Adhesive Electrical Interconnection System for Modular Wiring
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Solution Overview
Problem
Current modular electrical systems require significant labor and materials for connecting modules to an electrical service panel or devices, as they necessitate the use of junction boxes and individual connectors, which complicates the installation process.
Innovation Solution
An electrical interconnection system featuring partially insulated conductors embedded within a membrane with an exposed conductive surface, allowing for adhesive attachment and electrical connection of modules, along with an insulating adhesive for environmental protection and a peel-and-stick installation method.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional wiring methods with male and female connectors and junction boxes are used to connect modules to electrical panels, then reliable electrical connection is achieved, but installation time and labor requirements increase significantly
Solution Approach 1:
The patent combines the electrical connection function and mechanical attachment function into a single integrated connector assembly. The connector includes conductive elements that electrically connect modules to the electrical panel while simultaneously providing mechanical mounting, eliminating the need for separate wiring steps and junction boxes.
Solution Approach 2:
The connector assembly serves multiple functions: it provides electrical conduction between modules and the panel, mechanical attachment of modules to the mounting surface, and structural support for the wiring. This multi-functional design reduces the number of components and installation steps required.
2Reliability
If traditional wiring methods with individual connectors and junction boxes are used, then proper electrical connection is achieved, but the number of components and materials required increases
Solution Approach 1:
The patent merges multiple separate components (individual connectors, junction boxes, and wiring) into a single integrated connector assembly. This consolidation reduces the total number of components required while maintaining reliable electrical connections between modules and the electrical panel.
3Reliability
If wiring is run along the backside of modules or inside wiring chases, then electrical connections are established, but the complexity of installation and the number of materials required increase
Solution Approach 1:
The patent extracts the wiring from separate routing paths (backside routing or wiring chases) and integrates it directly into the connector assembly itself. The conductive elements are built into the connector structure, eliminating the need for separate wiring routes and reducing installation complexity.
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
This system simplifies the installation of electrical modules by enabling simultaneous connection and attachment, reducing labor and materials needed for physical connectors, while providing a protected and efficient pathway for electrical conduction.
Implementation Method 1
The adhesive coating provides an electrical connection between the conductive surface and the electrical module contacts
Implementation Method 2
an electrically insulating adhesive coating a surface area between a first side of the membrane and the electrical modules, creating an air tight and moisture tight seal encapsulating the electrical connection area
Data Source
AI summary
An electrical interconnection system is disclosed. An electrically conductive material is embedded into a membrane providing both an electrical pathway to connect multiple electrical modules and a connection system to connect the modules to the membrane. Electrical modules are connected to the membrane by removing a protective backing material from an adhesive area covering electrical contacts on a bottom side of an electrical module, and adhering to an adhesive area on the membrane, connecting the contacts to the electrically conductive material in the membrane. No external wiring, connectors or devices are required to make the electrical connection between the modules and the membrane. Contacts are integral and embedded into the surface of each individual module. The modules have adhesive on the back to allow them to be adhesively attached to the membrane without any additional mounting hardware.