Innovative Automotive Door-handle Based On R2R Printing Process, Hybrid And Heterogeneous Integration

Innovative Automotive Door-handle Based On R2R Printing Process, Hybrid And Heterogeneous Integration

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Description: Two plastic sheets and conductive traces separated by insulators, generating a sensor response due to pressure. Innovative and competitive technology in distributed pressure sensors. Technology especially suitable to monitor large areas.

Compatibility with the manufacturing techniques for the electronics sector. Easy installation and integration capability in complex systems. Competitive in price compared to other sensor technologies due to the materials used.

Flexible and light, hence adaptable to multiple surface format.

 
Author: Jaime Herran PhD  | Visits: 433 | Page Views: 656
Domain:  High Tech Category: Consumer 
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Contents:
Innovative automotive door-handle
based on R2R printing process, hybrid
and heterogeneous integration
2016 Flex Conference, Grenoble (France), 25th October 2016.

Dr. Jaime Herrán

Outline

 Pressure sensors technology

 Roll-Out project
 Door-handle development
 R2R pressure sensor fabrication
 Overmolding process
 Conclusions

Outline

 Pressure sensors technology

 Roll-Out project
 Door-handle development
 R2R pressure sensor fabrication
 Overmolding process
 Conclusions

Pressure sensors technology
PRESSURE SENSORS: TECHNOLOGY

 Two plastic sheets and conductive traces separated by insulators, generating a sensor
response due to pressure.
 Innovative and competitive technology in distributed pressure sensors.
 Technology especially suitable to monitor large areas.
 Patents:ES2264900B1,ES2302436B1,WO2007006833A2,EP1912051A2,US8294226B2

Pressure sensors technology
PRESSURE SENSORS: ADVANTAGES

 Compatibility with the manufacturing techniques for the
electronics sector.

 Easy installation and integration capability in complex systems.
 Competitive in price compared to other sensor technologies
due to the materials used.
 Flexible and light, hence adaptable to multiple surface format.
 For Punctual and / or continuous monitoring
 Sensor response < 2 ms.
 Durability > 106 cycles.
 Fabrication on plastic substrates, textiles and paper.

Pressure sensors technology
PRESSURE SENSORS APPLICATIONS

SMART SEAT
256 sensor elements distributed over the surface of

BALANCE CONTROL
PLATFORM

an automotive seat, for activation of security

elements: air bag, ergonomics, safety controls.

Graphic representation of pressure values in the
smart automotive seat

HYPER Project- Spanish National Grant (CONSOLIDER-INGENIO)
Hybrid Neuroprosthetic and Neurorobotic Devices for Functional
Compensation and Rehabilitation of Motor Disorders

Pressure sensors technology
PRESSURE SENSORS APPLICATIONS

MONITORED BEDS

SMART TEXTILES

Monitored beds by means of distributed pressure sensors to

Pressure sensors integrated

monitor pressure, and to alert the medical/support staff

in textiles.

about the risk of existence of pressure ulcers.

ETORGAI NOVOSENS- Spanish National Grant
Competitive plastic based sensors for multisectorial products and processes

Pressure sensors technology
PRESSURE SENSORS APPLICATIONS

MONITORED FLOORS

EMBEDDED PRESSURE SENSORS
IN COMPOSITES

PAPER BASED PRESSURE
SENSORS FOR ASSITANT CARE
TACTASSIST
Spanish National Grant
Touch instrumentation and
assistant care

Outline

 Pressure sensors technology

 Roll-Out project
 Door-handle development
 R2R pressure sensor fabrication
 Overmolding process
 Conclusions

Roll-Out project
SMART INTERFACES
Development of thin, large-area, high-performance, smart, and autonomous systems comprising

integrated circuits, sensors, and electronics for packaging, automotive interiors and textile
industries.

ROLL-OUT
H2020- ICT-03-2014
High-performance, Flexible, AUTOnomous
Systems manufactured with Unique, Industrial
ROLL-to-roll equipments.

Outline

 Pressure sensors technology

 Roll-Out project
 Door-handle development
 R2R pressure sensor fabrication
 Overmolding process
 Conclusions

Door-Handle development
PRESENT SYSTEM

ROLL-OUT EVOLUTION

Door-Handle development
First prototype concept

Pick and Place Resistance (VTT)

FIRST R2R Prototype

Pressure Sensors (CIDETEC)






Fabrication VTT pilot line
Pressure sensor R2R integration
Pick and place resistors
Overmoulding

Outline

 Pressure sensors technology

 Roll-Out project
 Door-handle development
 R2R pressure sensor fabrication
 Overmolding process
 Conclusions

R2R pressure sensor fabrication

• Silver
• Insulator
• Adhesive

R2R pressure sensor fabrication
 Substrate: PET Melinex ST506 (width 300mm, thickness 125um)
 Inks
• Silver (DuPont 5064H, Asahi).
o Line speed: 2 m/s
o Temperature: 140ºC (4 ovens).
• Insulator (Marabu UVSW-970, Electrodag).
o Line speed: 2-5 m/s
o UV curing (125 W).
• Adhesive (3M).
o Silicone paper.
o Line speed: 2-5 m/s.
o UV curing (125 W).
 Laminated Conductive Polymer (Pedot from Agfa: Orgacon El-350).
After printing processes and polymer assembled, resistors have been bonding by and auto-mated pick-and-place system
(Resistors SMD 1 K).

Printed head

Rotary screens

R2R pressure sensor fabrication

Printing line

Processed rolls

Processed Samples

R2R pressure sensor fabrication
According to the sensor design, the device has been tested in order to
corroborate the working principle. In this context, as it has been showed, the
output voltage values will be as follows (R1=R2=R3= 1 K):
• Button 4 activated: Vout = 3 K
• Button 3 activated: Vout = 2 K
• Button 2 activated: Vout = 1 K
• Button 1 activated: Vout = single sensor resistance

Outline

 Pressure sensors technology

 Roll-Out project
 Door-handle development
 R2R pressure sensor fabrication
 Overmolding process
 Conclusions

Overmolding process
Set-Up

Injection moulding machine at VTT hybrid in-mould integration pilot line

Layout of the existing overmoulding tooling

Overmolding process
1st Experiment
Makrolon 2407 low viscosity PC
(BayerMaterialScience)
Melt temperature [°C]

255

Holding pressure [bar]

20

Injection rate [mm/s]

30

Holding time [s]

4

Injection pressure [bar]

75

Cooling time [s]

20

Overmolding process
2nd Experiment
Overmoulding materials
1. PC+ABS

Cycoloy CP8320

Sabic IP

MVR 13*

2. TPU elastomer

Pearlthane D91T80

Lubrizol

ShA 84**

*Melt volume rate at 260ºC with 5.0kg
**Nominal hardness

The most important overmoulding parameters
Material
Run

Dosering
[mm]

vspeed
[mm/s]

Tmel
[ºC]

Tmould
[ºC]

Pinjection
[bar]

Pholding
[bar]

Switch over point
[mm]

Melt cushion
[mm]

Cooling time
[s]

1.PC+ABS

30

22

250

60/60

50

32

8

3-4

20

2.PC+ABS

30

22

265

60/60

40

27

8

3-4

30

3. TPU

28

19

190

35/35

32

24

7

3-4

30

Overmolding process
2nd Experiment
Mould and sample processing

Overmolding process
2nd Experiment
Samples processed

Functional problem: electrodes
destroyed and stuck on the polymer

Next step:
Simulation and overmolding process

Overmolding process
Simulation

Process condition summary

3D moulding model with foil insert and cold runner
Item name
Filling Time

29.2668 (cc)

Flow rate profile Section-1

30.00 %

Flow rate profile Section-2

74.52 %

Flow rate profile Section-3

48.60 %

Section Number of Injection Pressure Profile

3

Packing Time

6.0000 (sec)

Maximum Packing Pressure

221.00 (MPa)

VP Switch by volume(%) filled

Reference
Run1
Run2
Run3

221.00 (MPa)

Injection Volume

Injection time [s]
1
1
0.5
1

60.0 (oC)

Maximum Injection Pressure

Tooling temperature [°C]
60
80
80
80

250.0 (oC)

Mold Temperature

Melt temperature [°C]
250
270
270
290

1.0000 (sec)

Melt Temperature

Variables of the overmoulding simulation

Item data

98.00 (%)

Mold Opening Time

5.0000 (sec)

Ejection temperature

96.0 (oC)

Air Temperature

25.0 (oC)

Cooling Time

20.0 (sec)

CycleTime

32.0 (sec)

Overmolding process
Simulation

Overmoulding simulation – conclusion


The injection pressure had constant distribution and the pressure drop was low because
the moulding part had relatively high and constant wall thickness.



Furthermore high heat capacity of the TPU increases the cooling time. It was quite an
obvious that the injection pressure did decrease in the function of the higher temperature.
The injection time had minor effect to the filling pressure.



As the conclusion higher melt temperature was tested in 3rd experiment. Furthermore a
higher flow resin Elix H605 (ABS) was selected to the 3rd experiment aiming to minimise
the filling pressure.

Overmolding process
3rd Experiment

Design parameters optimization
in sensor configuration:

Overmoulding materials
1. PC+ABS

Cycoloy CP8320

Sabic IP

MVR 13

2. TPU elastomer

Pearlthane D91T80

Lubrizol

ShA 84

3. ABS

Elix H605

Elix Polymers

MVR 25

Overmoulding experiments
Melt Injection p2
[bar]
temp2
[°C]

Melt
temp1
[°C]

Injection p1
[bar]

1. Cycoloy CP8320

260

38

280

28

2. Pearlthane D91T80

195

17

215

13

3. Elix H605

260

38

280

21

• Increase the gap between electrodes and polymer
increasing the insulator thickness (2 layers, around 30
mm).
• Additional design: the first design (insulator around
silver electrodes) and a second one (insulator between
silver electrodes).

Overmolding process
3rd Experiment
Results after experimental tests
• Sensor of all the samples (TPU, ABS and PC+ABS) seems to have similar
behavior.
• Electrodes are ok after printing process.
• In both designs, samples can be measured but sensors are activated. However,
design 2 (insulator between silver electrodes) is less activated that the first design
(higher resistance). Resistance change as a function of pressure is measured.
• After remove samples for thermoplastic piece, it can be observed as polymer is
complete stacked on the plastic part. Anyway, polymer electric properties are ok.

Conclusion
• Electrodes are ok after printing process.
• Functional properties of sensors are ok.
• However, it is not still working as before injection molding process because the
sensor was already activated without the pressure.

Overmolding process
4th Experiment
Based on the 3rd experiment, Elix H605 (ABS) with the lower melt temperature was the most promising
combination unlike it was expected. New sensor structures were fabricated for the 4 th experiment and lower
melt temperature was tested.
Regarding sensor configuration, it was decided to increase the gap between electrodes and polymer
increasing the insulator thickness (3 and 4 layers).

Overmoulding materials
3. ABS

Elix H605

Elix Polymers

MVR 25

Overmoulding experiments
Melt
temp1
[°C]
1. Elix H605

Injection p1
[bar]

240

30

Melt Injection p2
[bar]
temp2
[°C]
260

25

Overmolding process
4th Experiment

Results after experimental tests
• Electrodes are ok after printing process.
• Design 2 (insulator between silver electrodes) is not activated without pressure and the first
design is activated.
• Resistance change as a function of pressure is measured

Conclusion
• Electrodes are ok after printing process.
• Functional properties of sensors are ok.
• Optimal thickness should be between 2 and 3 insulator layers (30-40 mm).
• Signal conditioning must be updated (Resistors value optimization).

Outline

 Pressure sensors technology

 Roll-Out project
 Door-handle development
 R2R pressure sensor fabrication
 Overmolding process
 Conclusions

Conclusions
Conclusions


Pressure sensor technology developed by Cidetec has been scaled-up for R2R fabrication.



R2R fabrication has been carried out at VTT pilot line facilities.



Device functional properties has been successfully tested after printing process and resistor pick-and-place
assembly.



Overmolding process has been successfully simulated, designed and optimized.



Device functional properties has been successfully tested after overmolding process.



Next step: implementation in real automotive design mold.