IEE Heater Technology Dr. Alain Schumacher Senior Department Manager, Material Development, Innovation 20 th of June 2017
IEE Heater Technology
Dr. Alain SchumacherSenior Department Manager,
Material Development, Innovation
20th of June 2017
Agenda
2 Copyright IEE S.A. © All rights reserved
IEE at a glance
▪ Company profile
▪ Technology & product portfolio
IEE heater technology
▪ Key properties and benefits
▪ Integration benefit
▪ SafeHeat – PTC ink technology
▪ SafeHeat – product applications
Interior heating
▪ Vision & motivation
▪ Roadmap
▪ R&D activities
▪ Thermal concept vehicle
Summary
3
IEE at a glanceGrowth through innovation and diversification
Copyright IEE S.A. © All rights reserved
▪ Founded in 1989
▪ Consolidated turnover: 461 m EUR (2016)
▪ 3,650 people and ~ 10% dedicated to R&D
▪ Markets
▪ Automotive
▪ Building Management & Security
▪ Sports & Healthcare
▪ Connectivity
▪ Energy Management
▪ Global leader in automotive safety sensing systems for occupant detection and classification
▪ More than 300 million vehicles equipped worldwide and direct co-operations with 80 automotive OEMs
▪ Highest quality, environmental and health & safety standards
▪ More than 200 patent families
IEE at a glance
4
IEE Group global footprint
Copyright IEE S.A. © All rights reserved
HeadquartersR&D, Sales, Plant
2014
South KoreaSeoulDevelopment & sales office
ChinaBeijing / LangfangDevelopment & sales officeChina plant
LuxembourgContern/Echternach
HeadquartersEurope plant
SlovakiaVel’ká IdaDevelopment Europe plant
ChinaTianjinDevelopment
MexicoAmericas plant
U.S.Auburn Hills
Development & sales office
BrazilSao Paulo
Development & sales office
FranceOrleans/ Bayonne
Electronics plant
TunisiaTunisElectronics plant
JapanTokyoDevelopment & sales office
GermanyIngolstadtADAS Competence Centre
2015
ALL CIRCUITS – Our Alliance Partner (MSL, BMS, TIS, AC)Industrial experts in EMS
Copyright IEE S.A. © All rights reserved
▪ Customer Program Engineering
▪ Electronics and Semiconductor Development
▪ Algorithmic and Embedded Software Development
▪ Development of Optical Systems
▪ Material Development
▪ Simulation-based Development / Virtual Engineering
▪ Customer Program Engineering
▪ Electronics and Semiconductor Development
▪ Algorithmic and Embedded Software Development
▪ Development of Optical Systems
▪ Material Development
▪ Simulation-based Development / Virtual Engineering
▪ Process & Production Engineering
IEE at a glance
5
Engineering & research teams
Key Technologies and Product PortfolioTechnology Principle Products
Force Sensing Resistor (FSR)
Uses variable resistance to detect pressure applied to a sensor cell
▪ Passenger Presence Detection (PPD) & Classification (OC)▪ Seat Belt Reminder (SBR)▪ Pedestrian Protection and Crash Sensing▪ Input Devices, Sports & Healthcare
Electromagne-tic Sensing
Communication between car seat antenna and child seat resonators
▪ Child Seat Presence and Orientation Detection (CPOD)
Electric Field Sensing
Evaluates change in electrical field to classify seat occupancy
▪ BodySenseTM
▪ Smart Opener (SO)▪ Hands off Detection (HOD) (ADAS)
Optical Sensing
Measures time-of-flight of modulated infrared light to provide topographic image
▪ People Counter▪ Tailgate Detector TDflex™▪ Volumetric Object Surveillor▪ ADAS
Interior Radar Uses radio technology to detect occupants
▪ Interior Motion Detector, VitaSense (low power)▪ ADAS
Foil Heaters (Seat, Panel)
Screen printed, heater layer optional with PTCPositive Temperature Coefficient
▪ Safe Heat, inherent safety due to T-self limiting ▪ Panel heaters for slim, near surface integration
Copyright IEE S.A. © All rights reserved 7
Simple, near surface integration▪ Fast temperature ramp up▪ Moderate heater surface
temperature ▪ Avoids local aging
of decor layer
BoM flexibilityTypical thickness range 75 to 140 µm
Protection
Heater layer
Bus bar layer
Polymer Foil
Fixation tape
Key properties & benefits of IEE heater
technologyHigh design flexibility, complex designs
Homogeneous heating of large and complex surfaces with only one heater circuit
Standard operation voltages:12V, 24V, 48V
Standard P/A: 500 to 1000 W/m2
Several kW/m2 possibleHigher voltages possible
Screen printing of versatile ink materials▪ Different functionalities, e.g. PTC inks▪ Electrical resistances▪ Cost efficiency
8
Near surface integration enables fast T-ramp up▪ Benefit evaluation of near surface integration benchmark, wire vs. foil panel heater
▪ Wire integrated with 4mm foam lamination to avoid imprints on trim surface and local overheating
▪ For foil heater 0.5mm was sufficient
▪ Ramp up from -10°C
▪ Power per heater: 22W
Thermal images of arm rest décor surface
Higher local T for wire heater on décor (50 vs. 45°C), T stationary
Wire Foil
Integration benefit
-10
-5
0
5
10
15
20
25
30
35
40
45
50
0 100 200 300 400 500 600 700 800 900
Surf
ace
tem
pe
ratu
re [
°C]
Time [s]
Benchmark wire vs. foil heater in arm rest
Wire heaterPadding thickness: 4mmP = 22WTmax : 136°C
Foil HeaterPadding thickness: 0.5 mmP: 22 WTmax: 89°C
Copyright IEE S.A. © All rights reserved
Integration benefit
9 Copyright IEE S.A. © All rights reserved
Unique selling points of IEE’s heater technology
Main characteristics … leads to advantages … leads to savings (€) / benefits
Thin foil technology ✓ NTC (if requested) can be easily placed on the foil (small & flat)
✓ No, or less, additional development effort/ spending
✓ No, or less, investment in implementation process
Picture Source: IEE
SMD NTC sensor
Bus bars
Heater elements, can be printed w/ and w/o PTC functionality
Arm rest heater design printed on thin polyester film
10 Copyright IEE S.A. © All rights reserved
Main characteristics … leads to advantages … leads to savings (€) / benefits
Thin foil technology ✓ Heating function is added w/o change in armrest part design
✓ Same tools can be used for heated and non-heated version
✓ Less tooling costs✓ Fewer parts, less stock inventory✓ Less complex workflow in production ✓ circa 3% piece cost reduction
Picture Source: Yanfeng Automotive Interiors
Wire heater
Foil heater
Heated interior part Non-heated interior component version
Integration benefitUnique selling points of IEE’s heater technology
Basis for IEE SafeHeat product applications
Copyright IEE S.A. © All rights reserved 11
▪ Strong Positive Temperature Coefficient
▪ Good time to temperature at moderate heater surface temperature due to PTC characteristic
▪ Low resistance at cold temperatures leads to a high current flow, which drives the strong heating power
▪ Inherent temperature limitation due R(T).
▪ Self-regulating, no ECU required
▪ High cost efficiency
▪ Inherent safety, no overheating if controller fails
▪ No temperature fluctuations
0,0
0,5
1,0
1,5
2,0
2,5
3,0
3,5
4,0
4,5
5,0
0
5
10
15
20
25
30
35
40
45
50
55
-35 -25 -15 -5 5 15 25 35 45 55 65 75
Cu
rre
nt
[A]
Re
sist
an
ce [
Oh
m],
Po
we
r [W
]
Temperature [°C]
PTC Resistance
Power @ U=13.5V
Current @ U=13.5V
Resistance, power, current evolution
P(T) = U2 / R(T) = U*I(T); U=R(T)*I
PTC ink technology
SafeHeat
Copyright IEE S.A. © All rights reserved 12
Product application: seat heater with PTC ink technology
Time to temperature performanceTest person: 85kgHeater P: 54 WP/A: 1000 W/m2
Starting T: -20°C
-30
-20
-10
0
10
20
30
40
50
60
0 5 10 15 20 25 30 35
Tem
pe
ratu
re [
°C]
t [min]
Trim surface T~43°C
Time to temperature on seat surface
SafeHeat
13 Copyright IEE S.A. © All rights reserved
Product application: arm rest heater with PTC ink technology
▪ Applicable for e.g middle armrest and door panel arm rest
▪ Can be equipped with printed switches and/or Linpots from IEE
▪ Covered switches below cover material
▪ Foil-based heaters could be covered with several materials
Picture Source: IEE Picture Source: IEEPicture Source: Yanfeng
SafeHeat
14 Copyright IEE S.A. © All rights reserved
Picture Source: IEE
Product application: footmat heater
Heater integrated into footmat via lamination process
Interior heating
15 Copyright IEE S.A. © All rights reserved .
Vision: interior will become the ‘Heart of the Car’▪ Market development driven by the automotive industry’s mega trends:
▪ energy/CO2 saving requirements
▪ electrification (e-cars)
▪ autonomous driving assistant systems (ADAS)
▪ passenger cabin transfers to a living room
Motivation for development of panel heater for car interiors
▪ Heating energy is delivered by the power train of a car – combustion engines, or the batteries for e-cars
▪ Thus the efficiency of the heater system has a direct impact on emission values resp. km-range
▪ Potential to improve heating efficiency due to:
▪ integration close to the passenger
▪ efficient conversion of electrical energy to useful heating for the passenger
Energy efficieny & passenger comfort significantThe Mercedes-Benz F 015
Luxury in Motion research car
Interior heating
16 Copyright IEE S.A. © All rights reserved .
Background / Literature
▪ Infrared heating as an adjunct to achieve vehicle occupant thermal comfortCollins et al. Extreme Physiology & Medicine 2015, 4(Suppl 1):A82; http://www.extremephysiolmed.com/content/4/S1/A82
▪ Simulation and Measurement of an Energy Efficient Infrared Radiation Heating of a Full Electric Vehicle*Bäuml T., Dvorak D., Frohner A., Simic D., AIT Austrian Institute of Technology GmbH, Giefinggasse 2, 1210 Vienna, Austria
▪ The Future of Automotive Research, Keynote lecture, CLEPA Strategic Workshop “Road Transport 2030 – European Suppliers scenarios”Aachen 6 April 2017 Univ.-Prof. Dr.-Ing. Lutz Eckstein, Institute for Automotive Engineering (ika), RWTH Aachen University
▪ Climatisation can cut the range of an electric vehicle by half.
▪ By a combination of measures and innovations, the energy demand for climatisation can be reduced by more than 50%
▪ Definition and validation of the comfort experience is decisive
▪ The comfort chart from (Bedford and Liese) shows a dependency on temperature of the wall to air temperature**
**
*T-distribution on a dummy and on a surface through the cabin. Heating: IR- and additional convective
Interior heating
17 Copyright IEE S.A. © All rights reserved .
Roadmap
What does a future energy-efficient car heating concept look like?
▪ Single system or combination of different technologies?
What is the thermal comfort / perception of the passenger?
Heater panels, complementary to HVAC systems
▪ Increased number ofsurfaces heated in passenger compartment
▪ Impact on thermal perception of passengers
▪ Smart control strategies for heater panel require specialised ECU
Panel heater as integral component of future novel HVAC systems
▪ Large portion of interior surface heated
▪ Significance of electrical heater panels to total heating power
▪ Control of panels by advanced HVAC control systems
HVAC, standard
Contact surface heating
▪ Seat
▪ Steering
▪ Armrest
Today Mid-term Long term
18 Copyright IEE S.A. © All rights reserved .
Interior heating
Project to evaluate the thermal comfort / benefits of panel heater
▪ Concept car: BMW 530d series with full option interior configuration
▪ Key criteria for car selection & set up
▪ Professional integration of panel heater
▪ Heaters respectively modifications not to be perceived by the test persons
▪ Fully equipped with state of the art heating / air conditioning technology
▪ Interior with leather trim
▪ Targeted investigations
▪ Thermal comfort studies with test persons in real car environment
▪ Thermal perception & perception latency
▪ What is perceived as comfort, heated regions, temperatures & temperature gradients,….
▪ Determine energy consumption required for individual thermal comfort
▪ Draw energy balance for different operation modi
▪ Pure panel heating vs pure HVAC▪ Combined with car HVAC system
IEE R&D on thermal comfort / Experimental
19
▪ Heater performance / operating specifications
▪ power density▪ target temperatures▪ heat-up time▪ …
▪ Optimized layout of heater mat
▪ electrical power consumption▪ heat flux @ contact area▪ radiant heat flux distribution▪ …
▪ Thermal comfort evaluation
▪ HVAC vs. panel heating▪ …
▪ Mechanical robustness▪ …
Copyright IEE S.A. © All rights reserved
Interior heating
ANSYS-Fluent Multi-Physics Modelling
IEE R&D on thermal comfort / Modelling Topics
Picture source: IEE, WBi - Basics & Mathematical Models
Picture source: IEE, WBi - Basics & Mathematical Models
20 Copyright IEE S.A. © All rights reserved
Interior heatingIEE Thermal Concept-Car
door panel
door arm rest
centre arm rest
footwell
footmat
sun visor
ceiling
U = 0 V U = 24 V
Picture source: IEE, WBi - Basics & Mathematical Models
21 Copyright IEE S.A. © All rights reserved
Thermal images of heated concept car interior
Interior heating
▪ Panel heater integrated near to décor surface
▪ No impact on haptic
▪ Highly homogeneous T-distribution
▪ Large heat radiating surface
▪ Spontaneous heat perception due to IR-radiation
▪ Additional convection heating
▪ Dashboard heater
▪ Heat perception through IR-reflection at windscreen
▪ Overall good themal perception
▪ High potential for efficient future heating systems
Picture Source: IEE
Copyright IEE S.A. © All rights reserved 22
Interior heatingConcept car heating tests Good and fast thermal perception▪ Total number of integrated heaters: 17
▪ Maximum possible electrical power of all heaters: 2,0 kW
▪ Heater designed with power density in the range of 500 to 1400 W/m2
▪ Ambient temperature: 6°C
0
200
400
600
800
1000
1200
0 200 400 600 800 1000 1200 1400 1600 1800 2000
Tota
l Po
we
r [W
]
Time [s]
Evolution of total heating power
Total Power
0
5
10
15
20
25
30
35
40
45
50
55
60
65
0 200 400 600 800 1000 1200 1400 1600 1800 2000
Tem
pe
ratu
re [°
C]
Time [s]
Time to temperature of different panel heatersCeiling Rear
Ceiling Front
Sunvisor Pass
Sunvisor Driv
Footmat Pass
Dashboard Pass
Footmat Driv
Dashboard Driv
MA Pass
MA Driv
Arm P
Door P
Arm D
Door D
Summary
23 Copyright IEE S.A. © All rights reserved
IEE heater technology = cost efficient, comfortable & safe heat
IEE thin foil technology for heating applications
✓ Screen printing technology enables high design & material flexibility
▪ Complex heater designs with only one heating circuit
✓ Panel heaters for interior car cabin heating
▪ Homogeneous temperature distribution at moderate heater temperatures
▪ Efficient heating due to near surface integration
▪ Heating through IR-radiation and convection
▪ Spontaneous heat perception due to IR-radiation
▪ High potential to be part of novel, energy efficient heating concepts
▪ IEE has a focus on panel heater R&D
▪ Concept car for thermal perception tests
✓ «Fail-safe» technology based on PTC ink technology
▪ Focus on safety, no overheating due inherent self-limiting heater circuits
▪ No ECU, NTC required, potential cost advantage
Contact us
24 Copyright IEE S.A. © All rights reserved
Thank you for your attention!If you need more information, please do not hesitate to contact us:
IEE S.A.
ZAE Weiergewan
11, rue Edmond Reuter
L-5326 Contern
Phone: + 352 2454-1
Fax: + 352 2454-3200
E-mail: [email protected]
Website: www.iee.lu
Dr. Alain Schumacher
Senior Department Manager
Material Development / Innovation
Phone: +352 2454 2273