John Paul Kusz

Research Projects
Selected Publications & Presentations
Product Development
Student Projects
Design & Education Philosophy
Resume

 

Product Development
Designing with the Environment in Mind

Safety-Kleen: Self-Service Parts Washer

The images below illustrate Safety-Kleen’s Self-Service Parts Washer, the first consumer product developed for Safety-Kleen Corporation. The purpose of the product was to bring the benefits of solvent cleaning to home mechanics and afford them the convenient recycling of the solvent after use through an in-store exchange program. A US Patent was issued for an air operated pump specifically designed for this product.

United States Patent 4,732,537.

 

  • SSPW on tubular stand with light fixture. This product was drawn steel with powder epoxy coated finish, accoutrements shown in subsequent slides were manufactured with several processes, including roto-casting, injection molding, and vacuum forming. Product met review by the Consumer Safety Products Commission and was listed by Underwriters Laboratories and Factory Mutual.

 

  • Fusible links designed to release at 140° Fahrenheit thereby closing the unit’s cover and reducing any potential fire damage.

 

  • Small parts cup designed to snap over the drain tube and slowly recirculate solvent around small parts (nuts, cotter pins, springs, etc.) creating both flushing and turbulence.

 

  • Roto-cast remote solvent reservoir. Caps that sealed the pump tube and the drain opening were stored in molded depression to store securely while the product was in use and assure their reuse when the solvent tank was returned to a store for exchange.

 

  • Parts cleaning brush designed with replaceable brush head. Brush head was a single piece with rolled threads molded on non-collapsing core with stripper plate, significantly reducing tooling costs. Brush handle is two-part, sonically welded, heavy wall copolymer.

 

  • Vacuum formed drain tray fitted to the remote reservoir for use at the end of the solvent cycle to collect crank case oil and include it in the return for recycling.
 

Paint Gun and Equipment Cleaner

The images below illustrate Safety-Kleen’s Solvent Recirculating Paint Gun and Equipment Cleaner developed with Drester Corporation of Sweden. The unit was designed to provide a safe and convenient means of cleaning paintbrushes, paint guns, cups, and other finish applicators. Unit was listed by Underwriters Laboratories and Factory Mutual. Unit was primary submittal in the Product Development and Management Association’s “Innovator of the Year Award” in 1991.
Shown are front view of the Paint Gun and Equipment Cleaner showing extraction collar and recirculating solvent canisters, rear view showing the external plumbing designed for ease of access for service and repair, close-up of the unit’s bowl showing recirculated and clean solvent spigots and purge nozzle for safely emptying the spray paint gun and cup, and the Paint Gun and Equipment Cleaner in typical body shop.

United States Patent 5,213,119.

 

Front view of unit.

 

Unit bowl area with recirculated and clean solvent spigots and purge nozzle

 

Back view of unit.

 

Unit setup in a typical body shop

 

 

Secure Coolant Container

The images below illustrate Safety-Kleen’s Secure Coolant Container with Secondary Containment. It was developed to replace the traditional use of 55-gallon drums to collect antifreeze while providing site security. Black Secondary containment unit was roto-cast of recycled LLDPE. An agreement with the molder allowed for the recapture and recycling of the product after its life cycle, creating a closed loop on the resources contained in the product.

United States Patent 5,353,951.

Coolant Container with Secondary Containment

Coolant Container

 

Container for Dry Cleaning Waste

The images below illustrate Safety-Kleen’s Hazardous Waste Container for Dry Cleaning Waste. This product was specifically designed for the company’s dry cleaning waste service and to replace the conventional 16-gallon steel drum used for this waste stream. The resulting product reduced hazards and extended the life of the drum by a factor of 6 (from 1 year to 6 years) the liner was developed with supplier to prevent chemical permeation using a multi-layered PE-EVOH material. The interior surface was fluorinated to reduce absorption and material softening by the chemicals in the environment. This was a simple appearing yet highly sophisticated product, and as such won the IDSA’s IDEA, Design of the Decade Award in 1990. Lead designer on the project was G. Ira of the product development team at Safety-Kleen.

Closed Container

Container Components

Stacked Containers

 

Combined Child Carrier Cargo Container

Slides (E) illustrate a Combined Child Carrier and Cargo Container. This product was independently developed and subsequently licensed to Troxel Manufacturing of Memphis, Tennessee. Shown are, first production unit and advertisement depicting the unit in both a pannier and child carrier configuration.
The intent of the product was to significantly extend utility by designing-in “life-after-life” (Carrier to Pannier). The product was also made of recyclable polypropylene and labeled for resource recovery.

United States Patent 4,367,829, United Kingdom Patent 2091176, Canadian Patent 1171396, and United States Patent Des. 274,333.

 

Production model in promotional piece on cycle in child carrier and cargo container configurations
Production model in promotional piece on cycle in child carrier and cargo container configurations


 

Center for Sustainable Enterprise
Stuart Graduate School of Business, Illinois Institute of Technology
565 West Adams Street, Chicago, Illinois 60661 
Phone: (847) 721 9590 Email: jpkusz@stuart.iit.edu