Printed Electrical Conductor Manufacturing Method
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Solution Overview
Problem
Existing electrical distribution systems face challenges in achieving low electrical resistance for high-current transmission and complex three-dimensional configurations while preventing conductor damage and buckling.
Innovation Solution
The method involves printing an electrically non-conductive liquid encapsulation material to form a first encapsulation layer, applying an electrically conductive particulate material, and curing it to create a conductor, with additional layers and heat treatment to achieve low resistance and a flexible, compact design. Additionally, a hollow structure is printed with non-conductive material and filled with conductive material to prevent damage and allow for complex configurations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional wiring harnesses are used, then electrical connection is achieved, but electrical resistance is high and suitable only for low-current transmission
Solution Approach 1:
The patent changes the physical and chemical parameters of the conductor material by using particulate conductive material (such as metal powder or conductive filler) embedded in a matrix material, rather than traditional solid wire. This parameter change enables low electrical resistance suitable for high-current transmission while allowing direct printing fabrication
Solution Approach 2:
The patent replaces the mechanical wire drawing and assembly process with a direct printing process. Instead of mechanically assembling traditional wires, the conductive particulate material is deposited layer-by-layer to form conductive traces directly, simplifying manufacturing while achieving low resistance through controlled material distribution
2Adaptability or versatility
If rigid wiring harnesses are used, then structural stability is achieved, but flexibility and adaptability to complex geometries are poor
Solution Approach 1:
The patent creates a dynamic structure where the wiring harness can be directly printed to match complex three-dimensional geometries. The particulate-based conductor embedded in flexible matrix material allows the harness to adapt its shape dynamically to different applications while maintaining structural integrity through the printed encapsulation
Solution Approach 2:
The patent applies different material properties locally: conductive particulate material is concentrated where electrical conduction is needed, while the surrounding matrix material provides mechanical support and flexibility. This local differentiation enables both flexibility for complex geometries and structural stability where required
3Productivity
If conventional manufacturing methods are used, then production is achieved, but manufacturing time and cost are high
Solution Approach 1:
The patent performs preliminary action by printing the encapsulation structure and conductor material in a single integrated process. The support structure and conductive traces are fabricated simultaneously in their final positions, eliminating subsequent assembly steps and reducing manufacturing time while maintaining precision through direct digital printing control
Solution Approach 2:
The patent merges multiple manufacturing operations into a single printing process. Instead of separately manufacturing conductors, insulation, and support structures then assembling them, all components are printed together in one operation, dramatically reducing manufacturing time and cost while maintaining conductor placement precision through digital guidance
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 results in electrical distribution systems with low electrical resistance suitable for high-current transmission, flexibility, and the ability to manage complex geometries, preventing conductor damage and enabling efficient manufacturing.
Implementation Method 1
the first carrier material is cured in time after application of the second particulate material to form the first coating layer
Implementation Method 2
The second particulate material is sintered under the action of heat and/or at least partially melted to form the first electrical conductor
Implementation Method 3
The second particulate material is sintered under the action of heat and/or at least partially melted to form the first electrical conductor
Data Source
Figure 1~3
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Figure 6~7
AI summary
The invention relates to an electrical distribution system (10), in particular a cable harness (15), and a method for manufacturing the electrical distribution system (10), wherein an electrically non-conductive liquid sheathing material (90) is printed along a predefined path (135) to form a first sheathing layer (140), wherein, after the application of the sheathing material (90), an electrically conductive second particle material (145) is applied to the first sheathing layer (140) to form a first electrical conductor (30), wherein the first sheathing layer (140) at least partially fixes the second particle material (145), and wherein the first carrier material (130) is cured to the first sheathing layer (140) after the application of the second particle material (145).