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BUS BAR – CONSUMER CIRCUITS BY PRE-PRINTED FOILS WITH FAST CONNECTORS FOR EASY ACCESS, REPLACEMENT AND UPGRADE

IP.com Disclosure Number: IPCOM000249884D
Publication Date: 2017-Apr-24
Document File: 6 page(s) / 127K

Publishing Venue

The IP.com Prior Art Database

Abstract

BUS BAR – CONSUMER CIRCUITS BY PRE-PRINTED FOILS WITH FAST CONNECTORS FOR EASY ACCESS, REPLACEMENT AND UPGRADE Until now the electrical systems in commercial aircraft have been relying on separate cables in harnesses. This system has obtained a robustness and high reliability. However, the electrical harnesses are heavy and complicated to install. The routings of their branches are not easy to carry out in practice and it is difficult to have an overview.

The objective of this invention is a system of lightweight, easily installable and replaceable electrical conductors located between the planned "bus bars" (high voltage main power lines located in flight direction) and the electrical end consumers. The invention is based on thin foils with pre-printed circuits, location for fast installation and access, and fast but reliable system connectors especially designed for thin foils.

A fast and reliable connection of two foils is shown. To the left in the figure two foils with pre-printed conductors are seen ready to be joined. The conductors continue to standardized "connector" positions with standardized geometry in plan. A cut-out enables a clamp to be inserted and correct position is ensured by standardized positioning holes for pins in the clamp. To the right in the figure the same two foils are seen now moved into joining position.

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BUS BAR – CONSUMER CIRCUITS BY PRE-PRINTED FOILS WITH FAST CONNECTORS FOR EASY ACCESS, REPLACEMENT AND UPGRADE

The technical field concerns printed electrical circuits, pre-printed foils, and electrical connectors. 1. PRIOR ART

Until now the electrical systems in commercial aircraft have been relying on separate cables in harnesses. Fig. 1 shows a typical situation inside a section of the fuselage. The airframe can be seen consisting of outer skin, stabilized by frames and stringers. A window belt stretches from the left to the right. Above the windows is seen one harness with branches. The branches typically serve different electrical consumers and stretch between the frames. At the interior the cabin side wall lining provides a protection and is covering all the components. At the bottom another electrical harness is seen.

Fig. 1. State of the Art; routing of electrical harnesses in fuselage, with branches between frames, covered by side wall linings This system has obtained a robustness and high reliability. However, the electrical harnesses are heavy and complicated to install. The routings of their branches are not easy to carry out in practice and it is difficult to have an overview. For the several reasons above, new technologies have been discussed and proposed to replace the harnesses. Most have involved integration of the individual cables by printing technology, on panels or on foils. One proposal has been made involving replacing the harnesses and /or their branches with pre- printed foils to be placed directly inside the airframe, as seen in Fig. 2 [1].

Fig. 2. Pre-printed foils with conductive circuits placed directly inside the airframe

Fig. 3. Connection of two pre printed foils by fastener needles Since thermal insulation is needed before the cabin lining is attached the placement immediately inside the outer skin/stringers may be well protected in most cases, however, is not very easily accesible. In addition it has been shown recently that power lines may require 5 mm and above circuit width, and may be best carried out by cold spray technology. It is not clear if cold spray functions well on thin foils. This implies that power lines will remian as separate cables or be integrated on stable background materials. Therefore the foils might not alone replace all today’s electrical harnesses. Furhtermore, the connection of such foils has not been addressed well. One proposal is busy with the idea of an attachment of two pre-printed foils to each other by means of fastener needles, that just get punched through both foils. Fig. 3 shows the use of such fastener needels. Trials with fastener needles have already been performed. Whilst functioning well on a rotorcraft in the beginning, gradual loss of connection was reported, and was found to be due to vibrations. 2. OUR IDEA

The objective of this invention is a system of lightweight, easily installable and replaceable electrical conductors located between the planned “bus bars” (h...