3D Electromechanical Component With Embedded Wire Skeleton
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Solution Overview
Problem
Existing methods for manufacturing 3D electromechanical components with embedded electrical conductors face limitations in mechanical robustness, conductive properties, and design complexity, particularly when integrating conductive meshes, leading to restricted applications and high production costs.
Innovation Solution
A method involving additive manufacturing to create a conductive skeleton within a structural hull, followed by filling with an insulating material and solidification, allowing for high mechanical robustness and optimized electrical conductivity, with sacrificial bridges for temporary mechanical and electrical connections.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conductive mesh is embedded in layer-by-layer AM substrate, then electrical conductivity is improved, but mechanical robustness deteriorates
Solution Approach 1:
The conductive element is segmented into discrete wire segments rather than continuous mesh, allowing strategic placement that maintains electrical connectivity while preserving mechanical integrity of the substrate structure
Solution Approach 2:
Sacrificial bridges are introduced as intermediary elements that temporarily support the conductive wire during manufacturing, then are removed to create clean electrical connections without compromising the mechanical structure
2Adaptability or versatility
If conductive wire is embedded in layer-by-layer fashion, then electrical functionality is achieved, but design and fabrication complexity increases
Solution Approach 1:
The conductive wire embedding process is merged with the additive manufacturing process itself, allowing both structural and electrical features to be created in a single integrated fabrication sequence rather than separate steps
Solution Approach 2:
Sacrificial bridges are pre-positioned at strategic locations before conductive wire placement, establishing a template that guides wire routing and simplifies the embedding process by eliminating complex real-time alignment requirements
3Reliability
If mesh is integrated in substrate, then electrical conductibility is improved, but current density decreases
Solution Approach 1:
Conductive wires are placed locally at specific high-current pathways rather than distributing conductive material uniformly throughout the substrate, concentrating current carrying capacity where needed while maintaining overall electrical functionality
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The method produces components with enhanced mechanical and electrical properties, enabling complex designs suitable for large-scale manufacturing and diverse applications, reducing assembly complexity and costs.
Implementation Method 1
implementing a solidification step to provide a solid-like behaviour of the insulating material
Data Source
AI summary
Method for manufacturing a 3D electromechanical component, having at least one embedded electrical conductor, comprising the steps consisting in:implementing an additive manufacturing operation for building an electrically conductive skeleton of the 3D electromechanical component including a structural hull and at least one conductive wire at least partially located inside the structural hull and having first and second ends, at least one of which is mechanically linked to the structural hull;filling the structural hull with an insulating material provided in a state in which it exhibits liquid-like behaviour;implementing a solidification step to provide a solid-like behaviour of the insulating material, the latter thus embedding at least partially an electrical conductor.