herman miller flexible foam substitute
TRANSCRIPT
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Herman Miller Foam Alternative
Group 4 Shira Bergman • Brian Della Mora
Boning Qu • Teresa Vasievich
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Overview1. Who is Herman Miller?2. Prioritization of Factors 3. Polyurethane: Gold Standard4. How Foam Works5. Our Solution6. The Program7. Shortcomings
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1. Who is Herman Miller?
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Herman Miller: The Customer● Ultimate consumer customization● Suppliers contact Herman Miller● All outsourced designers● Six R&D teams involved in materials search
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Herman Miller: Value Chain
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2. Prioritization of Factors
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Performance Properties
Manufacturing
Monetary Costs
Environmental Impact
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Prioritization: Performance PropertiesMatch or outperform polyurethane
● Foam properties of ‘Gold Standard’○ Elastic modulus○ Plateau stress○ Densification stress
● Comfort properties of ‘Gold Standard’
○ Foamed solution feels like PUR (IFD)
○ Diverse applications (i.e., arm pads, couches)
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Prioritization: Environmental Impacts● Manufacturing
○ Reduce use of harmful chemicals○ Consider impacts of ‘natural’ solutions
● Usage○ Chemically inert
● End-of-life management○ Recyclable○ Reusable
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Prioritization: Manufacturing & Monetary CostsManufacturing● HM does not manufacture furniture components● Target customer widened to manufacturing companies● HM has leverage to obtain any material
Monetary Costs● Cost increase must not exceed 20%● Few foamed alternatives
○ No raw materials comparison○ Initiation costs not accounted for
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3. Polyurethane: Gold Standard
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Polyurethane Foam● Polyurethane Foams
○ Open-cell ○ Two main ingredients
■ Isocyanates and polyols
● Flame Retardant Additives
Glass Transition
(K)
Density (g/cm3)
Elastic Modulus
(MPa)
Plateau Stress (MPa)
IFD (lbs-force)
Polyurethane Foam 290-300 0.016 0.34 0.003-0.004 ~3.1
500 μm
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4. How Foam Works
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Foaming Process
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How Foams Work● Material Properties of Solid
○ Young’s Modulus○ Resin Density
● Microscopic Properties of Foam○ Relative Density○ Cell Size○ Cell Density
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How Foams Work● In-Plane Compression
○ Linear elasticity○ Plateau○ Indentation Force Deflection○ Densification
● Governing Equations
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stress/strain at IFD
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How Foams Work - Darcy’s Law● Air flow through foam
○ Permeability of medium○ Dynamic viscosity of fluid (air)
● Governs recovery time
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5. Our Solution
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Program to Predict Foam● Inputs
○ Resin options■ Non-isocyanate involved■ Thermoplastic elastomer■ Resin density■ Resin elastic modulus
○ Relative density
● Outputs○ Stress-strain curve○ Recovery time○ IFD
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Factors Affecting Foam● Relative Density
○ Stress in each region
● Transition Points○ Strain at buckling○ Length of plateau
● Darcy’s Law○ Air velocity○ Recovery time
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Our Solution - Assumptions
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● Considered○ Physical blowing agents○ Resin properties○ Uniform cell size
● Overlooked○ Chemical blowing agents○ Foam additives○ Post-foaming processes
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ShortcomingsInaccuracy of Program● Lack of accurate foaming conditions● Lack of calibrated constants for each material
Problems with Solution● Environmental problems unresolved● ‘Ideal’ resin unknown
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Questions?
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Referenceshttps://ir.library.oregonstate.edu/xmlui/bitstream/handle/1957/2487/FPL_2031ocr.pdf;jsessionid=8D30129A19AA18B020122730E7BF353E?sequence=1
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