january 28, 2013 renewable materials for it applications to market/kuczynski... · glycerin (a...

© 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


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


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


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


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


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


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!


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


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


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


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


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


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


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


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


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


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


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.


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


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


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


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


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


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


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!

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