Covering Element Conductive Layer Folding for Integrated Electrical Contact
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing covering elements with electrical functionality require complex and costly cabling for connections, leading to high production costs and installation complexity when used as floor, wall, or ceiling coverings.
Innovation Solution
A method where an electrically conductive functional layer is applied to the base body of covering elements, with its side edge protruding beyond the bearing surface and folded over onto the base body's side face, enabling electrical contact through tongue-and-groove connections, eliminating the need for visible cabling and reducing production costs by up to 20%.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If cabling is used to connect covering elements for electrical functionality, then electrical connection is achieved, but installation complexity and production costs increase significantly
Solution Approach 1:
The patent combines the electrical connection function with the mechanical tongue-and-groove connection structure. The conductive functional layer is integrated into the base body such that when two covering elements are mechanically connected via tongue-and-groove, electrical contact is simultaneously established between adjacent elements, eliminating the need for separate cabling systems.
Solution Approach 2:
The covering elements automatically establish electrical connection through their own structural design. The folded-over conductive functional layer on the side edges creates self-contact when elements are assembled, requiring no external wiring or additional connection components.
2Reliability
If cabling is used to connect covering elements, then electrical functionality is provided, but production costs increase by up to 20%
Solution Approach 1:
The patent merges the electrical conduction function with the existing base body structure by integrating the conductive functional layer directly into it. This eliminates the need for separate cabling materials and reduces manufacturing steps, thereby lowering production costs while maintaining electrical functionality.
Solution Approach 2:
The patent extracts the electrical connection function from the complex cabling system and concentrates it into the simplified folded functional layer structure on the side edges, reducing material usage and manufacturing complexity.
3Ease of operation
If the functional layer is folded over onto the side face, then electrical contact is simplified, but the folding process adds manufacturing steps
Solution Approach 1:
The conductive functional layer is pre-positioned and folded over onto the side face during the base body formation process, before final assembly. This preliminary action ensures the conductive surface is ready for contact without requiring additional folding operations during manufacturing.
Solution Approach 2:
The folding of the functional layer is combined with the tongue-and-groove connection geometry formation in the same manufacturing process, eliminating separate operations and maintaining manufacturing efficiency while achieving the electrical contact configuration.
Data Source
Figure 1A
Figure 1B~1C
Figure 2
AI summary
The invention relates to a method for manufacturing a covering element (1), wherein corresponding tongue-and-groove connection geometries (4), preferably in the form of click connections, are incorporated into a base body (2) of the covering element (1) at at least one side edge (3), preferably at opposite side edges (3), and wherein at least one electrically conductive functional layer (5) is arranged on a bearing surface (6) of the base body (2). According to the invention, the functional layer (5) is applied and/or the tongue-and-groove connection geometry (4) is incorporated into the base body (2) such that at least one side edge (7) of the functional layer (5) projects beyond the bearing surface (6), and the side edge (7) of the functional layer (5) projecting beyond the bearing surface (6) is folded over onto at least one end face (8) of the base body (2).