Conductive Sandwich Panel with Insulating Mediator
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Solution Overview
Problem
Existing electrically conductive sandwich panels are fragile, difficult to work with, and offer inadequate fire protection, leading to a high risk of electrical device malfunction due to poor electrical contact when LED device pins are inserted.
Innovation Solution
A sandwich panel design featuring alternating layers of cardboard with insulating material, electrically conductive layers, and insulating material, with specific gluing and connector configurations to ensure reliable electrical contact and easy installation, along with self-drilling screws for secure fixing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a first layer of polyurethane foam is used in the sandwich panel, then the panel structure is simple and easy to manufacture, but the panel becomes fragile and difficult to work with, and fire protection is inadequate
Solution Approach 1:
The patent replaces the homogeneous polyurethane foam layer with a composite plasterboard structure consisting of two cardboard sheets trapping an electrically insulating material. This composite structure provides improved mechanical strength, fire resistance, and electrical insulation while maintaining ease of manufacture through standard building materials
Solution Approach 2:
The patent changes the material parameters of the first layer from polyurethane foam to plasterboard with specific thickness requirements (at least 12.5mm). This parameter change improves fire protection rating and mechanical strength while the cardboard sheets provide structural integrity for working with the panel
2Temperature
If the first layer of polyurethane foam is replaced with a plate applied directly against the power supply track, then fire protection is improved, but the electrical contact between the pin and power supply track is lost due to deformation of the plate
Solution Approach 1:
The patent introduces a second layer of electrically insulating material positioned between the plasterboard and the power supply track. This intermediary layer acts as a mediator that prevents direct contact between the deforming cardboard sheet and the electrical track, ensuring reliable electrical contact while maintaining fire protection
Solution Approach 2:
The multi-layer composite structure with alternating insulating and conductive layers provides both fire resistance from the plasterboard and reliable electrical contact through the controlled insulation layers, resolving the contradiction between fire safety and electrical reliability
3Strength
If the second sheet of cardboard deforms into a cone when the pin is inserted, then the plate provides structural support, but the pin is isolated from the power supply track by the deformed cardboard sheet
Solution Approach 1:
The second layer of electrically insulating material serves as an intermediary that separates the deforming cardboard sheet from the power supply track. This allows the cardboard to deform for structural support while the insulating layer ensures the pin maintains electrical contact with the track
Solution Approach 2:
The panel is segmented into distinct functional layers: the plasterboard for structural support, the second insulating layer for electrical isolation, and the conductive layers for power supply. This segmentation allows each layer to perform its specific function without interfering with others
Data Source
Figure 1~2
Figure 3
Figure 4~5
AI summary
The invention relates to an electrically conducting sandwich panel (10) allowing the powering of at least one electrical device that is to be plugged into the panel. Said sandwich panel (10) comprises two electrically conducting layers (13, 15) which are insulated from one another and a layer (11) formed of a board (12, 14) insulated from said electric layers. Said board comprises two sheets (111, 112) of cardboard enclosing an electrically insulating material such as plaster. Connectors are used to connect the electrically conducting wires to an electrical power supply. The panel can be screwed to a support using suitable screws and may be equipped with a suitable electrical device. A hole making tool allows plugging the electrical device into the panel to be performed with greater ease.