Shielded Electrical Connection Member for Flexible Grounding
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing electrical connection members fail to provide flexibility, water resistance, and durability in harsh environments while minimizing signal interference between multiple devices.
Innovation Solution
A method involving laminate structures with a conductive layer interposed between non-conductive layers, forming a Faraday cage, and using laser etching to expose conductive surfaces for grounding connections, with adhesive bonding for durability and moisture resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If the electrical connection member is made flexible to accommodate motion between power source and electrical equipment, then adaptability is improved, but structural integrity and protection against environmental factors deteriorate
Solution Approach 1:
The electrical connection member is divided into multiple laminated layers (conductive layer, non-conductive layers, textile layers) that can independently contribute to flexibility or protection. This segmentation allows each layer to be optimized for its specific function while working together as a unified structure.
Solution Approach 2:
The patent employs composite material construction with multiple layers including conductive material, non-conductive material, and textile material laminated together. This composite structure combines the flexibility of textile layers with the protective and functional properties of conductive and non-conductive layers, resolving the contradiction between flexibility and structural integrity.
2Reliability
If the electrical connection member is protected with multiple layers to resist moisture and dirt in harsh environments, then reliability is improved, but device complexity increases
Solution Approach 1:
The protective layers are pre-laminated onto the electrical conduit before final assembly, creating a pre-formed protective barrier. This preliminary action ensures water and dirt resistance is built-in from the start, reducing the need for additional protective components and simplifying the overall assembly process.
Solution Approach 2:
The laminated structure serves multiple functions simultaneously: the conductive layer provides shielding and grounding, the non-conductive layer provides electrical insulation and moisture barrier, and the textile layer provides mechanical protection and flexibility. This multi-functionality reduces the need for separate components, thereby reducing complexity while maintaining reliability.
3Object-affected harmful factors
If a Faraday cage structure is formed around the electrical conduit to minimize signal interference, then electromagnetic compatibility is improved, but manufacturing complexity increases
Solution Approach 1:
The Faraday cage structure is merged with the laminated protective layers rather than being a separate component. The conductive layer is integrated into the laminate structure itself, combining the electromagnetic shielding function with the protective covering, thereby simplifying manufacturing while maintaining electromagnetic compatibility.
Solution Approach 2:
The Faraday cage is implemented as a flexible conductive layer within the laminate rather than a rigid mesh structure. This thin-film approach maintains electromagnetic shielding effectiveness while being more flexible and easier to integrate into the laminated structure, reducing manufacturing complexity.
4Reliability
If grounding connections are exposed by removing non-conductive material, then electrical connectivity is improved, but vulnerability to environmental factors increases
Solution Approach 1:
Rather than completely removing the non-conductive layer at grounding points, the patent uses laser etching to create partial openings or patterns that expose the conductive layer sufficiently for grounding while retaining coverage over most of the grounding surface. This partial action maintains electrical connectivity while minimizing exposure to environmental factors.
Solution Approach 2:
The conductive layer itself acts as an intermediary between the internal electrical components and the external grounding connection. It provides a controlled interface that allows electrical connectivity while the surrounding non-conductive and textile layers continue to provide environmental protection around the exposure point.
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
The solution provides a flexible, water-resistant, and durable electrical connection member that minimizes signal interference and maintains structural integrity in challenging environments.
Implementation Method 1
bonding together the flanges of the first and second laminate structures to form a faraday cage around the electrical conduit
Implementation Method 2
etching a portion of the first non-conductive layer of the first laminate structure from a first direction
Implementation Method 3
bonding together the flanges of the first and second laminate structures
Data Source
AI summary
A method is provided for producing an electrical connection member that includes a textile cover and an inner electrical conduit. The method includes positioning an electrical conduit between first and second laminate structures that have a greater width than the electrical conduit and extend to form flanges either side of the electrical conduit. Each laminate structure includes a conductive layer interposed between a first and a second non-conductive layer. The method includes bonding together the flanges of the first and second laminate structures to form a faraday cage around the electrical conduit, etching a portion of the first non-conductive layer of the first laminate structure from a first direction; and exposing a first surface of the conductive layer of the first laminate structure in the first direction. The exposed first surface enables contact for a first grounding connection.