Rigid Electrical Panel with Embedded Flexible Circuit and Shield
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Solution Overview
Problem
Conventional electrical harnesses in gas turbine engines are bulky, heavy, and difficult to manipulate, leading to complex assembly and maintenance processes, susceptibility to mechanical damage, and increased maintenance times, while lacking effective protection against electromagnetic interference and lightning strikes.
Innovation Solution
The implementation of a rigid electrical panel with embedded flexible printed circuits and an electromagnetic protection layer, allowing for independent testing of the grounding and shielding, and using a lightweight yet robust organic matrix composite material for the panel, which provides protection against electromagnetic interference and lightning strikes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If conventional wiring harnesses with insulated wires and connectors are used, then electrical connectivity is achieved, but the system becomes bulky, heavy, and difficult to manipulate
Solution Approach 1:
The patent merges multiple separate electrical conductors into a single integrated panel structure. The circuit board integrates multiple electrical traces, connection points, and routing paths that were previously separate wires and connectors, consolidating the entire wiring harness into one rigid panel assembly.
Solution Approach 2:
The patent replaces the flexible mechanical wiring harness system with a rigid circuit board system. Instead of using flexible insulated wires with mechanical connectors, the invention uses a rigid panel with embedded conductive traces and integrated connection points, eliminating the need for flexible cable assemblies.
2Productivity
If conventional wiring harnesses with many components are used, then electrical connectivity is achieved, but assembly and maintenance become complicated and time-consuming
Solution Approach 1:
The patent combines multiple discrete electrical components (wires, connectors, routing elements) into a single integrated circuit board assembly. This consolidation reduces the number of individual parts that need to be assembled and handled, streamlining both installation and maintenance procedures.
Solution Approach 2:
The electrical panel is pre-assembled with all conductive traces, connection points, and routing paths already integrated into the rigid structure before installation. This preliminary integration eliminates the need for complex on-site assembly of individual wiring components, reducing installation time and potential errors.
3Reliability
If conventional wiring harnesses are used, then electrical connectivity is achieved, but the conductors are susceptible to mechanical damage
Solution Approach 1:
The patent integrates the protective function directly into the structural panel itself. The rigid panel material serves as both the structural support and the protective enclosure for the electrical conductors, eliminating the need for separate protective sleeves or reinforcement layers that would add weight.
Solution Approach 2:
The patent uses a rigid panel constructed from composite materials that provide both structural integrity and protective properties. The composite structure offers mechanical strength and durability to protect embedded conductors while maintaining a lightweight profile compared to traditional reinforced wiring harnesses.
4Volume of moving object
If conventional wiring harnesses are used, then electrical connectivity is achieved, but significant space is occupied within the gas turbine engine
Solution Approach 1:
The patent consolidates multiple electrical conductors and routing paths into a single flat panel structure. This integration dramatically reduces the volumetric space required compared to traditional harnesses that require three-dimensional routing through cable bundles and protective conduits.
Solution Approach 2:
The patent replaces the flexible, three-dimensional wiring harness system with a rigid, planar circuit board system. This substitution enables a more compact arrangement that occupies less volume within the engine compartment while providing equivalent electrical connectivity functions.
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 reduces the weight and size of the electrical system, simplifies assembly and maintenance, enhances protection against electromagnetic interference and lightning, and allows for efficient testing of the protection mechanisms, thereby decreasing maintenance times and costs.
Implementation Method 1
an electromagnetic protection layer, which is embedded in the rigid material at a same side of the rigid material as the flexible printed circuit and which surrounds the flexible printed circuit
Data Source
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AI summary
A rigid electrical panel has both a flexible printed circuit and an electromagnetic protection layer embedded therein. The flexible printed circuit has an integral electromagnetic shield. The integral electromagnetic shield and the electromagnetic protection layer are electrically isolated, so as to provide independent grounding paths. The independent grounding paths can be individually tested for safe operation.