Production technologies of piezo-modules with integrated ceramic composites and functional polymers for application in active metallic components
L. Kroll, J. Tröltzsch
Objectives
Production of µIMP-modules with adjusted preload of the piezo-ceramic as well as material immanent electromechanical functions based on thermoplastic piezo-ceramic composites for integration in metallic (A03) and plastic-based lightweight structures (T02) in large-scale production
- Fully automated fabrication of discrete µIM-piezo modules
- Variation of the material for thermoplastic piezo-ceramic composites for a robust processing by micro injection molding
- Specifically adjustment of process-related internal compressive stresses for optimal electromechanical properties in the µIMP
- Material modification for optimized polarization
Results
Morphology of CNTs in micro injection molded test samples of PEEK
- Orientation of the CNTs due to process-related near-surface shear zone
→ Directionality of electrical conductivity - Homogeneous distribution of CNTs with distinct network structure and without development of agglomerates
→ Percolation threshold at small percentages of CNTs - Very high proportion of CNTs at the surface of the micro injection molded test samples
→ Small electrical contact resistance
→ Slightly pronounced parasitic capacity
a) SEM micrograph of the surface of injection molded samples of PEEK
b) TEM micrograph of a partial cross-section perpendicular to the flow direction of the melt
b) TEM micrograph of a partial cross-section perpendicular to the flow direction of the melt
Investigation of process-related electrical conductivities at PEEK-CNT- nanocomposite structures
- High conductivity due to short filling process time
→ Optimal injection velocity at 550 mm/s - Large proportion of CNTs at the structural surface with increasing mold temperature
→ Formation of the shear zone close to cavity - Sufficient electrical conductivity already at 7 wt.% CNT for forwarding of small signals
→ Processability of nanocomposites by injection molding technologies
Electrical conductivity of PEEK filled with 7 wt.% CNT at different process parameters of injection molding
Micro injection molding process evaluation with µIMP-tool
- Newly gripper-concept with highly tempered mounting for micro structured piezo-ceramics
→ TPZT = 180°C at mold transfer with ± 5 µm positional tolerance - Proof of low internal stress µIMP in compact constructions
- Defined internal compressive stresses in PZT (10 to 30 MPa) by specific adjustment of the process parameters
→ Convenient electromechanical performance
a) µIMP micro injection molding tool; b) µIMP embedded in aluminum
Methods
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Tool and process simulation |
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Thermo mechanical deformation analysis
(Scaling factor: 10; red: max. 0.5 mm; green: 0.3 mm) |
| Production studies, sensitivity analysis | |
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Young’s modulus of PEEK filled with 7 wt.% CNT as a function of tool temperature and injection rate
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| µIMP-conditioning | |
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Surface activation of micro structured PZT in plasma atmosphere
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Publications
Reviewed Publications
| [Gra16] | Graf A, Kräusel V, Landgrebe D, Decker R, Kroll L (2016) Joining and forming of hybrid assembled composites with sensory function. Euro Hybrid Materials and Structures 2016. ISSN: 978-3-88355-414-3 |
| [Dec15] | Decker R, Heinrich M, Tröltzsch J, Kroll L (2015) Fertigungstechnologien für Piezomodule mit integrierten Keramikkompositen und Funktionspolymeren zum Einsatz in aktiven metallischen Bauteilen. Forum Spritzgießen: Funktionsintegration - Innovationen im Kunststoffbauteil, 2015. |
| [Dec15] | Decker R, Heinrich M, Tröltzsch J, Rhein S, Gebhardt S, Michaelis A, Kroll L (2015) Development and characterization of piezo-active polypropylene compounds filled with PZT and CNT In: Proceedings 5th Scientific Symposium CRC/Transregio 39, pp. 59-64, 2015. |
| [Fis13] | Fischer T, Wetzold N, Kroll L, Hübler AC (2013) Flexographic Printed Carbon Nanotubes on Polycarbonate Films - Yielding High Heating Rates. J Appl Polym Sci 1:1-9 |
| [Hei15] | Heinrich M, Decker R, Schaufuß J, Tröltzsch J, Mehner J, Kroll L (2015) Electrical contact properties of micro-injection molded Polypropylene/CNT/CB-composites on metallic electrodes In: Advanced Material Research, 1103: pp. 77-83, 2015. DOI: http://www.scientific.net/AMR.1103.77 |
| [Hei12a] |
Heinrich M, Sichting F, Kroll L (2012) |
| [Krä15] | Kräusel V, Graf A, Heinrich M, Decker R, Caspar M, Kroll L, Hardt W, Göschel A (2015) Development of hybrid assembled composites with sensory function In: CIRP Annals - Manufacturing Technology, 64(1), 2015. DOI: 10.1016/j.cirp.2015.04.054 |
| [Kro11] | Kroll L, Nendel W, Heinrich M, Stelzer R, Tröltzsch J, Walther M (2011) Bewertung prozessbedingter Eigenspannungen von mikrospritzgießverarbeiteten piezoaktiven Hybridmodulen. J Plast Technol 1:17-43 |
| [Nie13] | Niedziela D, Tröltzsch J, Latz A, Kroll L (2013) On the numerical simulation of injection molding processes with integrated textile fiber reinforcements. J Thermoplast Compos Mater 26(1):74-90 |
| [Sch13] | Schulze R, Heinrich M, Nossol P, Forke R, Sborikas M, Tsapkolenko A, Billep D, Wegener M, Kroll L, Gessner T (2013) Piezoelectric P(VDF-TrFE) transducers assembled with micro injection molded polymers. Sens Actuators A: Phys, doi:10.1016/j.sna.2013.12.032 |
| [Trö10] | Tröltzsch J, Kroll L (2010) Investigation of polymer melt impregnated fibre tapes in injection moulding process. In: Integr Syst Des Technol. Springer, Berlin, pp 67-78 |
| [Ulk13] | Ulke-Winter L, Klärner M, Kroll L (2013) Determining the damping behavior of fiber reinforced composites - A new approach to find mathematical relationships in data sets. Compos Struct 100:34-39 |
| [Wal10] | Walther M, Nendel W, Heinrich M, Klärner M, Tröltzsch J, Kroll L (2010) Initial stress behaviour of micro injection-moulded devices with integrated piezo-fibre composites. In: Integr Syst Des Technol. Springer, Berlin, pp 109-120 |
Andere Veröffentlichungen
| [Kro13] | Kroll L, Heinrich M, Nendel W (2013) Electrical and mechanical behavior of PEEK nano composites based on carbon nano tubes. In: Proc CRC/Transregio 39. Nuremberg, Germany, pp 49-52 |
| [Mül13] | Müller M, Peter S, Berg S, Heinrich M, Walther M, Hohlfeld K, Heberle J, Quentin U, Koriath H-J, Gebhardt S, Schmidt M, Michaelis A, Kroll L, Richter F, Neugebauer R (2013) Microstructured Piezoceramic and Fibre Composite Transducers for Active Semi-Finished Products. In: Proc CRC/Transregio 39. Nuremberg, Germany, pp 25-31 |
| [Hei12b] | Heinrich M, Kroll L, Sichting F (2012) Process-related mechanical properties of conductive Nanocomposites based on CNT-filled Polypropylen. In: Proc NanoSpain Conf. Santander, Spain |
Patente
| [Fra11] | Fraunhofer Gesellschaft zur Förderung der angewandten Forschung e.V. Piezoelektrisches Funktionsmodul und Verfahren zur Herstellung. Patentanmeldung WO002011038703A1. 2011-04-07 |
| [Tec09] | [Tec09] Technische Universität Chemnitz. Sensormodul, Verfahren zum Herstellen eines Sensormoduls sowie Signalerfassungs- und Verarbeitungsverfahren. Offenlegungsschrift DE102007056409A1. 2009-05-28 |
Contact
Project Manager:Univ.-Prof. Dr.-Ing. habil. Lothar Kroll
Chemnitz University of Technology
Institut für Allgemeinen Maschinenbau und Kunststofftechnik
Professur Strukturleichtbau und Kunststoffverarbeitung
09107 Chemnitz
Phone: +49 371 531-38081
E-Mail: lothar.kroll@…
Dr.-Ing. Jürgen Tröltzsch
Chemnitz University of Technology
Institut für Allgemeinen Maschinenbau und Kunststofftechnik
Professur Strukturleichtbau und Kunststoffverarbeitung
09107 Chemnitz
Phone: +49 371 531-35665
E-Mail: juergen.troeltzsch@…
