Multilayer Printed Circuit Power Control Unit for Home Automation
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Solution Overview
Problem
Existing home automation electrical units face challenges in ensuring effective insulation and safety between low voltage power circuits and very low voltage control circuits, while also minimizing heat generation and maintaining a compact design, especially when handling high currents in power lines.
Innovation Solution
The use of printed circuit technology with conductive and insulating layers to create a multilayer printed circuit board that integrates both power and control circuits, where conductors for different power lines are superimposed over parts of their length, and laminated conductors with junctions and chimneys to manage electrical connections and heat distribution.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional wiring with metal blades and plastic coating is used for power line connections, then insulation between power lines is provided, but the installation complexity and cost increase, and the insulation quality is insufficient
Solution Approach 1:
The patent combines multiple functions (conduction, insulation, connection, and mechanical support) into a single integrated printed circuit board structure. The PCB integrates the metal blades, plastic coating, and structural framework into one component that performs all necessary functions simultaneously, eliminating the need for separate insulation materials and simplifying installation while enhancing insulation reliability through factory-prepared quality control
Solution Approach 2:
The patent replaces the manual mechanical assembly of separate wiring components (metal blades requiring manual attachment and separate plastic insulation coating) with an automated printed circuit board manufacturing process. The PCB uses standardized electrical connection techniques and automated manufacturing methods to achieve precise, reliable insulation and conduction without manual intervention, thereby reducing installation complexity and improving insulation quality
2Temperature
If the block volume is reduced to minimize heating, then the space for heat dissipation decreases, but the amperage handling capacity must be maintained
Solution Approach 1:
The patent transitions from two-dimensional planar wiring to three-dimensional stacked PCB layers, allowing conductors to be arranged in multiple vertical levels. This enables compact routing of power lines through the thickness of the PCB rather than requiring lateral space, thereby reducing the overall block volume while maintaining adequate current carrying capacity and heat dissipation pathways through the layered structure
Solution Approach 2:
The patent nests multiple conductors and insulation layers within the thickness of the PCB, similar to nested dolls. The multilayer structure allows conductors to be embedded within the PCB substrate with insulation layers interspersed between them, maximizing the use of vertical space and reducing the lateral footprint and overall volume of the block while maintaining electrical performance and heat dissipation capabilities
3Reliability
If multilayer printed circuit with superimposed conductors is used, then insulation between power lines is enhanced and volume is reduced, but manufacturing complexity increases
Solution Approach 1:
The patent employs standardized multilayer PCB manufacturing techniques that are widely used in the electronics industry. The same PCB fabrication processes (lamination, etching, drilling, plating) used for conventional circuit boards are applied here, allowing the multilayer structure with superimposed conductors to be manufactured using existing, well-established industrial methods rather than requiring new or specialized manufacturing processes, thereby limiting the increase in manufacturing complexity
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 solution provides enhanced insulation, reduced installation complexity, and lower heating issues while allowing higher amperage without increasing the unit's size, ensuring safety and efficiency in controlling power lines with very low voltage circuits.
Implementation Method 1
the conductor of at least one electric power line is in the form of a printed circuit, that is to say at least one track of conductive material and of at least one insulating layer on which said track rests
Implementation Method 2
for all the power lines of the block, the conductor is in the form of a printed circuit, the conductors of at least two lines electrical, and preferably the conductors of all the electrical lines, forming part of the same printed circuit board that comprises the block, and in that for at least two electrical power lines, the conductor of a power line is superimposed to the conductor of another power line, over at least part of their length
Implementation Method 3
a conductor extending substantially from the first terminal to the second terminal and helping to put the first connection terminal and the second connection terminal into electrical communication
Data Source
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AI summary
The present invention relates to an electrical block comprising at least two power lines whose state it controls, a very low voltage circuit for its control, and, for each power line, firstly, a first connection terminal (3) located on one face of the electrical block, and a second connection terminal (5) located on a second face of the electrical block; and secondly, a conductor (7) extending substantially from the first terminal (3) to the second terminal (5) and serving to electrically connect the first connection terminal (3) and the second connection terminal (5). This electrical block is characterized in that the conductor (7) of each power line is in the form of a printed circuit board, with the conductors (7) of different lines being superimposed.