© 2009 IBM Corporation
Renewable Materials for IT Applications
Dylan Boday &
Joe Kuczynski
January 28, 2013
© 2009 IBM Corporation2
IBM Drivers for Renewable MaterialsCustomer interest in use of renewable vs. non-renewable feedstocksSurvey of customers indicate overwhelming support for greater
level of sustainability in IT HW
Potential for competitive advantage
Need to determine comparative environmental impactsNo “green washing”
Functional performance improvements Identification of current materials and their physical properties
with respect to electronics applications
Strategic policy developments European Union Lead Markets Initiative (LMI) supports actions to lower
barriers to bring new biobased products to market Japanese government’s goal that 20% of all plastics consumed in the
country be renewably sourced by 2020 US legislation introduced in March 2012 to foster a biobased economy
© 2009 IBM Corporation3
IBM Drivers for Renewable Materials Procurement criteria Emerging standards and guidelines
• US Department of Agriculture: Guidelines for Designating BiobasedProducts for Federal Procurement under revision to establish procedures for designating complex assembly products (multi-component assembled products with one or more component being made with biobased material) within the scope of the Federal biobased products procurement preference program
• US EPA Electronic Product Environmental Assessment Tool (EPEAT®) includes biobased plastic criteria in draft standards for imaging equipment and TVs which will likely be extended to servers and other IT products in new and revised EPEAT standards
Examples of proposed criteria:
The manufacturer shall declare the percentage of the combined weight of biobasedplastic materials, calculated as a percentage of total plastic (by weight) in each product – Required
Product containing five kgs of plastic or less shall contain on average a minimum of 10% biobased plastic materials. Product containing more than five kgs of plastic shall contain on average a minimum of 5% biobased plastic materials. Plastic content shall be calculated as a percentage of total plastic (by weight) in the product – Optional
© 2009 IBM Corporation4
IBM Smarter Planet Overview
SMART WORK
DYNAMIC INFRASTRUCTURE
GREEN & BEYOND
To improve the agility of enterprise business processes and the organization’s ability to benefit from and enhance the expertise and creativity of its people
NEW INTELLIGENCE
To manage the mountain of information generated daily by increasingly connected systems, devices and people, while extracting richer insights and making faster, better decisions
To support initiatives in response to escalating energy, environment and sustainability concerns, and stakeholder requirements for social responsibility
To provide the operational efficiency to drive down costs and the flexibility to assimilate change and drive competitive advantage
Major growth play for IBM using available data A pillar in the IBM’s smarter planet initiative is green and beyond Focus on sustainability concerns
© 2009 IBM Corporation5
IBM Advanced Materials Development
System z
Power System System x
System Storage
Anti-Corrosion FillersPatterned magnetic media
Renewable Materials Development
Laminate Development for PCBs ESD and EMI Materials Development
Chip Lid
Heat Sink
TIM
Thermal Solutions Development
© 2009 IBM Corporation6
IBM Renewable Materials InitiativeFormed Renewable Materials
Initiative 2010Project Focus Areas:Identify commercial, renewable alternatives to petroleum-based materials for IT applications; qualify new renewable materials (part and system level); establish road map for a sustainable IBM product line
Establish research in core sustainable technologies (via both internal lab capabilities and industrial/academia collaboration) to ensure road map is achieved
Influence the industry/field
© 2009 IBM Corporation7
Organization of Renewable Materials Initiative
Sustainable Materials Initiative
Dylan BodayJoe Kuczynski
Executive SupportISC
- CoE Global Environment Product Compliance -Global Procurement
-Global Execution
STG & Development-Engineering Services and Design Integration
-Systems Hardware Development-Client Advocacy & System Assurance-STG Materials & Process Engineering
Consultants-LCA practitioners
-Policy and Standards
Corporate Environmental Affairs-Toxicology and Chemical Management
-Environmentally Conscious Product Design- Environmental Policy and Programs
External Suppliers-Resin Suppliers
-Material Compounders-Foam Manufactures and Converters
-Plastic Recyclers
Industrial Partners-Automotive
-Business Equipment-IT
Marketing and Communication
Professional Societies-Partnering with ACS and RSC
-Organizing International Conference -Initiatives to drive U.S. policy
-Standards Boards and Committees
University Relationships-Collaborations meeting Strategic Business Needs
-Driving IBM agenda through relationship-Develop Experienced Professionals for Future
-Including in developing GEOS
© 2009 IBM Corporation8
Renewable Materials in IT ProductsThere are numerous locations where renewable materials can be used:
– Foams
– Thermoplastic Covers
– Fan housings
– Packaging materials
– Cabling
– EMC materials (fabric-over-foam
gaskets)
– Card shields
– Printed circuit boards
– Adhesives
– Connectors
– ElastomersThere are several challenges for
renewable materials in the IT industry!
© 2009 IBM Corporation9
Acoustic Foam Process
Handbook of Polymer Foams by David Eaves
Density = 2 lbs/ft3
Pore Count = 65-75 ppiTypical Ratio Polyol:Iso:H2O = 65:30:5
© 2009 IBM Corporation10
Bio-Polyols Evaluated for use in PUR Foam Manufacturing
Meier, A. R.; Metzger, J. O.; Schubert, U. S. Chem. Soc. Rev. 2007, 36, 1788.
• Invesitgated the replacement of petroleum based polyols with polyols derived from fatty acid esters
• Interested in soy bean and linseed oil• Common approach is to oxidize soy bean oil
and generate a polyol• Renewable polyol can be used in typical
polyurethane chemistry
© 2009 IBM Corporation11
Foam ConversionBuns of acoustic foam slit to width at converter
•Slit foam hot wire/die cut to shape
•PSA hot roll laminated to finished shape
© 2009 IBM Corporation12
Renewable Acoustic FoamsBiobased foam is one of the more
mature areas in the field • Seat cushions in the automotive
industryIdentified several replacement
materials for acoustic foam applications
Bio-polyol foams meet flammability requirement and have superior acoustic propertiesIntroduced into IBM product set in 4Q
2011Currently 15-30% bio-content
© 2009 IBM Corporation13
Renewable Acoustic FoamsBio-based acoustic foam currently shipping
on numerous products (> 50 PNs)
Approximately 600K board ft/yr
Replaces 30K lbs petro-based foam each year
Shipping on product in all geos
UL Yellow Card on file for biobased foam
Working with supplier to obtain polyol spec for desired acoustic foam properties Evaluating alternative sources for polyol
(vegetable based) Discussions with Emerys Oleochemicals
(polyols from tallow, i.e. animal fat)
Investigating use of recycled cellulose Superior acoustic properties UL 94 HB flammability requirement currently a
challenge Identified novel approach to render cellulose
ignition resistant
Manufacturing locations for foam assemblies
© 2009 IBM Corporation14
Future Directions for Renewable FoamsWorking with producers of bio-polyols from
glycerin (a waste product from biodiesel manufacture) to increase biocontent Above 30% mechanical properties decrease
Working with foam suppliers to obtain polyolspec for desired acoustic foam properties Drive new polyol development to meet our
application needs Contacted partners to explore joint
development work on polyurethane foams
Contacted adhesive suppliers to investigate renewable based PSAs Accounts for 50% of cost of acoustic foam
Formulating flame retardant cellulose Enables 100% sustainable content acoustic
absorber
Exploring other foam applications Replacing petroleum based polyol in EMC
fabric-over-foam gaskets with biopolyol Packaging materials
© 2009 IBM Corporation15
Thermoplastics Used as Electronic Enclosures
Key PC/ABS Properties:• Thermal resistance• Toughness at all temperatures • Easy processing• Easily rendered flame retardant• Dimensional stability • Hydrolytic resistance • Inexpensive
Phosgene
© 2009 IBM Corporation16
Materials Requirements for PC Replacement To be used in the IT industry the following must be met upfront:
RoHS compliant (Restriction of Hazardous Substances)• Lead, mercury, cadmium, hex. chromium, polybrominated
biphenyls and polybrominated diphenyl ethers. Halogen Free (not required, but EPEAT standard leaning in that direction) UL 94 V0 rating at 1.6 mm wall thickness
Mechanical properties comparable to a competitive PC/ABS •Tensile Modulus 2700 MPa•HDT 85-90°C @ 1.8 MPA•Tensile Stress- Break 50 MPa•Tensile Strain – Break >50 %•Yield Strain ~ 4.0 %•Yield Stress 60 MPa• Izod notched impact strength 10 KJ/m2
Cost neutral to market price of PC/ABS
© 2009 IBM Corporation17
Renewable Alternative Materials95% of plastic usage within IBM is polycarbonate (PC) based
Identified three main renewable materials for PC replacement• All identified replacements require additives
Polylactic Acid (PLA)• Max PLA content is 30-40 wt% • Typically blended with PC• Well established volumes• Difficult to render FRPolyhydroxyalkanoates (PHA)• Requires high filler content• Can reach 50 wt% PHA• Biodegradable • Difficult to render FR• Costly productionPolybutylene Succinate (PBS)• Requires blends• 30- 40 wt% content• Biodegradable• FR more achievable
Simply blending in commercial FR packages proved to be insufficient for IT flammability requirements
© 2009 IBM Corporation18
Of the materials evaluated, PLA blends are the furthest along Working to bring PHAs and
PBS to the same stage of PLA blends
Most challenging requirement is flammabilityMajority of mechanical properties
were achievedWith higher PLA content,
impact strength and ignition resistance degrades Server covers do not require
impact strength of PCConducted initial mold trial with
PC/PLA (30 wt%) blends Part not challenging just initial
test
Evaluation of Renewable Blends
DASD Cassette Tray
© 2009 IBM Corporation19
Renewable Material EnclosuresIdentified part with several key
features • Snap fits• Latches• High density pattern• Narrow walls
High density perforated pattern (high flow resin required)
Snap fits and latches (tensile strength and creep resistance required)
Once molded, conduct systems level testing:
• Shock and vibe; 4-corners T&H; Drop test; etc.
© 2009 IBM Corporation20
Completed Parts with Renewable ContentMolded blade server covers
• Blends molded contained 30 and 40 wt% PLA blended with PC
Blends were direct drop ins for PC/ABS materialsParts have successfully passed all
IBM system requirements To reach this point, it has taken 1
year of a collaborative effort Once systems level tests complete:
• Ensure volumes required can be achieved, throughout the supply chain
• Negotiate price (cost is King!)• Run Engineering Change to
designate as primary material• Identify legacy products for use • Drive material into all future
designs across all platforms• Drive volume via partnerships
Front
Rear
© 2009 IBM Corporation21
Current Renewable Research Efforts
• Current efforts focus future needs based on observed challenges for durable goods
• Mechanical properties• Non-mineral fillers• FR properties • Reliability of parts made
CNC
Functionality
Functionality
CNCs
Renewable Fillers
- Also exploring CNC film applications
New Renewable Polymers
Self-Healing Renewable Materials
• Investigating sustainable self healing materials, functional polymers
S. R. White, e.t. al. Nature, 2001, 409, 794.
• Investigating new polymers and copolymers based on above monomers
© 2009 IBM Corporation22
Autonomic Self Healing Systems
White, S.R.; Sottos, N. R.; Geubelle, P. H.; Moore, J. S.; Kessler, M. R.; Sriram, S. R.; Brown, E. N.; Viswanathan, S. Nature 2001, 409, 794Toohey, K.S.: Sottos, N. R.; Lewis, J. A.; Moore, J. S.; White, S.R. Nat. Mater. 2007, 6, 581Kersey, F.R.; Loveless, D. M.; Craig, S.L.; J. R.Soc. Interface 2007, 4, 373.Cordier, P.; Tournilhac, F.; Soulié-Ziakovic, C.; Leibler, L.; Nature 2008, 451, 977
• Each healing system offers an approach to induce autonomic self-healing of the polymer network
• Microcapsules for our applications were selected as the primary self-healing vehicle
• Ease of preparation, ability to encapsulate various cores and spherical size in the micron range
Moore, J.S.; Sottos, N. R.; White, S. R. Annu. Rev. Mater. Res. 2010 40, 179
© 2009 IBM Corporation23
Preparation of Microcapsules - ELSO Core
Average Size: 88.97 ± 19.51 µm
DI H2O (200 mL)5 wt% EMA (50 mL)
Urea (2.5g)NH4Cl (0.25 g)
Resorcinol (0.25 g)
pH 3.5
OctanolELSO (60 mL)
Fromaldehyde (11.5 mL)+
1000 rpm
• Microcapsules with ELSO cores were prepared with slight modification of literature preparations
• Average size of MC were ~ 88 µm• Slightly larger than DCPD MCs• Working to reduce the size
• Microcapsules were sieved through a 250 µm sieve and were dispersed in THF and filtered
Ruptured Microcapsule
© 2009 IBM Corporation24
Preparation of Composite Films
98.6 % PLLA1.4 % D-isomer
Provided by NatureWorks4032 D
+
Microcapsules w/ DCPD Core
catalyst
solvent
• PLLA with low D-isomer content was used for film preparation
• PLLA was dissolved in solvent and catalyst and microcapsules were added
• Varied concentration• Investigated preparation under inert and non-inert conditions
• Films were cast in solvent saturated chamber to allow sufficient film formation
© 2009 IBM Corporation25
Self-Healing PLA
24 h
Load
(N)
0
5
10
15
20
25
0.0 0.2 0.4 0.6 0.8 1.0 1.2 1.4 1.6 1.8
PLA Comp.: 2.5% Cat, 10% MC
Healed PLA Comp.:2.5% Cat, 10% MC
Ɛ (%)
•System developed for a crack to be healed autonomically at room temperature
•Recovered up to 56% of original strength of the PLA film
•Consisted up to 98% renewable content
•Developed to overcome brittleness with high PLA content blends
© 2009 IBM Corporation26
Summary
Drivers for renewable materials are plenty
IBMs interest and activities, plowing the road for IT application using renewable materials
Challenges for the renewable materials field; requires a concerted effort to overcome them.
We are on the cusp of a new paradigm with respect to renewable
materials and their use in IT applicationsThank You!