PopTouch: A Submillimeter Thick Dynamically Reconfigured Haptic Interface with Pressable Buttons.

The interactions with touchscreens rely heavily on vision: The virtual buttons and virtual sliders on a touchscreen provide no mechanical sense of the object they seek to represent. This work presents PopTouch: a 500 µm thick flexible haptic display that creates pressable physical buttons on demand. PopTouch can be mounted directly on touchscreens or any other smooth surface, flat, or curved. The buttons of PopTouch are independently controlled hydraulically amplified electrostatic zipping taxels (tactile pixels) that generate 1.5 mm of out of plane displacement. When pressed by the user, the buttons provide intuitive mechanical feedback thanks to a snap-through characteristic in their force-displacement profile. The snap-through threshold can be as high as 4 N, and is tuned by design and actuation parameters. This work presents two versions of PopTouch: a transparent PopTouch for integration on Touchscreens with built-in touch sensing, such as smartphones and a sensorized PopTouch, with embedded thin-film piezoelectric sensors on each taxel, for integration on substrates without built-in touch sensing, such as a steering wheel. PopTouch adds static and vibrating button-like haptics to any device thanks to its thin profile, flexibility, low power consumption (6 mW per button), rapid refresh rate (2 Hz), and freely configured array format.

Enhancing High-Pressure Capillary Rheometer Viscosity Data Calculation with the Propagation of Uncertainties for Subsequent Cross-Williams, Landel, and Ferry (WLF) Parameter Fitting.

Measuring the shear viscosity of polymeric melts is an extensive effort frequently performed in high-pressure capillary rheometers, where the pressures required to push the melt through a capillary at various temperatures and volumetric flow rates are recorded. Then, the viscosity values are obtained through Bagley and Weissenberg-Rabinowitsch corrections involving parameter fitting. However, uncertainties in those conversions due to pressure variations and measurement inaccuracies (random errors) affect the accuracy of the consequently calculated viscosities. This paper proposes quantifying them through a propagation of uncertainties calculation. This has been experimentally demonstrated for a polycarbonate melt. In addition, the derived viscosity uncertainties were used for the weighted residual sum of squares parameter estimation of the Cross-WLF viscosity model and compared with the coefficients obtained using the standard residual sum of squares minimization approach. The motivation was that, by comparison, individual poorly measured viscosity values should have a less negative impact on the overall fit quality of the former. For validation, the rheometer measurements were numerically simulated with both fits. The simulations based on the Cross-WLF fit, including the derived viscosity uncertainties, matched the measured pressures ~16% more closely for shear rates below 1500 1/s. Considering the uncertainties led to more precise coefficients. However, both fits showed substantial deviations at higher shear rates, probably due to substantial non-isothermal flow conditions that prevailed during these measurements. A capillary rheometer experiment was also simulated using arbitrarily chosen Cross-WLF parameters to exclude such systematic errors. A normally distributed error was then applied to the simulated pressures before re-fitting the parameters. Again, taking advantage of the derived viscosity uncertainties, the fit could recover the initial parameters better.

Parameter Study on Force Curves of Assembled Electronic Components on Foils during Injection Overmolding Using Simulation.

The integration of assembled foils in injection-molded parts is a challenging step. Such assembled foils typically comprise a plastic foil on which a circuit board is printed and electronic components are mounted. Those components can detach during overmolding when high pressures and shear stresses prevail due to the injected viscous thermoplastic melt. Hence, the molding settings significantly impact such parts' successful, damage-free manufacturing. In this paper, a virtual parameter study was performed using injection molding software in which 1206-sized components were overmolded in a plate mold using polycarbonate (PC). In addition, experimental injection molding tests of that design and shear and peel tests were made. The simulated forces increased with decreasing mold thickness and melt temperature and increasing injection speed. The calculated tangential forces in the initial stage of overmolding ranged from 1.3 N to 7.3 N, depending on the setting used. However, the experimental at room temperature-obtained shear forces at break were at least 22 N. Yet, detached components were present in most of the experimentally overmolded foils. Hence, the shear tests performed at room temperature can only provide limited information. In addition, there might be a peel-like load case during overmolding where the flexible foil might bend during overmolding.

Influence of Injection Molding Parameters on the Peel Strength between Plasma-Treated Fluoropolymer Films and Polycarbonate.

Light guiding is used to direct light from an emitting source to a different location. It is frequently realized through a clad-core structure with a difference in the refractive index of the materials. This paper explores the possibility of combining a fluoropolymer (THV) film of low refractive index, serving as a cladding layer, with a polycarbonate (PC) core, via injection molding. Pristine THV lacks adherence to the PC. However, when treated with O2 plasma prior to overmolding, bonding can be established that was quantified in peel tests. The effect of this surface treatment was further investigated by adjusting the plasma treatment duration and time to overmolding. Furthermore, parameter studies comprising the four molding parameters, namely packing pressure, injection speed, melt temperature, and mold temperature, were performed. Numerical injection molding simulations assessed the prevailing temperatures at the PC-THV boundary. Consequently, the temperature-time integral could be calculated and linked with the measured peel strengths by fitting a proportionality constant. While the plasma treatment duration showed minor influence, the activation diminished with time, halving the measured peel loads within 24 h. The adhesion was experimentally found to increase with a lower packing pressure, faster injection speed, and higher melt and mold temperature. Those same molding relations influencing the peel loads were also found with the temperature-time integral when scaled by the proportionality constant in the simulations (R2=85%). Apparently, adhesion is added by molding settings which promote higher interface temperatures that prevail for longer. Hereby, the faster injection speed increases the melt temperature through shear heating. A higher packing pressure, in contrast, presumably increases the heat transfer at the PC-THV interface, accelerating the cooling. The measured peel loads were 0.3-1.6 N/mm for plasma-treated samples and nearly zero for pristine THV.

Study of Pressure Distribution in Floor Tiles with Printed P(VDF:TrFE) Sensors for Smart Surface Applications.

Pressure sensors integrated in surfaces, such as the floor, can enable movement, event, and object detection with relatively little effort and without raising privacy concerns, such as video surveillance. Usually, this requires a distributed array of sensor pixels, whose design must be optimized according to the expected use case to reduce implementation costs while providing sufficient sensitivity. In this work, we present an unobtrusive smart floor concept based on floor tiles equipped with a printed piezoelectric sensor matrix. The sensor element adds less than 130 µm in thickness to the floor tile and offers a pressure sensitivity of 36 pC/N for a 1 cm2 pixel size. A floor model was established to simulate how the localized pressure excitation acting on the floor spreads into the sensor layer, where the error is only 1.5%. The model is valuable for optimizing the pixel density and arrangement for event and object detection while considering the smart floor implementation in buildings. Finally, a demonstration, including wireless connection to the computer, is presented, showing the viability of the tile to detect finger touch or movement of a metallic rod.

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

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.

Screen-Printed Ferroelectric P(VDF-TrFE)-co-PbTiO3 and P(VDF-TrFE)-co-NaBiTi2O6 Nanocomposites for Selective Temperature and Pressure Sensing.

Piezo- and pyroelectricity is an intrinsically combined material property for all ferroelectric materials. While the pyroelectric coefficients of most ferroelectric ceramics and polymers have the same sign, their piezoelectric coefficients have opposite ones. On this basis, we can create a polymer-ceramic nanocomposite material where either the piezo- or the pyroelectric effect is suppressed by a selective poling of the single constituents, a concept that was shown for composite pellets in the late 1990s. Motivated by the current demand for lightweight and low-cost piezoelectric sensors with reduced cross-sensitivity to temperature variations, we have taken up this idea and formulated screen-printable nanocomposite pastes from poly(vinylidene fluoride-trifluoroethylene (P(VDF-TrFE)) and lead titanate (PbTiO3, PT) or sodium bismuth titanate (NaBiTi2O6 or BNT) nanoparticles, respectively. We demonstrate that printed sensors on flexible substrates based on these materials can be conditioned by selective poling of the nanoparticles and the polymer matrix to show either only piezoelectric or only pyroelectric sensor response. We examined the degree of cross-talk between the thermal and pressure sensing channels and show a reduction of over 90% cross-sensitivity for the ferroelectric composites compared to pure P(VDF-TrFE) sensors.

Datasets for the analysis of dislocations at grain boundaries and during vein formation in cyclically deformed Ni micropillars.

The dataset together with the corresponding Python scripts and Jupyter notebooks presented in this article are supplementary data for the work presented in Samaee et al., 2019 [1]. The data itself consists of two parts: the simulation data that was used in [1] to analyze the effect of a particular grain boundary on curved dislocations and the precession electron diffraction (PED) strain maps together with post-processed data for analyzing details of the observed dislocation vein structures. Additionally, the complete stress tensor components, which are not shown in [1], have also been included. The data sets are accompanied by Python code explaining the file formats and showing how to post-process the data.

Quantitative in-situ TEM nanotensile testing of single crystal Ni facilitated by a new sample preparation approach.

Twin-jet electro-polishing and Focused Ion Beam (FIB) were combined to produce small size Nickel single crystal specimens for quantitative in-situ nanotensile experiments in the transmission electron microscope. The combination of these techniques allows producing samples with nearly defect-free zones in the centre in contrast to conventional FIB-prepared samples. Since TEM investigations can be performed on the electro-polished samples prior to in-situ TEM straining, specimens with desired crystallographic orientation and initial microstructure can be prepared. The present results reveal a dislocation nucleation-controlled plasticity, in which small loops induced by FIB near the edges of the samples play a central role.

Surfaces with combined microscale and nanoscale structures: a route to mechanically stable superhydrophobic surfaces?

Materials with superhydrophobic properties are usually generated by covering the surfaces with hydrophobic nanoscale rough features. A major problem, however, for any practical application of such strongly water-repellent surfaces is the mechanical fragility of the nanostructures. Even moderate forces caused by touching or rubbing the surfaces are frequently strong enough to destroy the nanostructures and lead to the loss of the superhydrophobic properties. In this article, we study the mechanical stability of superhydrophobic surfaces with three different topographies: nano- and microscale features and surfaces carrying a combination of both. The surfaces are generated by silicon etching and subsequent coating with a monolayer of a fluoropolymer (PFA). We perform controlled wear tests on the different surfaces and discuss the impact of wear on the wetting properties of the different surfaces.

Light-induced switching of surfaces at wetting transitions through photoisomerization of polymer monolayers.

We report on a method to generate surfaces whose wettability can be reversibly switched between a superhydrophobic and Wenzel state or a Wenzel and superwetting state just by a short UV or VIS irradiation. To achieve this, we generate a silicon surface with a nanoscale roughness ("black silicon") and attach a polymer monolayer to it. The polymer contains a fluorinated azobenzene moiety which can be switched between the cis and trans state depending on the wavelength of the light used during illumination. The surface energy of the polymer coating is carefully adjusted to the energy value which separates distinct wetting regimes of the nanorough surface. This coupling of light induced switching to a transition of the wetting regimes can cause changes in the water contact angle as high as Δθ = 140° in the advancing CA or more than 175° in the receding CA even when the surface energy is changed only in a rather small range. Short irradiation times with UV or VIS light are enough to change the roll-off angle from <5° to no roll off at all and back. We discuss the requirements necessary so that large changes in the contact angle occur during photoswitching processes on rough surfaces.