iee heater technology · fully equipped with state of the art heating / air conditioning technology...

IEE Heater Technology

Dr. Alain SchumacherSenior Department Manager,

Material Development, Innovation

20th of June 2017

Agenda

2 Copyright IEE S.A. © All rights reserved

IEE at a glance

▪ Company profile

▪ Technology & product portfolio

IEE heater technology

▪ Key properties and benefits

▪ Integration benefit

▪ SafeHeat – PTC ink technology

▪ SafeHeat – product applications

Interior heating

▪ Vision & motivation

▪ Roadmap

▪ R&D activities

▪ Thermal concept vehicle

Summary

3

IEE at a glanceGrowth through innovation and diversification

Copyright IEE S.A. © All rights reserved

▪ Founded in 1989

▪ Consolidated turnover: 461 m EUR (2016)

▪ 3,650 people and ~ 10% dedicated to R&D

▪ Markets

▪ Automotive

▪ Building Management & Security

▪ Sports & Healthcare

▪ Connectivity

▪ Energy Management

▪ Global leader in automotive safety sensing systems for occupant detection and classification

▪ More than 300 million vehicles equipped worldwide and direct co-operations with 80 automotive OEMs

▪ Highest quality, environmental and health & safety standards

▪ More than 200 patent families

IEE at a glance

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IEE Group global footprint


HeadquartersR&D, Sales, Plant

2014

South KoreaSeoulDevelopment & sales office

ChinaBeijing / LangfangDevelopment & sales officeChina plant

LuxembourgContern/Echternach

HeadquartersEurope plant

SlovakiaVel’ká IdaDevelopment Europe plant

ChinaTianjinDevelopment

MexicoAmericas plant

U.S.Auburn Hills

Development & sales office

BrazilSao Paulo

Development & sales office

FranceOrleans/ Bayonne

Electronics plant

TunisiaTunisElectronics plant

JapanTokyoDevelopment & sales office

GermanyIngolstadtADAS Competence Centre

2015

ALL CIRCUITS – Our Alliance Partner (MSL, BMS, TIS, AC)Industrial experts in EMS


▪ Customer Program Engineering

▪ Electronics and Semiconductor Development

▪ Algorithmic and Embedded Software Development

▪ Development of Optical Systems

▪ Material Development

▪ Simulation-based Development / Virtual Engineering

▪ Customer Program Engineering

▪ Electronics and Semiconductor Development

▪ Algorithmic and Embedded Software Development

▪ Development of Optical Systems

▪ Material Development

▪ Simulation-based Development / Virtual Engineering

▪ Process & Production Engineering

IEE at a glance

5

Engineering & research teams

Key Technologies and Product PortfolioTechnology Principle Products

Force Sensing Resistor (FSR)

Uses variable resistance to detect pressure applied to a sensor cell

▪ Passenger Presence Detection (PPD) & Classification (OC)▪ Seat Belt Reminder (SBR)▪ Pedestrian Protection and Crash Sensing▪ Input Devices, Sports & Healthcare

Electromagne-tic Sensing

Communication between car seat antenna and child seat resonators

▪ Child Seat Presence and Orientation Detection (CPOD)

Electric Field Sensing

Evaluates change in electrical field to classify seat occupancy

▪ BodySenseTM

▪ Smart Opener (SO)▪ Hands off Detection (HOD) (ADAS)

Optical Sensing

Measures time-of-flight of modulated infrared light to provide topographic image

▪ People Counter▪ Tailgate Detector TDflex™▪ Volumetric Object Surveillor▪ ADAS

Interior Radar Uses radio technology to detect occupants

▪ Interior Motion Detector, VitaSense (low power)▪ ADAS

Foil Heaters (Seat, Panel)

Screen printed, heater layer optional with PTCPositive Temperature Coefficient

▪ Safe Heat, inherent safety due to T-self limiting ▪ Panel heaters for slim, near surface integration

Copyright IEE S.A. © All rights reserved 7

Simple, near surface integration▪ Fast temperature ramp up▪ Moderate heater surface

temperature ▪ Avoids local aging

of decor layer

BoM flexibilityTypical thickness range 75 to 140 µm

Protection

Heater layer

Bus bar layer

Polymer Foil

Fixation tape

Key properties & benefits of IEE heater

technologyHigh design flexibility, complex designs

Homogeneous heating of large and complex surfaces with only one heater circuit

Standard operation voltages:12V, 24V, 48V

Standard P/A: 500 to 1000 W/m2

Several kW/m2 possibleHigher voltages possible

Screen printing of versatile ink materials▪ Different functionalities, e.g. PTC inks▪ Electrical resistances▪ Cost efficiency

Steering wheel/swh_02.avi

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Near surface integration enables fast T-ramp up▪ Benefit evaluation of near surface integration benchmark, wire vs. foil panel heater

▪ Wire integrated with 4mm foam lamination to avoid imprints on trim surface and local overheating

▪ For foil heater 0.5mm was sufficient

▪ Ramp up from -10°C

▪ Power per heater: 22W

Thermal images of arm rest décor surface

Higher local T for wire heater on décor (50 vs. 45°C), T stationary

Wire Foil

Integration benefit

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Benchmark wire vs. foil heater in arm rest

Wire heaterPadding thickness: 4mmP = 22WTmax : 136°C

Foil HeaterPadding thickness: 0.5 mmP: 22 WTmax: 89°C


Integration benefit


Unique selling points of IEE’s heater technology

Main characteristics … leads to advantages … leads to savings (€) / benefits

Thin foil technology ✓ NTC (if requested) can be easily placed on the foil (small & flat)

✓ No, or less, additional development effort/ spending

✓ No, or less, investment in implementation process

Picture Source: IEE

SMD NTC sensor

Bus bars

Heater elements, can be printed w/ and w/o PTC functionality

Arm rest heater design printed on thin polyester film


Main characteristics … leads to advantages … leads to savings (€) / benefits

Thin foil technology ✓ Heating function is added w/o change in armrest part design

✓ Same tools can be used for heated and non-heated version

✓ Less tooling costs✓ Fewer parts, less stock inventory✓ Less complex workflow in production ✓ circa 3% piece cost reduction

Picture Source: Yanfeng Automotive Interiors

Wire heater

Foil heater

Heated interior part Non-heated interior component version

Integration benefitUnique selling points of IEE’s heater technology

Basis for IEE SafeHeat product applications


▪ Strong Positive Temperature Coefficient

▪ Good time to temperature at moderate heater surface temperature due to PTC characteristic

▪ Low resistance at cold temperatures leads to a high current flow, which drives the strong heating power

▪ Inherent temperature limitation due R(T).

▪ Self-regulating, no ECU required

▪ High cost efficiency

▪ Inherent safety, no overheating if controller fails

▪ No temperature fluctuations

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PTC Resistance

Power @ U=13.5V

Current @ U=13.5V

Resistance, power, current evolution

P(T) = U2 / R(T) = U*I(T); U=R(T)*I

PTC ink technology

SafeHeat


Product application: seat heater with PTC ink technology

Time to temperature performanceTest person: 85kgHeater P: 54 WP/A: 1000 W/m2

Starting T: -20°C

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Trim surface T~43°C

Time to temperature on seat surface

SafeHeat


Product application: arm rest heater with PTC ink technology

▪ Applicable for e.g middle armrest and door panel arm rest

▪ Can be equipped with printed switches and/or Linpots from IEE

▪ Covered switches below cover material

▪ Foil-based heaters could be covered with several materials

Picture Source: IEE Picture Source: IEEPicture Source: Yanfeng

SafeHeat


Picture Source: IEE

Product application: footmat heater

Heater integrated into footmat via lamination process

Interior heating

15 Copyright IEE S.A. © All rights reserved .

Vision: interior will become the ‘Heart of the Car’▪ Market development driven by the automotive industry’s mega trends:

▪ energy/CO2 saving requirements

▪ electrification (e-cars)

▪ autonomous driving assistant systems (ADAS)

▪ passenger cabin transfers to a living room

Motivation for development of panel heater for car interiors

▪ Heating energy is delivered by the power train of a car – combustion engines, or the batteries for e-cars

▪ Thus the efficiency of the heater system has a direct impact on emission values resp. km-range

▪ Potential to improve heating efficiency due to:

▪ integration close to the passenger

▪ efficient conversion of electrical energy to useful heating for the passenger

Energy efficieny & passenger comfort significantThe Mercedes-Benz F 015

Luxury in Motion research car

Interior heating


Background / Literature

▪ Infrared heating as an adjunct to achieve vehicle occupant thermal comfortCollins et al. Extreme Physiology & Medicine 2015, 4(Suppl 1):A82; http://www.extremephysiolmed.com/content/4/S1/A82

▪ Simulation and Measurement of an Energy Efficient Infrared Radiation Heating of a Full Electric Vehicle*Bäuml T., Dvorak D., Frohner A., Simic D., AIT Austrian Institute of Technology GmbH, Giefinggasse 2, 1210 Vienna, Austria

▪ The Future of Automotive Research, Keynote lecture, CLEPA Strategic Workshop “Road Transport 2030 – European Suppliers scenarios”Aachen 6 April 2017 Univ.-Prof. Dr.-Ing. Lutz Eckstein, Institute for Automotive Engineering (ika), RWTH Aachen University

▪ Climatisation can cut the range of an electric vehicle by half.

▪ By a combination of measures and innovations, the energy demand for climatisation can be reduced by more than 50%

▪ Definition and validation of the comfort experience is decisive

▪ The comfort chart from (Bedford and Liese) shows a dependency on temperature of the wall to air temperature**

**

*T-distribution on a dummy and on a surface through the cabin. Heating: IR- and additional convective

http://www.extremephysiolmed.com/content/4/S1/A82

Interior heating


Roadmap

What does a future energy-efficient car heating concept look like?

▪ Single system or combination of different technologies?

What is the thermal comfort / perception of the passenger?

Heater panels, complementary to HVAC systems

▪ Increased number ofsurfaces heated in passenger compartment

▪ Impact on thermal perception of passengers

▪ Smart control strategies for heater panel require specialised ECU

Panel heater as integral component of future novel HVAC systems

▪ Large portion of interior surface heated

▪ Significance of electrical heater panels to total heating power

▪ Control of panels by advanced HVAC control systems

HVAC, standard

Contact surface heating

▪ Seat

▪ Steering

▪ Armrest

Today Mid-term Long term


Interior heating

Project to evaluate the thermal comfort / benefits of panel heater

▪ Concept car: BMW 530d series with full option interior configuration

▪ Key criteria for car selection & set up

▪ Professional integration of panel heater

▪ Heaters respectively modifications not to be perceived by the test persons

▪ Fully equipped with state of the art heating / air conditioning technology

▪ Interior with leather trim

▪ Targeted investigations

▪ Thermal comfort studies with test persons in real car environment

▪ Thermal perception & perception latency

▪ What is perceived as comfort, heated regions, temperatures & temperature gradients,….

▪ Determine energy consumption required for individual thermal comfort

▪ Draw energy balance for different operation modi

▪ Pure panel heating vs pure HVAC▪ Combined with car HVAC system

IEE R&D on thermal comfort / Experimental

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▪ Heater performance / operating specifications

▪ power density▪ target temperatures▪ heat-up time▪ …

▪ Optimized layout of heater mat

▪ electrical power consumption▪ heat flux @ contact area▪ radiant heat flux distribution▪ …

▪ Thermal comfort evaluation

▪ HVAC vs. panel heating▪ …

▪ Mechanical robustness▪ …


Interior heating

ANSYS-Fluent Multi-Physics Modelling

IEE R&D on thermal comfort / Modelling Topics

Picture source: IEE, WBi - Basics & Mathematical Models



Interior heatingIEE Thermal Concept-Car

door panel

door arm rest

centre arm rest

footwell

footmat

sun visor

ceiling

U = 0 V U = 24 V



Thermal images of heated concept car interior

Interior heating

▪ Panel heater integrated near to décor surface

▪ No impact on haptic

▪ Highly homogeneous T-distribution

▪ Large heat radiating surface

▪ Spontaneous heat perception due to IR-radiation

▪ Additional convection heating

▪ Dashboard heater

▪ Heat perception through IR-reflection at windscreen

▪ Overall good themal perception

▪ High potential for efficient future heating systems

Picture Source: IEE


Interior heatingConcept car heating tests Good and fast thermal perception▪ Total number of integrated heaters: 17

▪ Maximum possible electrical power of all heaters: 2,0 kW

▪ Heater designed with power density in the range of 500 to 1400 W/m2

▪ Ambient temperature: 6°C

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Total Power

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Time to temperature of different panel heatersCeiling Rear

Ceiling Front

Sunvisor Pass

Sunvisor Driv

Footmat Pass

Dashboard Pass

Footmat Driv

Dashboard Driv

MA Pass

MA Driv

Arm P

Door P

Arm D

Door D

Summary


IEE heater technology = cost efficient, comfortable & safe heat

IEE thin foil technology for heating applications

✓ Screen printing technology enables high design & material flexibility

▪ Complex heater designs with only one heating circuit

✓ Panel heaters for interior car cabin heating

▪ Homogeneous temperature distribution at moderate heater temperatures

▪ Efficient heating due to near surface integration

▪ Heating through IR-radiation and convection

▪ Spontaneous heat perception due to IR-radiation

▪ High potential to be part of novel, energy efficient heating concepts

▪ IEE has a focus on panel heater R&D

▪ Concept car for thermal perception tests

✓ «Fail-safe» technology based on PTC ink technology

▪ Focus on safety, no overheating due inherent self-limiting heater circuits

▪ No ECU, NTC required, potential cost advantage

Contact us


Thank you for your attention!If you need more information, please do not hesitate to contact us:

IEE S.A.

ZAE Weiergewan

11, rue Edmond Reuter

L-5326 Contern

Phone: + 352 2454-1

Fax: + 352 2454-3200

E-mail: [email protected]

Website: www.iee.lu

Dr. Alain Schumacher

Senior Department Manager

Material Development / Innovation

[email protected]

Phone: +352 2454 2273

mailto:[email protected]

iee heater technology · fully equipped with state of the art heating / air conditioning technology...

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