno-vative biotoner aims to do, can capture greater market share.

“The Innovation in Bioplastics Award was created to draw attention to solutions that are being created by the industry us-ing bioplastics, and to draw attention to companies that are using bioplastics not just as a novelty, but to actually solve real world issues because of their unique functionality,” said Keith Edwards of BASF, chairman of the SPI Bioplastics Di-vision. “Bioplastics isn’t a revolution, it’s an evolution and Eastman Kodak created a biobased toner that’s very innovative. Because it’s going to be used in a wide ar-ray of applications it has the potential to have a huge impact on the marketplace.”

“We congratulate Eastman Kodak be-cause they did something very new and we hope that their success helps other companies look to bioplastics for the so-lutions they can bring,” Edwards added.

According to Eastman Kodak, their biobased toner will be widely available by May or June this year.

The Society of Plastics Engineers, the Plastics Innovation and Resource Center of Penn College of Technology, and Paulson Training Programs, Inc. entered into an alliance to offer plastics resources for educational information, training programs and certifications.

Drawing on its wide reach within the plastics industry, SPE will market this training and certification alliance within the community and will also initiate out-reach programs to attract new members with their first year of premium mem-bership as part of their training and cer-tification packages. Paulson will provide discounts for existing SPE members who attend seminars through their Plastics Academy or onsite training. Penn College brings exclusive North American rights to the premiere Global Standards for Plas-tics Certification (GSPC) program. GSPC is the only recognized method of appren-ticeship certification in the world for the plastics industry. It provides universal recognition of plastics worker’s knowl-edge and capabilities, as well as demon-strated economic benefits to companies.

Those interested in learning more about how to get started, sign up for new membership, or sign up for individual or company training can contact SPE head-quarters for details.

“As a combination of a robust indus-try association, a technical college and a world-class professional training com-pany, this new alliance offers individuals and companies everything they need to know to make the most of their career and business opportunities in the plastics industry,” said Russell Broome, managing director of SPE. “Existing and new mem-bers of SPE and the plastics community at large will benefit by having immediate ac-cess to the outstanding range of resources this new alliance brings.”

The alliance partners have already identified the shortages of skilled worker and of new employees as critical industry challenges that they can help to address. Most plastics processors have ranked lack of enough skilled employees as their number one problem.

“Our alliance with Penn College and SPE is aimed squarely at these issues by providing technical training and by

working to get the next generation of workers interested in plastics as a very lu-crative and exciting career opportunity,” said Craig Paulson, president of Paulson Training. “Our company, for example, has been giving seminars and marketing in-plant training solutions to the plastics industry for over 35 years.”

Paulson will be supplying training in several formats including online, CD-based and seminars through the Paulson Plastics Academy and ProMolder Certifi-cation.

The academic and certification aspect of the alliance will be the specialization of Penn College of Technology, which, along with Paulson and SPE, will be of-fering GSPC certification to all plastics processors throughout North America. Hank White, director of Penn College PIRC, is looking forward to working in this partnership to maximize the number of industry personnel who have a known global certification.

“The GSPC program is designed to give employers the ability to know that the people they are hiring have met certain standards in knowledge and skills,” said Hank White, director of PIRC at Penn College of Technology. “On the employee side, having GSPC certification is a big plus on any resume.”

Broome of SPE cited this example of how the alliance has already served as a resource for an industry company. “Soon after completing the alliance agreement, SPE received a call from a company in California looking for a training program for their injection molding business. SPE referred them to Paulson, and Paulson assisted the company immediately, of-fering the growing business a discount in SPE membership with a purchase of one of their products, and Penn College supplied research information and details about the GSPC certification program.”

The alignment of the three entities couldn’t have come at a more oppor-tune time, according to Broome. “The economy is showing promising growth, especially in the domestic manufacturing sectors, causing more and more compa-nies looking to obtain key industry in-formation and to find qualified skilled people.”<

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Venture Plastics, Inc., a full-service, ISO/

TS-16949-certified custom thermoplas-

tics injection molder with processing

facilities in Newton Falls, Ohio, and El

Paso, Texas, hired Tim Fisher as account

manager.

Fisher brings to Venture Plastics more

than 30 years of industry experience

with extensive knowledge of the business

and technical aspects of the market. His

background includes management-level

positions in product development, sales

and marketing. He has also owned and operated two successful plastics broker-age firms and was most recently technical sales engineer for a plastic recycling and processing company. Fisher is a gradu-ate of the University of Miami with a Bachelor of Science degree in chemistry. He has also completed graduate-level course work in business administration and polymer science.

For more than four decades, Venture Plastics has provided customers with high quality technology and services, including engineering and design sup-port, project management, injection and structural foam molding, over-molding, insert molding, gas-assist molding, dec-orating, plating, assembly, welding, plus expertise in a wide variety of engineered materials with UL traceability.

The Consumer Electronics Associa-tion congratulated Kacie Hackett, spe-cialist, CES conferences, CEA, for being selected as a member of the Professional Convention Management Association’s 2015 class of 20 in their twenties.

The 20 in their twenties program, sup-ported by the Austin Convention and Visitors Bureau and the Austin Conven-tion Center, is designed to engage the best and brightest young professionals in the meetings industry by recognizing emerging leaders — and their talents — which help accelerate the industry and carry it into the future. CEA is the pro-ducer of the annual International CES, the gathering place for the global tech-nology community.

“Kacie’s dedication helps us deliver a top-notch conference program at the In-ternational CES, which has helped CEA set the tone for the convention industry year after year,” said Karen Chupka, se-nior vice president, International CES and corporate business strategy, CEA. “Kacie helps manage the logistics for over 800 speakers and is a rising star at CEA. I’m thrilled to congratulate her for her well-deserved honor.”

Twenty in their twenties applicants

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must be employed full time in the meet-ings industry, be 29 years old or younger and demonstrate ways they consider themselves to be industry leaders. A committee made up of veterans and members of the inaugural class of 20 in their twenties recipients reviewed doz-ens of applications in detail before de-ciding on the inaugural class.

Hackett was recently promoted to spe-cialist of CES conferences as a result of her increasing responsibilities for CES. In this role, she assists in managing CES conference vendors and partners, including respective relationships, to execute conference program logistics at CES. She has worked for CEA for over three years, starting in their internship program after graduating from Ameri-can University in 2011.

Hackett was recognized at the Con-vening Leaders and Education Confer-ence in January, as well as in Convene Magazine and other PCMA communi-cations.

Heidenhain Corporation announces the new hire of two sales executives dedicated to the Etel brand: Andy Mehdi, regional sales manager and Julius Rurangirwa, sales and applications engineer.

Etel’s motors and motion systems are available in North America through parent company Heidenhain Corporation.

Mehdi and Rurangirwa are now posi-tioned to assist North American custom-ers and prospects of Etel products with application information and products as needed. They also serve as a liaison to Etel’s worldwide corporate headquarters in Switzerland.

As a regional sales manager for Etel, Me-hdi is responsible for supporting west coast semiconductor industry customers and is located in San Jose, Calif. Providing Etel’s motion systems, actuators and controllers, Mehdi comes to Heidenhain holding a de-gree from Wichita State in electrical engi-neering. With over 20 years’ experience in the semiconductor field, Mehdi has served in many capacities for related companies

with titles such as manufacturing engineer, product support engineer, corporate trainer and applications engineer, to name a few.

As Heidenhain’s new sales and applica-tions engineer for Etel, Rurangirwa is now responsible for supporting key accounts, serving as a first level of technical inter-face to customers and prospects, as well as providing internal support with relevant market research and presentations. Ru-rangirwa holds two electrical engineering degrees, one from the Milwaukee School of Engineering in Wisconsin and the other from the University of Applied Science in Lubeck, Germany, where he completed his course of studies during a one-year foreign exchange program. He is currently a mem-ber of IEEE.

Etel S.A. is based in Switzerland and is a leading international supplier of direct drive and motion control components and integrated systems. Etel supports high tech industry with linear motors, torque mo-tors, positioning stages, and motion con-trollers/systems.

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Flow International Corporation an-nounced the appointment of David Crewe as senior vice president of en-gineering.

“I am excited to join such a strong team as we push forward in developing next generation waterjet products and technologies,” said Crewe.

Crewe will be responsible for tech-nology development and new product development, and will manage the en-gineering research and development teams globally. As a key member of the Waterjet Holdings leadership team, Crewe will participate in common strat-egy development and execution.

Stratasys appointed Joshua Claman as chief business officer, effective imme-diately.

In this newly created role, Claman will oversee the company’s global sales, service and channel organizations. He will be particularly focused on driving commercial and go-to-market synergies across the company’s different business units, including Stratasys direct manu-facturing and MakerBot. He will report directly to David Reis, CEO of Stratasys.

“I am excited to announce the ap-pointment of Josh Claman as CBO, and am certain that his proven ability to successfully lead complex businesses around the world will bring tremendous value to Stratasys,” said Reis. “As CBO, he will play a critical role in support-ing our strategic initiatives as we work to improve collaboration, customer in-timacy and enhance our go-to-market strategy. We continue to see additive manufacturing being used to transform manufacturing processes across indus-tries and we look forward to benefit-ing from Josh’s significant expertise as we build on our strong track record of growth and execution.”

Claman said, “Stratasys is a respected leader in the 3D printing space with a strong portfolio of solutions and servic-es, and significant future growth pros-pects. I am excited to work with this talented team to solidify the company’s leading position in additive manufac-turing.”

Previously, Claman served as presi-dent of ReachLocal, a global online marketing and advertising solution provider. Prior to ReachLocal, Cla-man spent over 10 years at Dell, where he held a variety of senior positions including VP large enterprise business Americas, VP public sector EMEA, VP channel sales EMEA and GM of

Dell’s UK/Ireland operation. Prior to

that, Claman spent 15 years at NCR,

a computer hardware, software and

electronics company, where he was VP

services, Europe. Claman received a

BA from the University of Illinois and

an MBA from the University of South

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CONNECTORS & CORDS

Connectors are

frequently an

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Appliances incorporate complex electromechanical and electronic systems, and

designers tend to focus on implementing new features in their designs—particularly higher end models. These electronic systems include more sophisticated user interfaces as well as more complex electronic control systems. How those designs electrically connect with each other has a significant impact on manufacturability. New, more advanced connection technologies are being developed for use with some of those features. But the electrical/electronic connector that interconnects these items continues to play a key role in this function. While incorporating the latest consumer-pleasing features in new appliance designs, engineers must also consider issues such as ease of manufacture, space, heat resistance and durability.

Connectors are frequently an underappreciated aspect of an appliance design. In some instances, the basic connector design has not changed in 25 years or more—in spite of manufacturers developing internet-connected and

automatically controlled equipment for the appliance itself.

Consequently, as appliance makers strive to provide more efficient and more easily controlled machines delivering greater functionality, the need for improving reliability has become a high priority for designers. These needs affect every aspect of appliance design including the electrical/electronic interconnection systems.

Power is another primary design concern in appliances. The same connector in the appliance is frequently used for power and signal lines, which means that consolidating the power and signal connection is needed to simplify connectivity and machine assembly. Dealing with the signal aspects of interconnection may be considered rather straightforward, but connector designs that maintain the integrity of these low level circuits over the life of the appliance is no small consideration. At the same time, connector designers are also faced with the challenge of power delivery, since power for pumps and motors requires carrying higher amperage than other

by david erickson

David Erickson is a field application engineer with the appliances business unit of TE Connectivity (TE). David has been

a member of the appliances team at TE for the past 11 years. During his 27-year career

with the firm, he has also been associated with the automotive, aerospace, industrial

and automation controls industries. For more information, email [email protected]

or visit www.te.com.

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CONNECTORS & CORDS

system components.Quick-disconnect electrical connectors

have been around for over 65 years, but they have continued to evolve to support appliance assembly and engineering goals in the latest appliances. Many billions of these terminals are in service today, in applications ranging from appliance to automotive wire harnesses, including high temperature applications, electric motors and power supplies controls. In the appliance design world, connectors must support broad engineering goals as well as industry agency requirements and approvals.

Broad engineering goalsWhile new features are a focus of design

efforts, even the most elegant designs will fail unless they can be manufactured and shipped reliably and at minimal cost. Among the many factors appliance designers consider are three broad criteria:

Simplicity – A design should be easy to assemble. Simpler designs require fewer internal connections and provide adequate space for the assembler to work. Assembly steps should be easily accomplished without strain on the assembler, so they can be quickly repeated many times each day.

Reliability – An appliance must withstand tens of thousands of duty cycles to provide the reliability consumers expect. Internal components must be able to endure heat cycles and vibration.

Size – As appliances become more complex, additional lines of electrical and electronic interconnect are required. While the overall exterior size of an appliance remains much the same, capacity growth becomes a point of differentiation on the retail sales floor. Higher capacity washing machines, greater interiors to refrigeration and freezer compartments and larger oven cavities have become critical in new designs. This means that the available space for interconnections is decreasing with each design cycle.

The role of connectorsSo how do connectors support these

goals? Basically, a connector terminates an electrical connection and allows engineers to design subsystems that can be easily plugged together. In simplest terms, a connector is a conductive piece of metal (an

electrical terminal or contact), sometimes encased in an insulated housing, designed to mate with or accept another conductive piece of metal. But connector designs have evolved to enable better, surer connections that can withstand heat and vibration while being easy to assemble. Some connectors are designed to carry both power and signal, eliminating the need for separate connectors. Some of today’s products support a broad range of wire sizes, from 10 to 24 gage to accommodate both power and signal. Let’s look at some connector engineering challenges and see how evolved connectors are addressing them.

Temperature – Some connector applications call for heat resistance—in the igniter in a gas range, for example, or for a resistive heating element in an electric range. For the connector designer, this means choosing the right materials for housings and terminals. Sometimes it’s a matter of choosing modifications to the alloys used in the terminals, perhaps selecting nickel steel instead of brass. Plastics selected must also withstand high temperatures, up to 250 degrees Celsius. Additionally, many appliance connectors must now withstand glow wire testing to comply with IEC standards.

Space – Appliance designers are dealing with a finite amount of internal space, and continually adding new features means that some subassemblies must get smaller. Connector designers are responding by modifying the size or profile of a connector so it fits into smaller spaces. Quick-connect/quick-disconnect terminals are a case in point; there are different sizes used throughout applications associated with the amount of current these devices must carry. For some time we have had connectors that use a standard size of 110 thousandths of an inch wide, but connector manufacturers now have lowered the connector profile so it’s easier to fit into smaller spaces. Similarly lowered profiles are also offered for standard 187 and 250 series quick-disconnect terminals. Smaller subassemblies make things easier to assemble and maintain. While a lot of subassembly work is done in highly automated operations, connecting those subassemblies together is still very often a manual process.

Space also comes into play with PC board connections. As additional features

are added to control boards, real estate on the board is becoming ever more valuable. Center-to-center pitches of PC board connectors continue to shrink in order to maximize use of the available area. At the same time, new standards have come into existence that require greater spacing on the PC board for line voltage applications.

Ease of use – One key objective is to make connectors easier to assemble, since this greater throughput reduces assembly time and lowers manufacturing costs. When low insertion force connectors are introduced into a manufacturing plant, the assemblers can accomplish their jobs more quickly. Assemblers may make hundreds or even thousands of connections per day, so ease of use is key.

Lowering the insertion force associated with mating electrical contacts plays a very significant role in ease of use. Connector designers are developing modified mating interfaces which reduce the insertion force required while providing additional contact points and better terminal guidance for secure connections. While important for single connections, this reduction in force can be even more noticeable in multi-contact connectors where perhaps 20 or more connections are being made simultaneously.

Improved ease of use also applies to connector and terminal housings. If the appliance uses a quick connect terminal housing with a flat surface that assemblers can press against rather than a sharp-edged or irregularly shaped surface that is more difficult to press against, it makes a difference. Designers also use multi-position connectors with rounded edges

Power Triple Lock connector system plug housings have been designed with a latch that provides an audible “click” when fully engaged in the receptacle housing or header, helping to ensure that the housings are fully mated. Source: TE Connectivity


CONNECTORS & CORDS

because they are easier on fingers and create less drag on other parts of the appliance as the wire harnesses are being pulled through the appliance during assembly.

Another connector feature that impacts ergonomics as well as durability is latch design. In some cases the wires can snag on the connector latch when a connector is pulled through the interior of an appliance during assembly. Newer designs have added guards to the latches to create a more snag-resistant design. This reduces assembly time, relieves frustration on the part of assembly personnel and can reduce unintended breaking of the latches

For durability, connector latches have evolved to be more secure. For many years, connector housings have often incorporated a single latch to hold a mated connector together; however, those latches sometimes lacked sufficient robustness when the connections were subjected to strain, vibration or pressure during assembly, transit or operation. These unintended disconnections were sometimes not detected until the appliance was installed in a home, resulting in an expensive service call.

It sometimes has been difficult for an assembler to realize whether the connectors had latched, as there was no positive feedback provided. Some newer connector designs provide both a tactile indication and an audible click when they latch.

Today, more connectors feature secondary locking devices such as Terminal Position Assurance (TPA) devices to help ensure the electrical contacts are seated in a housing and remain that way, even when under vibration or strain. Additionally, Connector Position Assurance devices (CPA) can be used with the latch on newer connectors to help prevent connections from accidentally coming apart, even under heavy vibration or unintentional pressure on the latch.

In the future, appliance designs will incorporate even smaller connectors, as long as they can handle the amount of power required and as long as they remain easy to assemble.

Changes in connector designs may be incremental, but they still impact ease and cost of manufacturing as well as connection reliability. Designers should choose connectors carefully to support these goals.

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QUALITY & STANDARDS

by ed mcmenamin

Ed McMenamin is the associate editor of appliance DESIGN. He can be reached at

[email protected].

Clothes dryers use more energy than any other home appliance. Yet unlike clothes washers, which use 70

percent less energy than in 1990, the energy use of most dryers has not improved.

The EPA is looking to change that with its first-ever Energy Star standard for clothes dryers, rolled out this year. Manufacturers have responded with more than 45 models that are at least 20 percent more efficient compared to standard dryers.

“It’s really the last frontier in major appli-ances for Energy Star,” says John Taylor, LG Electronics vice president of public affairs and communications. “Energy Star certified refrigerators and washing machines have been on the market for many, many years. And they have shown tremendous improve-ments in energy efficiency. The incremen-tal improvements are getting smaller and smaller as years go on, and that’s why it’s very exciting to have a new category.”

New techThe new category is the result of two

emerging drying technologies, says Denise Durrett, the Environmental Protection

Agency’s communications manager for Energy Star products.

One is more accurate moisture sensors that tell a dryer to turn off when the clothes are dry, as opposed to a flat timer.

Durrett says part of the impetus for the standard was an effective test for the mois-ture sensors to see which models achieve claims made by the manufacturers. She said some early versions of the sensor technol-ogy did not live up to promises.

“They were making dryers that were not effectively stopping the dryer when the clothes were dry,” she says.

The new test procedure now allows Energy Star to identify (through third-party testing) which moisture sensors are actually meeting expectations.

“We create the demand for them through the certification of these products, because consumers have come to recognize the Energy Star label as meaning that this prod-uct will actually save energy and money on your utility bills,” she says. “And the third- party certification is kind of what seals the deal for them.”

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QUALITY & STANDARDS

pump technology. Non-heat pump dryers must be 20 percent more efficient to earn the label, but dryers using the heat pump design can display the rating only if they are at least 40 percent more efficient than con-ventional models.

Heat pump dryers recapture hot air used by the dryer and pump it back into the drum. By re-using most of the heat, a heat pump dryer is more efficient and avoids the need for ducts. Heat pump dryers were used in Europe for several years, but those early models did not dry clothes fast enough for the U.S. market, Taylor says. It could take “two to three hours to dry your clothes. That’s just not going to fly in the U.S. with consumers. Our approach to the U.S. mar-ket was to leverage the benefits of the heat pump, and combine it with the convention-al drying technology.”

The resulting LG model is its most effi-cient, the Eco Hybrid. LG says it uses up to 53 percent less energy than a conventional electric dryer and dries clothes in about 70 minutes.

Cost and energy savingsRecent data from the Association of

Home Appliance Manufacturers shows that major appliance consumers rank energy efficiency third on the list of important features — right behind cost and performance.

The first and third items on that list — cost and efficiency — are often two sides of the same coin. New Energy Star dryers are typically more expensive than their coun-terparts, though the Energy Star website hosts a database of rebates available for buyers of Energy Star dryers. The energy savings over the life of the dryer will also typically make up for the higher up-front price tag.

“The money savings adds up to about $25 a year for dryers,” Durrett says. “These are pretty conservative numbers, because you’ve got different scenarios for how peo-ple do laundry. But consumers who replace old dryers can save $245 over the lifetime of the dryer (with an Energy Star-certified model).”

Collectively, the cost saving and green-house gas reductions would be palpable. According to Energy Star, if all clothes dryers 10 years and older in the U.S. were replaced with certified clothes dryers, the

country would save more than $1.5 billion and prevent the greenhouse gas emissions equivalent to two million vehicles.

“When we look at savings at the EPA, we don’t just look at the cost savings, but we look at the environmental impact,” she continues. “And that’s a huge amount of greenhouse gas prevented from efficient dryers.”

Buying bothThe EPA and appliance manufactur-

ers hope the consumers will see the new Energy Star dryers as a complementary unit to Energy Star washers for combined efficiency.

“When you put your clothes in the dry-er, they’re a lot less damp than they used to be in the old days,” Taylor remarks. “So the dryer doesn’t have to work quite as hard as it used to, thanks to the high spin speeds on the final cycle of your washer. Those are things the EPA is starting to look at — the combined energy savings.”

Energy Star washers are 25 percent more efficient and use 40 percent less water than models without the sticker. The standard was introduced in 1997 and is now in its 7th update. As efficiency advances in wash-ers have become more incremental, more noticeable gains could come from dryers.

“Energy efficiency in many appli-ance product categories has increased so greatly in the past 15-20 years that we are now beginning to see a plateauing of energy savings across multiple categories with an Energy Star program, where we have already transformed the market,” says Whirlpool Government Relations Specialist Sean Southard. “In the future, the industry focus should be on improving energy efficiency in categories like clothes dryers that have not reached the point of diminishing or diminished returns and have significant opportunities for energy efficiency and a clear benefit/cost savings to the customer.”

In addition to the complementary effect an Energy Star rating for a pair of washers and dryers can create together, Taylor adds that Energy Star ratings also tend to have a “halo effect” around the entire product.

“It has come to signify that you don’t have to sacrifice performance or style to have energy efficiency,” he says. “And I think more and more consumers today are understanding that they can take small steps that have an impact on fight-ing climate change, and Energy Star is a

part of that.” <

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by rob connelly

Rob Connelly is the vice president of additive manufacturing at Proto Labs. For more information, call (763) 479-7719 or visit www.protolabs.com.

Architects don’t build without mod-eling. They create “blueprints,” produce renderings, and build 3-D

models. But while these planning tools may resemble the actual building in shape, there is no resemblance in size or materials. As a result, except in the case of manufactured or modular buildings, the finished prod-uct will be the first time that real building materials have come together in exactly that configuration. That is one of the reason that architecture tends to be conservative in its rate of change. Without real-world testing, big change is risky.

Product development is different. Today’s products are designed to be manufactured in thousands or hundreds of thousands, and both parts and assembled products can be built and tested throughout the develop-ment process. That, in part, explains today’s high rate of product innovation. But it also puts a lot of pressure on the prototyping process. New products have to meet or exceed buyer expectations in a very com-

petitive market. In many cases, their value proposition is their innovation, the fact that they are different from anything that has existed before. And they have to be devel-oped and rolled out quickly to beat com-petitors to market. Smart prototyping can support all of those goals; the challenge is choosing the right prototyping processes at each point in development.

Additive manufacturing, or 3-D print-ing as it’s regularly called, is a process that uses digital CAD models to build phys-ical, often layered, real-life objects. The appropriateness of the technology depends on the application of the part. A concept model of a brain, for example, has inherent medical value to a doctor during surgical planning, but it would never go into pro-duction because only one or two printed pieces are needed in a plastic-like mate-rial. Other times, additive manufacturing might be used to create fully functional end-use parts in small quantities of engi-neering-grade metals.

3-D Printing

Technologies for

Prototyping and

Production

HOW TOLEVERAGE ADDITIVE MANUFACTURING TO BUILD BETTER PRODUCTS

PROTOTYPINGThe green part was built in an ABS-like micro-resolution material in stereolithography. Source: Proto Labs


PROTOTYPING

However, if manufacturing will eventu-ally entail a process like injection molding, 3-D printing will have more limited use in development. In the later stages of develop-ment of a cast or molded part, for example, it will be important to test parts that are identical (or nearly so) to final production parts. This will involve injection molding plastic or metal prototypes in a repeatable fashion. Thus, the method of prototype manufacturing can shift during the devel-opment process depending on application, material requirements, manufacturability and other factors.

Early-stage prototypes are typically pro-duced in very small numbers and don’t nec-essarily have to hold true to all the function-al characteristics of production parts. Since material selection and internal structure of

the part are not as critical at this stage, pro-totypes can be produced using a variety of additive technologies that are both fast and affordable.

Uses of parts produced by additive pro-cesses include: Production partsTooling patterns and components Functional modelsJigs and fixtures Visual aidsConcept models Fit and assembly testingPatterns for casting

The Right Tool for the Job Different prototyping methods serve

different purposes. Take, for example, a designer or engineer who is developing a

handheld device containing moving parts. The development process might begin with a series of 3-D CAD models. These allow quick creation and virtual assembly of the components. When ready for first physical prototypes, the designer might produce additive prototypes from the CAD models, choosing SL prototypes for the shell com-ponents for that method’s superior surface finish and SLS prototypes for the internal components for that method’s good mate-rial properties. As development proceeds, there might be several iterations using those processes as the shell and internal part designs evolve.

When it comes time for functional test-ing—seeing how the internal parts perform under load and how the case withstands being dropped—the designer might initial-ly send out the 3-D CAD models to have one or several prototypes of each compo-nent machined from appropriate materials. These prototypes would have the physical characteristics of production parts and, par-ticularly in the case of the shell, duplicate the cosmetic appearance. For larger-scale testing, the same CAD models could be used to produce rapid injection-molded parts for physical and market evaluation. If testing indicated that the product was ready for the market, those same molds could be used to produce parts for market while steel tooling was being milled for high-volume production.

Making the Un-manufacturable Manufacturable

Building a part in thousands of thin lay-ers affords those designing CAD models for 3-D printing the opportunity to create highly complex geometries that are often impossible to mold—internal channels and holes that are unreachable by end mills, or

OUTSOURCED PROTOTYPINGWhile a few of the processes described can be carried out in-house, the majority of this kind of prototyping is outsourced. Outsourcing allows the developer to choose the best methods for any particular need. That can entail using multiple prototyping methods over the course of a single project. In selecting a vendor, consider the needs and goals of your project:

Can the manufacturer provide suitable prototyping methods for your specific needs?

Can it help you select the best method at each stage of the process?Does it offer any kind of design assistance?If you need a series of prototypes, can the manufacturer provide

continuity?How experienced is the manufacturer in the processes you will use?Can it produce the maximum quality available for each proto-

typing method?If necessary, can it provide secondary operations for your pro-

totypes?If material is critical, what materials can the manufacturer offer

in the selected method, and if a particular method cannot utilize your preferred material, can it offer other methods?

What turnaround times does it offer?What is the manufacturer’s reputation for meeting deadlines? <

This part was built in selective laser sintering in a stiff nylon material. Source: Proto Labs

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PROTOTYPING

entire assemblies printed as a single piece. But what happens when additive prototypes are ready to graduate to injection mold-ing? Moving from stainless steel prototypes built by direct metal laser sintering (DMLS) into low-volume metal injection molding (MIM) works as a good product develop-ment example. Whereas the importance of molding-specific design considerations like draft, radii and uniform wall thickness are minimal in 3-D printing, once a shift is made into MIM, these elements become much more critical.

Economies of Scale Additive processes all share the common

impracticality of mass production into the thousands and tens of thousands. Is a new frontier of additive scalability an area that additive could soon explore? According to Terry Wohlers, from independent consult-ing firm Wohlers Associates Inc., medical and aerospace industries are beginning to embrace increased printed part production as well as companies in dental and jewelry fields. For a seismic shift to occur, it will likely take more than that. Currently, addi-tive plastic materials are typically 50 to 100 times more expensive than traditional man-ufacturing, according to Wohlers, not 50 to 100 percent more. So presently, low quan-tities are suitable for additive manufactur-ing. When equipment throughput increases and equipment and material decrease, the potential for larger production volumes will increase. Until then, processes like injec-tion molding—that involve an initial tool-ing investment, but lower per-part price as quantities increase—remain a logical next step after prototyping.

Choosing Processes There isn’t necessarily a preferred addi-

tive prototyping process. The challenge is finding the best prototyping methods for your project and for each phase of your project. Variables among prototyping methods include speed, cost, appearance, supported materials and a variety of phys-ical characteristics. In some cases, all you need is something you can hold in your hand; in others, fit with other components is required.

Binder jetting is one of the simplest and most basic additive prototyping processes. An inkjet print head moves across a bed of powder, selectively depositing a liquid binding material, and the process is repeat-ed until the complete part has been formed. After completion, the unbound powder is removed, leaving the finished object.

Fused deposition modeling (FDM) melts and re-solidifies thermoplastic resin (ABS, polycarbonate or ABS/polycarbon-ate blend) in layers to form a finished pro-totype. Because it uses real thermoplastic resins, it is stronger than binder jetting and may be of limited use for functional testing.

Stereolithography (SL) uses a com-puter controlled laser to build parts in a pool of UV-curable resin. As each layer is drawn by the laser, the part is lowered in the pool of liquid resin allowing the next layer of liquid to be solidified. Quality of the fin-ished part depends largely on the quality of the equipment and process used.

Selective laser sintering (SLS) employs a computer controlled CO2 laser to fuse layers of powdered material such as nylon from the bottom up. Strength is bet-ter than that of SL but lower than that pro-duced by subtractive processes like injec-tion molding or CNC machining. It also has some use as a production method.

PolyJet (PJET) uses a print head to spray layers of photopolymer resin that are cured, one after another, using ultraviolet light. The layers are very thin allowing supe-rior resolution. The material is supported by gel matrix that is removed after comple-tion of the part.

Digital light processing (DLP)-based additive manufacturing digitally slices a solid into layers, which a Texas Instruments DLP chip projects, one after another, onto the surface of a liquid photopolymer bath.

The projected light hardens a layer of liquid polymer resting on a movable build plate. The build plate moves down in small incre-ments as new images are projected onto the liquid, hardening each subsequent layer to produce the finished object. The remaining liquid polymer is then drained from the vat, leaving the solid model. The process can be useful for producing low volumes of small, highly detailed parts but is less suitable for larger parts, especially those requiring smooth finishes.

Direct metal laser sintering (DMLS)is the leading additive method for making metal prototypes. It is similar to selective laser sintering of plastic resin, but is suitable for use with metals including aluminum, stainless steel, titanium, cobalt chrome and Inconel. It offers good accuracy and detail, and excellent mechanical properties. DMLS can be used for very small parts and fea-tures, and because it is an additive process, it can reproduce geometries that might be impossible to machine such as enclosed spaces. Layers can be as thin as 20 microns, and tolerances on small features can be as small as ±0.002 inches. Secondary oper-ations on parts produced by DMLS can include machined drilling, slotting, mill-ing and reaming, and finishing procedures including anodizing, electro-polishing, hand polishing, and powder coating or

painting.

Precision metal sintering machines build production quality parts in metals like stainless steel, cobalt chrome, aluminum and others. Source: Proto Labs

Through an annual subscription service you can repurpose our editorial content for your own use. Tap into the editorial expertise of appliance DESIGN and save your c the valuable time and resources needed for content creation.

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electrolux professional SpA Green&Clean Hood Type BY ELECTROLUX PROFESSIONAL DESIGN FIRM ELECTROLUX PROFESSIONAL DESIGN DEPARTMENT

T he voting is done and the winners have been selected for the 2015 Excellence in Design Awards. Winning designs were selected by an independent panel of design experts on the basis of creativity, ease

of use and visual appeal. Gold, Silver and Bronze awards have been given across eight product categories. In addition to the following profiles of the winning products, a permanent section of the appliance DESIGN website is dedicated to the competition at appliancedesign.com/eid. Congratulations to all the winners and, without further ado:

I Twenty-Eighth Annual EID Winners

Electrolux Green&Clean is a hood-type dishwasher guaranteeing the best performance to the Restaurants market segment thanks to the implementation of innovative product and process technologies and smart workflow configuration.

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Category: Business MachinesPrice range: Top of the LineMarket: Worldwide

The results of applianceDESIGN’s 28th Annual Excellence in Design Awards.

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A commercial grade single motor upright vacuum that is durable, easy to repair and easy to operate and maneuver. The intended user is a commercial cleaner either a house cleaning professional or a contract cleaner. The commercial cleaner will use this vacuum to effectively clean in education facilities (k-12 schools & universities), hospitality locations and commercial office buildings. The ProGen 12/15 has two power heads that serve the needs of different use scenarios.

Category: Floor CarePrice Range: Top of the lineMarket: United States

Freedom Scientific TOPAZ PHD, Portable Video Magnifier BY FREEDOM SCIENTIFIC DESIGN FIRM BRESSLERGROUP

ProTeam ProGen 15BY EMERSON TOOL COMPANY

Freedom Scientific’s assistive technology empowers people with low vision or blindness to live independently. The new TOPAZ PHD, Portable Video Magnifier, is a lightweight, transportable version of Freedom Scientific’s popular desktop magnifier. This portable model folds away like a laptop, extending the usability and productivity features to mobile users (students and frequent travelers) as well as to those seeking a sleeker, more inconspicuous solution for their home. Users describe their TOPAZ video magnifiers as “life-saving” devices. See the TOPAZ PHD in action at www.freedomscientific.com.

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Category: Consumer ElectronicsPrice range: Mid-RangeMarket: UK, France, Germany, US, Australia, New Zealand, Austria, and Canada

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I Twenty Eighth Annual EID GOLD Awards

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Category: HVACPrice range: Mid-rangeMarket: USA, Europe and Asia

The Garage Light brings brilliant, energy-efficient light to personal spaces such as garages, workshops,

boathouses and more. The Garage Light transforms the lighting in smaller commercial or industrial shops as well. These

high-quality LEDs provide performance, efficiency and illumination that’s unmatched by typical fluorescent and metal halide fixtures. The Garage Light

is housed in a single piece of anodized, extruded aluminum, which provides superior heat dissipation and impact resistance.

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The LG Smart AC Module enables smartphone control of select duct-free LG air conditioning systems. Working in tandem with the Smart AC app (available for Android and iOS smartphones), the module is a key component in helping consumers enhance their personal comfort and conserve energy – even on the go. While the module’s hardware was designed with simplicity and convenience in mind, the app works to easily connect and communicate with the module to control various functions and settings of connected LG indoor units, such as temperature, fan speed and air flow, ensuring consumers’ homes consistently remain at an ideal temperature. www.lghvac.com

LG Electronics Smart AC Module BY LG ELECTRONICS USA

The Garage Light by Big Ass Light™ BY BIG ASS SOLUTIONS

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Category: LightingPrice Range: Top of the lineMarket: United States


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On average in the U.S., one in three attempts to seek intravenous access in adults and one in two attempts in pediatrics result in failure. Vascular access is especially difficult with extreme cases such as elderly, obese, and seriously ill patients, but even otherwise healthy patients can prove a challenge. This common procedure too often results in complications such as infection and thrombosis when practitioners are forced to access a central line. Sonic Window is a self-contained, ultra-compact, handheld ultrasound device designed to improve patient outcomes by enabling clinicians to quickly and easily achieve vascular access at ‘first stick.’


Analogic Ultrasound Sonic Window BY ANALOGICDESIGN PARTNER BRESSLERGROUP

LG’s Side-by-Side Refrigerator with Door-in-Door® adds a level of sophisticated design to the kitchen. This refrigerator offers a sleek and modern look, incorporating clean lines with contoured doors and hidden hinges. With this unit, LG’s Door-in-Door® technology appears on a Side-by-Side model for the first time in the U.S. The technology that LG first pioneered in 2010 allows quick and easy access to beverages and snacks via a magnetically sealed section on the right refrigerator door that releases and allows access to a built-in door without having to open the entire refrigerator (thereby reducing cold air loss).

www.lg.com

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Category: Medical Equipment & DevicesPrice Range: Economical Value LineMarket: North America

Category: Major Appliances and Commercial Vending Price Range: Mid-rangeMarket: United States

LG Electronics Side-by-Side Door-in-Door® Refrigerator (model LSC22991ST) BY LG ELECTRONICS USA


The Jacuzzi Hydrotherapy Shower is a walk-in, aging-in-place shower with novel hydrotherapy features that can be easily installed in the standard 60” x 32” bathtub footprint found in many American homes. It provides a wide swathe of aging consumers with a highly functional, safe showering space and fills a void in the marketplace for an affordable, elegant, accessible solution.


Jacuzzi Hydrotherapy Shower BY JACUZZIDESIGN PARTNER BRESSLERGROUP

Category: Small AppliancesPrice range: Top of the LineMarket: Most international markets

Haiku® with SenseME™ is the world’s first smart ceiling fan. Designed with an array of sensors and microprocessors, this fan makes decisions to keep you comfortable – automatically. SenseME monitors environmental conditions, detects occupancy and learns user preferences to make adjustments to speed and airflow patterns. Big Ass Fans proudly makes each Haiku with SenseME in the USA.

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Haiku® with SenseME™

BY BIG ASS SOLUTIONS


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MEETTHEJUDGESTUCKER VIEMEISTER, FIDSA, PRESIDENT OF VIEMEISTER INDUSTRIES, NEW YORKTucker Viemeister builds design groups. He was a founder of Smart Design (famous for Oxo GoodGrips), opened Frog Design’s New York office, established Razorfish’s physical design capability group, and developed Springtime-USA. He recently served as lab chief at Rockwell Group, then built a small research and development team into a teeming interactive business and is now president of Viemeister Industries headquartered in NYC.

Clients include Apple, Coca-Cola, Cuisinart, Black & Decker, Remington, OXO, Viking, J&J, Timex, Levi’s, Phat Farm, Nestlé, Unilever, Motorola, Toshiba, Sharp, Seibu, Toyota, Nike, Knoll, Steelcase, Kate Spade, Cosmopolitan Casino, Yotel and the NYC Board of Education. His work is in MoMA and awards include the

first Presidential Design Award. He taught at Pratt, Yale, Parsons and NYU. He is the Architectural League of New York’s vice president, Rowena Fund chair and an IDSA Fellow. He holds 32 US utility patents. Named after a car, he is a graduate of Pratt Institute. Contact him at [email protected].

JOHN C. DAVIS, VP OF MARKETING & PRODUCT MANAGEMENT, UNIFIED BRANDS, FORT WORTH, TX

John is the VP of marketing & product management for Unified Brands located in Conyers, GA. He joined Unified Brands, an Operating Company within Dover Corp, in 2014. Previously he held several positions during 15 years at

Traulsen and Hobart of the ITW Food Equipment Group after beginning his career at Arneg US.His experience includes roles in engineering, manufacturing, service & parts management, sales, business

development, marketing, and business management. He earned his Masters of Business Administration at Wright State University and Dayton OH after completing a Bachelors of Science in Mechanical Engineering at Lehigh

University. In addition John has completed a Graduate Marketing Program at Tulane University.

JEROME CARUSO, INDEPENDENT CONSULTANT AND DIRECTOR OF JEROME CARUSO DESIGN STUDIO, LAKE FOREST, IL. Jerome Caruso has a unique, virtual studio, with five decades of product design success for major companies. The efficiency and design continuity of his one-man studio has contributed to the brand strength of companies ike Sub-Zero, Wolf, and Herman Miller. With his creative direction of product design strategy at Sub-Zero for 26 years, this company has become an American icon.

Jerome is the hands-on designer and employs the highest level of engineers, model makers, and researchers. The methodology of his studio is holistic, creative, and efficient because of the single-person contact with clients, concept creation, and product development.

Jerome practices and believes that the art of invention and innovation is key to long-term product success. His deep understanding of materials and manufacturing methods has made possible an efficient, proven development process. "A vision of what should be is my key to breakthroughs in aesthetics as well as functional products that represent progress." Contact him at [email protected].

RICHARD WATSON, PARTNER, ESSENTIAL, BOSTON, MA As a founding partner at Essential, Richard Watson is a leading advisor to companies on product and service innovation and an authority in the field of design strategy. Richard drives innovation in organizations, helping

them navigate complex design issues for rapidly changing environments. Watson believes that design strategy is about tangibility, delivering solutions an organization can understand, internalize and act upon. He strives to solve

problems and envision solutions that enable organizations to get a clear vision about what’s next. Richard is a firm believer in the power of collaborative thinking and engaging teams across disciplines, he

speaks on design strategy, design vision and understanding consumer needs. He is an active and extremely accomplished designer of successful award winning products and services. He leads the design direction for a

variety of industries and clients, including Dell, iRobot, Philips Healthcare, P&G, Johnson and Johnson, EMC and Puma. Prior to founding Essential, Watson was vice president of design at Fitch, where he led the product development team. Prior to Fitch he was part of an international design team at GE Plastics that envisioned products to express the company’s strategic marketing initiatives.

Watson is an expert blogger for Fast Company's Co. Design blog and a member of the Industrial Designers Society of America, Design Management Institute, and Association of Professional Design Firms. He holds a Master of Arts in Industrial Design from Manchester

Metropolitan University in England and a Bachelor of Arts in Silversmithing from Montford University in [email protected], www.essential-design.com, Twitter: @_Essential

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Price range: Top of the lineMarket: USA, Australia, New Zealand, countries of the European Union, Russia, and the Middle East

Category: Business Machines

Price range: Top of the line

Market: United States

Category: HVAC


Market: North America

Fellowes Jupiter 2 125 #57341BY FELLOWESDESIGN FIRM FELLOWES DESIGN TEAM

The Kirby Avalir Multi-Surface Shampoo System BY THE KIRBY COMPANYDESIGN FIRM THE KIRBY COMPANY

Hyper-Heating INVERTER™ (H2i®) MSZ-FH Single-Zone Heat Pump SystemBY MITSUBISHI ELECTRIC US, INC. COOLING & HEATING DIVISIONDESIGN FIRM MITSUBISHI ELECTRIC US, INC. COOLING & HEATING DIVISION

The Kirby Avalir Multi-Surface Shampoo System converts the Kirby vacuum into a complete foam scrubber for both carpets and hard surface floors. It allows the user to shampoo carpets, scrub uneven grout and tile floors, and damp mop delicate hardwood floors thanks to a series of interchangeable brush rolls and mops. It can even be used to apply a polymer finish to hard surface floors. Small and compact, it saves the homeowner space in their closet and money in their pocket when compared with purchasing and storing multiple cleaning units to accomplish these same tasks. www.kirby.com

The Jupiter 2 125 is a general office laminator that has been designed to eliminate key issues with office laminating. Key features include: the AutoSense system detects pouch thickness and self-adjusts to the optimal laminating setting. InstaHeat technology warms up the laminator in a minute. The Jupiter has a rapid laminating speed of 30” per minute. A robust 6-roller system delivers superior lamination quality. Laminates hot pouches up to 10-mil thick; as well as cold pouches. Includes reverse mode disengages pouch for re-centering or removal. Auto shut-off prevents overheating when not in use. www.fellowes.com

The H2i MSZ-FH is among the most energy-efficient residential ductless zoning systems in the U.S. market at 30.5 SEER. With a 13.5 HSPF rating, it offers efficient, year-round cooling and heating and eliminates the need for a backup heat source in most areas. It operates at 100% heating capacity at 5° F and continues providing efficient heating down to -13° F, giving it the lowest ambient performance at the highest SEER rating in the industry. Indoor units feature i-see Sensor™ 3D technology for improved performance and efficiency, which detects human heat signatures to deliver conditioned air to occupied areas only. www.mehvac.com

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Commercial Vending

Price range: Mid-range


Category: Small Appliances



Category: Medical Equipment & Devices


Market: Australia, New Zealand, Japan, Brazil, South Africa, Korea, Canada and countries accepting CE-IVD mark

LG’s 4-Door Refrigerator incorporates features that help provide added convenience and keep family favorites easily accessible. The unit’s Door-in-Door® compartment is a magnetically sealed section of the right refrigerator door that releases and allows consumers access to a built-in door (via a button on the door handle) without opening the entire refrigerator. It also reduces cold air loss by up to 47%* to help preserve food freshness while conserving energy. The CustomChill™ drawer, located between the refrigerator and freezer, offers additional refrigerator or soft-freezer space with four temperature settings. *As compared to opening one French Door for 10 seconds. www.lg.com

The LMHM2237ST is an over-the-range microwave oven that offers the benefit of LG’s proprietary EasyClean® technology, which allows for quick and easy clean up with the simple wipe of a damp cloth (no harsh chemicals or scrubbing necessary). This model also features the industry’s first ExtendaVent™ 2.0 feature, which provides more powerful and complete ventilation to capture more smoke and cooking smells over virtually the entire cooktop. Lastly, this model offers 2.2 cubic feet of capacity, so there is always plenty of room to heat large dishes. www.lg.com

LG Electronics 4-Door Door-in-Door® Refrigerator with CustomChill™ (model LMXS30776S) BY LG ELECTRONICS USA

LG Electronics Over-the-Range Microwave with EasyClean® (model LMHM2237ST) BY LG ELECTRONICS USA

Becton-Dickinson Diagnostics BD Totalys Multiprocessor BY BECTON-DICKINSON DIAGNOSTICSDESIGN FIRM BRESSLERGROUPThe BD Totalys Multiprocessor provides highly automated sample preparation for cytology and molecular testing for cervical cancer with a balance of automation and flexibility that enhances lab productivity, streamlines processes, and removes inefficiencies. www.bresslergroup.com

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trutankless is a self-aware, smart-home compatible electric tankless water heater that provides endless, on-demand hot water for an entire household. The heater employs highly accurate sensors, robust solid state electronics and proprietary software to power one of the most efficient heat exchangers ever produced. www.trutankless.com

trutankless TR 29 BY TRUTANKLESS, A DIVISION OF BOLLENTE COMPANIESDESIGN FIRM JUGGERNAUT DESIGN

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Market: United States and Europe

Kooltronic Hazardous Location Air Conditioner HL SeriesBY KOOLTRONIC INC.DESIGN FIRM KOOLTRONIC INC.

Kenyon International SilKEN2 Induction Cooktop B81321, B81331BY KENYON INTERNATIONAL, INC.DESIGN FIRM KENYON INTERNATIONAL, INC.

The HL Series Kooltronic air conditioner is designed to remove component damaging heat from within a sealed electrical enclosure located in hazardous environments. They are specifically designed for use in NEC Class I, Division 1 Groups A, B, C & D and Division 2 Groups A, B, C & D locations in conjunction with types X and Z purged enclosures where hazardous gases are or may be present; and are also suitable for corrosive environments. Applications include oil and gas exploration, production and petrochemical applications. The patent pending design improves safety, reliability and serviceability providing a lower cost of ownership. www.kooltronic.com

The Kenyon SilKEN® 2 combines high-energy induction cooking with the latest technology. Stainless steel colored graphics provide a polished look that modernizes any kitchen. This revolutionary cooktop offers cooking by temperature or power setting, quick heat dissipation, pot retention and user-friendly controls. The silicone mat covers the entire cooktop and is easily removed for cleaning by placing in your sink or dishwasher. The raised rim surrounding the mat helps to control cooking accidents such as spillovers. The patent pending integrated heat sensing disc relays temperature feedback from the cooking vessel to the touch control system for accurate cooking. www.cookwithkenyon.com

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BUYERS GUIDE2015


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America, Europe, Australia

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Market: Asia Pacific

Category: Water Processing

Appliances

Price range: Economical Value Line


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The V-PRO® 60 Low Temperature Sterilization System is an innovative sterile processing department (SPD) solution from STERIS Corporation that offers the pharmaceutical and healthcare industry the productivity and flexibility they require to reprocess their medical devices. www.pdt.com

Designed to reduce the cost and hassle of replacing a conventional 40-gallon tank-type water heater, the new EZTR40 Condensing Tankless Water Heater streamlines the tankless-for-tank changeout process in three ways: Using two-inch, flexible polypropylene tubing threaded directly through the old tankless water heater’s existing B-Vent, the EZTR40 does not require a new vent. Its top-mounted water connections allow for quick and easy reconnections, without the need for new plumbing. Lastly, EZTR40 reduces labor time by up to half by utilizing the old tank unit's half-inch gas line, substantially reducing installed cost to the homeowner. www.noritz.com

Product Development Technologies (PDT) V-PRO® 60 Low Temperature Sterilization System VP40002401BY PRODUCT DEVELOPMENT TECHNOLOGIES (PDT)DESIGN FIRM PRODUCT DEVELOPMENT TECHNOLOGIES (PDT)

Noritz America EZTR40 Condensing Tankless Water Heater BY NORITZ AMERICA

Havells Supermix Haandi/GHFMGAXH050 BY HAVELLS INDIA LTD.DESIGN FIRM HAVELLS INDIA LTD.

The product is a Mixer Grinder typically used in almost every Indian kitchen. Primarily used for daily needs of Dry/Wet grinding (pulses, rice batter, etc.), Blending (shakes) and Chutney/Puree making. Main parts/features include 03 nos. Stainless Steel jars of capacity 1.5L , 1.2L and 0.4L for the above applications, a 500 W Copper wound universal motor with an overload protector as a safety device, 03 speed switch knob with Pulse function. Other features include a Big size Speed control Knob for Easy operation, Cord Winding and Break resistant Polycarbonate Lid for the Blending Jar. The Unique design of Haandi Grinding Jar in Stainless Steel 304 Grade delivers 8% Finer Grinding, 15% Less Power Consumption and 10% Faster Grinding as compared to conventional designs. www.havells.com

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LCR MeterCal Test Electronics introduces the new

Global Specialties LCR-600. The LCR-600 is a high precision test instrument used for measuring the inductance (L), capacitance (C), and resistance (R) of an electrical component. The LCR-600 has an operational frequency range of 100 Hz to 100 kHz and a basic measurement ac-curacy of 0.3%. There is a dual LCD dis-play, measurement voltage fixed at 0.6 V, auto-detect function, and open-circuit /short-circuit compensation. Use the me-ter to check ESR values of capacitors and inductors, sort and select components, identify unknown components, and mea-sure general LCR values.

Product features:• Measures: Ls, Lp, Cs, Cp, Rs, Rp, D, Q, ESR,

EPR, Z, Ø, DCR• Frequency range: 100 Hz to 100 kHz• Auto range• Auto detect• Sorting function• Open circuit compensation• Short circuit compensation• Basic accuracy of 0.3%• Two displays• Display hold• Two-year warranty

Cal Test Electronics(714) 221-9330www.caltestelectronics.com

Profile SensorLMI Technologies (LMI) announced

the official release of the Gocator 2320 Profile Sensor and an update to Gocator’s Firmware. The 2320 is the latest addi-tion to the Gocator 2300 series of smart, all-in-one 3D sensors and features high resolution, high accuracy, and an expand-able field of view, all in a thin industrial housing. Gocator Firmware 4.1 adds new

NEW PRODUCTSLeak Detector

The new ASM 340 is a high-perfor-mance and robust leak detector for pro-duction testing. The wide range of ap-plications in the Refrigeration and Air Conditioning industry include compres-sors, coils, valves, sub and final assemblies, etc. The compact leak detector is suitable for both global vacuum chamber testing and sniffing applications.Reliable leak detection for production assuranceShort cycle time and high throughputHigh performance and sensitivity with easy operation Helium and Hydrogen leak detection for global (chamber) testing or sniffing applica-

tions

The ASM 340 with a powerful vacuum roughing pump (11 cfm) may negate the need for additional vacuum systems for chamber testing. For sniffing applications the ASM 340 offers the industry’s highest sensitivity when using either helium or diluted hydrogen and can detect leaks as low as 0.0001 oz/yr refrigerant equivalent.

A large selection of configurable interfaces enables easy integration of the de-tector into production lines and automatic test systems. The removable graphical user interface and simple menu structure makes set up fast and easy. Data can be saved to the integrated SD card and then downloaded to an external device for further analysis. The wireless remote control enables operation from a distance of up to 100 meters. Thanks to the robust design and the minimal maintenance required, service costs are also very low.

With its extensive accessories, the ASM 340 can be adapted to specific applica-tions. A special transport cart also enables mobile use of the device. Existing accessories for leak detectors in the ASM series are also compatible with the new device.

To complement the market introduction of the ASM 340 Pfeiffer Vacuum pres-ents the Leak Detection Compendium. This handbook offers combined leak test-ing and leak detection expertise.

Pfeiffer Vacuum, (978) 430-2829, [email protected], www.pfeiffer-vacuum.com

features such as rich filtering, material se-lection, Countersunk Hole measurement, and improved visualization for displace-ment sensors.

The Gocator 2320 produces highly ac-curate and repeatable results to meet the demanding standards of the electronics assembly line. The sensor’s narrow hous-ing also allows it to be mounted in tight spaces so OEMs and System Integrators can easily integrate it into inspection ma-chines already crowded with other devic-es and equipment. The Gocator 2320 also has the built-in ability to mount multiple sensors side-by-side, expanding the field of view as many times as needed. And like all Gocator sensors, the 2320 comes in a robust industrial IP67 rated housing,

with an intuitive experience that is un-matched in the 3D sensor market.

The upgrade to Gocator Firmware from version 4.0 to 4.1 improves process optimization with the addition of rich filtering for removing noise and outliers from sensor data; material selection for achieving the best possible data on tar-gets with challenging material surfaces; a new Countersunk Hole Tool to measure center position, depth, outside diameter, bevel angle; and improved visualization for displacement sensors including range and intensity data.

LMI Technologiesmarketing.lmi3d.com/gocator-2320-learn-morewww. lmi3d.com


NEW PRODUCTS

LSR MaterialProto Labs Inc. has introduced med-

ical-grade liquid silicone rubber (LSR) material to its quick-turn injection mold-ing capabilities. The rapid manufacturing company now offers Dow Corning QP1-250 moldable silicone in addition to its standard and optical-grade LSR materi-als. Medical-grade LSR is a low-viscosity thermoset material particularly well-suit-ed for medical applications. Proto Labs can manufacture 25 to 5,000+ parts in 1 to 15 days.

Parts created in LSR are strong and elastic with excellent thermal, chemical and electrical resistance. They maintain their physical properties at extreme tem-peratures and withstand sterilization. LSR is biocompatible so it is frequently used in products that require skin contact. As a result, moldable silicone lends itself well to surgical and dental applications, consumer health care products and other components that have human contact.

Proto Labs, Inc. www.protolabs.com

Air FiltersAFPRO Filters announces the new Low

Energy series air filters with an A+ energy label. This new A+ label is the highest rat-ing according to the new energy efficiency classification by Eurovent, which was in-troduced on January 1st 2015.

The new A+ label places much higher demands on the energy use of air filters compared to the other Eurovent labels, and adds a new dimension to the filter ef-ficiencies. In the past, air filters were clas-sified only by their filter efficiency and this new energy classification is far more precise.

AFPRO Filters continued focus on in-novations related to energy savings re-

sulted in being one of the first companies in Europe to develop an energy-efficient air filter rated A+.

The new Low Energy series from AF-PRO Filters can be used in both new construction projects as for replacing air filters (All F7, F8 and F9) in existing ventilations systems. As this new filter is a compact filter, it’s taking up less space in ventilation systems and are often used in for example datacenters, industries, gas turbines and renovation projects where space is limited.

AFPRO Filterswww.afprofilters.com

Control InterfaceMIPI® Alliance announced an updated

version of its MIPI RF Front-End Control Interface for mobile devices: MIPI® Alli-ance Specification for RF Front-End Con-trol Interface (RFFE℠), Version 2.0.

The new release, v2.0, adds numer-ous features that enhance control of the increasingly complex RF front-end envi-ronment in a mobile device, which can include 10 to 20 components such as power amplifiers, antenna tuners, filters and switches. The interface can be applied to the full range of RFFE components to

simplify technology design, configuration and integration and to facilitate interop-erability of components supplied by dif-ferent vendors. The convenient interface makes it easier for manufacturers to de-velop scalable solutions, expediting time to market for new solutions and address-ing end-user needs for faster data speeds and better call quality. It is also backward-compatible with products based on the earlier specification, MIPI RFFE v1.x.

MIPI RFFE v2.0 brings five important technical features to the popular inter-face. The features include: Extended range of bus operating frequen-

cies, effectively doubling the number of command sequences that can be trans-ferred on the bus in a given amount of time to increase overall data speeds for end users

Synchronous read, which allows more types of data propagation on the bus by the slave devices to increase the range of bus loading and enable the use of extended frequencies

Multi-master configuration to support carrier aggregation system architectures and the use of multiple transceivers and dual-SIM designs

Interrupt-capable slave functionality, which enables a quick polling method of the slave devices to the master controller on the bus, and

Light GuideGlobal Lighting Technologies (GLT)

has introduced a new 4 x 4-in. LED-based light guide developed to demonstrate its higher efficiency, better durability, longer life, and lower cost than a comparable OLED panel.

GLT’s LED-based 4 x 4-in. square light guide is intended as a superior solution for applications considering similar-size OLED panels with similar diffused-light

output, albeit at a much lower cost. It is an economical design option unique in the marketplace for wall and ceiling lighting, luminaires and custom interior lighting in corporate, hospitality, residential and other applications. The light guide as-sembly is only 3.5 mm thick. The panel itself measures a slim 2 mm and is thinner than prior GLT products while offering enhanced light extraction. The light guide would typically be edge lit from one or more sides using industry standard LEDs, with a small frame concealing the LEDs in place. The current product provides an efficiency of over 115 lumens/watt while producing up to 250 lumens when fully powered.

Global Lighting Technologies (GLT), Inc., (866) 922-4584, [email protected], www.glthome.com

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NEW PRODUCTS

New reserved registers that improve the efficiency of hardware and software devel-opment

Expected users of the specification in-clude RF device vendors, baseband and transceiver vendors, and mobile device OEMs.

The MIPI RFFE Working Group, which led the development of the new specifi-cation, surveyed MIPI Alliance members and members of the International Wire-less Industry Consortium (IWPC) to as-sess the market’s RFFE interface needs and identify features to include in the new release. Companies surveyed represent the full range of RF front-end products used in mobile devices.

With v2.0 now available to companies, the working group has begun to gather ideas for further MIPI RFFE enhance-ments. Potential areas to be addressed in-clude RFFE electrical and digital details, flexible bus configuration and multiple message types. The working group wel-comes additional members and contribu-tions to this effort.

To support the user community in its adoption and use of MIPI RFFE v2.0, and in conjunction with the release of the specification, MIPI Alliance has also com-pleted two supporting documents:

• “Application Note for RFFE℠ v2.0, App Note v2.0,” and “FAQ for RFFE℠ v2.0, FAQ v2.0.” For more information about the specification, its supporting docu-ments and the MIPI Alliance RF Front-End Working Group, please visit http://bit.ly/1CjEiwm.

MIPI Alliance (MIPI)www.mipi.org

Hot Melt AdhesiveEllsworth Adhesives Europe con-

firmed availability of EA-4600, the newly launched hot melt adhesive from Dow Corning.

Dow Corning EA-4600 is a solvent free, one-component, moisture-cure silicone material offering longer open time and pot life, as well as lower odor and lower levels of volatility compared to conventional organic-based hot melt adhesives.

Designed for the electronic devices

Flash MemoryMicrochip Technology

Inc. announced a new fam-ily of 3V Serial Quad I/O™ interface (or SQI™ inter-face) SuperFlash® memory devices—the SST26VF. This three-member “26 Se-ries” SQI interface family is available with 16-Mbit, 32-Mbit or 64-Mbit of memory, and is manufactured using Microchip’s high-performance CMOS Su-perFlash technology, which provides the industry’s fastest erase times and superior reliability.

The SST26VF memory family provides faster erase times due to its use of Super-Flash technology. Sector and block erase commands are completed in just 18 ms, and a full chip erase operation is completed in 35 ms. Competing devices require 10 to 20 seconds to complete a full chip erase operation, making the SST26VF ap-proximately 400 times faster. These fast erase times can provide a significant cost savings to customers, by minimizing the time required for testing and firmware updates, and therefore increasing their manufacturing throughput.

Microchip’s SQI interface is a low pin count, high-speed 104 MHz quad-bit ad-dress and data multiplex I/O serial interface, which allows for high data through-put in a small package. This interface enables low-latency execute-in-place (XIP) capability with minimal processor buffer memory, reducing the overall design footprint compared to traditional parallel memory interfaces. The SST26VF fam-ily provides faster data throughput than a comparable x16 parallel Flash device, without the associated high cost and high pin count of parallel Flash. The SQI interface also offers full command-set backward compatibility for the ubiquitous Serial Peripheral Interface (SPI) protocol.

Designed for low power consumption, the SST26VF is ideal for energy-efficient embedded systems. Standby current consumption is 15 µA, typical, and the ac-tive read current at 104 MHz is 15 mA, typical. The combination of 3V operation with low power consumption and small-form-factor packaging makes the SST-26VF devices an excellent choice for applications such as servers, printers, cloud computing systems, HDTV, Internet gateways, appliances, security systems, and a broad range of embedded systems.

The SST26VF devices also offer excellent quality and reliability, with 100 years of data retention and device endurance of over 100,000 erase/write cycles. En-hanced safety features include software write protection of individual blocks for flexible data/code protection; the upper and lower 64 Kbytes of memory are par-titioned into smaller, 8-Kbyte sectors that can both read- and write-lock. In ad-dition, the devices include a One-Time Programmable (OTP) 2 Kbyte Secure ID area, consisting of a 64-bit, factory-programmed unique ID and a user-program-mable block. These features protect against unauthorized access and malicious read, program and erase intentions. The devices also include a JEDEC-compliant Serial Flash Discoverable Parameter (SFDP) table, which contains identifying in-formation about the functions and capabilities of the SST26VF devices for simpler software design.

Microchiphttp://www.microchip.com/SST26VF064B-030915ahttp://www.microchip.com/SST26VF064B


NEW PRODUCTS

market, Dow Corning Hot melt adhe-sive EA-4600 promises to deliver en-hanced reliability, reworkability and waterproofing for smart devices. With its room temperature vulcanization (RTV), this black adhesive provides im-proved assembly of consumer electron-ics and other high-volume demanding manufacturing operations.

Formulated to dispense easily, Dow Corning EA-4600 achieves instant green strength, allowing electronic assemblies to be handled immediately after its ap-plication. EA-4600 can be applied neat-ly as a liquid melt in very thin bonding lines of less than 0.5mm.

EA-4600 offers extended service tem-peratures from -40°C to 150°C. The ma-terial will soften when exposed to high temperatures, but revert to its typical properties after cooling. Unlike conven-tional polyurethane-based hot melt so-lutions, Dow Corning EA-4600 Silicone Hot Melt Adhesive incorporates ultra-violet (UV) markers to support auto-mated UV inspection of finished parts. It can also be easily reworked within 24 hours of application. Once fully cured, Dow Corning EA-4600 Hot Melt Adhe-sive delivers outstanding, durable pro-tection against chemicals, water and dust to enhance the reliability and per-formance of high-value electronics as-semblies.

As a reactive material, EA-4600 cools quickly and cures at room temperature to become a viscoelastic polymer pro-viding strong, flexible, primerless ad-hesion to an abundance of plastic and metal substrates.

Ellsworth [email protected] www.ellsworthadhesives.co.uk

ConnectorTE Connectivity (TE) introduces new

wire-to-board headers as part of its Pow-er Triple Lock connector product line; thereby expanding the family of connec-tors targeting appliances into a growing number of HVAC, automation and con-trol, and automotive designs. The con-nectors’ combined attributes of higher-current ratings, connection reliability

assurance options and higher tempera-ture operation provide an exceptional value-added solution to customers when compared to similar pin-and-socket connectors.

The 6.0mm center line connectors in the Power Triple Lock connector family offer higher current ratings than com-petitive products (20A vs.18A). Their higher temperature ratings (150 vs. 130 degrees C) help increase reliability in cooking and other high-temperature ap-plications. For assembly reliability, the family offers an optional – and unique – CPA (Connector Position Assurance) device that helps keep the connector ful-ly mated and engaged during shipment, installation and use. Another optional mechanism, the TPA (Terminal Position Assurance) device, provides secondary locking of the contact into the connec-tor housing. To ease assembly, Power Triple Lock connectors feature rounded edges and an anti-snag design. They also

feature a latch that audibly clicks to in-dicate that the header or cap and plug are mated. Additionally, the connectors’ design helps reduce fretting to prevent corrosion in applications, which is a key reliability concern in HVAC and auto-motive designs.

The Power Triple Lock connectors are V-0 rated (UL 94 V-0) and are color cod-ed. The family consists of existing wire-to-wire and new wire-to-board versions. The connectors offer nine keying op-tions in different housing colors to help improve assembly efficiency and prevent mismatch. For versatile harness and cir-cuit board positioning, the wire-to-wire connectors are available in single row (2, 3, 4, 5), dual row (2x3, 2x4, 2x5, 2x6) and matrix (3x3, 3x4, 3x5) configurations. The wire-to-board versions are offered in single row (2, 3, 4, 5) configurations.

TE Connectivitywww.powertriplelock.com

Optical Angle Encoder

NUMERIK JENA’s RIK kit-style optical angle encoder with-out bearing is ideally suited for those mo-tion feedback appli-cations where space is limited. The scanning unit has a very low height profile and the

graduation carrier is a coated aluminum disk with a wide range of available sizes. Now available in North America through Heidenhain Corporation, this flat angle encoder serves applications in a wide variety of industries such as semiconductor, medical, metrology, and automation.

The encoder disks have a graduation of 20µm with outer diameters ranging from 26mm to 200mm and have large through holes from 6mm to 160mm re-spectively. The encoder disks need to be bonded to a hub, where the customer can bond themselves, or depending on the hub design, NUMERIK JENA can offer the disk bonding process as a service.

The scanning units are small in size with a height dimension of only 6mm. The scanning units can be programmed once installed to the disk in order to maximize the signal quality and build in signal margin for long life of the machine operation. The scanning units output either a 1 Volt Peak to peak analog or TTL interface. Rotational speed of the disk varies with signal interface and diameter, but can be up to16,600 RPM. Total line counts after TTL quadrature evaluation can be up to 9,600,000.

NUMERIK JENA, (847) 490-0387, [email protected]


NEW PRODUCTS

Electronic Temperature ControlEXAIR’s digital ETC (Electronic

Temperature Control) is now available for Dual Cabinet Cooler® Systems in-stalled on large or high heat load en-closures. An ETC Dual Cabinet Cooler system will keep electrical enclosures cool while minimizing compressed air use. Systems produce 20°F air to elim-inate high temperature malfunctions and protect sensitive electronics from harsh environments. They are avail-able in cooling capacities up to 5,600 Btu/Hr.

The ETC accurately maintains a constant temperature in the electri-cal enclosure that is slightly under the maximum rating of the electronics. It permits just enough cooling for the electronics without going so cold as to waste compressed air. A digital LED readout displays the temperature of the electrical enclosure (°F or °C), then dis-plays the user temperature setting when pressing the “push to set” button. When that setting is exceeded, the Cabinet Cooler System is activated.

The ETC is suitable for NEMA 4, 4X and 12 environments and works with our UL listed Dual Cabinet Coolers sys-tems which are available with cooling capacities of 4,000, 4,800 and 5,600 Btu/Hr. All systems include an automatic drain filter separator to keep moisture in the compressed air out of the enclo-sure. Models are available for 120 VAC or 240 VAC and lower cooling capacities are available. All products are CE com-pliant. Prices start at $1,701.

EXAIR Corporation(800) [email protected]/dualetc.htm

Pretreatment SystemPPG Industries’ industrial coatings

business has introduced the Versab-ondTM pretreatment system, a fast kinet-ic-efficient zinc-phosphate pretreatment formulation that improves the corrosion resistance of mixed-metal substrates while enabling manufacturers to realize the en-vironmental and energy-saving benefits of extended bath life, reduced sludge and lower processing temperatures.

Based on proprietary hypernucle-ation technology developed by PPG, the Versabond system incorporates a rinse conditioner that causes small, densely packed zinc-phosphate crystals to deposit on mixed-metal substrates, accelerating bond formation with the coating, partic-ularly on surfaces with higher concentra-tions of aluminum.

The proprietary zinc-phosphate for-mulation in the Versabond pretreatment system precipitates onto metal surfaces about twice as fast as traditional zinc-phosphate products and produces a tight,

lattice-like network of microcrystals. The

result is greater metal adhesion and fewer

voids in the coating system, which leads

to more effective corrosion protection.

Depending on the composition of the

metal mix, the Versabond pretreatment

system may process at temperatures up

to 20 percent lower than those required

for conventional zinc-phosphate formu-

lations. It also extends average bath life

from two weeks to eight weeks and gener-

ates 30 to 50 percent less sludge, resulting

in less waste, lower energy consumption

and fewer maintenance demands.

The Versabond pretreatment system is

engineered to improve the corrosion re-

sistance of underbody truck and vehicle

parts such as springs, control arms, tie

rods, frames and exhaust system compo-

nents.

PPG Industries(888) 774-2001www.ppgindustrialcoatings.com

PolyamideFoster Polymer Distribution an-

nounces its official partnership with Mitsubishi Gas Chemical to distrib-ute MX-Nylon to the North Ameri-can medical market. Mitsubishi’s MX-Nylon, a meta-xylene diamine polyamide, offers excellent mechani-cal and barrier properties for molded components and devices, and medical pack-aging applications.

Polymer components are frequently preferred over metal in medical equipment since they do not interfere with magnetic resonance imaging (MRI), computer-ized axial tomography (CAT), fluoroscopy and x-ray imaging. Mitsubishi’s MX-Nylon is a high strength metal replacement material with a flexural modulus 50% greater than traditional polyamide 6/6 and 15% greater than polyetheretherketone (PEEK). At less than 25% the price of PEEK, MX-Nylon is an economical option for components that must be radiolucent and high strength.

MX-Nylon also offers superior gas barrier properties against oxygen and car-bon dioxide compared to all commercially available polyamides, as well as eth-ylene-vinyl alcohol (EVOH) copolymers, acrylonitrile (PAN) copolymers, and polyvinylidene chloride (PVDC) copolymers. Excellent heat stability and a wide processing window, allows this unique polyamide to be co-extruded or co-injec-tion molded with other polymers, such as polyethylene terephthalate (PET), poly-propylene (PP) or polyethylene (PE) for multi-layer medical packaging or con-tainment systems that require low oxygen permeation. MX-Nylon is also suitable for applications that must withstand sterilization by gamma, e-beam, ethylene oxide and retort methods.

Foster Polymer Distribution, www.fosterpolymers.com


NEW PRODUCTS

Fiberglass Light PipeSchurter announced the capability of integrating a fiberglass

light pipe as an optional feature to its popular appliance outlets. The light pipe provides operational or other function status indi-cation in power distribution units (PDUs). It is designed to chan-nel light from LEDs on the pc board to the front of the connec-tor. The new technology offers flexible design options including the number of light pipes, 1-4, as well as options for light pipe lengths and diameters. The flexibility of design allows for efficient customer-specific solutions while enabling increased opportunity to signal status information from the power grid to the user.

The light pipes installed in the outlet are designed to channel light coming from LEDs mounted on a printed circuit board to the surface of the outlet. Each outlet generally has its own cir-cuitry and, depending on the complexity of the monitoring system, may offer several types of indicating functions. The outlets are capable of providing up to four light pipes, one in each of the four corners of the connector. The side of the outlet with the ground pin provides extra space around the two corners, allowing for the most prominent and thus popular position.

A typical application consists of power distribution units used in data centers. Today, these units are most likely to have moni-toring systems with indicating display panels or controls. These display panels are often centrally located. With SCHURTER’s new appliance outlet, it becomes easier to extend the systems monitoring capabilities from the centralized display to each outlet. Service technicians are able to clearly see which systems are working properly, or respond to required maintenance adjustments. A connector could, for example, signal an outage with a red LED, or a critical power consumption pattern with a yellow LED. In this way, both repairs and preventive maintenance can be done more simply and efficiently. n

Schurter, (800) 848-2600, [email protected], www.schurterinc.com

630-860-6514 www.capablecontrols.com790 Maple Lane Bensenville, Illinois 60106

630-860-6514 www.capablecontrols.com790 Maple Lane Bensenville, Illinois 60106

e Controls Inc.

Capable Controls Inc.

Manufacturing gas ignition controls since 1990


Series 8X: Dual output relays extends the useful life to approximately twice that of our competitors with extensive diagnostics.

CE EN 298:2003 Certified to StandardsAG206 and AG210


C US

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We offer replacements for all Honeywell and Johnson Controls

Series 9X: Our Worldwide controlcarries North American, European

and Australian approvals.



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PRODUCTS & SERVICES

applianceDESIGN’s


The appliance DESIGN MUST SEE Gallery provides a glimpse at the latest innovations entering into the market. Please visit the company’s website or email them for more information.

UV Curable System Features High Tg Master Bond UV25 offers exceptional thermal stability over the broad service temperature range of -60°F to +500°F. This

one part, moderate viscosity UV curable system bonds well to glass, surface treated metals and many plastics. Additionally, it is optically clear with a refractive index of 1.55 at room temperature.

www.masterbond.com

“Hands-On” Evaluation, Sampling and Prototyping Global businesses and Design Engineers of electronic devices and products of all types have used our Basic Evaluation Kits and proprietary magnetic shielding materials for evaluation. Optional Lab Kits including a Gaussmeter or Pickup Probe are available.• LK-110 Basic Lab Kit• Samples Include: Co-NETIC® | NETIC® | AA CABLE SHIELD• Technical Guide

Magnetic Shield Corporation USA & Worldwide888-766-7800shields@magnetic-shield.comwww.magnetic-shield.com

CLOSURES FOR PRODUCT PROTECTION, FINISHING AND MASKINGMOCAP manufactures and stocks a wide assortment of Vinyl Caps, Plugs and Grips along with numerous styles of Polyethylene Caps and Plugs for immediate shipment. We have also recently completed tooling on many styles of Threaded and Non-Threaded Caps and Plugs. Free Samples are available.

[email protected]


Helium Recovery Units

Pfeiffer Vacuum Helium Recovery Units reduce your helium costs by recovering used helium test gas regardless of the leak detection system manufacturer. Depending on the process parameters, up to 98% of the inert gas can be recovered with helium concentrations between 20% and 95%. The standalone automated system meets environmental certification requirements under DIN EN ISO 14001.

Pfeiffer Vacuum, Inc603-578-6500 | Toll Free: 800-248-8254 [email protected]

Fast, Sensitive, Reliable Leak Detection

The Pfeiffer Vacuum ASM 340 performs helium or hydrogen leak detection in vacuum and sniffer modes. Sensitivity is down to 5x10-12 mbar l/s vacuum and 5x10-9 mbar l/s sniffing (< 0.001 oz/yr refrigerant equivalent). It is an easy to use, high performance and durable leak detector providing short cycle times and high throughput.

Pfeiffer Vacuum, Inc603-578-6500 | Toll Free: 800-248-8254 [email protected]

Electronic Switch Harnesses for Gas Appliances The high quality of our switch harness assembly guarantees a reliable and consistent operation. Our switch harnesses can be quickly customized and configured to suit your application.

Cesar-Scott, Inc.Phone: (915) 543-3212Email: csmail@cesar-scott.comwww.cesar-scott.comwww.electronicgasignitor.comwww.heatshrinktubing.netwww.wirecableassembly.net

Key Features:• Customizable to fit any valve• Custom designed harnesses and color schemes• Color coded rotors for easy identification• Life expectancy up to 40,000 cycles

POWER TRIPLE LOCK A GAME CHANGER FOR APPLIANCESAs appliance makers strive to provide more efficient and more easily controlled machines, the need for improving reliability, especially in appliances with electrical connections, has become a high priority for designers. Introducing the Power Triple Lock from TE Connectivity. In stock and ready to ship from TTI.

TTI, [email protected]/PTL

Orion Fans “smart” thermal-controlled fans and fan trays can reduce energy costs up to 30% by increasing or decreasing fan speed according to ambient air

temperature. These fans feature a low noise profile for sound sensitive applications, and a simple AC input. The ball-bearing design results in reduced noise levels of 37 to 45dB.

Orion Fanswww.orionfans.com/products/smartfans

Energy Saving Smart Fans & Fan Trays from Orion Fans & Digi-Key


ASSOCIATION REPORT: CONSUMER ELECTRONICS ASSOCIATION

Shawn DuBravacchief economist of the Consumer Electronics

Association (CEA) and the author of

Digital Destiny: How the New Age of Data

Will Transform the Way We Work, Live, and Communicate, from which this essay is

excerpted. Follow him at @ShawnDuBravac.

Like the Old Internet, the New Internet will

definitely be experienced in the home. It makes

sense that the place where you spend most of

your time will be the place where the Internet of

Things—connected objects with sensors—will be

highly operational. The Internet of Things is another

step toward removing the distance and the friction

between data and action. Connected objects capture

and analyze the data in a quantity and at a speed that

human beings could never match—and then they

will act on it, removing the human element from the

equation.

According to the “Digital Universe” report from

International Data Corporation (IDC), “data just from

embedded systems—the sensors and systems that mon-

itor the physical universe—already accounts for 2 per-

cent of the digital universe.” By 2020, that will rise to 10

percent. IDC estimates that the total number of “con-

nectable things” in the world is around 200 billion. Of

those, around 20 billion are actually wired and talking

to the Internet now. They are able to do so through a

network of around 50 billion sensors that track, moni-

tor, and feed data to those connected things. By 2020,

however, the number of “connected things” will grow

by 50 percent, to 30 billion. And the network of sensors?

We’re talking about a trillion or so.

So what will this new, fully-connected world look

like in practice?

6:42 a.m.: Your alarm goes off. Is it strange that your

alarm went off at the forty-second minute and not the

fortieth minute? Not if your alarm knows your sleep

cycles and wakes you during your lightest moment of

sleep, a much more natural way to wake up than being

shocked awake when you might be in deep REM sleep.

Gently, the ambient lighting of your bedroom turns

on, brightening at the same rate that your eyes can

adjust. At the same moment, your shower turns on as

well—adjusting the water temperature to match your

personal preference, which it has learned. After you

shower, your calendar matches the day’s events with

options in your wardrobe, prompting you with differ-

ent options and predicting your preferences among

the choices presented.

7:30 a.m.: Your coffee is fresh and waiting for you,

brewing based upon past behavior and sensor data

from throughout your home. You arrive in the kitchen

and are prompted with several breakfast choices. The

option with the highest uses the last of the strawber-

ries because your refrigerator sensed that they were

about to go bad. As you eat, you glance through the

day’s news on one of several screens around you,

your favorite news sites arranged in the order you

like to read them, with news stories chosen to match

your interests. Or maybe you prefer the television in

the morning, in which case the TV program deliv-

ers the news in the way you prefer: sports first, then

weather, then local, and finally national and foreign.

Or perhaps the stories are delivered to you in an

order derived from the number of friends or col-

leagues who have “liked” or “recommended” them. A

ding from your watch lets you know precisely when

you need to leave if you’re going to make your 8:30

appointment—relying on a real-time feed from traf-

fic monitoring systems like Waze or future systems

relying on V2V and V2I… You step into the garage

where your driverless car is already on, with the inside

temperature adjusted perfectly to the outside weather

and your personal preference. It zips away while you

continue reading the news or perhaps take the time

to return some emails or make some calls. You didn’t

have to worry about turning off the lights, turning the

thermostat up or down, or checking whether you have

enough food for dinner. As devices in your home were

digitized, sensorized, and connected, those tasks were

turned into data, and algorithms are now automating

them on your behalf.

The sensorization of everyday objects will become

so commonplace that we won’t see these “connect-

ed things” as high tech. They’ll just be things. Take

for example the proliferation of motion sensors in

use today. We don’t give a second thought when we

approach the door of a retail store and it opens as we

approach it. I’m sure the first door to integrate motion

sensors felt a little like magic. And that’s what tech-

nology does. It takes the magical and makes it mun-

dane. This, in a single example, is the long march of

technological progress: making the remarkable ordi-

nary—even invisible. The world isn’t getting more

high tech, the tech is meeting us down on the ground.

It’s becoming commonplace, as ordinary as the ham-

mer in your toolbox—in the great democratization of

technology. <

How the IoT will Play Out in Our Homes


AD INDEXSALES TEAMcompany name page number web site

AK Steel 23 www.aksteel.comBokers Inc 54 www.bokers.com/adCapable Controls, Inc. 18, 53 www.capablecontrols.comCesar-Scott, Inc. 55 www.cesar-scott.comCoorsTek IFC www.coorstek.comEPCOS TDK 55 www.epcos.com/ag_consumerETCO 16, 19 http://edge.etco.comHoneywell 1, BC www.honeywell-blowingagents.comICO Mold 15 www.icomold.comIntertek 25 www.intertek.com/appliances-electronicsMagnetic Shield Corporation 54 www.magnetic-shield.comMasterBond 54 www.masterbond.comMetal Coaters 7, 21 www.metalcoaters.comMOCAP 54 www.mocap.comOrion Fans 55 http://orionfans.com/products/smartfansPfeiffer Vacuum, Inc. 55 www.pfeiffer-vacuum.comProto Labs, Inc. 3, 29 www.protolabs.comQuality Show 17 www.qualityshow.comSelco 11, 13 www.selcoproducts.comSoler & Palau North America 11, 13 www.soler-palauinc.comRealMatch 45 www.appliancedesign.com/jobs TE Connectivity 55 www.te.comTower Manufacturing Corporation 5, 26 www.towermfg.comWS Packaging Group, Inc. 9, 37 www.wspackaging.com

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

sales teamDarrell Dal Pozzo - Group [email protected] Phone: (847) 405-4044

Dawn LeRoux - Associate [email protected]: (248) 633-4818 Fax: (248) 283-6558 AK, AZ, CA, CO, HI, IA, ID, IL, KS, MI, MN, MO, MT, NE, ND, NM, NV, OK, OR, SD, TX, UT, WA, WI, WY, Western Canada and International (Europe & U.K.)

Brad [email protected]: (216) 233-6943 Fax: (216) 803-6151 AL, AR, CT, DC, DE, FL, GA, IN, KY, LA, MA, MD, ME, MS, NC, NH, NJ, NY, OH, PA, RI, SC, TN, VA, VT, WV, Eastern Canada

reprintsRenee [email protected] Phone: (248) 786-1661Fax: (248) 283-6588

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for the OEM design engineers worldwide.

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