50th AnniversaryProceedings of the

50th Annual InternationalAppliance Technical Conference

Held in cooperation withPurdue University

atUniversity Inn & Conference Center

West Lafayette, Indiana, U.S.A.

May 10—12,1999

ORGANIZED BY:The Steering Committee of the

International Appliance Technical Conference

IN COOPERATION WITH:Association of Home Appliance Manufacturers (AHAM)Association of Home Equipment Educators (AHEE)Air-Conditioning and Refrigeration Institute (ARI)American Society of Heating, Refrigerating

and Air-Conditioning Engineers (ASHRAE)Canadian Appliance Manufacturers Association (CAMA)(Canada)European Committee of Manufacturers of Domestic Equipment

(CECED) (Belgium)Federation of Engineering Societies—China Association for

Science and Technology (FES-CAST) (China)Gas Appliance Manufacturers Association (GAMA)Groupement Interprofessionnel des Fabricants d'Appareils

d'Equipement Menager (GIFAM) (France)Institute of Electrical and Electronics Engineers (IEEE)National Housewares Manufacturers Association (NHMA)Zentralverband Elektrotechnik- und Elektronikindustrie e.v. (ZVEI)

UB/TIB Hannover119 803 356

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Table of Contents

Session A-1Materials

Characterization of a Unique New Polystyrene Vacuum InsulationFiller 1

—by Mr. John Hagen, Mr. Pete Pendergast, and Mr. Bruce Malone,Dow Chemical

Wear Performance of Injection Molded Thermoplastic Gears 11—by Mr. Edward H. Williams III, LNP Engineering Plastics

Adding Value to Polypropylene for the Appliance Industry 20—by Mr. Scott Suddoth and Mr. Paul Kenny,M. A. Hanna Engineered Materials

Session B-1Special Fasteners Panel

Selecting the Proper Fastener for Automation 32—by Mr. John J Souza, Quality Screw & Nut Company

Overview of the Fastener Quality Act (FQA) 44—by Mr. Michael L. Mowins, Phillips Screw Company

Adaptability of Finished Steel Fasteners Engineered for Use in Mild toExtreme Environments 55

—by Mr. Brian P. Lowry, Curtis Metal Finishing Company

Session C-1HVAC

Application of Fuzzy Sets to Photovoltaic Air Conditioning 66—by Dr. Manohar Prasad, Dept. of Mechanical Engineering,

Mr. Kirti Kumar Dhawan, Mr. G. K. Dubey, and Mr. B. G. Fernandes,Dept. of Electrical Engineering, Indian Institute of Technology, INDIA

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Sequencing Control and Boiler Operating Efficiency 78—by Mr. Thomas Neill, Hydrotherm

An Outlook on Residential HVAC&R Applications in 2020 83—by Mr. Glenn C. Hourahan, P.E.,Air-Conditioning and Refrigeration Technology Institute

Session A-2Refrigerants

Advances in Fluorescent Leak Detection 93—by Mr. John T. Duerr, Spectronics Corporation

The Use of R-134a and Alkyl Benzene Oil to Service R-12Refrigeration Systems 105

—by Mr. Brent Junge and Mr. Alan Mitchell, Whirlpool Corporation

Session B-2Special Fasteners Panel

Fastening System Design for Thermoplastic Materials 114—by Mr. Rick Smith, ATF, Inc.

Comparing Pre-Applied Thread Locking and Installer-Applied LiquidAnaerobic Thread Locking Methods from a Capability and CostPerspective 122

—by Mr. Sean Costin, ND Industries

Session C-2HVAC

The Wood Pellet Burner: A Platform for Introducing "RenewableBiomass Fuels" into Residential Central Heating 727

—by Dr. Jerry Whitfield, Pyro Industries Inc.

Indoor Air Quality and the Mills Boiler 139—by Mr. Thomas Neill, Smith Cast Iron Boilers

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Session A-3Refrigeration

Magnetic Cooling for Appliances 144—by Dr. Karl A. Schneider, Jr. and Mr. Vitalij K. Pecharsky,Ames Laboratory, Iowa State University, and Mr. Carl B. Zimm,Astronautics Technology Center, Astronautics Corp. of America

Development and Testing of a Linear Compressor Sized for theEuropean Market 155

—by Mr. Reuven Unger, Sunpower, Inc.

The Development of Energy Efficient Refrigerators by ITRI 166—by Dr. Jyi-Yu Sun and Dr. Jian-Yuan Lin,Industrial Technology and Research Institute,Energy and Resource Laboratories, TAIWAN

Session B-3Changing Lifestyles

The Major Appliance Information and Training Needs of Educatorsand Practicing Professionals 178

—by Dr. JoAnn M. Emmel and Dr. Rebecca P. Lovingood,Department of Near Environments,Virginia Polytechnic Institute and State University

Japan: The Land of the "Rising" Appliance Technology 190—by Dr. Pat McCallister, Eastern Illinois University

Appliance Recycling: Holding Tough as Steelin the Face of Adversity 202

—by Ms. Maribeth Rizzuto, Steel Recycling Institute

Session C-3Standards and Codes

Getting Ready for IEC 60335—What It Means to North AmericanManufacturers 209

—by Mr. Mark Leimbeck, Underwriters Laboratories

IX

An Understanding of Electromagnetic Compatibility Requirementsfor Household Appliances and Similar Apparatus (as defined byCISPR 14) 220

—by Mr. Robert DeLisi and Mr. Corey Hyatt, P.E.,Underwriters Laboratories, Inc.

Justification for Sidewall Vent-Terminal Locationsfor Gas Appliances 231

—by Dr. Jim Reuther, Battelle, Mr. Neil Leslie, Energy International,and Mr. Robert Hemphill,Gas Research Institute

Session A-4Refrigeration

Simulation and Experimental Study on the Air Flow and Heat Loadsof Various Designs for the Cooling of the Refrigerator Cabinet. .243

—by Dr. Jyi-Yu Sun, Dr. Hsua-Chyi Hsu, and Dr. Jian-Yuan Lin,Industrial Technology and Research Institute,Energy and Resource LaboratoriesTAIWAN

Refrigsim Software 254—by Prof. Miha Kavcic and Prof. Alojz Poredos,University of Ljubljana; and Mr. Berislav Bukovnik,Mr. Zonko Visnjic, and Mr. Bojan Skrt, Gorenje d.d.SLOVENIA

New Energy Test Procedures for Refrigeratorsand Other Appliances 266

—by Mr. Alan Meier, Mr. Kaoru Kawamoto, Mr. Stefan Ernebrant,and Mr. Mats Wihlborg,Lawrence Berkeley National Laboratory

Performance Evaluation and Retrofit Studies of HFC-134aCompressors (Presenter unable to attend; paper not delivered) 276

—by Mr. M. K. Chandrashekhar, Mr. K. Ram Kumar,Mr. M. Varghese Jacob, Mr. Mahesh M. Kulkani,Mr. Mahesh Murthy, and Mr. G. Dattukumar,BPL Engineering Limited,INDIA

Session B-4Changing Lifestyles

Pervasive Computing: The Blending of Appliance and InformationTechnology 290

—by Mr. Ron Ambrosio, IBM T. J. Watson Research Center

Adoption of Microwave Ovens Among a Sample of Older Adults inBlacksburg, Virginia 300

—by A. Nagarajan, M.S., R. P. Lovingood, Ph.D. CFCS,J. 0. Beamish, Ph.D., CKE, and K. R. Parrott, Ph.D., CKE,Virginia Polytechnic Institute & State University

A Lifestyle Battle:Time for the Appliance Industry to Join the Fray 311

—by Mr. Steven J. Drucker and Mr. Robert Thompson,Microwave Science LLC

Session C-4Dishwashers/Laundry

Test Procedure Development for Residential Dishwashers 320—by Ms. Natascha S. Castro,National Institute of Standards and Technology

Wet Cleaning—A New Washing Technology for Outer Wear? .. .332—by Prof. Dr. Hans-Giinter Hloch and Dr. Helmut KruGmann,wfk-Research Institute for Cleaning Technology, GERMANY

Vibration and Noise Reduction in a Washer Application withMetal/Polymer/Metal Laminates 344

—by Dr. Lezza A. Mignery, MSC Laminates and Composites

Session A-5Materials

A New Compact and Versatile Hot Surface Ignition Design 356—by Mr. James M. Olson, Mr. Roger J. Lin, Mr. Craig A. Willkens,and Mr. Dean D. Croucher, Norton Igniter Products

XI

Safer Solvent Alternatives 368—by Ms. Lauri Kirby, Dynaloy Inc.

A Novel Polysilicon-AIN Heating Element 379—by Dr. Petar Biljanovic' and Mr. Dalibor Grgec,Faculty of Electrical Engineering and Computing,University of Zagreb, CROATIA

Electronic Controls

A New Solid State Switch for Home Appliances 388—by Dr. Laurent Gonthier, STMicroelectronics, FRANCE

An Appliance Controller that Learns 400—by Mr. Chuck A. Maher, P.E., Consultant forTridelta Industries,Mr. Craig Farnsworth, Tridelta Industries,and Mr. John Pottenger, Pitco Frialator, Inc.

Electronic Start Switch for a Capacitor Start Motor 410—by Mr. Jason S. Anderson, Therm-O-Disc, Inc.

Session C-5Cooking Appliances

The Stone Stove for Kitchen and Professional Use 418—by Dr. Mera Kuse, TechnoCook Technologies,GERMANY

An Analysis of Fan Failure Diagnostic Techniques Using MultiprobeDiagnostics in Convection Ovens 421

—by Mr. Dave Rado,Food Automation—Service Techniques, Inc. (FAST)

Control System for Consumer Hobs 432—by Mr. Uwe Has, BSH Bosch und Siemens Hausgerate GmbH;Mr. Jorg Schieferdecker, E G & G Heimann Optoelectronics GmbH;and Mr. Dimitar Wassilew, DIAS Angewandte Sensorik GmbH,GERMANY

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Session A-6Materials

Optimization of the Surface Attributes of Embossed Steel Sheet forImproved Corrosion Resistance, Paintability and Appearance.. .444

—by Mr. Adel F. Bastawros and Mr. Leo J. Deistler,Bethlehem Steel Corporation; andMr. Gene Schuchert and Mr. Bruce Janvrin,Amana Refrigeration

Tolerancing for Sound 456—by Mr. Richard H. Lyon, RH Lyon Corp

Session B-6Electric Power

Benefits for Appliance Manufacturers: A Proposed National Study ofResidential Power Quality 469

—by Mr. Daniel L. Brooks and Mr. D. Daniel Sabin,Electrotek Concepts, Inc.

Leaking Electricity in Domestic Appliances 478—by Mr.Alan Meier and Ms. Karen Rosen,Lawrence Berkeley National Laboratory

Session C-6Research-Design-Analysis

Experimental Design and Analysis During Development of aHousehold Oven 486

—by Mr. Urban Wahlby and Ms. Christina Skjoldebrand, SIK—theSwedish Institute for Food and Biotechnology, SWEDEN,and Mr. Elmar Junker, Electrolux GPD HOT Tech-Centre,DENMARK

Can Openers: A Proposed Research Methodology 499—by Dr. Elizabeth A. DeMerchant, Ms. Anna A. Creery,Mr. Brian P. Williams, and Mr. Christopher Zachwieja,Hamilton Beach/Proctor-Silex

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