Composite Board With Embedded Electrical Conductors
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Solution Overview
Problem
Current composite boards used in construction, such as wood plastic composite and fiberglass boards, do not facilitate easy installation of electrical systems, requiring significant time and expense for contractors to conceal and run wiring within or behind the structure.
Innovation Solution
A composite board with embedded electrical conductors, manufactured using a pultrusion process, allowing for the integration of electrical devices like lights and power supplies directly into the board, eliminating the need for extensive wiring installation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If traditional composite boards are used, then structural integrity and durability are maintained, but electrical wiring installation becomes complex and time-consuming
Solution Approach 1:
The patent combines electrical conductors directly into the composite board structure during manufacturing. The conductors are embedded within the board layers, merging the structural and electrical functions into a single integrated component, thereby eliminating separate wiring installation steps
Solution Approach 2:
The electrical conductors are pre-installed and positioned within the composite board during the manufacturing process. This preliminary action of embedding conductors before the board is installed in the structure eliminates the need for subsequent wiring work, saving time and reducing installation complexity
2Productivity
If electrical wiring is installed after structure construction, then structural integrity is maintained, but construction time and expense increase significantly
Solution Approach 1:
The electrical conductors are pre-installed and positioned within the composite board during the manufacturing process. This preliminary action of embedding conductors before the board is installed in the structure eliminates the need for subsequent wiring work, saving time and reducing installation complexity
Solution Approach 2:
The patent combines electrical conductors directly into the composite board structure during manufacturing. The conductors are embedded within the board layers, merging the structural and electrical functions into a single integrated component, thereby eliminating separate wiring installation steps
3Ease of manufacture
If composite boards without embedded conductors are used, then manufacturing simplicity is maintained, but electrical system integration becomes tedious and expensive
Solution Approach 1:
The patent combines electrical conductors directly into the composite board structure during manufacturing. The conductors are embedded within the board layers, merging the structural and electrical functions into a single integrated component, thereby eliminating separate wiring installation steps
Solution Approach 2:
The composite board serves multiple functions simultaneously: it provides structural support while also serving as an electrical conduit. The embedded conductors enable the board to function both as a building material and as an electrical distribution medium, reducing the need for additional wiring infrastructure
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
Enables efficient and cost-effective integration of electrical systems into composite boards, reducing construction time and enhancing the structural integrity and aesthetic appeal of outdoor structures like decks and walkways.
Implementation Method 1
pulling reinforcing fibers or matting through a vat of resin and then through a heated die where the resin cures or sets and encases the fibers
Data Source
AI summary
A board fabricated from a composite material that can be used to build a structure. Electrical conductors may be embedded into the board to distribute electric power to electrically powered devices attached to the board. The board may further comprise elongated supports that can be used to partially enclose threaded fasteners. A plurality of cavities may be formed above the supports so that a fastener head can be recessed into each cavity to allow for a relatively planar upper surface.