Aziz Rezig | ADDEV Materials: Can we print high-efficiency flexible heaters directly onto 125-micron substrates?
00:02:45 - 00:03:47
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Summary of the clip:
How do we optimize the power density of flexible, roll-to-roll printed electronics while working within the strict current-carrying limitations of functional inks?
In the rapidly evolving landscape of printed electronics, achieving high-performance thermal and electrical management requires a precise balance of substrate characteristics and deposition methods. Utilizing thin, highly flexible 125-micron substrates featuring a conductive layer on one side and electrical insulation on the reverse enables seamless integration into roll-to-roll (R2R) and sheet-to-sheet manufacturing workflows. This dual-sided architecture provides a robust foundation for high-throughput screen printing of complex circuitry.
The selection of functional inks—specifically conductive silver and copper formulations—is dictated by the precise thermal and electrical requirements of the target application, including input power and desired temperature profiles. However, material constraints impose strict operational boundaries, particularly a maximum current threshold of three amperes due to the inherent limitations of these conductive inks. Within these parameters, engineers can engineer solutions that safely achieve power densities ranging from one to two watts per square meter.
By carefully balancing input power against the physical limitations of screen-printed silver and copper traces, developers can design highly efficient, flexible circuits tailored for demanding thermal applications. Understanding the interplay between substrate flexibility, ink chemistry, and current limits is essential for scaling these printed systems from laboratory prototypes to high-volume roll-to-roll production.
In this short video, you can learn:
* How to leverage 125-micron dual-sided substrates in roll-to-roll and sheet-to-sheet screen printing processes.
* The critical role of functional silver and copper inks in meeting specific temperature and power output requirements.
* The physical limitations of printed inks, including a three-amp current ceiling and achievable power densities of one to two watts per square meter.
📋 **Clip Abstract** The speaker discusses the manufacturing of thin, flexible electronics using 125-micron substrates with conductive and insulating layers via roll-to-roll or sheet-to-sheet screen printing. He explains how functional silver and copper inks are used to print circuits based on power and temperature requirements, noting a current limit of three amps and achievable power densities of one to two watts per square meter.
🎤 Speaker: Aziz Rezig
🏢 Company: ADDEV Materials
📅 Event: Printed Electronics Innovation Day 2024
📍 Location: TechBlick | Online Platform
🌐 Learn more at the next TechBlick event: https://www.techblick.com
#FlexiblePrintedHeaters, #ConductiveInks, #RollToRollPrinting, #ThinFilmHeaters, #PrintedElectronics, #ThermalManagement
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00:05:51 - 00:07:22
How do you redirect thermal energy in the Z-axis on flexible polymer substrates?
How do you redirect thermal energy in the Z-axis on flexible polymer substrates?
Operating printed heaters in extreme sub-zero conditions poses unique thermodynamic challenges, especially in automotive interiors where rapid cabin warming is required. In a raw configuration, a printed flexible heater on a thin polymer substrate struggles to project heat outward, barely reaching a 30°C surface temperature when starting from sub-zero baselines. This inefficient omnidirectional radiation wastes valuable energy to the underlying support structures.
To solve this, a backside thermal reflector is integrated into the multilayer stack. This structural addition successfully redirects the thermal flux along the Z-axis, allowing the device to achieve a massive 70°C temperature delta (spanning from -7°C to 70°C). This directional control is crucial for energy-sensitive applications like electric vehicles where battery efficiency directly correlates with thermal waste.
Furthermore, the Neo Heater architecture is fully customizable to survive complex industrial manufacturing steps. By selecting compatible substrate polymers like PET, PEN, or polycarbonate, these flexible heaters can be seamlessly integrated directly into injection molding and over-molding processes, enabling smart, heated structural components.
In this short video, you can learn:
* The thermodynamic impact of using backside thermal reflectors to control heat flow in the Z-direction
* Achieving a 70°C thermal gradient from sub-zero start temperatures in automotive interior testing
* Customizing encapsulation substrates (PET, PEN, and polycarbonate) for high-pressure polymer injection molding
📋 **Clip Abstract** This clip demonstrates how integrating a backside reflector into a printed heater stack redirects heat along the Z-axis to achieve a 70°C temperature delta. It also discusses substrate customization options that allow these flexible heaters to withstand the over-molding processes used in automotive manufacturing.
#PrintedHeaters, #BacksideThermalReflectors, #InMoldElectronics, #FlexiblePolymerSubstrates, #EVThermalManagement, #AutomotiveInteriors
00:08:14 - 00:09:53
Can screen-printed silver track surface temperatures without heavy external sensors?
Can screen-printed silver track surface temperatures without heavy external sensors?
Traditional positive temperature coefficient (PTC) inks offer self-regulation but lack precise surface temperature monitoring and can suffer from non-linear response curves. To achieve reliable closed-loop control on flexible surfaces, engineers must find a way to integrate sensing capabilities without adding bulky thermocouple wires that compromise flexibility. The solution lies in screen-printing co-planar resistive sensors alongside the heating circuits.
By printing a precise resistive circuit using specialized silver inks, the system exploits the predictable temperature coefficient of resistance (TCR) of the metal. As the surface temperature rises, the sensor's resistance increases consistently, matching the precision of commercial rigid temperature devices. This flexible RTD-like sensor operates reliably on simple polyester (PET) substrates.
Integrating this printed sensor within a multi-layer stack alongside the primary heating element enables smart, closed-loop regulation. A dedicated electronic control unit monitors the real-time resistance shifts of the printed sensor and dynamically modulates the input power to maintain the target temperature profile automatically.
In this short video, you can learn:
* Why co-planar screen-printed silver resistive sensors outperform traditional PTC ink solutions
* How the temperature coefficient of resistance is leveraged to mimic rigid commercial sensors on flexible PET
* The architecture of a closed-loop smart heating system combining printed heaters, sensors, and controller electronics
📋 **Clip Abstract** This clip explains the development of screen-printed silver resistive temperature sensors on flexible substrates as an alternative to PTC inks. It details how these sensors leverage resistance changes to enable closed-loop, self-regulating smart thermal systems.
#ScreenPrintedSilver, #PrintedRTD, #TCRSensors, #FlexibleThermalSensors, #PrintedElectronics, #FlexibleElectronics