David Savastano, Editor11.03.10
There is plenty of discussion about the opportunities for printed electronics (PE), but one of the major keys will be the interest PE generates from leading printers and converters. When a major converter showcases PE technology, that is big news.
Working in conjunction with Blue Spark Technologies, a leader in the printed battery field, and Novalia, a leading PE designer, GPI produced a box of cookies that transforms into an interactive toy fire truck after the cookies are consumed. A film-based flexible circuit consists of a programmable microchip, an eco-friendly flexible printed carbon-zinc battery, a piezoelectric speaker and conductive ink-based printed graphics and connectors. The design is compatible with high-speed automated packaging lines.
Alan Fontaine, R&D new business development manager for Graphic Packaging International, said that GPI has been working on developing printed circuits for at least eight years, and has been collaborating with Blue Spark and Novalia on the technology.
“We wanted to see what kind of reaction we got for this piece, and I am quite surprised to be one of the finalists,” Fontaine concluded. “Blue Spark and Novalia are great to work with, and I think we have made a lot of progress. I hope to see this in production by the first quarter of 2011.”
“We were really pleased about the 2020 Project. In essence, we are looking at how to create a product experience rather than just a technology,” Dr. Kate Stone, director of Novalia, said. “Together with Graphic Packaging and Blue Spark, we were able to design a carton that becomes a fire truck. We have also designed a carton that becomes a toy piano, which is very holistic and an experience that will totally intuitive. For us, an important challenge is getting the demos into the hands of companies, who can then show their customers what we can do.”
Matt Ream, vice president marketing, Blue Spark Technologies, said that the fire truck measures 2.5 inches by 6 inches, and has a little ladder as well as seven different switches.
“We submitted an interactive fire truck, which married traditional packaging with printed electronics,” said Ream. “The fire truck doubles as a cookie or candy box, and has printed circuits built in that play different sounds when you press down on the buttons. The package becomes a toy once the food is finished. This could be a tremendous differentiator.”
Fontaine noted that these printed devices will be priced as a premium item, and one of the major challenges is making sure that these products are fully functional when they reach the consumer.
“The biggest concern is whether every item will be fully functional once it reaches the consumer,” Fontaine said. “We are putting quite a lot of time and money into making sure everything works well, and we are doing a distribution study to make sure that these products work properly after they go through the whole supply chain to reach the market.”
“We have to design the product for end-users, but it must also be able to go down the production line,” Dr. Stone added.
Fontaine said that customers are noticing the potential for printed electronics, and it is critical to be able to bring these technologies to the market.
“Printed electronics is an emerging technology,” Fontaine said. “We have been working on developing printed circuitry for packaging, first using etched metallization and then conductive inks. Printed electronics are challenging, but if you do your homework up front, it is doable.
“We are concentrating our efforts on custom designed electronics using printed batteries,” Fontaine added. “Printed electronics are going to happen, and we want to be ready to offer solutions to our customers. We are getting ready to open it to the marketplace as a promotional item.”