Sandwich Component Conductor Integration with Barrier Layers

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Solution Overview

Problem

Aircraft cabin sandwich components require electrical stability against water droplets and moisture, but existing solutions often rely on separate protective housings and seals, which add weight and complexity.

Innovation Solution

The integration of polyvinyl fluoride barrier layers on both sides of electrical conductors within the sandwich component creates a vapour-tight and water-tight enclosure, eliminating the need for additional protective housings and allowing for higher protection classifications like IP67 without external seals.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If separate protective housings and seals are used to protect conductors from water, then electrical stability against water droplets is improved, but device complexity and weight increase

Engineering Contradiction:

Improveelectrical stabilityVSAvoidcomplexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent merges the protective function with the sandwich component structure itself by integrating barrier layers directly into the component during manufacturing. This eliminates the need for separate protective housings and seals, reducing device complexity while maintaining electrical stability against water droplets.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The patent employs thin film barrier layers (such as polyvinyl fluoride or polyethylene terephthalate) within the sandwich component to provide water and moisture protection. These thin films achieve the protective function without requiring bulky separate housings, thus reducing complexity while ensuring reliability.

Inventive Principle:

Principle #30Flexible shells and thin films

2Reliability

If separate protective housings and seals are used to protect conductors from water, then electrical stability against water droplets is improved, but weight increases

Engineering Contradiction:

Improveelectrical stabilityVSAvoidweight

Core Design Contradiction:

ReliabilityVSWeight of moving object

Solution Approach 1:

The protective function is merged into the sandwich component structure through integrated barrier layers, eliminating the need for additional separate protective housings and seals. This integration significantly reduces the overall weight while maintaining electrical stability against water droplets.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The patent uses thin film barrier layers (such as polyvinyl fluoride or polyethylene terephthalate) that provide effective water and moisture protection with minimal weight addition. These thin films are integrated directly into the sandwich component, avoiding the weight penalty of separate protective housings.

Inventive Principle:

Principle #30Flexible shells and thin films

3Reliability

If separate seals are used to protect conductors, then protection against water and moisture is improved, but the quantity of components and materials increases

Engineering Contradiction:

Improveprotection against water and moistureVSAvoidseal requirements

Core Design Contradiction:

ReliabilityVSQuantity of substance

Solution Approach 1:

The protective function is merged into the sandwich component structure through integrated barrier layers, eliminating the need for separate seals. This reduction in component quantity simplifies the overall structure while maintaining effective protection against water and moisture.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The sandwich component structure is designed to perform multiple functions simultaneously: structural support, electrical insulation, and water/moisture protection. The integrated barrier layers provide universal protection without requiring additional specialized sealing components, reducing the total quantity of materials needed.

Inventive Principle:

Principle #6Universality (Multi-functionality)

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 protection against water and moisture, reduces weight and seal requirements, and enables integrated LED lighting within the sandwich component.

Implementation Method 1

two barrier layers which in each case are vapour-tight and in particular are diffusion barriers are placed as further components in the pre-assembly state

Methodology Applied

Scientific EffectDiffusion barrier: Diffusion Barrier

Data Source

PatentUS10286622B2Conductors integrated in a watertight manner in sandwich components

Publication Date: 2019.05.14 DIEHL AVIATION LAUPHEIM GMBH

AI summary

In a method for manufacturing a sandwich component having a first and a second flat side, in a pre-assembly state all components of the sandwich component in relation to one another are placed in a nominal position: at least one shape-imparting structural layer and a conductor layer having an electrical conductor, and are connected in an assembly step with an adhesive, wherein in the pre-assembly state on both sides of the conductor layer two barrier layers which are vapor-tight are placed as further components and interconnected in such a manner that said two barrier layers enclose the conductor in a vapor-tight manner. A sandwich component having flat sides, manufactured according to the above method, has at least the structural layer and the conductor layer with the conductors, said structural and conductor layers being disposed between the flat sides and connected with the adhesive, and on both sides of the conductor layer the barrier layers as further components are interconnected in such a manner that said two barrier layers enclose the conductor in a vapor-tight manner.