6. MULTI-FUNCTIONAL CARS’INTERIOR MATERIALS PROTOTYPES 67
need to be smaller or the coil optimized to produce a higher field. Both solutions could be used with benefits for the final application but would demand further development.
A new coil could possess a smaller size that would help the embedment, while a tinnier magnet usage meant the creation of more pixelized deformation that could be interesting for complex applications. Despite the promising solutions presented, at the moment of the development, neither was able to be implemented, leading to the course of prototype creation diverging from the primary idea to the proven one of permanent magnets with a controllable mechanical system.
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PROGRAMMABLE MAGNETIC ATTRACTIVE MATERIALS: AN APPROACH FOR SHAPE-CHANGING CARS’INTERIORS
Initially, the tests were performed with a programmed gap between the disks and sam-ple of two millimeters, attenuated when the material was put in place due to the immedi-ate attraction. When activimmedi-ated, the system displayed the predicted result with the sample deforming differently with the rotation of the servo. Yet, the deformation amplitudes ob-served were insufficient to detect what magnet was below a certain point. Therefore, the distance between the sample and the disks was reduced to only a millimeter, enabling the possibility of determining each magnet’s position and following their rotation, as demon-strated in figure6.7. On the left side (A), it is possible to observe the deformations caused by the magnets at the initial angle, while on the right side (B), is comprehended the motor rotation by displacement of the deformation marked in red*.
(A) State of the sample right after servo motor power up (0◦)
(B) State of the sample after servo motor power up for a half rotation (160◦)
FIGURE6.7: Magnetic sample deformation obtained in the rotating permanent magnets prototype
The oscillations observed in the material’s shape had distinct forms, amplitudes, and exposure times without any hysteresis or defect resulting from that, independently of the used frequency. As a consequence, the prototype demonstrates an initial capability of long-time exposure to deformations, showing the viability of the concept proposed in the project. Additionally, the modulation capability of the amplitude of the oscillations in the material, by varying the gap between the sample and magnets, adds an extra feature that will be used in future prototypes to create more complex shape-varying programs.
Nevertheless, the performed evaluations were with low-intensity magnets, meaning that for bigger and intenser magnets, the results can differ from this. Yet, their usage in similar setups has an additional constraint, which is the spacing between them, or else they will attract each other and not remain in the intended spot.
*Video of the complete functioning of the Rotating magnets prototype can be seen here https:
//drive.google.com/drive/folders/1ViXEuzd3J7JsN1OHYtSvQk-sPc2h-stU?usp=sharing or through the QR code present in figureA.5on appendixA
Chapter 7
Conclusions and future work
Evolution and development in the automotive industry have grown massively with the transitioning of power sources, from fossil fuels to electric or hybrid. That change also influenced other improvements among the vehicles, which include their interiors that are much more modern, dynamic, and multi-functional. Along those lines, the possibility of turning the dashboards, door panels, backseats, etc. into magnetic shape-changing mate-rials presented itself as a promising concept for decorative applications and as actuators or indicators of signals for the occupants, being a completely innovative concept.
Thus, the work was initially focused on the development of magnetic field generators, which possessed three principal characteristics: small dimensions for easy embedment, high magnetic field output, and the possibility to be programmed by the user. Planar coils were initially tried due to their compactness and reduced size, presenting an excel-lent solution for an embedded system. Nonetheless, the fabrication method used denoted some problems with the coils, such as the pad connections, that, associated with the mesh degradation and the unknown magnetic field produced, led to stoppage of their produc-tion and exploraproduc-tion of other possibilities like the permanent magnets and regular copper coils. Those options had different inconveniences, the lack of programming of magnets and the substantial size of the coils. Yet, the combination of both was the most favorable solution obtained within all the possibilities tested since it enabled the usage of a smaller coil, which could be programmable, that could vary larges fields with the movement of the magnet inside.
After, the focus shifted toward the production and characterization of the MnFe2O4
69
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PROGRAMMABLE MAGNETIC ATTRACTIVE MATERIALS: AN APPROACH FOR SHAPE-CHANGING CARS’INTERIORS
nanoparticles that demonstrated the predicted magnetic and structural properties but dis-played a substantial agglomeration problem, which would become critical for the fabri-cation of the magnetic samples. Those produced samples consisted of one layer of PVC paste and two layers of lacquer, being the NPs embedded within the paste and top lac-quer, to understand their influence with the weight percentage increment. From the ten specimens developed, it was possible to denote the impact of the MNPs clusters in high concentration samples due to the enormous failures in the product caused by them dur-ing production. Nevertheless, the magnetic and structural analysis showed the influence of the nanoparticles among the sample, being the main component detected for samples above 10wt%. Specifically, samples 9 and 10, with a weight percentage of 13wt% of NPs in PVC paste, were able to reach a saturation magnetization of 6.1emu/g, making them-selves the most promising for the prototypes, even though their overall lack of integrity did not allow large sample areas of each. As a consequence, S9 was used to perform the proof of concept, deforming as expected in both and conforming the possibility of the presented project.
Finally, following the remarkable results of the proof of concept, prototypes were de-veloped by combining the magnetic field generators and magnetic samples while envi-sioning a future application in a possible vehicle. From chapter 4, permanent magnets and their combination with regular coils were still possibilities, which led to the initial at-tempt of utilizing the coil+magnet combo that promoted successful deformations on the magnetic material. Yet, the waveform generator used had an embedding problem and was incapable of being programmed, leading to the idealization of prototype two, where an Arduino was used as a replacement. Even though the embedment problem was solved, the maximum output power allowed by the Arduino (meant I = 0, 02Ain the coil) was insufficient to create substantial deformation, demanding amplification before the coil connection. Two amplifiers were tested to double the Arduino’s power, demonstrating imperfect amplification in both cases but enough to see the oscillation programmed in the Low-noise Amplifier case. However, its usage would also be problematic for the em-bedment procedure and did not resolve the current supply failure obtained when the coil entered the circuit. Given that, an alternative mechanical prototype was developed us-ing only the permanent magnets with an oscillatus-ing system that, in the case of prototype three, was a rotating plate. Number three confirmed the possibility of multiple defor-mation points within the same sample from independent sources, yet, it would present
7. CONCLUSIONS AND FUTURE WORK 71
greater effort for its application in a car, adding to the low versatility of variation.
Therefore, further work on different crucial points of the project must be done to reach the complete viability for application into a car’s interior. The usage of nanoparticles with higher magnetizations, such as FeCo or NiFe, could be in the cards to reduce the magnetic field needed to attract the samples, turning the overall mechanism simpler and demand-ing weaker coils or magnets. Regardless of that optimization, the integrity problem of the high weight percentage samples will still be present. Yet, it can be countered initially by multiple strokes with the cleansed of the knife in between, but, for more advanced productions, a study must be done to obtain fewer clusters with millimetric dimensions, which are responsible for the problems observed. Some options are the usage of NPs in a solution, reducing, that way, the probability of cluster formation, or some separation methods like an ultrasonic bath before production.
Besides the referenced fabrication constraints, prototypes also demand considerable development, mainly if the initial objective of not using mechanical components remains the primary goal. In that case, the chosen route should be through magnetic MEMS with different methods that allow a more precise and reproducible production while being able to produce, for example, planar coils capable of outputting high magnetic fields. Lithog-raphy on a more solid substrate to create copper planar coils would be a possible solution, having already some valid results, which also resolved the contacts restrain that designs and silver ink presented [73,74]. Whereas if the project follows the direction of prototype three, then an upgrade on the background system must be done to allow more possibil-ities of deformations in the material. Using mechanical actuators with magnets, like M3 and M5, on their tip capable of moving up and down would be an outstanding solution, being the movement controlled by an Arduino, for example. With that system, multi-ple programs could be developed to create different dynamics in the actuators’ motion that enabled enormous system customization by the user and the developer. In addition, the motion of the actuators would only have a span of 3mm maximum, meaning that the system, even though it is less compact, would not be a considerable problem for an embedment in a car.
Yet, the road from these initial prototypes and proof of concept until a concrete plication into a car interior is long and hard, demanding crucial steps that were not ap-proached. Examples of these steps are the fabrication of complete samples with three
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PROGRAMMABLE MAGNETIC ATTRACTIVE MATERIALS: AN APPROACH FOR SHAPE-CHANGING CARS’INTERIORS
layers, the top one the magnetic, which can reduce the magnetic interaction, and the in-corporation of dye within the magnetic layer to match the rest of the car. Then, the mate-rials must be modulated to their specific application and tested in a real car environment, which will present challenges for the embedment of the system components. Addition-ally, there is also the possibility of using the concept in areas other than automotive. An example could be the deposition of a reflective layer on top of the material capable of re-flecting a beam in distinct and controllable angles, depending on the deformation caused.
Nevertheless, all the constraints combined mean work for some years with multiple ob-stacles but, if accomplished, would revolutionize the cars’ interior, creating incredible dynamic features for every occupant with the possibility of much further development and modification.
Appendix A
Additional figures, tables and graphs
Chapter 4 appendix
L2 mesh coils parameters
TABLE A.1: L2 mesh spiral coil design parameters: coil number, internal diameter, ex-ternal diameter, number of turns, spacing between lines, width of line, inex-ternal contact
diameter, external contact dimensions Coil parameters
Coil dint dext Number Spacing Width dintcontact dimextcontact
# (mm) (mm) of turns (mm) (mm) (mm) (mm×
mm)
1 6.00 30.00 10 1.20 0.30 6.00 7x3
2 6.00 20.00 7 0.99 0.30 6.00 7x3
3 5.00 30.00 10 1.25 0.30 5.00 7x2
4 5.00 20.00 7 1.01 0.30 5.00 7x2
5 4.00 30.00 10 1.29 0.30 4.00 7x2
6 4.00 20.00 7 1.12 0.30 4.00 7x2
7 5.00 36.00 15 1.02 0.30 5.00 7x3
8 5.00 24.00 9 1.05 0.30 5.00 7x3
13 5.00 32.00 7 1.93 0.30 5.00 7x2
14 5.00 24.00 5 1.89 0.20 5.00 7x2
15 5.00 36.00 8 1.93 0.20 5.00 7x2
16 5.00 26.00 6 1.74 0.30 5.00 7x2
21 5.00 30.00 10 1.25 0.20 5.00 7x3
22 5.00 24.00 8 1.18 0.20 5.00 7x3
23 5.00 30.00 12 1.04 0.20 5.00 7x3
24 5.00 24.00 7 1.35 0.20 5.00 7x3
73
74
PROGRAMMABLE MAGNETIC ATTRACTIVE MATERIALS: AN APPROACH FOR SHAPE-CHANGING CARS’INTERIORS TABLEA.2: L2 mesh mesh-type coil design parameters: coil number, wave height, num-ber of waves by column, numnum-ber of columns, spacing between columns, width of line,
contacts dimensions
Coil parameters Coil hwave Waves
per
Number
of dcolumn Width dimcontacts
# (mm) column columns (mm) (mm) (mm×
mm)
9 2.00 6 8 3.00 0.30 7x3
10 2.00 8 8 4.00 0.30 7x3
11 2.00 2 20 3.00 0.30 7x3
12 1.50 4 20 4.00 0.30 7x3
TABLE A.3: L2 squared-spiral coil design parameters: coil number, internal square size, external square size, number of turns, spacing between lines, width of line, internal
con-tact square size, external concon-tact dimensions Coil parameters
Coil lint lext Number Spacing Width lintcontact dimextcontact
# (mm) (mm) of turns (mm) (mm) (mm) (mm× mm)
17 6.00 30.00 7 2.00 0.30 3.00 7x3
18 5.00 20.00 9 1.00 0.30 3.00 7x3
19 6.00 30.00 14 1.00 0.20 3.00 7x3
20 4.00 20.00 5 2.00 0.20 2.00 7x3
L1 mesh for Screen Printing
FIGUREA.1: L1 mesh used for current withstand tests on PET and Kapton substrates
A. ADDITIONAL FIGURES,TABLES AND GRAPHS 75 Coil + permanent magnet working video QR code
FIGURE A.2: QR code for a demonstration video of the oscillating movement of the magnet inside the coil
Chapter 5 appendix
SQUID parameters of the nanoparticles and magnetic samples
TABLE A.4: Superparamagnetic hysteresis loop characteristic values for MnFe2O4
nanoparticles powder
Sample superparamagnetic parameters
Label Msat MR HC
# (emu/g) (emu/g) (mT)
MnFe2O4
NPs powder 62±3 −0.03±1.09 0.03±1.22
TABLE A.5: Superparamagnetic hysteresis loop characteristic values for samples with NPs on PVC (S3-S10)
Sample superparamagnetic parameters
Label Msat MR HC
# (emu/g) (emu/g) (mT)
3 1.04±0.05 −0.001±0.027 0.07±1.32 4 1.00±0.05 −0.001±0.031 0.06±1.36 5 1.91±0.09 −0.002±0.048 0.05±1.33 6 2.4±0.1 −0.004±0.064 0.08±1.39 7 2.4±0.1 −0.003±0.062 0.07±1.35 8 2.8±0.1 −0.002±0.074 0.04±1.22 9 6.1±0.3 −0.02±0.14 0.1±1.2 10 5.7±0.3 −0.009±0.142 0.09±1.39
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PROGRAMMABLE MAGNETIC ATTRACTIVE MATERIALS: AN APPROACH FOR SHAPE-CHANGING CARS’INTERIORS
Proofs of concept videos QR code
FIGUREA.3: QR code for the demonstration video of oscillating magnets proof of con-cept
Chapter 6 appendix
Prototypes experimental videos QR code
(A) Waveform generator prototype QR code for
videos with various frequencies and amplitudes (B) Arduino based prototype QR code FIGUREA.4: QR codes for the demonstration video of the two prototypes with the coil
FIGUREA.5: QR code for a demonstration video of the Rotating magnets prototype
A. ADDITIONAL FIGURES,TABLES AND GRAPHS 77 Oscilloscope videos of Arduino-based prototypes QR code
(A) OP07 OpAmp QR code (B) Low-noise amplifier QR code FIGUREA.6: QR code for the oscilloscope videos with and without the coils presence in
the circuit
Appendix B
Arduino scripts for prototypes experimentation
Single coil prototype
1 int t = 0;
2 unsigned long T1 = 0;
3 unsigned long T;
4 //Seno(Amp, freq, phase) 5
6 void setup() { 7 }
8
9 void loop() { 10 T = millis();
11 if (T - T1 < 16000) {
12 t++;
13 analogWrite(4,seno(1,1,0));
14 }
15 else if (T - T1 >= 8000 && T - T1 < 16000) {
16 t++;
17 analogWrite(4,seno(.5,1,0));
18 }
19 else if (T - T1 >= 16000 && T - T1 < 30000) {
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PROGRAMMABLE MAGNETIC ATTRACTIVE MATERIALS: AN APPROACH FOR SHAPE-CHANGING CARS’INTERIORS
20 t++;
21 analogWrite(4,seno(1,.3,0));
22 }
23 else if (T - T1 >= 30000 && T - T1 < 50000) {
24 t++;
25 analogWrite(4,seno(1,7,0));
26 } 27 else { 28 T1 = T;
29 } 30 } 31
32 int seno(float A, float f, int p) {
33 int a = (A*sin( (f * t + p) * PI / 180 ) + 1) * 100; //offseted and multiplied by 100 to obtain integer values all above zero 34 int a1 = map(a, 0, 200, 0, 255); //map to analog outputs
35 return a1;
36 }
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