Polycarbonate Membrane Drivers Consolidate Control Board Wiring
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Solution Overview
Problem
Conventional methods for assembling electric control boards require significant labor, time, and materials due to the need for multiple cables and holes, which complicates the installation process and increases costs.
Innovation Solution
The use of a polycarbonate membrane with integrated electronic circuits and a five-way cable to replace multiple drivers and cables, utilizing a SLAVE and MASTER module system for communication and control, reducing the number of wires and installation time.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional methods are used to assemble drivers on control board, then each driver can be individually installed and connected, but the number of cables and holes increases significantly, complicating the installation process
Solution Approach 1:
Multiple separate driver connections are merged into a single integrated polycarbonate membrane with embedded conductive traces. The membrane consolidates multiple cables into one unified connection interface, reducing the number of individual cables and holes required while maintaining all necessary electrical connections between drivers and the control board
Solution Approach 2:
The polycarbonate membrane serves multiple functions simultaneously: it acts as a structural support, an electrical connector, a protective cover, and a mounting surface for drivers. This multi-functional component replaces what previously required separate cables, connectors, and mounting hardware, simplifying the overall assembly
2Productivity
If multiple individual cables are used to connect drivers, then each connection can be made separately, but the labor and time required for assembly increases significantly
Solution Approach 1:
The electrical connections are pre-configured into the polycarbonate membrane during manufacturing, with conductive traces already positioned and connected to the appropriate terminals. This preliminary preparation eliminates the need for on-site cable routing, connection-making, and testing that would otherwise consume significant assembly time
Solution Approach 2:
Multiple cable connections are combined into a single membrane assembly that can be installed as one unit. This consolidation reduces the number of discrete assembly steps from installing multiple individual cables to installing a single integrated component, dramatically improving assembly speed
3Ease of manufacture
If multiple cables and components are used for driver connections, then the system can be assembled using standard components, but material costs and waste increase
Solution Approach 1:
Multiple separate cables and connection components are merged into a single polycarbonate membrane structure. This consolidation eliminates redundant materials such as excess cable insulation, connector housings, and mounting hardware, reducing overall material consumption and manufacturing waste while maintaining manufacturing simplicity
Data Source
AI summary
A control board drivers with polycarbonate membrane that includes drivers with an adhesive polycarbonate membrane and electronic circuits, with an opening for passing a connection FLET between the membrane and a SLAVE module, and a five-way cable projecting from the SLAVE module. The five-way cable has two data communication wires, two feeding wires and one spare wire that connects the SLAVE module and a MASTER module. The adhesive membrane, along with the SLAVE module and the MASTER module, allow for the replacement of all components (drivers) in an electric control board.