Engineering Failure Analysis 12 (2005) 81–98

www.elsevier.com/locate/engfailanal

Failure of plastic press release buttons in automobile seat belts

Russell F. Dunn *,1, Richard H. McSwain, Terry Mills, Brian Malone
McSwain Engineering, Inc., 3320 McLemore Drive, Pensacola, FL 32514, USA
Received 6 May 2004; accepted 6 May 2004
Available online 20 July 2004

Abstract

In the late 1980s and early 1990s Honda, Nissan, Mitsubishi, Mazda, Suzuki, Subaru, Isuzu and Daihatsu and other
automobile manufacturers modified their restraint system seat belt buckle assemblies in several models of vehicles.
These automobile manufacturers incorporated plastic seat belt buckle assemblies manufactured by Takata Corporation
as the 52 and A7 model series [National Highway Transportation Safety Administration (NHTSA), 1997, p. 1]. These
seat belt models were introduced as early as 1986 and soon it was reported that numerous complaints of the mal-
functions of the seat belt locking and release mechanisms had occurred. The National Highway Transportation Safety
Administration (NHTSA) issued voluntary Recall No. 95V-103.001 on May 24, 1995, concerning 1986–1991 Honda
Accords with model 52 and A7 series Takata seat belt buckles after there were numerous reported failures of these
buckle assemblies. This issue has been the subject of numerous engineering investigations and failure analysis and, to
date, the root cause of the seat belt failures has been attributed to the selection of an inappropriate material of con-
struction for the seat belt press release button (acrylonitrile–butadiene–styrene plastic or ‘‘ABS’’); however, the evidence
presented has been inconclusive and had been debated in the literature. This paper will present failure analysis of the
seat belt buckle assembly, including polymer materials property review, optical microscopy and scanning electron
microscopy, Fourier transform infrared spectroscopy, pyrolysis gas chromatography/mass spectroscopy and Finite
Element Analysis modeling. Prior failure analysis has concluded that the root cause of the failures was that the ABS
press release buttons were fracturing due to a loss of material strength as a result of photolytic degradation (exposure to
sunlight) [Eng. Fail. Anal. 1999 6 (l) 13]; however, this paper presents failure analysis that not only casts doubt on this
root cause of failure but also provides evidence that for an alternative root cause of the failures, specifically that the
design of the ABS press release buttons without the inclusion of rib reinforcement provided inadequate strength for the
button to withstand the stress exerted from the insertion of the latch plate.
Ó 2004 Elsevier Ltd. All rights reserved.

Keywords: Polymers; Failure analysis; Seat belts; Automotive failure; Fatigue

*
Corresponding author. Tel.: +1-850-937-9311; fax: +1-850-937-8309.
E-mail addresses: rdunn@polymerchemtech.com (R.F. Dunn), rhmcswain@mcswain-eng.com (R.H. McSwain), tmills@mcswain-
eng.com (T. Mills), bmalone@mcswain-eng.com (B. Malone).
1
Now at: Polymer and Chemical Technologies, LLC, 1431 Glenmore Drive, Cantonment, FL 32533, USA.

1350-6307/$ - see front matter Ó 2004 Elsevier Ltd. All rights reserved.
doi:10.1016/j.engfailanal.2004.05.003
82 R.F. Dunn et al. / Engineering Failure Analysis 12 (2005) 81–98

Table 1
52 and A7 series Takata seat belts with ABS press release buttons in vehicles produced from 1986–1991 [1]
1986 1987 1988 1989 1990 1991 Total
Mitsubishi 299,291 357,328 336,912 427,112 570,880 498,455 2,489,978
Nissan 874,000 854,000 918,000 779,374 599,570 4,024,944
Mazda 383,436 472,888 277,415 226,228 1,359,967
Suzuki 57,042 74,072 36,672 41,306 209,092
Isuzu 95,057 306,756 401,813
Daihatsu 24,088 5,968 30,056
Subaru 21,152 81,956 59,918 22,804 35,996 221,826
Honda 973,130 1,196,958 1,397,254 1,299,768 1,743,956 881,350 7,492,416
Total 1,272,421 2,449,438 3,110,600 3,251,758 3,550,246 2,595,629 16,230,092

1. Introduction

1.1. Seat belt failure history

In the late 1980s and early 1990s Honda, Nissan, Mitsubishi, Mazda, Suzuki, Subaru, Isuzu and Dai-
hatsu and other automobile manufacturers incorporated new seat belt assemblies in several models of
vehicles. Vehicles produced by these automobile manufacturers utilized series 52 and A7 seat belt buckle
assemblies manufactured by Takata Corporation [1]. The 52 and A7 seat belt assemblies were used in these
vehicles as early as 1986 and introduced the use of acrylonitrile–butadiene–styrene (ABS) plastic press
release buttons. Soon after the introduction of the Takata 52 and A7 series seat belts it was reported that
numerous complaints involving malfunctions of the seat belt locking and release mechanisms had occurred.
In fact, 900 complaints and 90 injuries had been reported by 1995 [3]. Over 18 million of the 52 and A7
model Takata seat belt buckle assemblies were used in automobiles from 1986 to 1991, with approximately
7.5 million used in Honda automobiles, 4 million used in Nissan automobiles and the remaining number
used by the other automotive manufacturers previously listed. Table 1 is included as a breakdown of the
usage of the 52 and A7 series seat belts by the various automobile manufacturers.

1.2. Takata ABS press release button design

The press release buttons used by Takata in the 52 and A7 series seat belt assemblies for use in auto-
mobiles from 1986 to 1991 were injection molded from ABS plastic resin. Fig. 1 is a front view of a Takata
52 series seat belt ABS press release button in the seat belt housing that was removed from a 1987 Honda
Accord. Fig. 2 is the same seat belt mechanism after disassembly. Fig. 3 is the ABS press release button
after removal from the housing and Fig. 4 is a side view of the ABS press release button.

1.3. Takata press release button – ABS plastic properties

The specific ABS resin used by Takata for the production of the press release buttons manufactured by
the Japan Synthetic Rubber Company as resin grade JSR XT-04. Properties of this grade of ABS resin are
provided in Table 2 [1].

1.4. Takata ABS press release button fracture and seat belt mechanism failure

Prior analysis of broken ABS press release buttons have indicated that fractures originated on the ex-
terior surface of the underside of the buttons [1]. This fracture location is indicated with an arrow on the
 R.F. Dunn et al. / Engineering Failure Analysis 12 (2005) 81–98 83

Fig. 1. ABS press release button in a Takata 52 series buckle assembly from a 1987 Honda Accord.

Fig. 2. ABS press release button mechanism removed from a 1987 Honda Accord.

broken button in Fig. 5 for the model 52 press release button and Fig. 6 for the model A7 press release
button. Photographs of intact press release buttons are also provided for direct comparison. This fracture
location is consistent with a force applied to the bottom exterior of the button. Broken press release button
fragments can lodge in the spring mechanism in the buckle assembly and, if this occurs, the lodged fragment
can render the buckle assembly inoperable. Fig. 7 shows a seat belt buckle assembly with a broken fragment
from the press release button lodged in the spring mechanism. The National Highway Transportation
Safety Administration (NHTSA) issued voluntary Recall No. 95V-103.001 on May 24, 1995, concerning
1986–1991 Honda Accords with 52 and A7 model Takata seat belt buckles in response to numerous re-
ported failures of these buckle assemblies.
84 R.F. Dunn et al. / Engineering Failure Analysis 12 (2005) 81–98

Fig. 3. ABS press release button disassembled from the buckle mechanism removed from a 1987 Honda Accord.

Fig. 4. Takata ABS press release button removed from a 1987 Honda Accord.

Table 2
JXR XT-04 ABS resin properties
Test item Units Value
Specific gravity 1.05
Tensile strength kgf/cm2 460
Flexural strength kgf/cm2 780
Flexural elasticity kgf/cm2 23700
Izod impact strength (with notch) kgf cm/cm 10
Rockwell hardness R104
Heat deformation temperature °C 111
Vicat softening point °C 132
Melt index g/10 min 1.9
Quarter elliptical method chemical sensistivity CRC 0.7

2. Industry solutions for the seat belt failures

2.1. Short-term solution

As noted earlier, no formal automobile recalls resulted in the US concerning the fragmentation of the
press release buttons [2]. Instead, NHTSA instituted a voluntary recall in which car owners could take their
 R.F. Dunn et al. / Engineering Failure Analysis 12 (2005) 81–98 85

Fig. 5. Takata model 52 ABS press release buttons.

Fig. 6. Takata model A7 ABS press release buttons.

vehicles to authorized dealers for inspection and free repairs, as required. The voluntary recall allowed
owners to return vehicles to the dealer where a Honda mechanic would conduct a brief visual inspection of
the front seat belt receptacles. If no breakage of the release buttons was noted, the mechanic would install a
small plastic impact guard on each seat belt receptacle [4]. Fig. 8 shows a Takata seat belt assembly with the
impact guard installed and Fig. 9 shows the impact guard after disassembly. If severe degradation of the
release buttons was noted, the mechanic would replace the seat belt receptacles with new assemblies.
Having the discretion to simply add the impact guard instead of replacing the entire assembly saves Honda
roughly $100 per vehicle in parts and labor. Prior studies have suggested that the impact guard is unlikely to
be completely effective in eliminating impact damage to the seat belt release buttons [2].
86 R.F. Dunn et al. / Engineering Failure Analysis 12 (2005) 81–98

Fig. 7. ABS press release button with a broken fragment in the spring mechanism.

Fig. 8. Press release button impact guard.

Fig. 9. Press release button impact guard – disassembled.

 R.F. Dunn et al. / Engineering Failure Analysis 12 (2005) 81–98 87

2.2. Long-term solution (NHTSA, 0283)

In November of 1990, Takata introduced a modified press release button intended to eliminate the prior
failures associated with the ABS press release buttons. Specifically, Takata reported the following to
NHTSA [1]:
1. The release button material of construction was changed from ABS to a copolymer polyoxymethylene
(POM) plastic resin, which is also commonly referred to as polyacetal polymer. The specific grade of
POM resin selected was M90-45 manufactured by Polyplastics Corporation [1]. Properties of this grade
of POM are provided in Table 3.
2. The release button shape was modified and rib reinforcement was added under the leading edge of the
button, specifically in the area of fracture of the ABS buttons [1]. Fig. 10 is included to show the POM
button design and an arrow indicates the rib reinforcement.
3. The release button change in material of construction from ABS to POM resulted in an ‘‘improvement
of productivity’’ [1]. While this phrase is not clearly explained by Takata, it is hypothesized that the
improved productivity is a result of reduced injection molding cycle time for the release button. Produc-
tivity of injection molded parts is increased when the molding cycle time is reduced, i.e., more parts can
be produced in a given period of time. POM molded parts have been reported to have typically lower
cycle time than ABS molded parts (reference).
4. The release button change in material of construction from ABS to POM resulted in a ‘‘standardization
of materials’’ [1]. Again this is not clearly explained by Takata and it is hypothesized that Takata was
manufacturing other plastic components from POM resin and that this change was made to consolidate
the materials of construction used by Takata. Consolidation of materials of construction allows manu-
facturers to buy larger volumes of the resin, thus reducing the unit cost of the resin.

Table 3
Polyplastics corporation duracon M90-45 POM resin properties
Test item Units Value
Specific gravity 1.41
Tensile strength kgf/cm2 600
Flexural strength kgf/cm2 780
Flexural elasticity kgf/cm2 24,000
Izod impact strength (with notch) kgf cm/cm 6.0
Heat deformation temperature °C 110

Fig. 10. POM press release button.

88 R.F. Dunn et al. / Engineering Failure Analysis 12 (2005) 81–98

Henshaw et al. [2] have reported that the unit cost of ABS resin was less than POM resin; however,
purchase of the plastic in bulk to reduce the cost and the effect of cycle time reductions were not considered
as part of their analysis.

3. Prior failure analysis of the Takata 52 and A7 model seat belt assemblies

3.1. Takata studies

Takata conducted numerous studies in an effort to determine the root cause of the ABS release button
failures [1]. Laboratory studies cited reductions in the strength of the ABS button under the following
conditions:
(a) Exposure to light (UV) for a period up to 300 h. No further degradation was noted after continued
exposure beyond 300 h.
(b) Contact with certain chemicals.
(c) Exposure to light (UV) followed by exposure to intense cold ()30 °C or )22 °F).
Takata concluded that breakage of the release buttons involved at least two factors:
(a) Excessive forces applied to the bottom exterior surface of the button, probably by the latch plate.
(b) Reduction in the strength of the button from at least the following factors: (i) sustained exposure to
sunlight (ii) contact with contamination and (iii) temporary exposure to very low temperature.

3.2. University studies

Researchers at the University of Tulsa and the University of Illinois studied the failure of the Takata
ABS release buttons in 1998. The history of the Takata release button and subsequent laboratory analysis
was provided by Hensahaw et al. [2]. These studies concluded:
(a) The Takata ABS press release button failures resulted from a classic ‘failure chain’ of events and con-
ditions. These included a polymer susceptible to environmental degradation (ABS), the presence of re-
peated, low energy impacts over a period, perhaps, of years, a hostile environment that included
temperatures up to 75 °C, ultraviolet radiation, oxygen, and a design that allowed fragments of the re-
lease button to interfere with the function of the release mechanism. These researchers further con-
cluded that had any one of the elements in this failure chain been absent, it is likely that the
widespread failures of the subject seat belts would never have taken place.
(b) There are three reported modes of seat belt mechanism failure. Each of the three reported modes of
failure can be explained in terms of a specific location within the seat belt mechanism in which a frag-
ment of the release button becomes lodged.
(c) The short-term solution to the problem agreed upon by industry and government (that is, the installa-
tion of the plastic impact guard) was economical, if less than satisfying from a safety standpoint.
(d) The longer-term solution arrived at (the specification of the more environmentally resistant material
POM) breaks the failure chain and appears to be satisfactory.
(e) This seat belt release button, with a manufacturing cost of approximately $0.05, nearly resulted in the
most expensive automobile recall in industry history. Thus, the failure of even the humblest of parts can
have grave consequences.

3.3. Additional analysis

The failures of the Takata ABS press release buttons were recently considered as a case study involving
polymer failure analysis [3]. Although no additional laboratory studies were conducted, serious doubts were
 R.F. Dunn et al. / Engineering Failure Analysis 12 (2005) 81–98 89

raised concerning the conclusions that were previously cited by Henshaw and coworkers. The concerns
raised were:
(a) ABS is known to discolor and surface craze after several years of exposure to sunlight; however, ABS
has been used, and continues to be used, extensively in components found in the interior of automo-
biles.
(b) Other seat belt manufacturers use, and continue to use, ABS plastic components for seat belt press re-
lease buttons without any serious problems. The authors further stated that Takata has not produced
any documents that indicate that the JSR XT-04 ABS resin is substandard in terms of UV degradation
versus any other versions of ABS.
(c) The origin of the release button fractures are on the underside of the button. This is not consistent with
the area of the button that receives the most UV exposure. In fact, the fracture locations coincide with
the point of maximum stress, not the point of maximum UV degradation.
The following section describes an additional failure analysis conducted by the authors to further study
the Takata ABS press release buttons to identify the root cause of the failures and to address the issues
raised by prior conflicting opinions on this matter. The focus of this effort was directed toward the analysis
of seat belt assemblies removed from 1986 to 1998 Honda Accords; however, the conclusions reached are
applicable to the other vehicle makes and models with the 52 and A7 series Takata seat belt assemblies with
the ABS button design.

4. Failure analysis results

4.1. Failure analysis protocol

Standard failure analysis protocol for investigating materials failures, particularly polymers and plastics,
was used for analysis of the Takata press release buttons [5,6]. The specific protocol used is [7]:
1. Information gathering.
2. Preliminary visual examination.
3. Nondestructive testing.
4. Characterization of material properties through mechanical, chemical and thermal testing.
5. Selection, preservation and cleaning of fracture surfaces, secondary cracking and surface condition.
6. Microscopic examination.
7. Identification of failure mechanisms.
8. Stress/fracture mechanics analysis.
9. Testing to simulate failure.
10. Product failure history research.
11. Data review and formulation of conclusions.
12. Report preparation.

4.2. Chemical characterization of Takata ABS press release buttons

4.2.1. Press release button plastic identification

Fourier Transform Infrared Spectroscopy (FTIR) was conducted using a Thermo Nicolet Protege 460
Spectrometer to verify the plastic material of construction for the press release buttons that were analyzed.
Fig. 11 is included as an FTIR spectrum of an ABS press release button and Fig. 12 is included as an FTIR
spectrum of a POM press release button. The spectral peaks corresponding to key chemical groups are
indicated in Figs. 11 and 12 and these spectra correspond closely to literature [8].
90 R.F. Dunn et al. / Engineering Failure Analysis 12 (2005) 81–98

Fig. 11. FTIR spectrum of an ABS press release button from a 1987 Honda Accord.

4.2.2. Chemical resistance

Chemical resistance of the ABS press release buttons is sufficient and can not account for the large
number of release button fractures. Takata tested a number of ABS press release buttons returned through
Honda’s warranty system and no specific chemical attack could be identified as a root cause of the button
failures. Thus, a lack of sufficient chemical resistance of the subject type press release button made with
JXR XT-04 ABS is not the root cause of the ABS press release button failures [1].

4.3. Environmental characterization of Takata ABS press release buttons

4.3.1. Heat resistance

Heat resistance of the ABS press release buttons is sufficient and can not account for the large number of
release button fractures. Takata tested a number of ABS press release buttons and determined that intense
cold, )30 °C for 4 h, reduced the strength of the buttons but did not result in button fractures when a load
was applied. Thus, a lack of sufficient heat resistance of the subject type press release button made with
JXR XT-04 ABS is not the root cause of the ABS press release button failures [1].
 R.F. Dunn et al. / Engineering Failure Analysis 12 (2005) 81–98 91

Fig. 12. FTIR spectrum of a POM press release button from a 1992 Honda Accord.

4.3.2. UV resistance
UV resistance of plastics is a major concern and the lack of sufficient UV resistance of the Takata ABS
press release buttons has been cited by Takata as the root cause of the fracture of the buttons and other
independent researchers agreed with this assessment [2]. However, scientific inconsistencies surrounding
these conclusions were recently published and were discussed previously in this paper.
Exposure to sunlight of plastic components used in automotive applications can result in UV degra-
dation. To address this issue UV stabilizers have been added to plastic components in small quantities,
typically less than 0.5 wt%. Takata press release buttons made from the JXR XT-04 ABS resin were an-
alyzed via pyrolysis/gas chromatography (GC)/mass spectroscopy (MS) using a CDS Pyroprobe 1000
linked to a Thermo Finnigan TRACE DSQ GC/MS to determine if UV stabilizer had been incorporated
into these release buttons. Fig. 13 is included as a gas chromatograph and mass spectra of an ABS press
release button from a 1987 Honda Accord. Detailed analysis shows the presence of a component that was
eluted at 30.9 min on the gas chromatograph and the mass spectra of the compound eluted at that time
exhibited the highest abundance of mass weight at 225 atomic mass units. The key gas chromatograph and
mass spectra peaks are highlighted in Fig. 13.
UV stabilizers commonly used in plastics are in the benzotriazole chemical family [9,10]. Fig. 14 is
included as a gas chromatograph and mass spectra of phenol, 2-(2H-benzotriazole-2-yl)-4-methyl, a
member of the benzotriazole family of UV stabilizers, and the chromatogram/spectra was generated
from a pure sample of this UV stabilizer. The gas chromatograph shows the presence of a single
compound (pure sample) that was eluted at 30.7 min and the mass spectra of the compound eluted at
that time exhibited the highest abundance of mass weight at 225 atomic mass units, as shown by
Fig. 14. Thus, a comparison of Figs. 13 and 14 validates that this UV stabilizer was used in the
Takata ABS press release buttons. Furthermore, a significant reduction in the ABS release button
strength as a result of UV exposure is highly improbable. It is also worth noting that the POM press
92 R.F. Dunn et al. / Engineering Failure Analysis 12 (2005) 81–98

Fig. 13. Gas chromatograph and mass spectra of an ABS press release button from a 1987 Honda Accord.
 R.F. Dunn et al. / Engineering Failure Analysis 12 (2005) 81–98 93

Fig. 14. Gas chromatograph and mass spectra of a benzotriazole UV stabilizer.

Fig. 15. Takata POM press release button exhibiting UV degradation.

release buttons exhibit sever UV degradation, as shown by the faded exterior of the POM press
release button in Fig. 15; however, there have been no complaints regarding fractured POM press release
buttons.
94 R.F. Dunn et al. / Engineering Failure Analysis 12 (2005) 81–98

4.4. Mechanical property characterization of Takata ABS press release buttons

4.4.1. Impact resistance

Impact resistance of notched JXR XT-04 ABS resin is higher than Duracon M90-45 POM resin, in that
the butadiene phase of the ABS resin provides improved impact strength and toughness to the ABS resin.
Specifically, JXR XT-04 ABS resin has a notched izod impact strength of 10 kgf cm/cm compared to a
notched izod impact strength of 6 kgf cm/cm, as shown previously in Tables 2 and 3.

4.4.2. Forces acting on the Takata ABS press release button

Installation of a seat belt impact guard was implemented by Honda in 1995 to reduce/eliminate button
fracture. The primary function of the press release button impact guard is to minimize the angle of impact
on the press release button in order to address the prying/cantilever force on the protruding button edge,
the origins of the fracture locations. Figs. 16 and 17 are included to illustrate the force acting on the
protruding button edge.

Fig. 16. Force from the latch plate to the protruding edges of the Takata press release button.

Fig. 17. Force from the latch plate to the protruding edges of the Takata press release button [1].
 R.F. Dunn et al. / Engineering Failure Analysis 12 (2005) 81–98 95

4.4.3. Finite element analysis of the Takata ABS press release button
Laboratory measurements have shown that the angle of impact of the latch plate onto the protruding
edge is as high as 12.5° and that installation of the latch plate guide reduces the angle of impact to less than
1°. Figs. 18 and 19 are included as finite element analysis (FEA) of the stress on the protruding button edge
at 12.5° and 1° angles, respectively, with equivalent insertion force of the latch plate. This analysis, con-
ducted using Design Space FEA software, shows that the greatest stress regions occur in the area of the
fracture locations and that reducing the angle of impact reduces the stress exerted on the protruding edge of
the button by a factor of approximately 25. Latch plate insertion into the Takata buckle assembly without
the guide could be at an angle as high as 12.5° which causes a high stress on the back edge of the button
surface. Finite element analysis (FEA) was used to show areas of high stress on the press release button

Fig. 18. FEA analysis of stress exerted from the latch plate when inserted at a 12.5° angle.

Fig. 19. FEA analysis of stress exerted from the latch plate when inserted at a 1° angle.
96 R.F. Dunn et al. / Engineering Failure Analysis 12 (2005) 81–98

during latch plate insertion. A graphical representation of the high stress locations on the ABS press release
button is shown in Figs. 18 and 19 as the red regions.

4.5. Fractography of the Takata ABS press release button

Fig. 20 shows fatigue fracture features as evidenced via optical microscopy and scanning electron mi-
croscopy (SEM) with a Hitachi S-2460N scanning electron microscope. The ABS seat belt press release
buttons can be fractured due to repeated impact damage fatigue combined with insufficient reinforcement
strength in the button leading edge design.

4.6. Design modifications by Takata to improve the press release button

Takata added extra reinforcement ribs for the POM press release buttons in 1990, as previously shown in
Fig. 10. FEA was conducted to determine the stress exerted by the latch plate onto the press release button
designs with and without rib reinforcement and at 1° and 12.5° latch plate insertion angles. FEA analysis
shows that the inclusion of these reinforcement ribs in the original ABS design would have substantially
reduced the stress that caused the button fracture and fragmentation issue and these results are shown in
Fig. 21.

Fig. 20. ABS press release button fractography.

 R.F. Dunn et al. / Engineering Failure Analysis 12 (2005) 81–98 97

Fig. 21. Results of the finite element analysis of press release buttons with and without rib reinforcement.

5. Conclusions

1. The Takata ABS seat belt press release buttons in the model 52 and A7 seat belt assemblies used in
1986–1991 automobiles fractured due to repeated impact damage fatigue.
2. In 1992, Takata replaced the ABS press release buttons with press release buttons made of POM plastic.
The POM press release buttons included rib reinforcement under the protruding edge of the button.
3. Finite element analysis of the press release button shows that the greatest stress regions occur in the area
of the fracture locations and that reducing the angle of impact, via the incorporation of the impact
guard, reduces the stress exerted on the protruding edge of the button by a factor of approximately 25.
4. Chemical and heat resistance of the ABS press release buttons is sufficient and can not account for the
large number of release button fractures.
5. A benzotriazole UV stabilizer was used in the Takata ABS press release buttons. Furthermore, a signif-
icant reduction in the ABS release button strength as a result of UV exposure is highly improbable. POM
press release buttons have exhibited severe UV degradation; however, there have been no complaints re-
garding fractured POM press release buttons. Thus, excessive exposure to UV radiation can not account
for the large number of release button fractures.
6. Impact resistance of notched JXR XT-04 ABS resin is higher than Duracon M90-45 POM resin. Thus,
the press release button material of construction can not account for the large number of release button
fractures. Furthermore, the change from ABS to POM for the press release button material of construc-
tion was most likely driven by economics, not an improvement in strength.
7. Inclusion of the reinforcement ribs in the original ABS design would have eliminated the button fracture
and fragmentation issue.
8. The root cause of the press release button fractures and fragmentation is the improper end product
design, specifically the lack of the reinforcement ribs.

6. Final thoughts

Careful product design must consider the properties of the materials of construction (ABS vs. POM),
end product design (press release button) and the ultimate end product use (multiple impacts). This case
involved the improper end product design when considering the ultimate application of the end product.
98 R.F. Dunn et al. / Engineering Failure Analysis 12 (2005) 81–98

Both plastic materials of construction would have been sufficient if the rib reinforcement had been included
in the ABS design of the press release button.

Acknowledgements

The authors are appreciative of the technical assistance provided by Mr. Darryl McKinley.

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