The integration of electronic circuits in plastics using injection technologies: a literature review

Bakr, Mona; Bossuyt, Frederick; Vanfleteren, Jan

doi:10.1088/2058-8585/ac6719

Cited by 3 publications

(3 citation statements)

References 64 publications

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“…Injection moulding technology has been increasingly widely applied in modern industry on account of its high efficiency, manufacturing flexibility, and high level of automation [1][2][3]. However, during injection moulding, due to improper * Author to whom any correspondence should be addressed.…”

Section: Introductionmentioning

confidence: 99%

A novel deep learning algorithm applied to machine vision inspection for surface defects of injection moulded products

Fan,

Qiu

2024

Meas. Sci. Technol.

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In modern industry, the surface defect inspection of injection moulded products is crucial for controlling product quality and optimizing the manufacturing process. With the development of optical measurement and computer technology, machine vision inspection methods have been widely adopted instead of manual inspection. However, current machine vision inspection methods are difficult to simultaneously ensure the accuracy and efficiency of surface defect inspection of injection moulded products. Considering this problem, a novel deep learning algorithm applied to machine vision inspection for surface defects of injection moulded products is proposed. To train and evaluate the proposed deep learning algorithm, an image acquisition platform is established and the dataset of surface defects in moulded products is obtained. In the proposed deep learning algorithm, reparameterization-based convolution modules are employed for feature extraction and feature fusion. A median iterative clustering algorithm based on hierarchical clustering initialization is proposed to obtain prior anchors that are highly matched with the actual distribution of defect sizes. A novel Focus-Entire Union over Covering (Focus-EUoC) loss function is utilized for bounding box regression. On these bases, the proposed deep learning algorithm applied to machine vision inspection is evaluated on the dataset of surface defects in moulded products. The experimental results indicate that compared to the traditional inspection algorithms and other deep learning algorithms currently used in machine vision inspection, the proposed deep learning algorithm exhibits superior inspection accuracy and inspection efficiency on the acquired dataset. The inspection precision reaches 0.964, the inspection recall reaches 0.955, and the inference time for each subgraph is only 6.1ms, confirming its effectiveness.

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Section: Introductionmentioning

confidence: 99%

A novel deep learning algorithm applied to machine vision inspection for surface defects of injection moulded products

Fan,

Qiu

2024

Meas. Sci. Technol.

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“…Therefore, it is sufficient that the electronic systems fit a convenient form factor of the shape into which they will be integrated. Many researchers worked intensively to integrate different electrical functionalities like light emitting diodes (LEDs), light guides, numerous touch switches or slides, and near field communication (NFC) antennas into plastic products using the in-mold process [ 3 , 4 ]. By fabricating optical touch panels, organic light emitting diodes (OLEDs), foils, and disposable healthcare sensors, T. Alajoki et al [ 5 ] demonstrated the feasibility of hybrid in-mold integration.…”

Section: Introductionmentioning

confidence: 99%

A Study on Over-Molded Copper-Based Flexible Electronic Circuits

et al. 2022

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Over-molding has been proposed in recent years as an integrated functional flexible circuit board in a plastic part. This method uses the conventional process for film insert technology. Over-molding has attracted significant attention across many industries due to its potential to deliver different electrical functions in a variety of different part geometries, especially in automotive interiors and home appliances. While it has great application potential, manufacturing challenges continue throughout foil fabrication and injection molding. This raises challenges for designers and researchers responsible for maintaining the reliability of such electronic flexible circuits. Therefore, the purpose of this research paper is to improve some of the over-molding process parameters. On 0805 and 1206 over-molded zero-ohm resistors, electrical, mechanical, and failure characterization was performed. Those components were mounted in parallel, perpendicular, and 45° angled arrangements on two different polymer substrates, polyimide (PI) and polyethylene terephthalate (PET) using lead-free solder, low-melt solder, and conductive adhesive paste. Moreover, as an over-molding material, polycarbonate (PC) with medium viscosity was used. The effect of using different mold shapes (corner mold, 2 mm flat mold, and 3 mm flat mold) and injection molding process parameters (injection speeds and melt temperature) was studied.

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“…In recent years, the integration of electronics in injection-molded parts to manufacture “smart” mechanical, durable and light products cost-effectively has gained traction [ 1 , 2 ]. One way is to adapt the in-mold decoration (IMD) process.…”

Section: Introductionmentioning

confidence: 99%

Process Optimization of Injection Overmolding Structural Electronics with Regard to Film Distortion

et al. 2022

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The integration of structural electronics in injection-molded parts is a challenging step. The films—comprising of laminated stacks with electronics—are exposed to shear stresses and elevated temperatures by the molten thermoplastic. Hence, molding settings have a significant impact on the successful, damage-free manufacturing of such parts. In this paper, test films with polycarbonate (PC) sheets as outer and two different thermoplastic polyurethanes (TPUs) as middle layers incorporating conductive tracks on a flexible printed circuit board (flexPCB) are manufactured and overmolded with PC. Parameter studies investigating the influence of the melt temperature, mold temperature, injection speed and used TPU layer were performed. The molded parts were inspected visually and compared with a numerical simulation using injection molding software. A shear distortion factor for the TPU layer was derived based on the simulations that linked the shear stresses with the injection time and the softening (melting) of the TPU. The distortion of the films was found to reduce with higher melt temperature, lower mold temperature and faster injection speed. Films using the TPU with the higher melting temperature yielded significantly better results. Moreover, distortion on the films reduced with the increasing distance to the gate and a larger cavity thickness was found to be beneficial. All those relations could be correlated with the shear distortion factor.

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The integration of electronic circuits in plastics using injection technologies: a literature review

Cited by 3 publications

References 64 publications

A novel deep learning algorithm applied to machine vision inspection for surface defects of injection moulded products

A novel deep learning algorithm applied to machine vision inspection for surface defects of injection moulded products

A Study on Over-Molded Copper-Based Flexible Electronic Circuits

Process Optimization of Injection Overmolding Structural Electronics with Regard to Film Distortion

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