Recommendation – 1

In-Mold Structural Electronics (IMSE)

The solution to the problem is proposed by Duratech Industries

Technology Provider: Duratech Industries And TactoTek

Technology for integrating electric conductors in plastic components: In-Mold Structural Electronics® (IMSE) manufacturing technology

Type of Molding(injection and/or compression): Injection molding

Type of material used in molding: 

• Polycarbonate
• Polyester
• Acrylics (PMMA)
• Conductive inks

Advantages of Technology (Cost effectiveness/Large scale production): Cost-effective, durable components that are ready to flow into full-scale production

Application Area: Automotive(In-Mold Decorated (IMD) applications with backlit options, designs can be used for dashboard components, buttons and indicators, center consoles, and PRNDLs)

Licensing requirement: Yes (DuraTech is proud to partner with TactoTek, a deep tech company that develops and promotes IMSE with over 170 granted patents around the world)

Technology Readiness Level: 9

Safety/Regulatory Information: ISO certification and UL and CSA registrations

Summary of the Solution

Introduction

• Duratech create innovative human machine interface (HMI) solutions for many industries with In-Mold Structural Electronics® (IMSE) manufacturing technology. Known as the perfect union of form and function, IMSE fully integrates printed, conductive inks with In-Mold Decorating (IMD) to create a complete HMI solution in a single part. Sometimes referred to as in-mold electronics (IME), IMSE solutions simplify and accelerate product assembly. IMSE parts are lighter, more resistant to damage, simplify the bill of materials and ultimately reduce total cost of ownership. IMSE solutions represent proven processes and technology in a different form, creating significant benefits for manufacturers across industries.

Custom IMSE manufacturing capabilities

• DuraTech can deliver fully customized IMSE solutions to meet nearly any need. Company IMSE manufacturing capabilities allow them to incorporate various types of LED lights, buttons and controls, finishes and a wide range of colors for a unique user experience. Our IMSE capabilities allow us to create cost-effective, durable components that are ready to flow into full-scale production.

Illumination

• IMSE enables multiple styles of illumination for a superior user experience. Choose between single color or RGB in static and dynamic implementations from LEDs, all integrated within the 3D IMSE structure. Applications include localized icon backlighting, light lines showing control levels, and large area decorative ambient illumination.

Advanced IMSE technology and processes

• DuraTech is proud to partner with TactoTek, a deep tech company that develops and promotes IMSE with over 170 granted patents around the world. Company partnership gives them access to TactoTek's advanced technology and processes, allowing Duratech to enhance company IMSE offerings and provide manufacturers with more electronic functionality. Together, company capabilities enable new integrations while optimizing cost and manufacturability of IMSE for many diverse applications.

IMSE applications and benefits

• Reduced cost of ownership
• Unique, flexible design
• Extremely reliable capacitive switch because there are no moving parts
• Encapsulated circuit, sensors and other components
• Efficient variant management
• Simplified bill of materials
• The elimination of wires allows for a thin, lightweight, durable control panel
• No cracks or crevices around buttons for dirt and bacteria to hide
• Eliminates the need for bulky tech boxes
• Produces less waste, making the manufacturing process more environmentally friendly

Why choose DuraTech Industries

• Manufacturers choose DuraTech for custom in-mold structural electronics solutions because company have the knowledge, experience and technical skill to create outstanding products with every production run.
• Duratech materials science expertise and global reach provide exceptional value and help accelerate the product development process.

DuraTech

Summary: DuraTech has two manufacturing sites led by talented and dedicated experts. And with 12 support offices and local warehousing options, DuraTech can serve their customers closest to where they do business.

• Foundation Year: 1977
• Location: 3216 Commerce Street, La Crosse, Wisconsin 54603
• No.of Employees: 400+
• Type of organization: Private
• Phone: (608) 781-2570
• Website: https://www.duratech.com/
• President: Peter Johnson

Company Information

The people of DuraTech share a common culture where a passionate focus on addressing customer needs has produced long-term, enduring customer relationships. Using real-time feedback from customers, DuraTech Industries® continues to develop new offerings and capabilities that are aimed at improving the DuraTech experience.

In addition to traditional support, DuraTech Industries® offers customers value-added services such as supplier managed inventory, warehousing options, on-site design engineering support, and extended services geared towards improving business activity.

DuraTech is strategically positioned to provide consistent, reliable service from all facilities. Our long-term customer relationships around the world are testament to the dedication of the DuraTech team.

To substantiate repeatable performance, DuraTech holds these certifications:

• ISO 9001:2015 certified
• UL/CSA approved constructions

The manufacturing process

IMSE manufacturing has four main process steps. IMSE combine cosmetics, structure, and function into single injection-molded 3D designs, reducing assembly and integration challenges compared with conventional electronics.

• Screen Printing IMSE manufacturing starts with printing. Decoration, if desired, is printed on film insert molding (FIM) material, followed by printing electronics including conductive circuitry, touch controls, antennas and proximity sensors.
• Surface Mounting Electronic components are mounted using standard high-speed pick-and-place (SMT) equipment. Components are attached to the FIM substrate using conductive and structural adhesives.
• Thermoforming Thermoforming transforms the flat electronics film into its 3D shape. TactoTek® design rules and verified material stacks maintain mechanical and electrical system integrity through the forming process.
• Smart film insert molding The formed electronics film is used as an insert for injection molding, resulting in a single-piece structure with encapsulated electronics. Typical molding materials include high pressure, high temperature plastics such as polycarbonate and thermoplastic polyurethane (PC and TPU).

TactoTek

Summary: TactoTek develops and licenses injection molded smart structure technologies that enable brands to create sustainable, differentiated, and compelling user experiences.

• Foundation Year: 2011
• Industry: Appliances, Electrical, and Electronics Manufacturing
• Location: Automaatiotie 1 90460 Oulunsalo
• No.of Employees: 100
• Type of organization: Private
• Website: https://www.tactotek.com/
• CEO: Jussi Harvela

Company Information

• 100 employees from 10 different countries.
• 3 Represented on three different continents with offices in Finland, Germany, USA, Japan, and South Korea
• 260 Industry leading portfolio of intellectual property and patents
• 10+ Years of Experience in IMSE®

Recommendation – 2

US20240112969A1 - In-mold electronics device

The solution to the problem is proposed by Industrial Technology Research Institute ITRI

US20240112969A1 Published in 2024

Summary of the Solution

Technology Provider: Industrial Technology Research Institute ITRI

Technology for integrating electric conductors in plastic components: Injection molding technology

Type of Molding(injection and/or compression): Injection molding

Type of material used in molding: 

• Polyethylene terephthalate, poly (ethylene terephthalateco-1,4-cylclohexylenedimethylene terephthalate), polycarbonate, polyimide, polymethylmethacrylate, polyethersulfone, polydimethylsiloxane, acrylonitrile-butadiene-styrene copolymer, acrylic
• Gold, silver, copper, aluminum, nickel, tin
• Acrylic, epoxy resin, phenol, polyester, urethane, silicone, or polyimide

Advantages of Technology (Cost effectiveness/Large scale production): 

• Reduce product development time
• Improving reliability

Application Area: Automobile industry

Licensing requirement: ITRI uses innovative IME design guidelines and development platform for creative versatile types of circuit, contact and interface design to reduce product development time.

Safety/Regulatory Information: Effectively solving the problem of the release of organic gas and dust (formaldehyde PM 2.5) into the environment and maintaining treatment efficiency at over 70%

Introduction

• ITRI is a world-leading applied technology research institute with more than 6,000 outstanding employees.
• Its mission is to drive industrial development, create economic value, and enhance social well-being through technology R&D.
• Founded in 1973, it pioneered in IC development and started to nurture new tech ventures and deliver its R&D results to industries.
• ITRI has set up and incubated companies such as TSMC, UMC, Taiwan Mask Corp., Epistar Corp., Mirle Automation Corp., and Taiwan Biomaterial Co.

Services

• ITRI is ceaselessly developing advanced technologies and strengthening interdisciplinary integration to respond the latest industry trends.
• Moreover, it offers comprehensive R&D collaboration and business consulting services, such as contract research, small-scale pilot production, process improvement, calibration and measuring, technology transfers, and IP value-added services.
• With its open labs and incubators to promote startups and entrepreneurship, ITRI is active to speed up technological development in industries and nurture emerging high-tech businesses.

Method of manufacturing the IME device

• The IME device provided in one or more embodiments of the disclosure is able to mitigate the issue of the abnormal interface structure (e.g., peeling or wrinkles) caused by the heating and molding process, thereby enhancing the reliability for the IME device provided in one or more embodiments of the disclosure. 
• In addition, according to some embodiments, the issue of the abnormal interface structure (e.g., peeling or wrinkles) caused by the thermoforming process at the structural gap may be mitigated by arranging the gap compensation layer between the second portion of the second conductive layer and the other portion of the first conductive layer, ensuring the second portion of the second conductive layer to overlap the gap compensation layer in the Y direction, and aligning the second side surface of the second conductive layer with the side surface of the gap compensation layer away from the dielectric layer, thereby improving the reliability of the IME device having the gap compensation layer

Summary:

Industrial Technology Research Institute (ITRI) is one of the world's leading technology R&D institutions aiming to innovate a better future for society. Founded in 1973, ITRI has played a vital role in transforming Taiwan's industries from labor-intensive into technology-oriented. Over the years, ITRI has incubated over 240 innovative companies, including well-known names such as UMC and TSMC, and cultivated more than 140 CEOs.

• Foundation Year: 1973
• Industry: Research Services
• Location: 195, Sec. 4, Chung Hsing Rd., Chutung, Hsinchu, Taiwan 310401
• No.of Employees: 6000+
• Type of organization: Not-for-profit research institute
• Phone: +886-3-582-0100
• Website: www.itri.org.tw
• Chairman: Tsung-Tsong Wu

Company Information - ITRI

ITRI focuses on the fields of Information and Communications; Electronics and Optoelectronics; Material Chemical and Nanotechnology; Medical Device and Biomedical; Mechanical and Systems; and Green Energy and Environment. In addition to its headquarters in Taiwan, ITRI has branch offices in Silicon Valley, Tokyo, Berlin and Eindhoven in an effort to extend its R&D scope and promote opportunities for international cooperation around the world.

Global Partners

• Canadian Standards Association
• lululemon
• Next Generation Manufacturing
• Canada
• NRC
• QPS Evaluation Services
• University of British Columbia
• ZeeOne
• Applied Materials
• HealO Medical
• Ohio State University
• Stanford University
• ARM
• IEEE
• Optimal
• TESLA
• Battelle Memorial Institute
• Intel Corporation
• Plug and Play
• UC Berkeley
• Caltech
• Janssen
• Qualcomm
• UCLA
• Citrine Informatics
• Microsoft
• RAND
• UL
• Corning Incorporated
• MIT
• Rockwell Automation
• University of Washington
• DuPont
• NIST
• Synopsys
• University of Southern California
• Etherdyne Technologies, Inc