On the Cutting Edge

UL research programs address key safety issues

For over 113 years Underwriters Laboratories (UL) has been researching ways to increase public safety and reduce tragedies related to fire, shock and personal injury hazards. Over a century ago the new, untested electrical industry burst onto the scene, it’s progress initially marked by building fires and electrocutions due to a lack of adequate safety testing and requirements. UL’s early research into electrical safety and the subsequent development of safety standards directly impacted the lives of generations in public and private spheres.

Since then, UL’s research has continued to advance public safety in multiple arenas, though one might think that over 100 years of safety research would reduce the need for modern-day safety research. Nothing could be further from the truth.

UL’s research efforts have expanded to cover a number of key initiatives. Donald J. Talka, vice president and chief engineer, says, “UL is proud of its history of research contributions, both singly and in collaboration with likeminded organizations, to mitigate safety challenges in our society. Such efforts are at the core of our public safety mission.”

Current and recent research projects include the following:

Alternative Fuels

UL completed a comprehensive research study of E85 fuel-dispensing equipment. This study focused on compatibility of materials and equipment with test fluids representative of actual conditions when dispensing ethanol/gasoline blends. UL also visited ethanol dispensing operations in the Midwestern US and Brazil. This work led to publication of E85 dispenser certification requirements in October 2007. UL is continuing its E85 research work with the U.S. Department of Energy on dynamic testing of E85 dispensers running five days per week.

Grounding Electrode Project

UL participated in the Fire Protection Research Foundation (FPRF) National Electrical Grounding Research Project. The goal of this multi-year effort was to study and evaluate the performance of various types of buried grounding electrodes over time. Some features of the project included electrode resistance measurements, earth’s resistivity, temperature, moisture and the effects of direct current on electrodes that were installed at several different sites. After being buried for extended periods, some electrodes were exhumed and studied for corrosion analysis and observation. The report of the project’s findings, issued in 2007, provides information for regulators, standards development organizations and industry for use in developing new or improved grounding electrodes.

Improved Body Impedance Model

Risk of electric shock is reduced by requirements in installation codes and product safety standards such as NEC Class 2 voltage and current limits. Under specific conditions, these requirements mitigate unwanted physiological effects, injury and death. UL is presently engaging in global collaborative research efforts to better understand the impedance characteristics of the human body and the distribution and effects of electric current flow through the body. The objective of this research is to gain knowledge that will help improve protection against electric shock for a variety of different physiological effects and contact conditions.

Lithium-ion Batteries

UL has been investigating the failure modes of uncharged and charged Li batteries. This research is focused on (1) the development of a reliable and repeatable test method to verify that Li batteries are stable when they experience an internal short circuit, and (2) the characterization of separator materials as a critical component in the Li battery design. One interesting result of this research is the development of a Blunt Nail Penetration Test, designed to induce single-layer and point-of-short modes inside Li batteries. The test determines whether a battery design can withstand penetration without inducing a fire or explosion.

Nanotechnology

UL is assessing nanotechnology and its impact on product safety in international standardization, in the use of “nanoadditives” in materials and the impact of “nano-enabled” functionality on traditional product safety. UL has discovered over 600 products that claim a form of nanotechnology functionality, but their claims have not been independently verified. UL is also chairing the International Electrotechnical Commission (IEC) technical committee (TC 113) on the electrotechnical standardization of nanotechnology subcomponents and systems.

Smoke Characterization Project and Result Analysis

UL, in conjunction with the FPRF, conducted a research study designed to more fully characterize the products of the flaming and non-flaming combustion of materials and furnishings commonly found in today’s residential settings. For more on this project, see Asia On the Mark — Issue 22, Summer 2007.

UL is currently collaborating with James A. Milke, Ph.D., University of Maryland, on an in-depth analysis of the research data generated by the smoke characterization project. The research focus is the structure-property relationship between material chemistry and smoke properties, including particle size, particle size distribution and gas-phase composition.

Residential Electrical System Aging

Together with the CPSC, electrical equipment manufacturers, insurance companies and other interested parties, UL is participating in the FPRF Residential Electrical System Aging Research Project.

The goal of this project is to characterize the condition of various residential electrical systems, according to age. The project will survey a representative sampling of installed systems from homes across the country, then document how aging and installation may relate to residential electrical fire causes. The project will be completed in early 2008.

Upholstered Furniture Flammability

UL recently held roundtable discussions with industry and fire service stakeholders to discuss a research plan related to the flammability of upholstered furniture. The future research plan could include analysis of furniture designs, components, raw materials, manufacturing processes, testing methodology and the potential approaches to compliance and surveillance. The compliance and surveillance program would provide the industry a framework for designing and manufacturing residential furniture with enhanced fire resistance.

UL’s Corporate Research division is also conducting research in the following areas:

	•	Printed Wiring Boards
	•	Photovoltaic Systems
	•	Light Electric Vehicles (LEV)
	•	Fuel Cells
	•	Structural Stability of Engineered Lumber under Fire Load Conditions
	•	Plastics Characterization and Reliability

The effectiveness of safety requirements in model codes, regulations and product safety standards relies on a solid research base. UL’s ongoing research initiatives cover a wide range of topics, many involving state-of-the-art equipment and products. Future research projects will continue the company’s tradition of public safety protection by being instep with safety concerns that arise as society progresses.

by Tom Chapin, Director, UL Research and Development