Materials and processes for smart products Pluridisciplinarity and Integration in product oriented research Júlio C. Viana PIEP – Innovation in Polymer.

Materials and processes for smart products

Pluridisciplinarity and Integration inproduct oriented research

Júlio C. Viana

PIEP – Innovation in Polymer Engineering

I3N/IPC – Institute for Polymers and Composites

University of Minho4800-058 GuimarãesPortugal

Ciência 2009

29-30 Julho 2009, Lisboa

Next generation products

• high degree of customization

• value-added product-specific services

• communication skills

• sensitive to user emotions

• legislation (e.g., end-of-life)

FUTURE PRODUCTS FEATURES

smart bandage, Battelle

concept electric car

New Designs and Technological solutions

Products manufacturers point of view:

Product delivery product function

Active/Smart Products

“One feature of future products will be their growing embedded intelligence.”[1]

embedded chips or micro-devices

computational and networking capabilities

added value services:

product reconfiguration, upgrade, customisation

[1] Workshop 1: “New intelligent and networked products” (9 February 2005), ICT for Manufacturing Report of Meeting with Group of Representatives of Five Expert Panels

NOKIA Morph

Active/Smart Products

SMART PRODUCTS TRICORDERSciFi STAR TREK

device capturing physical data from the environment, such as: temperature

• life presence• type of materials• magnetic field• …

Fetal monitoring, Battelle THE BUGS, http://www.buglabs.net/

Active/Smart Products

SMART PRODUCTS

FUNCTIONSmonitoring awareness of their statussensing they sense the environmentadaptive they respond to a stimulus

FEATURESenvironment embedded integrated networked devicessituated recognize situational context personalized tailored to the userpro-active anticipate user’s plans and intentions

Active/Smart Products

Source:EADS

Aeronautics PackagingAutomotive

Source: GM/MIT

SMART PRODUCTS APPLICATIONS

Pluridisciplinary research

InformationCommunicationTechnology

Manufacturing Technology

SmartMaterials

Smart polymer products

Active/Smart materials

• Multifunctional polymer nanocomposites – electric, magnetic, luminescent, electro-chromic, thermo-electric, …)

• Electro-active polymers– Ionic Polymer-Metal Composites (IPMC), Conductive/Conjugated Polymers, Electro/Magneto-Rheological Elastomers, Ionic

Polymer Gels (IPG)– dielectric elastomers, electrostrictive grafted elastomers, electro-viscoelastic elastomers, ferroelectric polymers

• Shape Memory Polymers– Thermoresponsive polymer that modifies its shape in response to temperature changes.

• Self-X polymers– Self-monitoring, self-diagnostic, self-healing, …..

Manufacturing technologies

MicroSystemsTechnology

NanoTechnology

AdvancedManufacturing

• Non-Conventional moulding techniques– multi-material injection moulding, micromoulding techniques (microinjection, hot-embossing, …

• Micro-patterning/micro-featuring techniques– Hot-embossing, micro-injection moulding, (imprinting), …

• Deposition techniques– Inkjet printing, (CVD)

• Nanotechnologies – nanostructured polymers

Information Communication Techn.

• (Plastic electronics)– Flexible and stretchable

– Smart polymers for MEMS

– Built-in conductive paths

– Mass production/low costs

• Energy harvesting solutions– Dynamic motions– Temperature, heat – others

• Embedded electronic systems– RFIDs, LEDs – Sensors & actuators– Antennas (mobility), wireless (communication)

Simulations

• Coupled piezo-mechanical simulation– Electrodes positioning– New product designs– Enhanced behaviour

Plate PP

Strip PVDF

Strip PVDF

Multifunctional self-sensing TPE

Case study I

0

20

40

60

80

100

120

140

160

0.0 0.5 1.0 1.5 2.0 2.5 3.0 3.5 4.0

ln

Str

ess

(MP

a)

0.5% CNF

1% CNF

0.5 HSCB

1% HSCB0

2

4

6

8

10

0.0 0.5 1.0 1.5 2.0 2.5 3.0

ln

Str

ess

(MP

a)

Nanofilled conductive TPE• different % incorporation of nanoparticles (TPU)

= 0 = 1.68 = 1.87 = 2.22 = 2.48 = 3.00

05.% CNF

Approach for self-sensing TPE • Multifunctional nanofilled conductive TPE

70

75

80

85

90

95

100

105

110

115

120

0.0 1.0 2.0 3.0 4.0

compression distance (mm)

Resi

stan

ce (G

Ohm

)

TPU-CNF-PZTTPU-CNF

R10V

advanced technologies

• Vibration damping components– Non-conventional injection moulding (multi-material)– Active materials

Moldação integrada multitecnologia

Self-sensing material (monitoring)

Mechanical active (acting)

R10V

R10V

Embedded electronics

Case study II

Safe-luggage projectwww.mala-segura.com

RFID

WSNWi-Fi

Bluetooth

Integration of identification,

sensing & communication

devices into injected

componenets

Development of a "smart bag”: management, control and monitoring system for suitcases

Smart luggage, with identifiers embedded in the body of the bag

self-sensing solutions

• Embedded strain sensors

R2 = 0.99

R2 = 0.84

340

345

350

355

360

365

370

375

380

0 1 2 3 4

compression length (mm)

Resi

stivi

ty (O

hm)

horizontal - insidevertical - lateral

RV

Strain gage inside (horizontal)

RV

Strain glued laterally (vertical)

Fibre Bragg Grating

inte

rro

gat

or

optical systems

Lighting systems

LEDs integration into componentspolymer light-guiding systemsaesthetic solutions in the automotive door

interiors (electro-chromic effect, embedded lighting)

Embedded sensing solutions embedded optical sensors in mouldings

(OF, FBG)advanced mouldings with surface grating

PEGASUSEU Integrated Project for SMEs – IPSME

Smart polymersmultifunctional polymers nanocompositesactive polymers/elastomers (conductive, piezoelectric)shape memory polymers

Design and Integration of functions in mouldingsadvanced simulations (e.g., FEA)embedded sensors in mouldingsadded lightning effects to mouldingsinnovative products

Advanced manufacturing for active mouldingsintelligent integration of components and processes novel product-process integrationtechnical moulded components with added functionalities

Technology & Product Integration

Smart polymer products

Pluridisciplinary research

InformationCommunicationTechnology

Manufacturing Technology

SmartMaterials

Smart polymer products