Feature: Sustainable electronics
Figure 1: On-Mould Sustainable Electronics (OMSE) integrating electronic systems through highly-recyclable Flexi-Hibrid technologies – the PCBA is seen just above the number plate; also, see Figures 2-6
and interior of vehicles, the more we need to think about their end-of-life recyclability. The idea that recycling electronics is a good thing the way we do it today simply does not hold true. We need to find solutions for full circularity, to reuse parts at their end of life rather than discard them. We must preserve our world’s finite resources, and the automotive market has an obligation, with its ever- increasing appetite for electronics, to move the game on.
What are the solutions? Today, the conventional go-to method is a very predictable mix of separate electronic units and sensors that are connected with a wiring harness. All these components are produced separately, shipped individually to the OEM, and installed on dedicated mounting systems. The connection system is a standard harness, with connectors for each component or group of electronics, heaters and sensors. There is a growing trend in the industry toward in-
mould electronics to deliver the end goal. The technology essentially injection-moulds a three-dimensional shape around a printed electronic foil, embedding the conductors and electronic components into the unit, producing a single part in a highly protected environment. The gains from this approach are significant. A lifecycle
assessment (LCA) shows a demonstrable reduction in transport costs of individual items and materials, as well as the energy needed to produce a full shield. At first, this seems the panacea to the integrated shield design. However, the technology does not lend
Figure 3: A close-up of the circuit built into car showing components and receptive moulded cavities
Figure 2: Multi-layer Flexi-Hibrid circuit assembly, ReUSE sealed and bonded to inner form of moulded shield
www.electronicsworld.co.uk October 2023 37
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