philips plastic design guideline

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Rev.3



CONTENTS

CHAPTER            Page No.

        1.        RAW MATERIAL SELECTION        4
                1-1        MAIN TYPE OF PLASTICS APPLIED ON MONITOR        4
                1-2        CHARACTERISTICS OF PLASTICS MATERIAL        6
                1-3        CRITERIA FOR PLASTICS SELECTION        8
                1-4        FLAME RETARDATS        8
        2.         CABINET DESIGN GUIDELINES        12
                2-1        GENERAL        12
                2-2        MATCHING WITH PICTURE TUBE        18
                2-3        CRT SHIFT PREVENTION        18
                2-4        MAIN CASSIS FIXATION        19
                2-5        CRT BOARD FIXATION AND LIMITATION        21
                2-6        DESIGN FOR ASSEMBLY AND TRANSPORTATION        22
                2-7        DESIGN FOR DISASSEMBLY        22
                2-8        DISPLAY OPENING SIZE        22
                2-9        LCD DISPLAY        23
        3.         PICTURE TUBE FIXATION         25
                3-1        AN AUTO-ADJUSTING DEVICE IS NEEDED TO PREVENT THE CABINET DEFORMATION DUE TO LARGE TOLERANCE IN HEIGHT OF CRT’S EARPLUG        25
                3-2        CRT FIXATION TYPES        25
                3-3        CRT MOUNTING ON THE METAL FRAME        29
        4.         CONTROLKNOB UNIT        30
                4-1  POWER BUTTON        30
                4-2  CONTROL BUTTON        36
        5.         POPOUT KNOB DELET        36
        6.         LIGHT GUIDE        38
                6-1        PRINCIPLES OF LIGHT GUIDE        38
                6-2        MATERIALS        45
                6-3        SURFACE TREATMENTS        46
                6-4        DESIGN PROCEDURES (ILLUSTRATED BY AN EXAMPLE)         47
        7.         SPEAKER GRILLE FIXATION        49

        8.         SAFETY CONCERNED RELATED
                  TO MECHANICAL        50
                8-1        MATERIALS FOR ENCLOSURES AND FOR DECORATIVE PARTS        50
                8-2        OPENINGS IN ENCLOSURES        50
                8-3        REQUIRED SAFE DISTANCES        51
                8-4        ADJUSTABLITY OF DISPLAY SCREEN        52
                8-5        GLOSS FACTOR OF DISPLAY SCREEN CASING        52
                8-6        PHYSICAL REQUIREMENTS        53
                8-7        CONTROL AND INDICATORS        53
                8-8        THE RADIUS OF OUTSIDE EDGES AND CORNERS OF PLASTIC HOUSING OF PRODUCT SHOULD BE NOT LESS THAN 2 MM        53
                8-9        THE WARNING TEXT FOR CRITICAL COMPONENT IS GIVEN BELOW: (ON BACK COVER INSIDE)         53
        9.         COLOR INSPECTION CRITERIA        54
                9-1        SCOPE        54
                9-2        APPLICATION        54
                9-3        MEASUREMENT INTRODUCTION        54
                9-4        STANDARD COLOR DATA        58
                9-5        COLOR APPROVED PROCEDURE/ STANDARD COLOR DATA STORAGE OFRESIN        58
                9-6        STANDARD COLOR CHIP        60
10.         REQUIREMENT FOR DECORATIVE SURFACE        63
                10-1        INSPECTION INSTRUCTION        63
                10-2        CONDITIONS FOR INSPECTION        63
                10-3        LIMIT VALUES        64
                10-4        DEFECTS PER ZONE FOR TABLE 1        65
                10-5        DEFECTIVE PHENOMENA FOR TABLE 2&3&4        65
                10-6        “PHILIPS” FINSHED SET APPEARANCE ZONE CLASSIFICATION        66
11.         PEDESTAL DESIGN GUIDELINES        67
                11-1        DESIGN GUIDELINE         67
                11-2        SPECIFICATION OF TILT FORCE        71

PLASTIC
DESIGN
GUIDELINE

期望中

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RAW MATERIAL SELECTION
   
                1-1. MAIN TYPE OF PLASTICS APPLIED ON MONITOR

                PC/ABC
    PC/ABC is a material which can be moulded in thin wall, has a high impact strength and is considered environmentally friendly, because of the use of phosphorous based flame-retardants.
   
                    ABS V0
    This material is used very widely and is most suitable. It is not halogen/Sb2O3 free, but its price makes it the lowest cost flame-retardant alternative.

                    HIPS V0
    HIPS V0 in light colour is susceptible to yellowing, although by taking appropriate measures this can be avoided.

                    ABS (Acrylonitrile Butadiene Styrene)
    ABS offers more gloss and impact strength than HIPS, but is also much more expensive. If using a non-flame-retardant material, then HIPS is better option for dark coloured products. In telefax business formerly ABS V0 was used, but now a normal ABS is used in combination with metal/flameretardant shield of a few critical parts, such as the power supply.

                   HIPS
HIPS is used for TV cabinet. It is used in high end monitors, where an internal metal shield provides fire protection. HIPS in light colours is also susceptible to yellowing although by taking appropriate measures this may be avoided. (Except USA, at least 94V-1 for USA market)

                          Mod. PRO (Noryl)            
    Noryl is PRO/HIPS blend, which used phosphorus based flame-retardant. The main disadvantage of this material is the bad UV stability (yellowing ), predominantly in light colours. The advantages include thin wall moulding, shorter cycle times, lower density and moderate price level. GE Plastics holds the monopoly in this material (Noryl).
               
Remarks:
1.         If these monitors have an internal metal shielding, the cabinet material can be developed in ABS-HB or HIPS-HB in considerable price reduction. (94-HB is not allowed for USA)
2.         *) If the net weight of monitor <18 kg, the cabinet material should be V0.
3.         The monitors allowed only two kinds of plastics to fulfill TCO99.


Correct wording of flammability class as following

1.        94V-0
2.        94V-1
3.        94V-2
4.        94HB
5.        94-5V













                1-2. CHARACTERISTICS OF PLASTICS MATERIAL

          The following table lists the main physical properties, which are crucial to design requirements:

        PC/ABS:
        PC/ABS SPECIFICATION QUICK REFERENCE

Supplier/Type        IZOD impact
(kg-cm/ cm)
1/4 t         Heat deflects.
Temperature
(°C)         Melt flow
Index
(g/10min)         Tensile
Strength
(psi)

        Specific
Gravity
        Mold
Shrinkage
( ﹪)        UL V-
0
mm
        UL
5V
mm         UV resists.
E
(300h)


        Blue Angel/
TCO95
G.E.
C2800
C2950HF
C6200
       
43.6
43.6
54.5        
>80
>80
>80        
       
8500
9300
9700        
1.17
1.18
1.18        
0.4~0.6
0.4~0.6
0.4~0.6        
1.5
1.5
1.5        
2.3
2.5
2.3        
<1.5
<1.5
<1.5       
OK
OK
OK
BAYER
FR-90

FR2000       
50

20       
80

80        
14~26
(CM&sup3;/ 10MIN)
30
(CM&sup3;/ 10MIN)       
6525

       
1.17

1.18        
0.4~0.6

0.4~0.6       
1.6

1.6        
2.3

2.3       
–        
OK

OK
CHEIL
NH-1000A       
60       
80       
40       
8700       
1.22       
0.4~0.6       
1.6                       
OK
CHEIL
NH-1000T       
40       
76       
40       
9490       
1.17       
0.4~0.6       
2.12       
2.54               
OK
Remark: Please refer Suppliers’ spec. for more details in specification if required.














ABS:
        ABS-FR

Supplier/Type        IZOD impact
(kg-cm/ cm)
1/4 t         Heat deflects.
Temperature
(°C)         Melt flow
Index
(g/10min)         Tensile
Strength
  (psi)        Specific
Gravity
        Mold
Shrinkage
( ﹪)        UL
V-0
mm        UL
5V
mm         UV resist.
E
(300h)         Blue Angel/
TCO95
CHEIL
VH-800P
VH-0810
VH-0815
VE-0855
VE-0856
VE-0812
       
24
19
22
18
18
17
       
77
76
75
79
79
81        
25
5.5

3.5
3.5       
6000
6000
5800
5700
5700
5800        
1.20
1.20
1.19
1.19
1.19
1.19        
0.3~0.6
0.3~0.6
0.4~0.7
0.3~0.6
0.3~0.6
0.3~0.6        
1.6
2.6

2.1
2.1        
-
-
2.7
2.6
2.6
2.6        
3
12
-
1
3
3       



N.A.

CHEIL
PA-765B
PA-764B       
20
15.5       
79
79        
2.6
3.0       
5670
6340       
1.16
1.19        
-        
2.6
2.5        
3.2
3.2       
–        
N.A.
G.P.
D-1000
D-2000       
23
22       
76
84       
3.5
2.2       
6800
7200       
1.21
1.19       
-
-       
1.6
2.6       
S2.6               
N.A.
FORMOSA
ANC100       
18       
80       
3.2       
5700       
1.21       
-       
1.6               
<8       
N.A.
LG
AF-312       
20       
       
       
6640       
1.19       
0.4~0.8       
1.5       
3.0               
N.A.
GE
SEA2X
VW55       
31.6
27.25       
71/75
81/86       
       
5800
5500       
1.14
1.15       
-
-       
2.3
2.3       
2.5
3.0       
6-8
1.5-3       
N.A.
N.A.

        PS-HB

Supplier/Type        IZOD impact
(kg-cm/ cm)
1/4 t         Heat deflects.
Temperature
(°C)         Melt flow
Index
(g/10min)         Tensile
Strength
  (psi)         Specific
Gravity
        Mold
Shrinkage
( ﹪)        UL
V-0
mm        UL
5V
mm         UV resist.
E
(300h)         Blue Angel/
TCO95
CHEIL
HR-1360       
10       
83       
4       
4640       
1.04       
0.3~0.6                               
OK
CHI-MEI
PH-88       
9.0       
82       
5       
3550       
1.05                                       
OK

        PS-HB

Supplier/Type        IZOD impact
(kg-cm/ cm)
1/4 t         Heat deflects.
Temperature
(°C)         Melt flow
Index
(g/10min)         Tensile
Strength
(psi)        Specific
Gravity
        Mold
Shrinkage
( ﹪)        UL
V-0
mm        UL
5V
mm         UV resist.
E
(300h)         Blue Angel/
TCO95
CHEIL
SD-0150       
23       
91       
1.8       
6540       
1.05       
0.3~0.6                               
OK
CHI-MEI
PA-717C       
28       
88       
1.4       
6380       
1.04                                       
OK
CHEIL
SD-0150       
27       
88       
4.5       
5950       
1.04                                       
OK
CHEIL
SD-0150       
15       
94       
3.9               
1.05       
0.4~0.6       
1.6                       
OK

                1-3. CRITERIA FOR PLASTICS SELECTION

The following list is the preferred minimum threshold of physical properties for cabinet design:

Type        Notch Impact
kj/m&sup2;        Specific
Gravity         Tensile strength
N/mm&sup2; (Psi)        Heat deflection
Temperature C        Color Stability
UV E(300hr)
        Shrinkage
Rate ﹪        UL
V-0
(mm)        rating
5V
(mm)
ABS        >20        <1.25        >40(5800)        >78        <8        0.3~0.6        <2.1        <2.7
PC/ABS        >40        <1.2        >45(6525)        >80        <3        0.4~0.6        <1.6        <2.5


1-4. FLAME RETARDANTS

A:         2 types of flame retardants used for plastics:
        -        Halogen + Antimony
                        - Halogen includes the following elements:
- Iodine, Bromine, Chlorine and Fluorine
- Bromide most often used because it is cheap and effective
                        - Antimony is necessary as a synergist
- Synergist increases the rate of reaction
- Plastics using this flame retardant includes : ABS, PS, etc.
        -                Phosphorus + Nitrogen
- Nitrogen act as a synergist for phosphorus
- Plastics using this flame retardant includes : PC, PPO, etc.


B:         Flame retardant ratings for plastics
        -UL 94 Horizontal Burn Test
                The burning rate of a horizontal test specimen
Most engineering thermoplastics can pass HB test without flame retardants.

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