Circular Design Challenge kick-off event (Ruud Balkenende)

CLOSING THE LOOPS Ruud Balkenende Delft University of Technology

CIRCULAR DESIGN CHALLENGE

Kick-off Event

Friday June 10

© Daniel Disselkoen

3 Ruud Balkenende, TUD-IO, Circular Design Challenge, 10-6-2016


Materials in LCD TV (‘Early’ LCD TV, 32”, 22kg, 2005)

Engineering Perspective: weight

Data: Jaco Huisman, TUD


Environmental impact of Materials

Policy Perspective



Value of Materials

Business Perspective



Electronic waste as mining ore

Consider product as an ore: Low amount of target material

relative to total Concentration is not sufficient:

• Total mass • Homogeneity • Dispersion • Impurity, contamination • Regulations • Ease of disassembly

lamp PCB + L2


Product life cycle

Raw materials

Final Assembly

Packaging

Waste

Use

Design & Production

Sales


Parts supply

Distribution

Collection

User

Manufacturing

Recycle

Part harvesting

Refurbish

Service

Enablers

Circular Economy

Waste

Materials

CIRCULAR PRODUCT DESIGN • Enable multiple life-cycles

with minimal loss of quality and value

• Maximize remaining value

• Minimize required energy input

• Modular design for easy disassembly

• Create re-usable platforms

COLLABORATION • Cross value chains

• Cross business sectors

• Financial and Social Partners

REVERSE LOGISTICS • Enable efficient closed loops

• Collection of materials

• Legislation compliance

NEW BUSINESS MODELS • Service/Solution Delivery vs.

Asset Ownership

• Easy access and affordable prices

• From transactions to relationships


Parts supply

Distribution

Collection

User

Manufacturing

Recycle

Part harvesting

Refurbish

Service

Circular Economy

Waste

Materials

CIRCULAR PRODUCT DESIGN • Enable multiple life-cycles

with minimal loss of quality and value

• Maximize remaining value

• Minimize required energy input

• Modular design for easy disassembly

• Create re-usable platforms

Optimize performance and experience during all (re)use-stages


Parts supply

Distribution

Collection

User

Manufacturing

Recycle

Part harvesting

Refurbish

Service

Circular Economy

Waste

Materials


Recyclability: use end-of-life insights

Connections limit separation



Observations

Fixed connections keep parts connected: screws, glue, potting

Relate design aspects to dismantling result: Recyclable materials Separable materials


• Get PCB out in one piece ( smelting)

• Enable easy/fast detection of materials

• Use materials that can be recycled

• Use of compliant coatings

• Limit the number of different materials

• Avoid fixed connections

• Break-down (by shredding/disassembly) to

o Pieces with uniform composition

o Pieces of relatively large size (>1 cm)

materials

connections

electronics

Design Rules for Recycling not compromising performance or increasing cost

Design taking recycling into account


Standard MR16

random fracturing PCB and shell often still attached

MR16 low voltage lamp


MR16 with fracture lines

17

fracturing along fracture lines (in brittle materials)

screws released

PCBs detached

Assist and guide fracture in the case of brittle housing


MR16 redesign with stacked parts

LED PCB

driver

collimators

driver clamp

heat sink top / fixation

heat spreader LEDs

heat spreader driver

contact pins

shell


heat spreader LEDs

heat spreader driver

contact pins

shell

collimators

driver clamp


LED PCB

driver

One recyclable main material, thinner design, single fixed connection


Stacked MR16: recycling results

19

Aluminum parts fold, capturing PCBs

Sand potting prevents folding

Increase rigidness of structure in the case of ductile housing


Slimstyle bulb

• Optical part also acts as housing

• Polycarbonate parts connected by ultrasonic welding


Slimstyle bulb

Shredding result


Recycling


make it

with design for

easy

modular design to

and optimizing for

upgradable for endless performance and adaptability

disassembly to allow

maintenance for optimal performance

remake products

recovery end of life

Disassembly

Recycle

Modular

Maintenance Upgradable

Last long

Use long

Recovery

Service

Remake

Material

Product

Component

CE product design


CLOSING THE LOOPS Ruud Balkenende Delft University of Technology

CIRCULAR DESIGN CHALLENGE

Kick-off Event

Friday June 10