Copper Tine Grid on Plastic Substrate for Insect Control
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Solution Overview
Problem
Existing insect control devices using electrified grids face challenges with material resistance leading to overheating and increased costs due to the need for thicker wires and reduced voltage to prevent fires, limiting their effectiveness and design flexibility.
Innovation Solution
A thin copper tine grid with alternating positive and negative charges adhered to a plastic substrate allows for controlled voltage and amperage, enabling higher voltage operation and flexible design configurations, including cylindrical shapes, using photo chemical etching and specific adhesive and substrate thickness considerations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If steel, stainless steel, nickel or aluminum alloys are used for grid wires, then the grid material is resistant to electrical current and durable, but the voltage is reduced and the wire heats up
Solution Approach 1:
The patent changes the material parameter from high-resistance materials (steel, stainless steel, nickel, aluminum alloys) to low-resistance copper material. This parameter change reduces electrical resistance, allowing higher voltage operation without excessive heating, thereby resolving the contradiction between durability and temperature control
Solution Approach 2:
The patent uses a composite structure combining copper tines (for low electrical resistance) with a plastic substrate (for structural support and insulation). This composite approach maintains grid durability while enabling higher voltage operation without the heating problems of pure metal grids
2Stability of the object's composition
If thicker wires are used to span the gap, then the grid structure is more stable, but the cost increases and assembly becomes more difficult
Solution Approach 1:
The patent employs thin copper tines (0.002 to 0.020 inches thick) adhered to a plastic substrate, replacing the need for thick free-standing wires. The thin film approach maintains structural stability through substrate support while dramatically reducing material cost and simplifying assembly, directly resolving the contradiction between stability and ease of manufacture
3Reliability
If higher voltage is applied to kill larger insects, then the insect killing effectiveness increases, but the wire heating and fire risk increase
Solution Approach 1:
The patent changes the electrical resistance parameter by using copper material with significantly lower resistance than traditional grid materials. This allows the system to operate at higher voltages (1000-6000V) needed to kill larger insects like moths and beetles without the wires overheating to dangerous levels, thus resolving the contradiction between killing effectiveness and fire hazard
Solution Approach 2:
The plastic substrate acts as an intermediary that provides structural support and thermal management for the thin copper tines. This intermediary structure enables the copper tines to carry high voltage currents without overheating, allowing effective insect killing while preventing fire hazards
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 solution effectively eliminates nuisance insects while reducing material costs and preventing overheating, allowing for efficient and versatile insect control device designs.
Implementation Method 1
The grid 1 is designed to be connected to a voltage source 2 and comprises copper tines 3... the copper grid has a very low resistance to electrical current flow
Implementation Method 2
A specially designed grid utilizing very thin copper tines, in a grid pattern, with alternating positive and negative charges that is adhered to a plastic substrate
Implementation Method 3
when the insect contacts the wires it causes a short circuit and allows the electrical current to pass through the insect body and electrocutes the pest
Data Source
AI summary
A copper grid which is attached to a rigid, non-conductive substrate, and configured to be connected to a voltage source such that the grid is electrified for the purpose of controlling insect populations.