SURFACE ENGINEERING FOR LOOK & FEEL

E.M. Kuiper N. Peeters

October 2008

TABLE OF CONTENTS
Introduction ..........................................................................................................................................................................................3 Problem defenition ............................................................................................................................................................................4 Theory ..................................................................................................................................................................................................5 Method .................................................................................................................................................................................................6 Practice ................................................................................................................................................................................................8 Results ...................................................................................................................................................................................................9 Conclusion ......................................................................................................................................................................................... 12 Redesign ........................................................................................................................................................................................... 13 Literature .......................................................................................................................................................................................... 20

Surface Engineering | University Of Twente

INTRODUCTION

A pan is a product in which grip plays an important role in terms of safety and comfort. The grip on the handle needs to be good enough to prevent any accidents caused by slipping hands from happening. Therefore not only the shape of the handle is important but also the surface. It should be rough enough to provide sufficient grip and smooth enough to ensure comfort. The problem definition will contain the detailed problem description. The problem definition will end in a research question for the further research. A literature study will give a background of grip and friction of different materials; like metal, plastic and wood. After the literature study the theory will be tested in practice. First a method will be created to test some aspects of the theory. On the basis of this method the practice will be executed. After discussing the results, these results will be used for the redesign of the handle.

Surface Engineering | University Of Twente

PROBLEM DEFENITION

Some pan handles are better than others. For this research a handle was found that was in need of some improvement. To find and select this handle a series of test were conducted. The temperature of the handle was measured while cooking water and the relative grip with dry and wet hands was estimated by hanging a five kilogram weight from the panhandle. Figure 1 gives an example of this experiment. These results have been used to quickly asses the price quality ratio of the different pans, where quality is assessed as the amount of grip the handles provide. From these results it appeared that the grip of a certain Tefal frying pan was relative poor compared to its price. This pan is thus chosen as a subject for further studies and redesign by surface engineering to improve grip. This can be summarized in the following research question; How do the current surfaces of the Tefal pan look like and how can these surfaces be altered to improve grip and maintain a similar look. Figure 2 shows the Tefal frying pan which will be used for further research.

Figure 1: Testing

Figure 2: Tefal frying pan

Surface Engineering | University Of Twente

THEORY

In earlier studies research was done concerning the static friction at the hand/handle interface [1]. An overview of the results can be found below in figure 3. In this figure MVC is the Maximum Voluntary Contraction measured with an EGC. EMG or Electromyography gives the absolute value of the force exerted on a handle.

Figure 3: Static friction

From this research it appeared that the best grip was conceived when stainless steel was used. But this is only valid in wet and dry conditions. If lubrication is used like soap the conventional stainless steel surface doesnt give as much grip as possible. Texturing the surface will improve the lubricated grip, but decreases the normal dry grip. According to another study [2] this is caused by hydrophilic and hydrophobic effects of these materials. In essence, the friction of skin increases when the skin is wet. This increase can be ascribed to an increase in the real area of contact resulting from the specific effects of water plasticization on the epidermis. The epidermis tends to get softer and more flexible due to this effect. But the conclusion that wet skin always increases the friction is not true. Another effect of water is lubrication and hydrophilic materials form a more stable layer of water molecules reducing thus the friction. On the other hand, hydrophobic materials allow the skin to get wet but prevent the formation of a stable lubricating water layer.

Surface Engineering | University Of Twente

METHOD

As stated before grip and heat build up are the main subjects for this research and redesign. In order to quantify data from the preliminary research a more scientific approach was chosen. This research was conducted in two separate experiments, one for temperature or heat build up and a second one for investigating surfaces of different materials with different finishes. In the first only the current situation will be analysed whereas in the second experiment also alternative materials get a closer look. This is done because the heat temperature distribution and heat build up is depending on geometry and design of the overall construction and is harder to replicate with different materials.

Temperature and heat build up

For this experiment the research question was how temperature changes in the different materials of the pan handle when the pan remains at the same temperature. Of course the temperature of the pan needs to be significantly higher than the ambient temperature, but also constant during the experiments. To accomplish this, the pan will be filled almost to the top with 1 litre of boiling water from a water cooker and kept boiling at the furnace. Now with the pan at a constant temperature it is important to monitor its temperature over time. Therefore a thermocouple thermometer will be used which will be attached to the pan handle and at certain time intervals the temperature will be noted using the scheme below in Figure .
time (s) Tmetal (C) Tplastic (C) 0 30 60 90 120 150 180 210 240 270 300

Figure 4: Measuring table

Since only one thermometer is available the experiment will be conducted twice, measuring the different materials. The time will be kept with the use of a stopwatch.

Surface Engineering | University Of Twente

Surface structure
In order to quantify surface a spectral analyses will be made of the different materials using a specialized microscope. Several samples are made from different surface finishes and different materials as well as the current pan handles. This spectrum analyses results in a set of data from which a three dimensional image of the surface can be created using the microscopes software 123. The area that is analysed has a surface of roughly 500m by 500m. The peaks and dents can be highly exaggerated to make them visible. The program interface and the adjustable variables are shown in Figure 5.

Figure 5: the 123 microscope control program

Surface Engineering | University Of Twente

PRACTICE

With the functional tests described earlier on in the method section more insight was gained regarding temperature increase of the handle materials as well as surface structures of the currently used materials and proposed alternatives.

Heat and temperature

In practice there were a few problems regarding measuring the temperature. At first the pan handles temperature increased due to holding the pan and placing it on the furnace. It was also difficult to keep the thermometer at the same spot. This was later on solved by taping it to the handle. Also little drops of boiling water on the thermometer and panhandle influenced the first attempts to measure the temperature.

Surface texture
With the use of a microscope and moir interference patterns a 3D image of the surface of the handle and several other materials were made. Due to the metallic transparent coating on the plastic parts of the handle making a straight forward surface image wasnt possible. With the use of special two component rubber, with a resolution of 0.1m, a negative mould was made from the surface and then examined under the microscope. The analysis of the surface texture of wood was made with the use of the same two component rubber. Unfortunately the rubber sticks to the wood sample, so it wasnt possible to make reliable analysis. Hiziroglu (2007) [3] made 2D surface texture analysis of different wood samples with the use of a stylus method. Figure 6 shows the roughness of three types of wood; particleboard, overlaid particleboard and hardboard. These types of wood cannot be used for the redesign of the handle, because of the composites and the non-water resistants of the material.

Figure 6: Roughness profiles of wood samples

Surface Engineering | University Of Twente

RESULTS

Results of these tests were collected, visualised and analysed in several ways.

Heat and Temperature

As can been seen from the test results temperature rise in the metal parts of the handle arent a real problem. In fact, temperature drops in time. This is probably due to the fact that the handle was still warm from body heat and holding the handle. But since temperature decreases in a period of 5 minutes it is unlikely it will raise after 10 minutes. See figure 7.

Figure 7: Temperature diagram of the handle

The plastic handle parts formed a heat buffer between the boiling hot pan and the thin metal inlay at the top of the handle. Another aspect that prevents the user from burning his hand is the fact that the metal inlay is very thin and thus the heat capacity of the inlay is very low. Although heat is conducted very rapidly by the metal, the amount of heat is very low preventing the user from neither burning his or her hands let nor feel the temperature of the metal inlay.

Surface texture
The results from the surface scan are several 2D and 3D images. Figures 8 and 10 below shows at the surface of the plastic handle parts and figures 9 and 11 shows the surface of the polished metal inlay. Compared to the surface on the right side from the metal inlay, the plastic is very rough. These images were compared with the results from samples that had other surface treatments. Figure 12 shows the surface of plain rolled stainless steel. On the right side, figure 13, is the surface of a piece of stainless steel that was sanded with a 320 grain. 9 Surface Engineering | University Of Twente

Figure 8: Handle plastic 3D

Figure 9: Handle RVS 3D

Figure 10: Handle plastic 2D

Figure 11: Handle RVS 2D

Figure 12: RVS rolled 3D

Figure 13: RVS sanded 3D

10

Surface Engineering | University Of Twente

Figure 14: RVS rolled 2D

Figure 15: RVS sanded 2D

Figure 16: Handle plastic profile

Figure 17: Handle RVS profile

Figure 18: RVS sanded profile

Figure 19: RVS rolled profile

11

Surface Engineering | University Of Twente

CONCLUSION

The first conclusion that can be made is that although the thermal resistance of metal is low and heat is conducted in a high rate the amount of heat that could be transferred from the metal to the hand of the user is limited due to the low heat capacity. Therefore heat wont be an issue if nothing changes in the dimensions of the metal inlay. Also the temperatures to be deled with are way below body temperature and thus of no real significance. Of course, that is this panhandle, whereas for other panhandles this might very well be a mayor issue. From the surface research the conclusion can be made that the polished metal inlay is by far the smoothes surface. From earlier studies it was know that smooth surfaces have better dry grip compared to the grip on rough surfaces and that wet hands improve grip overall. Therefore in the handle that was examined the metal inlay provides the dry grip and the plastic parts serve as a heat buffer. The use of two materials is in fact very clever. So to improve grip the metal should be smoother and preferable of a hydrophobic material. Only when surface textures exceed the microscopic level they improve grip. But in that case other effects come into play where terms like friction are of less importance. One of the first ideas was to sand the metal part to improve the wet friction, but this has a negative influence on the dry friction and the surface roughness is doubtfully large enough to rely on other grip mechanisms than just friction. Another suggestion was to make the metal inlay not from polished stainless steel but instead of chromed metal, since this is supposed to be much smoother. Then again, from earlier research it shows that chrome has a relative low dry grip and relative high dry grip. So the application of chrome is possible but the dry friction has to come from the plastic parts of the handle. Afterwards it would have been interesting to also examine the surface of a chrome sample and compare it with the polished stainless steel.

The conclusions made above will be used to develop several concepts in redesign.

12

Surface Engineering | University Of Twente

REDESIGN

From the conclusions made based on the experiments there are a set of new design requirements. The new panhandle has to have a similar configuration with the metal inlay to prevent any burns. The handle has to has a smooth surface in order to give sufficient dry grip The handle has to be made from a hydrophobic material or has to have a hydrophobic coating with the same characteristics. Macroscopic textures can be added for look or feel and to improve grip with other mechanisms than pure friction. This could also be a topic for further research.

Concept generation
For the redesign of the handle combinations of two applicable materials were made, mainly focusing on wet and dry grip. This results in three different concepts. These concepts were detailed and represented below.

13

Surface Engineering | University Of Twente

CONCEPT 1: CHROME

Wet grip: chrome inlay with hydrophobic coating Dry grip: super smooth plastic

The chrome is in fact a stainless steel part with chrome plating as a surface finish and a hydrophobic coating like Duralon from the German company Cotec. This results in a handle as shown below.

Figure 20: The chrome concept

14

Surface Engineering | University Of Twente

For the plastic part a plastic with a good hardness and strength is used which is polished after injection moulding. With the use of the material selection program CES polymers and elastomers were examined by their heat resistance and price. See figure 21 below.

Figure 21: CES melting point vs. price graph

From this the choice was made for Polyethylene which is good mouldable and has a high melting temperature and is relative cheap.

15

Surface Engineering | University Of Twente

CONCEPT 2: SANDED

Wet grip: smooth plastic with hydrophobic coating Dry grip: sanded stainless steel and smooth plastic

The wet grip comes from the same durable polyethylene as in the chrome concept with a high hardness which gets polished after injection moulding and a hydrophobic coating like Duralon from the German company Cotec. Dry grip comes from the sanded stainless steel where other mechanisms than friction act as well as from the plastic handle. Two renderings are made with different orientation of the sanded steel. These will be later assessed by a consumer audit.

Figure 22: The sanded concept

16

Surface Engineering | University Of Twente

CONCEPT 3: ROUGH

Wet grip: polished metal and textured plastic (perhaps only bottom surface) Dry grip: polished metal

The polished metal is a similar stainless steel inlay like the current frying pan has. The surfaces of the plastic parts of the handle are provided with rough like structures relying on other grip mechanisms than friction and is build-in in the mould. The plastic part of the handle is made from the same polyethylene as the other to concepts.

Figure 23: the rough concept

17

Surface Engineering | University Of Twente

Concept selection
Although all concepts are developed in such a way that they all provide excellent grip, some of them look very smooth and slippery. So concepts are assessed based on if they look;

Comfortable

Both the chrome and sanded concept look very comfortable. The textured plastic of the rough concept looks a little less comfortable.

Sufficient grip

All concepts are thus developed that they provide sufficient grip under wet and dry circumstances. Apart from that the chrome concept has a very smooth look and therefore cannot convince the consumer of the great amount of grip it is providing.

Durable

In the case of durability one could argue that all three concepts are made of the same basic materials and are thus all even durable. Apart from the coating this is true, but even the coating has a high durability and good resistance according to Cotec. Unfortunately this couldnt be assessed further with programs like CES since they do not provide the option to sort for hydrophobic properties.

Tefal product

Since the products did not change that much either concept has the Tefal-look. Only the rough concept does not emit the quality Tefal stands for. The high quality finish looks of the chrome and the sanded scores better in this area.

18

Surface Engineering | University Of Twente

Overall the sanded concept scores best on almost any area. Therefore this is the chosen concept and will be proposed as the improved redesign of the Tefal frying pan.

19

Surface Engineering | University Of Twente

LITERATURE
[1] [2] [3] Omeara D.M. and Smith R.M, 2002, Functional handgrip test to determine the coefficient of static friction at the hand/handle interface. Adams, M.J. and more, 2007, Friction and lubrication of human Skin. Hizirogly S. and Zarate S, 2007, Mechanical Properties and Surface Characteristics of Colombian Wood Composites.

20

Surface Engineering | University Of Twente