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CO2 Mechanics Blog

Practical knowledge, tools, tips and techniques for developing and implementing innovative CO2-enabled clean manufacturing processes, products, and production lines.

CO2 Backstory 1.3.6

Posted by David Jackson on Oct 12, 2020 8:30:05 PM
David Jackson
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Future CO2 Developments

CO2 Processing Units (CPU®)

CO2 technology innovation continues today with an emphasis on new market and application development, and more particularly the development and implementation of a new business model innovation uniquely adapted to this disruptive technology. For example, CO2 surface treatment technology performs three basic functions (or processes) – precision cleaning, cooling, and modification. CO2 technology performs these functions in unique ways which are lean, green, 100% dry, inherently compatible with materials and tools, and enhance performance of manufacturing processes requiring one or a combination of these functions [36]. 

Many customers who purchased our small CO2 composite spray cleaning products (i.e., MicroSno™ and PowerSno™) did not use the products as we intended – a benchtop spray cleaning solution with an operator interface. Instead, the small benchtop systems were integrated directly into manufacturing tools and production lines to provide the basic surface cleaning function during the manufacturing process absent an operator. For example, Hutchinson Technology, Minnesota, purchased several systems and adapted them to progressive stamping machines to provide in-situ cleaning of HDD flexures during iterative stamping operations to significantly reduce “dent defects” caused by stamping debris carry-over. The CO2 technology enabled the stamping process to operate continuously and eliminated the need for off-line cleaning operations. This adaptation saved the company hundreds of thousands of dollars per year. In another example, JDS Uniphase, New Jersey, integrated a CO2 system into a spray cleaning plus inspection cell following soldering operations to remove flux residues from fiber optic components.

The fact that CO2 surface treatment technology can exist within the manufacturing process, tool and production line is a very disruptive change, and one that solvent-based and aqueous technologies cannot mimic. This unique value proposition is the basis for the CO2 Processing Unit or CPU® program, to be discussed in detail in future CO2 Mechanics Blog posts.

Analogous to a central processing unit in a computer which provides necessary computation, logic, and programming functions to the larger system framework comprising for example a keyboard, mouse, and display monitor (Computer System), CO2 processes can be implemented alongside or integrated directly into virtually any manufacturing process, tool, and production line (Manufacturing System). Applicably, the various CO2 technologies detailed in this guidebook are referred to as CO2 Processing Units or CPU®.  CPU® provide surface cleaning, cooling, and modification functions as well as adjunct functions such as CO2 fluids processing prior to, concurrently with, or following a manufacturing operation.

Many new forms of lean and green value-added manufacturing tools – for example adhesive dispensers, wire bonders, precision abrasive grinders, drilling tools, welders, laser cutters, and collaborative robots – can be developed with built-in or side-by-side CO2-enabled surface cleaning, cooling, and/or modification functions. CPU® minimize lean and green wastes – time, space, labor, material, transport, and energy inputs – within the manufacturing system to improve product yields and quality, reduce cost of production, enhance the working environment, and improve profitability.

In closing Chapter 1, the CO2 Backstory, the CPU® business model is about transformation - from developing fundamental CO2 processes and stand-alone CO2-based production tools (the past) to the creation of new CPU® Powered manufacturing systems - processes, tools, and lines (the future). In this change process, CO2 technology disappears into and transforms the value-added manufacturing system, whatever it may be. These transformed manufacturing systems represent many of the possible future innovations for CO2 technology.

References:

  1. 1-36. A Disruptive Innovation: Making the Case for CO2, D. Jackson, CleanTech, Volume 4, Volume 2, February 2002

    DOWNLOAD EHS TODAY MAGAZINE PUBLISHED ARTICLE AUG 2009

   DOWNLOAD PROCESS CLEANING MAGAZINE PUBLISHED ARTICLE JUL/AUG 2009

    DOWNLOAD CONTROLLED ENVIRONMENTS MAGAZINE PUBLISHED ARTICLE SEP 2012

 

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Topics: The CO2 Backstory