Embedding Electronics in Surface Materials Using Sacrificial Scaffold

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Existing methods for embedding electronics into translucent or transparent surface materials, such as countertops, face challenges in maintaining the precise positioning of light sources and ensuring reliable power and data connections, leading to potential misalignments and functional issues.

Innovation Solution

Embedding electronic components like LED-based light sources, sensors, and control circuitry during the manufacturing process of surface materials using a scaffold or frame, with conductive elements like rails or wire mesh for power and data connectivity, accessible through methods like routing or drilling, to ensure precise placement and functionality.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If light sources and electronics are embedded in surface materials, then functional lighting and control capabilities are added, but positioning precision and alignment accuracy deteriorate due to potential shifting during manufacture

Engineering Contradiction:

Improvefunctional lighting capabilityVSAvoidpositioning accuracy

Core Design Contradiction:

Adaptability or versatilityVSManufacturing precision

Solution Approach 1:

The scaffold or frame structure is positioned and secured in the surface material before the material is fully manufactured. This preliminary placement ensures that the light sources and electronics are held in their correct positions throughout the manufacturing process, preventing shifting and ensuring alignment accuracy is maintained while adding functional lighting capabilities.

Inventive Principle:

Principle #10Preliminary action

2Manufacturing precision

If rigid holding methods are used to maintain component position, then positioning accuracy is improved, but ease of manufacture deteriorates due to additional complexity in the manufacturing process

Engineering Contradiction:

Improvecomponent position stabilityVSAvoidmanufacturing process complexity

Core Design Contradiction:

Manufacturing precisionVSEase of manufacture

Solution Approach 1:

A scaffold or frame structure serves as an intermediary element that facilitates the embedding of light sources and electronics. This intermediary structure provides the necessary rigid holding to maintain positioning accuracy while being designed to work seamlessly with the surface material manufacturing process, thereby avoiding excessive complexity and maintaining ease of manufacture.

Inventive Principle:

Principle #24Intermediary (Mediator)

3Reliability

If conductive elements are embedded for power and data connections, then reliability of electrical connections is improved, but device complexity increases due to additional interconnection requirements

Engineering Contradiction:

Improveelectrical connection reliabilityVSAvoidinterconnection structure complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The conductive elements for power and data connections are merged with the scaffold or frame structure and integrated into the surface material matrix. This merging approach ensures reliable electrical connections while minimizing the additional complexity, as the conductive elements serve dual purposes: structural support and electrical interconnection.

Inventive Principle:

Principle #5Merging (Combining)

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 approach allows for the creation of high-quality, aesthetically pleasing and functionally reliable lighted surfaces with embedded electronics, ensuring accurate positioning and reliable power/data connections, enhancing both the aesthetic and functional quality of the finished products.

Implementation Method 1

a scaffold or frame constructed of a sacrificial material, the same material as the finished surface material and/or another material used in the manufacture of the finished product

Methodology Applied

Scientific EffectSacrificial material dissolution/burning:

Implementation Method 2

conductive elements conductively connected to the plurality of embedded units

Methodology Applied

Scientific EffectElectrical conduction: Conduction (electrical)

Data Source

PatentUS7543956B2Configurations and methods for embedding electronics or light emitters in manufactured materials

Publication Date: 2009.06.09 SIGNIFY NORTH AMERICA CORP

AI summary

Methods and means for embedding electronic components, such as LED-based light sources and associated control circuitry, into molded or continuously cast surface materials (e.g., material manufactured under the trademark CORIAN®). During the manufacture of the surface material, the components can be held in position using a scaffold or frame constructed of a sacrificial material, the same material as the finished surface material and/or another material used in the manufacture of the finished product. The embedded components can include control circuitry, e.g., printed circuit boards, for separately controlling each component, power conductors and data busses. Conductors and/or busses can be in the form of conductive rails, wire mesh or sheets. Access to the conductors in the finished product can be made by a number of methods, including but not limited to sanding, grinding, drilling into, screwing into, and/or inserting pins into the finished material.