Vehicle Fairing Integrated PCB Electrical Routing
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Solution Overview
Problem
Conventional aircraft electrical routing systems are complex, heavy, occupy significant space, and have long installation times due to numerous components and cable harnesses, which also compromise aerodynamic performance by requiring additional fairing structures on the wing.
Innovation Solution
A vehicle fairing with an integrated printed circuit board (PCB) electrical routing system, where the PCB forms part of the outer surface and includes multiple substrate layers with conductive paths for signal and power transmission, providing a unitary assembly that is lighter, smaller, and quicker to install, with reduced components and no need for additional fairings.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional cable harnesses and raceways are used for electrical routing, then reliable power and signal transmission is achieved, but weight, volume, and device complexity increase significantly
Solution Approach 1:
The patent merges the electrical routing function directly into the fairing structure by integrating a printed circuit board (PCB) within the fairing's substrate. This consolidation eliminates the need for separate cable harnesses, raceways, and mounting brackets, thereby reducing device complexity while maintaining reliable electrical transmission between components such as fuel pumps and flight control systems
Solution Approach 2:
The fairing structure is designed to serve multiple functions simultaneously: it provides aerodynamic coverage, structural support, and integrated electrical routing through the PCB. This multi-functionality reduces the overall number of components needed in the system, addressing the complexity issue while preserving reliable electrical connections
2Object-affected harmful factors
If conventional cable harnesses with protective sleeves and braided mesh are used, then mechanical and electromagnetic protection is provided, but weight and volume increase
Solution Approach 1:
The protective functions previously requiring separate cable harnesses with braided mesh and sleeves are integrated directly into the fairing structure. The PCB is embedded within the fairing's substrate, which provides both mechanical protection and structural support, thereby eliminating the weight of redundant protective components while maintaining protection against mechanical damage and electromagnetic interference
Solution Approach 2:
The fairing substrate is constructed from composite materials that provide both mechanical strength and electromagnetic shielding properties. This allows the structure to protect the PCB and electrical connections without requiring additional heavy protective layers, thus reducing overall weight while maintaining protection against harmful factors
3Object-affected harmful factors
If additional fairing structures are disposed on the wing to cover external cables, then cable protection and aerodynamic performance are improved, but aerodynamic drag increases
Solution Approach 1:
The electrical routing is merged into the existing fairing structure rather than requiring separate external fairings. The PCB is integrated within the substrate of the fairing that already covers the wing surface, eliminating the need for additional protruding fairing structures and thus reducing aerodynamic drag while maintaining cable protection and aerodynamic performance
4Ease of operation
If conventional cable routing methods are used, then flexible cable installation is achieved, but installation time and labor complexity increase
Solution Approach 1:
The electrical routing paths are pre-defined and integrated into the fairing substrate during manufacturing, with the PCB already positioned and connected to appropriate terminals. This preliminary action eliminates the need for time-consuming on-site cable routing, clipping, and securing operations, thereby reducing installation time while maintaining the flexibility needed for proper electrical connections
Data Source
AI summary
A vehicle fairing includes an electrical routing for conducting power and/or control signals between spaced-apart components of a vehicle structure. The vehicle fairing includes an outer surface configured to form part of an outer surface of a vehicle body. The electrical routing includes a printed circuit board having a substrate and a first conductive path for conduction of electrical current or signals provided on the substrate. The substrate is substantially rigid and forms at least a portion of the outer surface of the vehicle fairing.