New collaboration between Clayens NP Group and NGK Insultators
Expanding automotive application possibilities with IME.
In developing high-performance IME, which helps improve vehicle weight reduction and design flexibility, there is a challenge...
IME is a technology in which functional printed electronic films are molded into 3D shapes by thermoforming and injection.
IME is attracting attention as a way to replace traditional structural parts that use installed metal wire harnesses in automobiles and aircraft, because it is expected to contribute to weight savings, design flexibility, part count reduction, and shorter experimental production lead times compared with the conventional approach of using rigid printed circuit boards and wire harnesses. Clayens NP, a French manufacturer of polymers and precision metal components, is also working on IME development.
ECU types are limited because of IME's higher electrical resistance.
IME aims to create electrical circuits on flexible boards before sealing them with resin by overmolding. The conductive pastes in these circuits are simply printed in a thin layer without sintering, so their electrical resistance is higher than that of conventional rigid printed circuits using thicker copper (high conductivity). As a result, it is impossible to carry a large current, and only a low-power device such as LED lighting or a haptic touch sensor can be used. An ECU equipped with a high-power control integrated circuit cannot operate.
ECU=Electronic Control Unit. 50 to 100 units are installed in a car.
The touch sensor provides physical feedback when touched. It enables smarter use compared with a general switch.
Energy storage devices that are applicable in IME have not been found...
To compensate for this lower conductivity, a so-called distributed power source was considered: an energy storage device installed near the ECU, instead of supplying each ECU from a car battery over a long distance via IME.
To do this, an energy storage device must be integrated into IME. However, no energy storage device can withstand the high temperature and high pressure applied during injection molding. In addition, a long service life is also required because it is difficult to replace an energy storage device after overmolding.
1. The ECU that can be driven by IME is limited because of its high electrical resistance.
2. An energy storage device that can withstand the high temperatures and pressures applied during the overmolding process is required for the distributed IME power source.
3. A long service life is also mandatory because it becomes almost impossible to replace the energy storage device after molding.
What can be achieved with the introduction of EnerCera
The discovery of a low-resistance, heat-resistant, long-life rechargeable lithium-ion battery opens the way to sophisticated IME functions!
1. The EnerCera cell can be recharged even with tiny power through the IME circuit, and can supply enough power to drive a high-power ECU, such as a wireless communication circuit, etc.
2. The EnerCera cell can withstand IME processing temperatures of around 300 ℃.
EnerCera enables highly functional IME.
At a meeting between the Clayens NP IME team and the marketing representative for NGK's EnerCera battery, NGK explained that EnerCera can be charged via the small amount of electrical power that flows through the IME circuit. In fact, EnerCera has low internal resistance and can discharge a sufficiently large current to power high-power integrated circuits such as wireless communications, etc. It was also explained that EnerCera may be able to withstand the IME process because it can tolerate 300 ℃ for a short period. Together with ongoing projects, the Clayens NP team saw strong potential in combining IME and EnerCera.
Clayens NP and NGK Insulators signed a partnership agreement and began research to deliver highly functional IME.
A propos d’NGK:
NGK Insulators (NGK) is a leading ceramics company. Since its founding in 1919, NGK has used its unique ceramic technology to create many groundbreaking products. Today, NGK operates in more than 20 countries worldwide, with activities focused on mobility, energy, IT, and industry.
Regarded as one of the largest manufacturers of ceramic substrates for automotive catalytic converters, NGK actively works to preserve the environment. NGK products also include the "NAS" energy storage system, as well as the compact, thin, high-energy-density rechargeable lithium-ion "EnerCera" battery range, which are essential tools for sustainable energy infrastructure.