1 Are You Overlooking a High-Performance Material Option? By Michael Balasko – Marketing Director, Geon Performance Materials, PolyOne Corporation Appliance manufacturers seeking a competitive advantage can benefit from a look at lower-cost material options that may improve overall economics while offering superior performance. One polymer with a proven history of helping appliance designers boost cost-effectiveness is rigid vinyl. Vinyl has successfully replaced polymers like PC+ABS and FR ABS in appliance applications since the 1980s. That’s right, the same polymer used for building and construction applications such as windows, siding, pipe & fittings, and electrical outlet boxes is versatile enough to provide solid value in appliances. In fact, many appliance manufacturers are turning to vinyl when designing new products or redesigning existing models because they know it provides excellent cost performance. FOUR REASONS APPLIANCE DESIGNERS VALUE VINYL Inherent Flame Resistance for User Safety – The U.S. government estimates 150,000 fires each year are caused by major appliances. Because user safety is a primary concern, U.S. safety standards for appliances are created by a consensus between appliance manufacturers, retailers, and government agencies. Any appliance in the U.S., Canada, and Europe that plugs into an electrical outlet requires a flame resistant housing for its electrical components to prevent the appliance user from getting an electrical shock and prevent a potential fire from spreading beyond the appliance. Polymers used for appliance housings must be certified as flame retardant by the UL 94 standard with ratings of 5VA or V-0. Because of the chemical make-up of vinyl, it is inherently flame resistant. This means additives are not required to make the vinyl formulation flame resistant. Avoiding flame retardant additives prevents potential surface appearance issues during the injection molding process that could result in higher scrap rates. In addition, vinyl’s inherent flame resistance allows it to meet the UL 94 5VA or V-0 rating with thinner parts. Figure 1 shows that although competing polymers used for appliance housings can achieve a 5VA rating, vinyl achieves the rating with a thinner wall. This gives more design freedom to engineers looking for cost-out options. In this white paper, you will learn: Why vinyl is valued in appliance designs How vinyl is being used in appliances today Innovations with vinyl in appliances What makes vinyl a responsible choice Helpful hints when switching polymers 0.00 0.02 0.04 0.06 0.08 0.10 0.12 0.14 Vinyl FR ABS FR PC FR PC+ABS Wall Thickness (in) Figure 1 – Minimum Wall Thickness for Polymer to Achieve UL 94 5VA Rating
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Are You Overlooking a High-Performance
Material Option?
By Michael Balasko – Marketing Director, Geon Performance Materials, PolyOne Corporation
Appliance manufacturers seeking a competitive advantage
can benefit from a look at lower-cost material options that
may improve overall economics while offering superior performance. One polymer with a proven history of
helping appliance designers boost cost-effectiveness is rigid vinyl. Vinyl has successfully replaced polymers
like PC+ABS and FR ABS in appliance applications since the 1980s. That’s right, the same polymer used for
building and construction applications such as windows, siding, pipe & fittings, and electrical outlet boxes is
versatile enough to provide solid value in appliances. In fact, many appliance manufacturers are turning to
vinyl when designing new products or redesigning existing models because they know it provides excellent
cost performance.
FOUR REASONS APPLIANCE DESIGNERS VALUE VINYL Inherent Flame Resistance for User Safety – The U.S. government estimates 150,000 fires each year are
caused by major appliances. Because user safety is a
primary concern, U.S. safety standards for appliances are
created by a consensus between appliance manufacturers,
retailers, and government agencies. Any appliance in the
U.S., Canada, and Europe that plugs into an electrical outlet
requires a flame resistant housing for its electrical
components to prevent the appliance user from getting an
electrical shock and prevent a potential fire from spreading
beyond the appliance. Polymers used for appliance housings
must be certified as flame retardant by the UL 94 standard
with ratings of 5VA or V-0.
Because of the chemical make-up of vinyl, it is inherently flame resistant. This means additives are not
required to make the vinyl formulation flame resistant. Avoiding flame retardant additives prevents
potential surface appearance issues during the injection molding process that could result in higher scrap
rates. In addition, vinyl’s inherent flame resistance allows it to meet the UL 94 5VA or V-0 rating with
thinner parts. Figure 1 shows that although competing polymers used for appliance housings can achieve a
5VA rating, vinyl achieves the rating with a thinner wall. This gives more design freedom to engineers
looking for cost-out options.
In this white paper, you will learn:
Why vinyl is valued in appliance designs
How vinyl is being used in appliances today
Innovations with vinyl in appliances
What makes vinyl a responsible choice
Helpful hints when switching polymers
0.00 0.02 0.04 0.06 0.08 0.10 0.12 0.14
Vinyl FR ABS FR PC FR PC+ABS
Wal
l Th
ickn
ess
(in
)
Figure 1 – Minimum Wall Thickness for Polymer to Achieve UL 94 5VA Rating
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Outstanding Chemical Resistance – Whether in the kitchen or the laundry room, appliances must hold up to
chemicals without discoloring or cracking. Kitchen appliances come into contact with foods, beverages, oils,
and cleaning products while laundry appliances need to withstand detergents, stain removers, and fabric
softeners. Selecting the wrong polymer for an
appliance can lead to a cracked or discolored
appliance which not only looks bad and damages
brand reputation, but can also lead to a shorter
product life. Appliance manufacturers test polymer
housings to insure they can withstand the chemicals
used during normal product use.
Vinyl’s chemistry helps it provide excellent resistance
to kitchen and laundry chemicals tested by appliance
manufacturers. By comparison, polycarbonate (PC) and
its alloys have less resistance to kitchen and laundry
chemicals making its housings more susceptible to discoloration and cracking from chemicals in the kitchen
and laundry room. ABS performs somewhere in between PC and vinyl.
Resistant to Color Shift for Long-Lasting Aesthetic Appeal – Kitchen and laundry appliances look bright and
shiny when they are displayed in the retail store or when they are first brought home. These appliances are
then exposed to light, whether ambient sunlight through
windows or indoor lighting in the home. Light can
breakdown polymers if they are not properly protected,
leading to discoloration and potentially a loss in physical
properties. Yellowing due to light exposure is frequently
seen in home and office products such as printers, fax
machines, computers, thermostats, and water coolers.
Appliance manufacturers use accelerated weathering
testing to evaluate a polymers ability to withstand
discoloration from exposure to light. These tests simulate an
appliance being exposed to light over an extended period of
time.
Vinyl is a versatile polymer that can be easily formulated to improve performance, including color retention
upon light exposure. Vinyl has a history of proven performance in outdoor applications such as window,
house siding, fencing, and decking. This technology can be translated indoors to appliance applications,
helping appliances look newer longer. In fact, some appliance manufacturers select vinyl for laundry
consoles because the color hold performance matches that of the painted metal frames. By comparison,
ABS has much less resistance to light while PC performs somewhere in between ABS and vinyl.
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1
2
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Vinyl FR ABS FR PC+ABS
del
ta E
Figure 3 – Color Change after 300 hrs of UV Exposure
Vinyl FR ABS FR PC+ABS
Ch
emic
al R
esis
tan
ce
Good
Fair
Excellent
Figure 2 – Chemical Resistance of Flame Resistant Polymers
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Competitive Advantage – Getting a polymer to meet the physical
requirements for appliances is only half the battle. If the resulting
polymer does not provide value, product designers will not even consider
it as a possible solution. A polymer can bring value in ways other than
just a lower cost per pound. A polymer solution can…
eliminate a secondary operation like painting
reduce warranty claims from yellowing or chemical cracking
reduce scrap rates during injection molding
Vinyl can bring value in all these areas. First, vinyl generally costs 15 to
30% less than FR ABS, PC+ABS, or FR PC on a cost per volume basis. That
advantage can also increase in times of rising energy prices. While
competing polymers like ABS, PC, and PC+ABS are produced from 90-
100% hydrocarbon feedstock, vinyl is made from only 43% hydrocarbon
feedstock. When energy prices rise, vinyl pricing remains more stable
than competing polymers.
Second, vinyl provides excellent appearance for highly visible consumer
products. It can be formulated in bright, deep saturated or metallic-look
colors with a high gloss or matte appearance. Not all polymers provide
this type of appearance so to get this look, other polymers need to be
painted. Vinyl’s excellent aesthetics gives designers an opportunity to
eliminate painting. Eliminating painting reduces production costs,
simplifies the supply chain, and eliminates concerns with VOC’s.
As mentioned earlier, vinyl has excellent chemical and UV resistance
which can help prevent discoloration, cracking, and product failure
during use of the appliance. Finally, vinyl does not need flame retardant
additives so using vinyl instead of FR ABS or FR PC+ABS can eliminate
surface issues during injection molding and thereby reducing scrap rates.
0
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4
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8
10
$30 $50 $70 $90 $110 $130 $150 $170
Po
lym
er P
rice
(ce
nts
/in
3)
Oil Price ($/bbl)
PC
ABS HIPS
PP PVC Resin
Data Source: Chem Data Inc. - Polymer Pricing Data Source: U.S. Energy Information Administration - Cushing, OK WTI Spot Oil Pricing
Figure 4 – Vinyl Pricing is More Stable When Oil Pricing Rises
Vinyl: A Responsible Choice Learning the facts about vinyl will help you make the best choice for your business. FACT: Vinyl is non-toxic – Vinyl polymer, or PVC, does not pose a toxic threat. Like other polymers, vinyl manufacturers use state-of-the-art processes and follow governmental regulatory guidelines and best practices to keep workers, communities, and consumers safe. FACT: Vinyl can be made with eco-conscious additives – The versatility of the vinyl polymer enables the use of eco-conscious ingredients to replace additives based on heavy metals and other substances of concern to customers. FACT: Vinyl processing is safe - Vinyl has been safely processed for decades and requires the same ventilation used with other polymers. FACT: Vinyl is tested and approved – From medical products to potable water to appliances, vinyl has been approved by regulatory agencies including the U.S. FDA, UL, and NSF. In fact, today’s vinyl compounds are suitable for use in children’s toys in accordance with strict guidelines set forth in the Consumer Product Safety Improvement Act FACT: Vinyl disposal is safe – Vinyl has been safely recycled, incinerated, and land filled for years. Millions of pounds of post-consumer vinyl are reclaimed and made into useful products annually. FACT: Vinyl is a responsible choice – For more information on vinyl and its benefits, visit any of the following sites:
Vinyl’s excellent flame, chemical, and UV resistance make it an excellent choice over FR ABS, PC+ABS, or metal.
Dishwasher Consoles
Vinyl’s excellent flame, chemical, and UV resistance make it an excellent choice over FR ABS, PC+ABS, or metal.
APPLIANCE APPLICATIONS WITH VINYL Rigid vinyl has been successfully used for years in a variety of major and small appliances, including:
Washer & Dryer Door Trim Ring
Vinyl’s excellent aesthetics without painting allow the trim ring to match the painted metal cabinet of the front load laundry unit. Vinyl’s structural integrity allow it to cost effectively replace metal.
Refrigerator Ice & Water Dispenser Housing
Vinyl’s excellent flame, chemical, and UV resistance make it an excellent choice over FR ABS, PC+ABS, or metal.
Blender Motor Housing
Vinyl’s excellent flame, chemical, and UV resistance make it an excellent choice over FR ABS, PC+ABS, or metal.
Room Air Conditioner Panels
Vinyl’s excellent aesthetics allows it to replace painted ABS.
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APPLIANCE INNOVATIONS WITH VINYL Applications for vinyl in appliances continue to grow because engineers see the value of vinyl and work with
suppliers to find new ways to use it. Here are some examples of how vinyl is used in new and innovative
ways.
Metallic-Look Vinyl to Replace Painting – Metallic-look
appliances are popular with consumers. To achieve a metallic
appearance, appliance manufacturers can choose metal,
chrome-plated plastics, or painted plastic. However, metal
restricts design freedom and shows dents and scratches,
while secondary plating and painting operations are costly
and present challenges associated with VOC emissions.
Pre-colored, metallic-look vinyl can achieve a metallic
appearance without the design limitations, costs, and VOC
challenges seen with alternative methods. A metallic appearance is achieved with the polymer housing right
out of the mold. It is important to note that a mold must be properly designed for a metallic-look vinyl
upfront to avoid issues with weld lines.
In-Mold Labeling with Vinyl – In-mold labeling (IML) has been
used with appliances for years. It involves placing a pre-
decorated polymer label or appliqué into an injection mold to
create a final molded part with a decorated surface. The
advantage of the IML process is that molten plastic adheres
to the label and makes it an integral part of the finished
molded part, eliminating the need for a secondary process to
affix the label.
Appliance manufacturers typically use PC+ABS for the molded part and PC+PET for the label. Because of the
chemistry differences between the molded polymer and the label polymer, an adhesive coating is required
on the label to obtain a proper bond. Additionally, the different chemistries means the label has to be
removed or “shaved” from scrap parts before they can be recycled. Using vinyl for both the label and
molded part eliminates the need for an adhesive and the need to remove the label prior to recycling scrap
parts.
Glass Encapsulation with Vinyl – Glass encapsulation is a
process that has been used primarily in refrigerator shelving,
but is now being expanded to laundry lids. It involves injection
molding rigid vinyl around a glass insert. The benefits include
lower cost to manufacture, improved recyclability, and greater
consumer appeal. Specifically, this process eliminates the need
for adhesives as well as additional assembly steps, while
increasing aesthetics and sustainability.
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SUMMARY The appliance industry has many challenges for design engineers.
Engineers must choose materials that produce safe, high quality
appliances while managing costs to keep their products competitive.
Whether it’s providing solid performance in a new product design or
reducing costs in an established appliance product, rigid vinyl can help
appliance design engineers meet their goals. Vinyl’s balance of flame,
chemical, and UV resistance in a cost-effective material has delivered
proven performance in an industry with stringent requirements and
replaced polymers such as FR ABS, PC+ABS, and PC. In fact, vinyl continues
to push the envelope of product design with innovations like metallic
appearance, IML, and glass encapsulation.
What if you could make your appliance designs more cost-effective? You
can when you design with rigid vinyl. Understanding the value of vinyl and
knowing where it can effectively be used can be a powerful tool in an
engineer’s toolbox.
www.polyone.com
CONTACT INFORMATION
PolyOne Americas 33587 Walker Road Avon Lake, Ohio 44012 United States
+1 440 930 1000
PolyOne Asia Chiling Industrial Zone Houjie Town, Dongguan City Guangdong 523940 People’s Republic of China
Converting from one polymer to another requires careful planning. Here are a few helpful hints to consider when switching polymers. 1. Cost per unit volume – Different
polymers have different specific gravities so a part made from one polymer will have a different weight than a part made from another polymer. Convert cost per weight to cost per volume to create an apple-to-apples comparison.
2. Mold Shrinkage – Polymers with
similar mold shrinkages can use the same mold while polymers with different shrinkages require different molds.
3. Mold Construction – Because
polymer chemistry can affect steel surfaces differently, consult with a polymer supplier to get a recommendation for which steel to use with their polymer.
4. Gates, Runners, and Wall Thickness –
The flow properties of a polymer can vary significantly between polymer chemistries and within a single polymer chemistry. Insure the gates, runners, and wall thicknesses of your mold are adequate for the polymer you are considering.
5. Technical Support from Supplier –
Knowledgeable polymer suppliers with effective technical support can be a great resource for manufacturers converting to the supplier’s polymer. A supplier’s Design Engineer can provide part and mold design recommendations as well as computer simulations to reduce the risk, time, and cost of the conversion. A supplier’s Field Technical Service Engineer can work with the mold builder and molder during the mold de-bugging and production start-up processes to insure the mold, molding equipment, and processing conditions are optimal for their polymer.
For additional information on Geon™ Rigid Vinyl from PolyOne, please
