Decoration meets Sensor. Non-conductive decoration inks for In Mold Electronics TACTOTEK IMSE TM Solution day Hans-Peter Erfurt

Transcription

1 1 Non-conductive decoration inks for In Mold Electronics

2 2 even closer and tighter by injection molding So far: k e e p i n g d i f f e r e n t Decoration in the mold to utilize benefits of IMD/FIM: Freedom of design by screen printing Accurate position of graphics in 3D plastic parts with backlighting option inner depth of designs possible by clever stacking Even larger parts up to full dashboard units Sensor by separate film with reverse lamination to the decor film: High volume sensor market in telecomm., electronics and automotive Customization by extra technologies e.g. gravure printing

3 3 even closer and tighter by injection molding Near: m a k i n g i n t o o n e I Going your own way Keeping technology and adding value in-house One-film-version: every layer of decoration, conductive and dielectric in one Two-film-version: injection molding combines both elements in one shot

4 4 Process steps in IMD/FIM Forming Injection molding Past times Breakthrough Today s routine Screen printing NORIPHAN Norilux DC UV-Curing Drying Cutting

5 5 General material sequence In-mould Film Insert Molding IMD/FIM Reverse Inmold Labeling IML/FIM transparent film Screen printing decoration Injection molding resin Dual Cure lacquer transparent film Screen printing decoration Injection molding resin transparent Injection molding resin transparent film Sreen printing decoration back molding front molding

6 6 Film PC Ink system NORIPHAN HTR N NORIPHAN PCI N NORIPHAN N2K NORIPHAN XWR NORIPHAN XMR Adhesion Promoter Injection molding material - PC, PC/ABS, PMMA,TPU, Silicone NoriPress SMK ABS, PA 6, PA 11, PA 12, PC NORIPHAN HTR N NORIPHAN N2K PC, PC/ABS, PMMA,TPU, Silicone NoriPress SMK ABS, PA 6, PA 11, PA 12, PC PMMA Noricryl - PMMA, ABS, SAN NORIPHAN N2K - PC, PC/ABS NoriPET - ABS, SAN PET NORIPHAN XWR NORIPHAN XMR NORIPHAN HTR N NORIPHAN N2K NoriPress SMK PC, PC/ABS, PMMA, TPU, Silicone ABS, PA 6, PA 11, PA 12, PC PP NORIPHAN XMR NoriPET PP Adhesion Promoter PP PA NoriAmid NoriAmid APM ABS, PA 6, PA 11, PA 12

7 7 Systematic Approach for Requirements on the ink for successful processing: Washout resistance Cohesion/Adhesion Formability on the part for successul application: Climate stability (durable adhesion and no visible effects/defects) increased further in recent times: Why? Interlayer adhesion Process window with 2 comp. inks Warpage in parts Larger parts Non conductive decor Integration of capacitive electronics Heat and climate tests New OEM / Tier 1 specifications

8 8 Adhesion and Cohesion Universality and long term experience with PC-Film NORIPHAN HTR N as benchmark Product optimization in 2012: HTR gets HTR N Peel strength F in N/cm 25,0 20,0 15,0 10,0 5,0 8,1 4,3 Diagram about ink cohesion 22,0 19,6 10,7 7,2 5,5 2,8 Film cracked 35, 0 30, 0 25, 0 20, 0 15, 0 10, 0 5, 0 0, 0 HT R 093 HT R N 093 HT R 108 HT R N 108 HT R 112 HT R N 112 HT R 225 HT R N 225 HT R 318 HT R N 318 HT R 321 HT R N 321 HT R 372 HT R N 372 HT R 412 HT R N 412 HT R 445 HT R N 445 HT R 471 HT R N 471 HT R 566 HT R N 566 HT R 570 HT R N 570 HT R 665 HT R N 665 HT R 770 HT R N 770 HT R 780 HT R N 782 HT R 790 HT R N 790 HT R 944 HT R N 944 HT R 945 HT R N 945 HT R 952 HT R N 952 HT R 953 HT R N 953 0,0 HTR N 952 HTR 952 HTR N 945 HTR 945 HTR N 566 HTR 566 Color shade HTR NHTR HTR N 093 HTR 093 Conditions: Proell Standard

9 9 Adhesion und Cohesion Serial application Renault Classic combination and compound: overall PC Typical example for cohesion failure (positive) inside black means inside one ink layer and no interlayer failure, peel strength about 7 N/cm

10 10 Adhesion und Cohesion Serial application Daimler Up to date combination and compound: overall PC Typical example for cohesion failure (positive) inside higher pigmented opaque white layer no interlayer failure, peel strength about 6 N/cm

11 11 Washout resistance Recommendation: Integration of NORIPHAN Xtreme Washout Resistant or NORIPHAN Xtreme Mild Odor Resistant Durchmesser der Auswaschung in mm x 2x 3x 4x 5x 6x Anzahl der Farbschicht en NORIPHAN Familie XWR 945 HTR 945 N2K 945 XWR 952 HTR 952 N2K 952

12 12 Pröll ink concept for decoration in IMD/FIM NORIPHAN X_R as functional ink for highest Cohesion Washout Resistance something else? Formability NORIPHAN HTR N complements

13 13 Compatibility with capacitive electronics Several demonstrator parts and serial expertise in different industries + Expertise in conductive inks by DuPont Expertise in IMD/FIM decoration inks and requirements Expertise in IMD/FIM part production und integration of electronics M a t e r i a l s u p p l i e r A p p l i c a t o r

14 14 The role of opaque black in capacitive sensors Risk of electrical damping and interference ( electromagnetic cloud ) disturbance of capacitive sensors range of electr. resistance Issue with NORIPHAN HTR N 952 opaque black 100 K Ohm HTR N 953 deep black 100 K Ohm recommended mixture with HTR N 093 (1:1) >G Ohm option: Caution: by subsequent drying, aging and other compression process optional change in conductivity Alternatives N2K 952 opaque black M Ohm to G Ohm XWR/XMR 952 opaque black > 534 G Ohm

15 15 The role of opaque black in capacitive sensors Percolation step with opaque black NORIPHAN HTR N R [MΩ] > HTR N 952 in [%] mixed with transparent HTR N 093

16 16 The role of opaque black in capacitive sensors drying Print 10 Min h 80 3 h 80 1,5 h 120 C Mixing ratio RØ RØ RØ RØ HTR N 952 : HTR N 093 1x > 534 GΩ > 534 GΩ > 534 GΩ > 534 GΩ 35: 65 2x > 534 GΩ > 534 GΩ > 534 GΩ > 534 GΩ HTR N 952 : HTR N : 60 HTR N 952 : HTR N : 55 HTR N 952 : HTR N : 50 HTR N 952 : HTR N : 45 HTR N 952 : HTR N : 40 HTR N 952 : HTR N : 35 HTR N 952 : HTR N : 30 1x > 534 GΩ > 534 GΩ > 534 GΩ > 534 GΩ 2x > 534 GΩ > 534 GΩ > 534 GΩ > 534 GΩ 1x > 534 GΩ > 534 GΩ > 534 GΩ > 534 GΩ 2x > 534 GΩ > 534 GΩ > 534 GΩ > 534 GΩ 1x > 534 GΩ > 534 GΩ > 534 GΩ 418,4 GΩ 2x > 534 GΩ > 534 GΩ > 534 GΩ > 534 GΩ 1x 386 GΩ 41,5 GΩ 5,8 GΩ 559 MΩ 2x > 534 GΩ > 534 GΩ > 534 GΩ 6,9 GΩ 1x 1,8 GΩ 184 MΩ 108 MΩ 66 MΩ 2x 307 GΩ 26,2 GΩ 9,3 GΩ 316 MΩ 1x 33,4 MΩ 10,8 MΩ 2,6 MΩ 5,8 MΩ 2x 16,3 GΩ 1,5 GΩ 341 MΩ 78 MΩ 1x 3,1 MΩ 0,8 MΩ 1,0 MΩ 1,7 MΩ 2x 1,8 GΩ 1,2 GΩ 26 MΩ 18 MΩ Electrical resistance in different ratio and drying stages

17 17 The role of opaque black in capacitive sensors Measured on day of printing x x Measured after 10 days, on x x Measured one year after, on x x R1 R2 R3 R4 R5 RØ 34,0 33,9 34,1 31,4 33,3 33 GΩ 27,5 27,6 21,3 20, GΩ 30,0 30,6 28,7 26,5 25,9 28 GΩ 27,4 18,7 22,4 19,1 19,2 21 GΩ 28,7 29,4 28,2 30,3 27,4 29 GΩ 26,5 20,2 20,6 23,6 19,6 22 GΩ Electrical resistance variation in the course of time with NORIPHAN XWR 952 (100 %, full opacity)

18 18 Technical Design-Trends: Bionic + Art well-balanced concept required! Creating moods Dual-Cure Lacquer Dual-Cure Lacquer Screen printing effect Semitransp. ink Transparent film or sheet Contrast ink Opaque ink Injection molding resin Norilux DC NORIPHAN

19 Decoration meets Sensor 19 Two-in-One Design-Examples: 1/2 Dual-Cure lacquer Silver semi transparent 0,2 2 mm transp. plate TACTOTEK IMSETM Solution day Hans-Peter Erfurt

20 Decoration meets Sensor 20 Two-in-One Design-Examples: 2/2 Dual-Cure lacquer Silver semi transparent 0,2 2 mm transp. plate CMYK halftone graphics Semi opaque decoration ink Transparent injection moulding resin TACTOTEK IMSETM Solution day Hans-Peter Erfurt

21 21 Two-in-One Design-Examples: 1/2 Dual-Cure lacquer Gold semi transparent 0,2 2 mm transp. plate

22 22 Two-in-One Design-Examples: 2/2 Dual-Cure lacquer Gold semi transparent 0,2 2 mm transp. plate Amber halftone graphics Transparent injection moulding resin

23 23 Serial applications of concept designs

24 24 U T I L I Z I N G Dual-Cure Lack Dual-Cure Lack Siebdruckeffektfarbe semitransparente Siebdr. transp. Folie oder Platte Kontrast-Siebdruckfarbe deckende Siebdruckf. Spritzgießmaterial Hardware = ink system Software = design Integral concept