MATERIALS IN DESIGN & PROTOTYPING FEATURE LIGHTER ENTERTAINMENT As technologies and materials are continuously restructured to meet evolving


consumer demand, the pressure is on for design engineers and manufacturers to create new electrical and electronics products with more sustainable materials, as Richard Thompson, commercial director of Alvant, explains


M


aterial innovations are driving smarter electrical and electronic applications to


meet sustainability targets and consumer demand. For every new iPhone, widescreen television (TV) or laptop released, the benchmark is re-set for the next model to be faster, smaller, lighter, thinner, quieter, more durable, smarter and more aesthetically attractive. Added to this is the need for sustainability. However, the desire and need to overcome such challenges is often the catalyst for innovation. Take TVs as one example.


Invented by John Logie Baird in 1924, this invention has survived almost a century. 1983 saw the invention of liquid crystal display (LCD) and, almost four decades later, they have evolved almost beyond recognition. Materials originally used by Baird to develop his first prototype, which included cardboard and even wax, have now been replaced with injection-moulded plastic. However, just as today’s electronic and


electrical applications are becoming more energy efficient, smarter, stronger and slimmer, they’re also growing in size.


ALUMINIUM METAL MATRIX COMPOSITES One potential solution is aluminium metal matrix composites (AMCs), a class of advanced materials. Advanced materials refer to a new material or the modification of an existing material, and it is these which have proven successful in meeting most of the rigorous specifications in applications where lightweight, high stiffness and moderate strength are pre- requisites. AMCs protect electronic devices from radiofrequency and thermal stress (they have a higher thermal operating range), and have wide application potential in the electronic packing system. As more electronics manufacturers are finding current materials a challenge, particularly when it comes to achieving thermal stability, this makes AMCs ideal for large screen TVs. These alternative materials can also offer a


solution for the screens of large display TVs as well as the stands. Growing screen sizes means the weight of a TV has generally increased, some as heavy as 50kgs. Tempered glass, while extremely stiff, is also heavy – which is not only a problem when handling, but also impacts logistics costs with global shipping and


and offer multiple advantages over other materials, including higher transverse strength and stiffness, superior damage tolerance and increased opportunity to recycle. This last factor may prove to be one of AMCs’ greatest legacies. Sustainability and durability are major areas


distribution. These extra kilos in turn make existing stands inadequate, with the risk


of damage under the TV’s own weight. There is potential for AMCs to create a hybrid back panel made from a thinner amount of glass to retain the aesthetic requirements by bonding AMC inserts to the glass in strategic locations to strengthen and stiffen. This offers a lighter and stiffer solution with a weight saving of 20%. The lightweight appeal of AMCs does not mean


a compromise in their sturdiness either. In fact their material properties have superior strength compared to steel at less than half the weight,


of concern in the electronics industry as products with a shorter shelf life are discarded by consumers. To tackle these issues, the focus on the entire product lifecycle and the ability to reuse is now a key factor in design development. The ability of AMCs to separate the fibres from the aluminium at its end-of-life stage is a major benefit to manufacturers who are ever-more conscious of environmental impact. And while the potential of AMCs may not be fully grasped just yet, one thing that remains clear is the growing awareness of specific disadvantages with other materials such as less sustainable carbon composites and polymer composites. AMCs, however, are also playing a pivotal part


in the aerospace industry, automotive industry and other engineering applications. Alongside the US and Germany, the UK is driving the market with steady growth forecast. As we emerge from COVID and Brexit, this can only serve us all well as we focus on becoming the leading global hub for technical innovation and sustainability over the coming years.


Alvant www.alvant.com NEW LONG-LIFE COATING FOR FOOD MACHINERY


Automated systems are essential in the food industry. But if a bottle falls over in the filling line or a packet of soup gets wedged between moving parts and tears open, this can lead to unplanned plant shutdown. Moving components with a low coefficient of friction are preferred to minimise plant damage and downtime. To give guide plates, metallic sliding parts or even parts with complex geometries high wear resistance, igus has now developed a new coating material. Blue in colour for visibility, this high-performance IC-05 polymer


complies with both FDA and EU10/2011 regulations and is therefore ideally suited for contact with food. According to the company, the superior material significantly reduces the coefficient of friction of the coated parts and increases the service life and availability of the equipment. It also improves product safety and reduces the costs of parts replacement. In addition, no lubrication is required. The powder material can be applied onto the desired


components, either by the customer or by igus. Layer thicknesses of 60 to 120 μm are possible. During tests, a part coated with IC-05 (FDA-compliant) was compared with an identical


part coated with the standard material IC-01 in various test set-ups. The IC-05 component recorded four times longer service life. In addition to IC- 05, igus offers five other coating materials for applications in the high- temperature range or with high chemical resistance.


igus / DESIGNSOLUTIONS www.igus.co.uk DESIGN SOLUTIONS | MARCH 2021 35


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