Integrated Electrical Component in Decorative Laminate
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Solution Overview
Problem
Conventional decorative laminates lack integration of electrical components, which limits their functionality and durability, particularly under high-pressure lamination processes where the risk of electrical component breakage and delamination is high.
Innovation Solution
A laminate with an integrated electrical component is created by forming via holes through a paper layer, depositing electrically-conductive layers, and encapsulating the component within the laminate using a high-pressure lamination process, ensuring electrical coupling and protection of the component.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If electrical components are integrated into decorative laminates, then functionality and electrical conductivity are improved, but the risk of component breakage and delamination increases under high-pressure lamination processes
Solution Approach 1:
The laminate is divided into multiple discrete layers (decorative layer, carrier layer, overlay layer) with the electrical component positioned between specific layers. This segmentation allows the electrical component to be protected from direct exposure to high-pressure lamination forces while maintaining integration within the laminate structure, thereby resolving the contradiction between functionality and component durability.
Solution Approach 2:
Protective structures are incorporated into the laminate design before the lamination process to cushion and protect electrical components from breakage during high-pressure lamination. The multi-layer construction with strategically positioned layers acts as a protective buffer, allowing the laminate to undergo high-pressure processing without damaging the integrated electrical components.
2Strength
If high-pressure lamination process is used to create laminate, then wear resistance and structural integrity are improved, but electrical component breakage and delamination risk increases
Solution Approach 1:
The electrical component is nested within the laminate structure, positioned between the decorative layer and carrier layer, and further protected by the overlay layer. This nested arrangement allows the laminate to achieve high structural integrity through high-pressure lamination while the electrical component remains protected within the nested layers, preventing breakage and delamination.
Solution Approach 2:
The multi-layer laminate structure provides beforehand cushioning for the electrical component, with each layer acting as a protective buffer against the high-pressure lamination forces. This pre-arranged protective structure allows the laminate to achieve superior wear resistance and structural integrity without exposing the electrical component to harmful pressure levels.
3Reliability
If electrical components are embedded within laminate layers, then durability and environmental resistance are improved, but manufacturing complexity increases
Solution Approach 1:
The electrical component is positioned between the decorative layer and carrier layer before the lamination process begins. This preliminary positioning allows the component to be integrated into the laminate structure in a single manufacturing step, achieving environmental resistance through encapsulation without requiring complex post-processing or assembly operations.
Solution Approach 2:
The integration of the electrical component is merged with the laminate manufacturing process itself. By positioning the component between layers before lamination and using the high-pressure process to simultaneously bond the layers and encapsulate the component, the manufacturing complexity is minimized while achieving superior environmental resistance and durability.
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 enhances electrical conductivity, durability, and resistance to environmental factors, allowing for the integration of electrical components into decorative laminates while maintaining aesthetic and functional properties.
Implementation Method 1
A high-pressure laminate process (HPL) is an irreversible thermal process wherein resin-impregnated sheets of kraft paper undergo a simultaneous pressing and heating process at relatively high levels of heat and pressure, such as temperatures greater than or equal to 125° C. and at least 5 mega Pascals (MPa) of pressure
Implementation Method 2
The first electrically-conductive layer is electrically coupled to the first via and the first electrical terminal, the second electrically-conductive layer is electrically coupled to the second via and the second electrical terminal
Data Source
AI summary
A laminate having an integrated electrical component disposed within the laminate is disclosed. The laminate includes a first paper layer having at least first and second vias through the first paper layer; a first electrically-conductive layer, comprising an electrically-conductive material, disposed over a portion of the first paper layer; a second electrically-conductive layer, comprising the electrically-conductive material, disposed over another portion of the first paper layer; an electrical component disposed over the first and second electrically-conductive layers; and an insulating layer disposed over the electrical component. The first paper layer and the insulating layer encapsulate the first electrically-conductive layer, the second electrically-conductive layer, and the electrical component. The first and second vias are in electrical contact with the first electrically-conductive layer and a first terminal of the electrical component, and with the second electrically-conductive layer and a second terminal of the electrical component, respectively.