Electroluminescent Cap Project

1. Electroluminescent Cap Project Milestone # 2-Project Proposal Faculty Advisor/Reviewers: Dr. Michael Frank Dr. Bing Kwan Dr. RajendraArora Team Members:Monica Pereira Monique Peregrina Liang Liufu IfedayoOgundana Sponsored by: Albert Daci

2. Project Management

3. The Team & their Qualifications Monica PereiraProject ManagerArea of expertise: advanced circuit design, electronics, power analysis. Monique Peregrina Assistant Project Manager/Documentation CoordinatorArea of expertise: advanced circuit design, electronics, power analysis. Liang LiufuTreasurerArea of expertise: advanced circuit design, electronics, computer architecture IfedayoOgundana Head of Research Area of expertise: Microprocessors, Computer System Architecture, Digital Logics, and Digital Communications Monica Pereira

4. Introduction/Overview of the Project • The purpose of this project is to design an original cap that implements electroluminescent technology. This cap will consist of a panel with flashing capabilities and with a hidden internal circuit. • Currently, there are a few similar designs in the market that implement electroluminescent wires, panels and tapes. However, the current designs have a bulky circuit while others have their wires and/or switches exposed in the back. • The design proposed by this team, would implement small rechargeable batteries in order to reduce the size of the overall circuit and use small components in order to make the cap comfortable while providing a slim design. • Each cap will implement a switch with three states (turn on, flash, turn off) and be provided with an internal circuit with water resistant capabilities. In addition, the cap will come with a mini-USB charger hidden underneath the bill of the cap. Monica Pereira

5. Intended Use, Users & Operating Environment • USE: The cap is designed to be used for everyday activities. It will be required to resist exposure to dusty conditions as well as water, sweat and any other agents that may cause excessive dampness within the hat so that it can be worn while being outdoors or performing extraneous activities. • USERS: Any individual from almost any age range can use this product as long as he/she follows the guidelines stated in the user’s manual for handle and care. • OPERATING ENVIRONMENT: The prototype is required to operate under normal conditions since it is intended for regular use. The cap must resist light rain, sunlight exposure, plus any other factors that might follow during daily activities. Monica Pereira

6. Concept generation & Selection

7. Component Selection

8. Approach • The approach followed for selection is based mostly on the size, weight, and ease of implementation of each part, since all of our components must fit within the cap.

9. Design Components • Fitted baseball cap • LiPo rechargeable battery • Battery charger • 10cm x 10cm EL panel • 3V DC battery inverter • IC chip • Liquid Encapsulating epoxy resin

10. Cap Selection Approach • The selection of a cap was carefully done based on its design since this determines how much room (within the inside of this hat) can be used for storing components. • As requested by our sponsor, only fitted caps can be used. Monica Pereira

11. Option 1: Fitted baseball Cap Benefits : • More comfortable for the consumer to wear • Has an easy and relaxed fitting Drawbacks: • Its lower crown may reduce allowed space to conceal circuitry and • Its Curved bill makes it more difficult to attach the switch and the battery charger in the bottom of the bill. Monica Pereira

12. Option 2: Fitted Flat-bill Cap Benefits Has a high crown which allows more room to conceal the circuit without causing discomfort to the user. Its flat bill allows better integration of a switch and mini-USB charger on the front of the hat. Drawbacks: Style may not attract certain users Monica Pereira

13. Battery Selection Objectives • Battery must power the circuit while remaining small and lightweight enough to not hinder the cap. Approach • Several factors must be taken into consideration when choosing this component: weight, size, voltage output, capacity, chemical composition, and availability. Liang Liufu

14. PRT-00339 Lithium Polymer Battery Specifications Dimensions: 0.23” x 1.32” x 1.86” (5.84x34x47mm) Weight: 0.77oz (22g) Nominal Capacity: 1000mAh Nominal Voltage: 3.7V Charge cut-off voltage: 4.20V Standard discharge current 0.2 C • Max discharge Current: 2C • Discharge cut-off voltage: 2.75V • Cell Voltage: 3.7-3.9V • Impedance: <300 Ohms Liang Liufu

15. PRT-00339 Battery Benefits Small and lightweight allows for good implementation into cap Rectangular size allows for easy mounting onto cap without need for battery housing Rechargeable: eliminates the need to buy more batteries, saving money for the consumer Higher capacity allows for longer use per charge Low discharge rate allows for longer storage times before depletion (0.1% per month) Very Stable: No explosion or fire when over charged, over discharged, short circuited, extrusion, and thermal shock. Durable: vibration, collision, and dropping it does not affect performance. Drawbacks Requires a charger and not easily replaced. Slightly larger size might present slight problem in order to fit inside the cap. Extra charger creates an additional component that needs to be added onto the hat Liang Liufu

16. Li-Poly Charger • Four voltage regulation options: 4.2v, 4.35v, 4.4v, 4.5v • Programmable charge current: 15mA to 500mA • Selectable Preconditioning: 10%, 20%, 40%, or disable • Automatic Power Down Specifications Regulated output voltage: 4.20V Precondition current ratio: 10 Precondition voltage threshold ratio: 66.5 Charge termination current ratio: 7.5 Recharge voltage threshold ratio: 96.5 Temperature range: -40C to +85C Dimensions: 29.4mm x 10.8mm Liang Liufu

17. Other Possible Battery Choices Liang Liufu

18. Li-Poly Charger Benefits Much smaller board allows for easier integration into cap Micro USB port is fairly common and can be easily recharged Automatic power down prevents over charging Drawbacks Exposed chip: requires an extra step to encase the chip Extra component that must be concealed within the cap Liang Liufu

19. Li-Poly charger for 3.7v cells, JST 2.0mm model USB-uLIPO • Specifications: • Regulated output voltage: 4.20V Precondition current ratio: 10 • Precondition voltage threshold ratio: 66.5 • Charge termination current ratio: 7.5 • Recharge voltage threshold ratio: 96.5 • Temperature range: -40 – 85C • Dimensions: 29.4mm x 10.8mm • Li-Poly charger, 3.7v mini-USB JST • Specifications: • 5V input via mini-B USB connector • 0.1” breakouts for battery, DC IN, and status LED • 3.7V output to battery • Supports 10k NTC Thermistor which has been filled by a 10k resistor • 0.2oz (5.7g) • Adjustable current by soldering a resistor • Dimensions: 1.3” x 1.4” x 0.3” (33 x 35 x 7mm) Other Possible Chargers Liang Liufu

20. EL Panel Specifications Glow size: 10cm X 10cm (3.95" x 3.95") Plastic Size: 10.4 cm x 10.4 cm (4.1" x 4.1"), about 0.5mm thick Panel lifetime: >25000 hours Operating voltage: 60-250VAC Operating Frequency: 50-5000HZ Current Draw: 0.14mA/cm2 (max) @ 110V / 400Hz Initial Brightness: 75 cd/m2 Operating Temperature: -50ᵒ C / 65ᵒ C 45 nF per panel Liang Liufu

21. EL Panels Benefits Ultra-thin material allows easy concealment within the cap Flexibility allows panels to be stitched to the shape of the cap High efficiency allows for maximum life of batteries Low temperature makes it cool to the touch Can be easily cut to the desired shape Vibration and shock resistant allows it to withstand common wear Can continue to operate even if punctured Drawbacks Cannot be folded: it cannot withstand being folded like a sheet of paper Uses more power than EL wires The connection is not waterproof (it is only heat shrink) Liang Liufu

22. Other EL material choices • EL Wire • Input voltage: 40-110VAC • Input frequency: 400-3000Hz • Electrical Current: <150mA • Twisting Angle: 30 degrees per meter • Bending Diameter: >10mm • Stretching Force: <1.5kg • Operating temperature: -10C – 60C • Operating humidity: <60% • Lifetime: 3000-6000 hours • Storage temperature: 5C – 35C • Storage humidity: <30% • EL Tape • Size: 100 cm x 1.5 cm about 1mm thick. The glowing part is 1cm wide. • Panel lifetime: >25000 hours • Operating voltage: 60-250VAC • Operating Frequency: 50-5000HZ • Current Draw: 0.14mA/cm2 (max) @ 110V / 400Hz • Initial Brightness: 85 cd/m2 • Operating Temperature: -50 C / 65 C • ~10 nF per meter Liang Liufu

23. Battery Inverter Selection Objectives • Select a battery inverter that can provide the necessary amount of AC voltage and current to the EL panel Approach • The first goal is to find an inverter that is small in size. The inverter, as with everything else, must fit easily within the confines of the cap. • The second goal is to find an inverter that can convert the voltage from the battery to 110V AC voltage to power the EL panel. IfedayoOgundana

24. Battery Inverter specifications IfedayoOgundana

25. 3 V ELI-IMC Battery Inverter Specifications External 3V or 1,5V (+/- 20%) power supply (or battery) needed Total EL fiberlength 0m-0.5m (0"-20") Frequency: 2500 Hz Size: 13 mm diameter x 10 mm height (0.5" diameter x 0.4" height) Weight: 2.2 g IfedayoOgundana

26. 3 V ELI-IMC Battery Inverter Benefits Very small size and light weight Can be used with battery and external power supply Suitable for use with both EL wires and panels Drawbacks Low hum noise is produced during operation No on/blink /off switch incorporated Capable of lighting only a small length/area. IfedayoOgundana

27. Timing IC Selection Objectives • Select a 555 Timer IC to control the blinking of the logo. • The IC is required to set a frequency which will allow the EL panel to blink. Approach • Size will be taken into consideration. • Minimal cost if also preferred Monique Peregrina

28. Timing IC Selection Monique Peregrina

29. Model LM555 timer IC (Intersil) Specifications Type: 555 type, Timer/Oscillator (Single) Supply Voltage: 2 V ~ 18 V Current: 60µA Operating Temperature: 0ºC to 70ºC Package/Case: 8-SOIC (0.154”, 3.90mm width) Frequency: 1MHz Monique Peregrina

30. Model LM555 timer IC (Intersil) Benefits Does not present a minimum unit order to be purchased Drawbacks Unit price is higher than other brands presented (for a single unit price is $0.78, for orders greater than 100 units the price drops to $0.38) Monique Peregrina

31. Waterproofing/Insulating component Selection Objectives • Select the best waterproofing and insulating material to encase the circuit within the hat. Approach • The first goal is that the material must be able to cover the entire circuit and remain water resistant even under normal wear and tear. • The second goal is that it must be dielectric because it will prevent any electric current from escaping the circuit which could ultimately cause harm to the consumer. Monique Peregrina

32. Waterproofing/Insulating component Selection Monique Peregrina

33. Specifications Color: black Pot life: 60 minutes Cure cycle: 24 hours at room temperature Viscosity: 11500 cps @ 20ºC Dielectric strength: 19.36 kV/mm Operating temperature range: -60ºC to 140ºC Liquid Encapsulating Epoxy Resin Monique Peregrina

34. Liquid Encapsulating Epoxy Resin Benefits Excellent electrical insulation properties Good storage stability Supports high temperatures Mechanical and impact resistance properties Drawbacks If exposed to great stress, the plastic may break It may shrink when it dries, stressing components in the circuitry Monique Peregrina

35. Proposed Design

36. Overall Circuit Design & Preliminary System Level Design

37. Internal Circuit • To design the circuit itself, the battery will be connected to both the charger as well as the switch. • Switch will be connected to the inverter for ON state and also to the control circuit for BLINK state • The inverter will then be connected to the panel. • The entire circuit will be waterproofed and insulated Monique Peregrina

38. Front View of Cap The logo will not exceed the dimensions of 3 inches by 3 inches. The logo will be cut out of the EL panel and stitched into the fabric. Monique Peregrina

39. Internal View of Cap The switch will be located on the bill of the cap. It will be connected to the inverter and the timing IC. The timing IC and inverter will be on the same PCB. The front of the cap will provide the most space to conceal the two components. The battery charger will be placed on the front underside of the bill. It allows ease of access for the user to plug in the micro-USB connector. The battery component will be placed within the sweat band of the cap and concealed within the layer of fabric. Monique Peregrina

40. Benefits of the Proposed Design • Comfort: circuit is small and unobtrusive to the user. • Ease of use: only one button and a recharger at the bill of the cap will be visible allowing for simple use by consumer. • Compact: by including as many components as possible into one small circuit design, space is saved. • Unit cost: the individual cap will be relatively cheap to manufacture • Waterproofness:with full coverage of the circuit in waterproof material, the risk of water damage will be minimal. • Insulation:the waterproofing material is also a dielectric, which will insulate the user from the circuit. Monique Peregrina

41. Drawbacks • Durability: even though the circuit is designed to withstand light wear and tear due to common use, it is not designed to withstand rough use or extreme weather condition. • Not machine washable Monique Peregrina

42. Risk Assessment

43. Uncertainties at Project Milestones • Required tool kit, components and materials to be used • Features and required capabilities to be incorporated • Incomplete knowledge and technical know-how of the technology • Costs at project milestones • Method and formulation challenges • Construction and Fabrication • Design Specifications • Imagination and Rationality • Technical feasibility IfedayoOgundana

44. Risk Assessment (Cont.) • Human Managerial factor • Physical loss and damage • Circuitry components malfunctioning IfedayoOgundana

45. Schedule

46. Gantt Chart Monica Pereira

47. Gantt Chart(Cont.) Monica Pereira

48. Budget Estimate

49. Liang Liufu

50. Budget Justification The budget is made such that the following is assumed: • $30/hr base salary considering 12hours of work per week (both semesters) • Equal base salary for individuals working on this project • Addition of 29% of the personnel subtotal for fringe benefits • 45% of the total direct costs was added to account for the overhead costs • Expenses for the assembly of the internal circuit is included in extra costs Liang Liufu