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    Product Development: The Electric Kettle Case Study

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    a4id
    The document discusses the case study for developing an electric kettle. It outlines the market requirements, functional requirements, and materials that were considered and ruled out. Polypropylene (PP) was selected as the material for the kettle body due to its low cost, suitable thermal resistance for boiling water, and ease of manufacturing using blow molding.

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    Product Development: The Electric Kettle Case Study

    Uploaded by

    a4id
    6K views23 pages
    The document discusses the case study for developing an electric kettle. It outlines the market requirements, functional requirements, and materials that were considered and ruled out. Polypropylene (PP) was selected as the material for the kettle body due to its low cost, suitable thermal resistance for boiling water, and ease of manufacturing using blow molding.

    Original Title

    Kettle Design Process

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    The document discusses the case study for developing an electric kettle. It outlines the market requirements, functional requirements, and materials that were considered and ruled out. Polypropylene (PP) was selected as the material for the kettle body due to its low cost, suitable thermal resistance for boiling water, and ease of manufacturing using blow molding.

    Copyright:

    Attribution Non-Commercial (BY-NC)
    Download as PDF, TXT or read online from Scribd
    Download as pdf or txt
    6K views23 pages

    Product Development: The Electric Kettle Case Study

    Uploaded by

    a4id
    The document discusses the case study for developing an electric kettle. It outlines the market requirements, functional requirements, and materials that were considered and ruled out. Polypropylene (PP) was selected as the material for the kettle body due to its low cost, suitable thermal resistance for boiling water, and ease of manufacturing using blow molding.

    Copyright:

    Attribution Non-Commercial (BY-NC)
    Download as PDF, TXT or read online from Scribd
    Download as pdf or txt
    of 23

    Product Development

    The Electric Kettle Case Study

    Tuesday, May 4, 2010


    Market Requirements

    Volume of boiling water = 2 liters


    Kettle weight include water < 3 kg.
    Demand of kettle is 2 million/year

    Tuesday, May 4, 2010


    Objective of Case Study

    Functional Requirements
    Automatically stops boiling when water is boiled
    Cordless design
    Easy to clean
    Handle remains cool and safe to touch

    Tuesday, May 4, 2010


    Objective of Case Study

    Materials that can be ruled out


    Polyphenylene oxide (PPO)
    maximum operating temp. is 105 degree Celsius

    discolor-able due to outdoor exposure

    difficult to mass produce (must be blended with polymers)

    Tuesday, May 4, 2010


    Objective of Case Study

    Materials that can be ruled out


    Polyethersulphones (PES)
    limited exposure to hot water

    changes dimension when exposed to moisture

    Tuesday, May 4, 2010


    Objective of Case Study

    Materials that can be ruled out


    Polyetheretherketones (PEEK)
    high cost

    excessive working temperature

    limited shaping process - difficult to manufacture

    Tuesday, May 4, 2010


    Objective of Case Study

    Materials that can be ruled out


    Aluminum (Al)
    corrosive prone

    require further treatment before processing

    Tuesday, May 4, 2010


    Objective of Case Study

    Materials that can be ruled out


    Magnesium (Mg)
    corrodes easily

    burns if reacted to water, thus coating will be required

    Tuesday, May 4, 2010


    Objective of Case Study
    Sketch and dimension of kettle body
    Dimension
    Half Side view

    - overall height : 10.5 cm.

    - inner radius: 8.003 cm.

    - base thickness: 1 cm.

    Tuesday, May 4, 2010


    Objective of Case Study
    Sketch and dimension of kettle body
    Sketch

    Tuesday, May 4, 2010


    Objective of Case Study
    Sketch and dimension of kettle body
    Sketch

    Tuesday, May 4, 2010


    Objective of Case Study

    Consider the mechanical properties affected


    wear resistance: considering wear bet ween
    kettle and plate since the t wo components have
    to be contacted during its operating life

    Tuesday, May 4, 2010


    Objective of Case Study

    Consider the mechanical properties affected


    thermal resistance: we have to consider thermal
    resistance of the kettle since the body is in
    direct contact with the boiling water. It is
    necessary to have a body which will not conduct
    heat out the the outer shell.

    Tuesday, May 4, 2010


    Objective of Case Study

    Consider the mechanical properties affected


    impact resistance: since we do not want the
    kettle to break when dropped, we should consider
    the impact resistance of the material used for
    the kettle body.

    Tuesday, May 4, 2010


    Objective of Case Study

    Consider the mechanical properties affected


    electrical insulation: the kettle consist of
    electrical system for the heating system, thus
    we should consider the importance of electrical
    insulators of the kettle

    Tuesday, May 4, 2010


    Objective of Case Study

    Consider the mechanical properties affected


    corrosion resistance: many materials can
    corrode when exposed to moisture, thus we must
    consider the corrosion of materials used for the
    kettle

    Tuesday, May 4, 2010


    Comparative Cost of
    Materials

    Tuesday, May 4, 2010


    Stiffness of Various
    Plastics:
    (GN/M2) Stiffness
    Polyamide (PA) 1.25
    Polypropylene (PP) 0.24
    Polyacetal (Polyoxymethylenes POM) 0.71
    Polyphenyleneoxide (PPO) 1.6
    Polyethersulphone (PES) 2.5
    Polyethertherketone (PEEK) 2.8

    Tuesday, May 4, 2010


    Materials Density (Kg/ Cost per kg Minimum Volume of Material
    M3) (rel. to steel) wall material cost per
    thickness (M3×10-4) casting (rel.
    (mm) to steel)

    Steel 7900 1 0.6 4.87 2.32638

    Al 2700 2 0.8 4.87 1.052

    Mg 1700 15 0.9 4.87 0.74511

    PP 910 5 5.6 4.87 2.21585

    POM 1200 8 3.8 4.87 4.6752

    PPO 1200 7 3.3 4.87 4.0904

    PES 1300 20 2.6 4.87 12.662

    PEEK 1300 30 2.5 4.87 18.993

    PA 1200 9 3.2 4.87 5.2596

    Tuesday, May 4, 2010


    Bench Marking for
    Materials

    Tuesday, May 4, 2010


    Criteria Weight PA PP POM PPO PES PEEK
    (100)
    Wear Resistance 5 2.5 3 3 3.5 4 3.5

    High Temperature Resist 15 3 3 4.5 3 3.5 4

    Insulator Properties 20 2.5 4 4 3 3 3

    Chemical Resistance 5 3 4 4 4 3 3.5

    Impact Resistance 5 3 4 3 4 3 4.5

    Cost 20 4 5 4 4 2.5 2

    Durability 15 3 3.5 3 4 3 3

    Ease of Manufacturing 15 3 5 2.5 2 4 3

    Total 100 307.5 407.5 360 322.5 317.5 307.5

    Tuesday, May 4, 2010


    Material to use
    From the benchmarking table, the most appropriate
    material for our kettle is PP or Polypropylene.

    Tuesday, May 4, 2010


    Objective of Case Study

    Choose the material(s) and process(es) for


    manufacturing the kettle
    The material we choose for kettle body is polypropylene (PP). Due to its
    low cost and ease of manufacturing, we think that this is the most
    appropriate material to use. Also, the thermal resistance of this material
    is suitable for such operation as boiling water. The manufacturing process
    which is the most suitable is blow molding, since the production volume is
    appropriate. Also the capital cost and tooling cost seems to be the most
    appropriate.

    Tuesday, May 4, 2010

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