WO1994003947A2

WO1994003947A2 - Modular panel for making a conductor network, associated connectors, and methods for fabricating such panels

Info

Publication number: WO1994003947A2
Application number: PCT/FR1993/000780
Authority: WO
Inventors: Louis Maurice Fradin
Original assignee: Societe Atlantique D'isolants Thermiques Expanses Chimiquement
Priority date: 1992-07-29
Filing date: 1993-07-29
Publication date: 1994-02-17
Also published as: FR2694322B1; FR2694322A1; AU4712493A; WO1994003947A3; EP0653109A1

Abstract

Modular panel for making a conductor network comprising at least three layers (24, 26, 28) of insulating material and at least two layers (20, 22) of conducting material separated by the insulating material layers, the panel being designed to receive at least one apparatus (10) fitted with penetrating connection pins (14, 16) each provided with at least one conducting area, whose length and number are adapted to the conductive layers to be reached, the panel being characterized in that it is comprised of a peripheral frame having elements provided with mechanical linking parts forming electric connection members, the elements of the frame being themselves connected to the corresponding layers of conducting material so as to achieve the connection between modular panels. The invention also relates to the connectors used therewith as well as to methods for fabricating such panels.

Description

Modular panel for producing a conductive network, associated connectors, and methods of manufacturing the panels. The present invention relates to a modular panel for producing a conductive network, the associated connectors, as well as the methods of manufacturing the panels. Currently, conductive networks, whether they are data or power supply networks, require sets of conductive wires specific to the transfer of current or data. These sets of wire bundles pose problems of bulk on the one hand and make the cabling systems complex or expensive. On the other hand, these bundles are not flexible to use because for any implementation of on-site implantation, it is necessary to add wires to the bundles or else to remove them or at least to move the wires concerned. by modification. This is even more true for temporary installations on stands at trade fairs, exhibition fairs or other similar events.

It should also be noted that not only is it often necessary to move the apparatus from the point of view of installation, but it is also necessary in certain cases to move all of the corresponding control boxes, which further increases the difficulty, time and costs involved.

Patent application FR-A-2 601 519 is known, which describes a device for assembling and supplying simultaneously a group of light-emitting diodes.

This device comprises a sheet obtained by the superposition of two layers of spongy electrically conductive materials which are separated and re-

REPLACEMENT SHEET covered by layers of insulating spongy material.

The layers of material are supplied with electric current. The diodes are equipped with pins which penetrate into the layers, the first pin stopping in the first conductive layer, the second pin stopping in the second conductive layer, after having passed through the first in an insulating sheath. Patent FR-A-1 638 914 describes an electrical current distribution device which takes up the structure described above. The connectors are applied more widely than just the diodes. These connectors include two plugs, or even a single plug comprising two independent conductive parts separated by an insulating zone. Patent application FR-A-2 131 075, with a structure of the same type as the previous ones, provides for the use of connectors forming a socket. The layers are more than two in number and the combination of the layers two by two makes it possible to obtain different results, blinking, constant feeding, for example. It turns out that many problems remain for the production of panels which function and which provide all the advantages expected when using the associated connectors.

In fact, when plugging in, the connectors have their plugs in perfect contact with the corresponding layers.

On the other hand, the connectors must be plugged in easily but simultaneously, they must be mechanically fixed to the panel, in particular during mounting on the ceiling. Another important problem is the connection of the panels to each other and the present invention provides an effective solution and its variant embodiments for electrically connecting the panels. The manufacture of the panels also poses numerous constraints. The present invention also relates to the development of panels.

The purpose of the present invention is to provide a modular panel for the production of a conductive network which eliminates the bundles of wires, which allows positioning and modifications at will and this immediately, which presents all the safety requirements when used for power supply, which is easy to install and which can be removable or fixed to demeu¬ re, the manufacture of which can be easily industrialized, the cost of which, depending on the choice of materials, may be relatively low, which nonetheless lends itself to the installation of sophisticated materials for certain particular applications, and which applies to many fields of activity while offering great reliability of con ¬ nection and operation. The present invention also relates to the associated connectors and to the methods of manufacturing the panels.

To this end, the modular panel according to the invention, provided for the production of a conductive network comprises at least one layer of insulating material and at least two layers of conductive material, separated by the layer of insulating material, provided for receive at least one device equipped with penetrating pins for connection with a conductive zone, of length and in number adapted to the conductive layers to be reached, this panel being characterized by a peripheral frame composed of elements fitted with mechanical connection pieces forming an electrical connection member, the elements of the frame being themselves connected to the corresponding layers of conductive material, so as to allow the connection of modular panels between them.

These electrical connecting members are the articulations of the panels and in particular the hinges. The invention also provides a connector intended to cooperate with such modular panels which include a base supporting an apparatus and at least two pins, this connector being characterized in that at least one of the pins is movable relative to the '' base at an angle greater than or less than 90 °.

According to another characteristic of the invention, the pins of the connector comprise at least one abrasive part arranged upstream and / or in line with the conductive zone of this pin in the direction of penetration so as to sand the layer of conductive material during this penetration. According to another characteristic, the connector takes intermediate penetrating sockets provided for receiving the pins. The invention also relates to a method of fabricating a panel which is characterized in that the various conductive and insulating layers are superimposed between two external plates of rigid material, in particular wood, so as to lay the layers together against others and allow cutting to size as needed. A variant of the manufacturing process consists of interposing layers of insulating material between layers of insulating material. In this case, the different sheets of the conductive material are joined together, in particular by sewing using a conductive wire. A particularly interesting variant of the manufacturing process consists in fixing the conductive material to the insulating material by fusion of this same conductive material.

According to the invention, the manufacturing process also provides for injecting the insulating material between the conductive layers, the injection parameters permitting setting and obtaining the desired thicknesses.

The present invention is described below with reference to the accompanying drawings in which: - Figure 1 shows a schematic sectional view of a panel with integrated conductive material, on which an apparatus is mounted,

FIG. 2 represents a first embodiment of a connector according to the invention, FIG. 3 represents an alternative embodiment of a connector according to the invention with sockets,

- Figure 4 shows an alternative embodiment of a connector according to the invention equipped with self-tapping screw, isolated on the unconnected part, - Figure 5 shows an alternative embodiment of a connector according to the invention with abrasive pins,

FIG. 6 represents a three-phase socket,

FIG. 7 represents the result obtained by the manufacturing process with a multi-sheet conductor,

FIG. 8 represents the result obtained using the manufacturing process by fusion, FIG. 9 represents a schematic view of ca¬ dres surrounding the panels allowing the connection of said panels,

FIG. 10 shows a particular embodiment of the invention with electrical connection by hinges,

FIG. 11 represents a detailed view of such a hinge,

FIG. 12 represents a schematic view of a first method of manufacturing by fusion,

FIG. 13 represents a variant of the fusion manufacturing process,

FIG. 14 represents another variant of the process of manufacturing by fusion, FIG. 15 is an alternative embodiment of panels, and

- Figure 16 shows a method of joining panels by tenons and mortises.

FIG. 1 shows an apparatus 10 equipped with a base 12, a first pin 14 and a second pin 16.

This apparatus is mounted on a panel 18 which comprises first and second conductive layers 20, 22, separated by layers 24, 26 and 28 of insulating material.

Each of the pins 14 and 16 has a conductive portion, respectively 15 and 17, which cooperates with the layers 20 and 22 of conductive material, the length of the pins 14 and 16 being adapted. This panel 18 is optionally covered with a finishing layer, not shown.

In Figure 2, there is shown a particular connector according to the invention which comprises a base 12, as well as two connectors 14 and 16 but one of the connectors 14 is inclined by a greater angle or less than 90 ° relative to the base so as to avoid tearing of the apparatus 10 according to arrow 30.

Of course, in order to simplify the representation, only one of the pins is inclined but the two pins can be inclined simultaneously provided that they are inclined so as to make them con¬ verging or diverging but avoiding any parallelism. . In FIG 3, the alternative embodiment of the con¬ nector comprises a second base 13 equipped with ^• bushings 32, 34 which have a connection function with the conductive material layers 20 and 22, these sleeves being designed to receive pins 14 and 16 of the apparatus 10 proper.

It is also possible to provide means for fixing these pins to the sockets in order to avoid re¬ drawing of the apparatus outside the sockets, especially in the case of suspended apparatus. In FIG. 4, the embodiment shown proposes pins 14 and 16 mounted free in rotation relative to the base and equipped with a file 36, 38 which allows a mechanical fixing of great solidity while ensuring a suitable electrical contact.

In Figure 5, there is shown an alternative embodiment of the pins of the apparatus 10, variant in which the pins 14 and 16 have an abrasive part 40 and 42, this part being located upstream and possibly as far as the right conductive parts 15 and 17 of each of the pins in the direction of penetration of the pins so as to cause slight abrasion of the conductive layers 20 and 22 during penetration. FIG. 6 represents a concrete embodiment of an electrical outlet corresponding to three-phase current equipped with earth, each of the plugs 44, 46, 48 and 50 being fixed to the panel using a corresponding screw 45, 47, 49 and 51.

The lengths of the screws allow the corresponding phases to be reached.

A standard color code can be applied to these different plugs and to the corresponding pins or screws.

Figure 7 corresponds to the result obtained by a manufacturing process which consists of interposing between the layers of material and the layers of multi-sheet conductive material. Thus, the layers 20 and 22 comprise a superpo¬ sition of thin sheets, the sum of these thicknesses corresponding to the thickness sought for the corresponding conductive layer. It is indeed possible to increase the conducting section without increasing the punching force since each of the sheets being very thin, remains easy to perforate.

An important advantage of the multi-sheet conductor is to allow frank contact with the connector.

Indeed, the glue may possibly disturb the contact of the connector with the first sheet or sheets in the direction of penetration by interposing as an insulator between the edge and the connector but not with the last sheets.

As regards the different sheets of the multi-sheet material, they can be connected between them by sewing using a wire of conductive material, by gluing, in this case a brittle adhesive will be used after hardening in order to bed the contacts and to prevent the glue from interposing between the conductive elements, but also by spot welding as is well known in the context of lattices. It is also possible to sew all of the conductive and non-conductive layers, but in this case an insulating wire will be used.

Another manufacturing process consists of using "bonding" by fusion. Indeed, the insulating materials, generally polymers, can be adhered to the layers of metallic material in different ways in order to avoid the interposition of 'glue. Schematic representations of these methods and of the corresponding devices are made in FIGS. 12, 13 and 14.

FIG. 12 simply shows the realization of an element comprising two layers 24, 26 of insulating material, and a conductive layer 20. In this case, the molten metal 52 is contained in a tank and pumped to be poured out by a supply fountain 54 onto the layer 26 of insulating material, this during the movement of these layers of insulating material, in the direction of arrow 56. Thus, the bowl shape of the layer of insulating material 26 allows the deposition of a layer of molten metal on which is pressed the second layer 24 of insulating material and the molten metal causes the adhesion of this second layer 24 of insulating material on the thin layer of entrained molten metal by capillarity through the first layer of insulating material 26.

The parameters of speed, melting temperature, nature of materials, shape of the bowl, metal flow, ... allow to adjust so the thicknesses of the different elements and thus lead to very large quantities.

This system has the advantage of being continuous, but it is possible to provide a discontinuous device, as shown in FIG. 12.

In this case, a base 58 supports a plate of insulating material 26, held flat by means of a suction symbolized by the tube 60. This base 58 has a particular profile with a bowl 62 in the central part in which is de¬ poured part of the molten material. As soon as the molten metal is poured into the cup 62, the second plate of insulating material 24 is pressed on the first and pressed strongly so as to spread the molten metal 52. Another discontinuous method consists in placing a layer of metallic material in the form of a thin sheet or lattice covered with a metal with a low melting point.

It then suffices to place this conductive material between two layers of insulating material and to pass a current through the conductive material. The Joule effect which results from the passage of current causes the previously deposited metallic material to melt, which causes the layers of insulating material to adhere.

It is noted that the adhesion leads to a high intensity mechanical connection because the molten material penetrates into the cells of the insulating material, which facilitates attachment.

Furthermore, the manufacturing process which consists in using a metallic material with a low melting point is also an element of security with regard to the panel because, in the event of a short circuit and overheating. ment abnormal to the right of the spindle, the metal melts and disconnects itself from the conductive part 15 or 17 of the corresponding pin. There is therefore an automatic "fuse" effect. With regard to the use of hot-melt adhesives, it suffices to deposit a layer of glue on a metallic core, to pass a current through this core, at the same time as the layers of insulating material are plated on this core. so that the glue in fusion adheres well during re¬ cooling.

In Figure 15, there is also shown a variant of a panel embodiment. A very thin metallic film 20 forming the conductive layer is interposed between two films of thermo-adhesive and two layers of insulator 24, 26. A direct or alternating electric current passing through the electric film causes the glue to melt. When cooling, everything is united.

In Figures 9, 10 and 11 there is shown the mechanical and electrical connection means of the panels between them. In order to reduce the risks of insulation by glue between the conductor and the connector, it is advantageous to use a deposit of glue in the form of meshes of great width compared to the diameter of the connector and lines of glue, preferably narrow. Thus, the connector has a very low probability of being surrounded by glue.

Indeed, it is a matter of achieving electrical continuity between the panels which generally are equipped with a peripheral frame. Thus in Figure 9 the two frames are conduc¬ tor and in the case of a low voltage current, it is sufficient to connect them to each other by metal elements to ensure the electrical connection of a panel to the other.

In fact, the corresponding metal layers are placed directly in contact with the uprights of the frame corresponding to the chosen phase. In Figure 10, there is shown schematically a mechanical connection by hinges 64, each of the hinges corresponding for example to one of the phases. These hinges, as shown in FIG. 11, are conductive only in the male part 66 and the female part 68 so as to be able to supply the panels with current from the sector with all the security necessary for the users.

Claims

1. Modular panel for producing a conductive network comprising at least three layers (24, 26, 28) of insulating material and at least two layers (20, 22) of conductive material, separated by the layers of insulating material, and designed to receive at least one apparatus (10) equipped with penetrating connection pins (14, 16), each provided with at least one conductive zone, of length and in number suitable for the conductive layers to be dyed, characterized in that 'It comprises a peripheral frame composed of elements fitted with mechanical connecting pieces (64) forming electrical connecting members, the frame elements being themselves connected to the corresponding layers of conductive material, so as to allow the connection of the pan¬ modular loops between them.

2. Modular panel according to claim 1, characterized in that the electrical connecting members (64) are mechanical joints of the panels such as hinges.

3. Modular panel according to claim 1, characterized in that it comprises at least one te¬ no and a mortise on at least one of the sides of the periphery so as to allow a mechanical and electrical connection.

4. Connector intended to cooperate with the modular panel according to any one of the claims 1 to 3, comprising a base (12) supporting an apparatus and at least two pins (14, 16), characterized in that l at least one of the pins is movable relative to the base at an angle greater than or less than 90 °.

5. Connector intended to cooperate with the modular panel according to any one of the res- dications 1 to 3, comprising a base supporting the apparatus and at least two pins, characterized in that one of the pins (14, 16) comprises at least one abrasive part (40, 42) disposed upstream and / or at right of the conductive area of this pin, in the direction of penetration so as to sand the layer (20, 22) of conductive material during this penetration.

6. Connector intended to cooperate with the modular panel according to claims 1 to 3, comprising a base (12) supporting the apparatus and at least two pins (14, 16), characterized in that it comprises sockets (32, 34) penetrating, intermediate, and designed to receive the pins.

7. A method of manufacturing a panel according to claims 1 to 3, characterized in that the various conductive (20, 22) and insulating (24, 26, 28) layers are superposed between two external plates of rigid material, in particular wood, so as to press the layers against each other and allow subsequent cutting according to needs.

8. A method of manufacturing a panel according to one of claims 1 to 3, characterized in that interposed, between the layers of insulating material, layers of multi-sheet conductive material.

9. A method of manufacturing a panel according to claim 8, characterized in that the different sheets of conductive material are joined together, in particular by sewing using a conducting wire.

10 A method of manufacturing a panel according to claims l to 3, characterized in that fixes the conductive material on the insulating material by fusion of this same conductive material.

11. A method of manufacturing a panel according to claims 1 to 3, characterized in that the insulating material is injected between the conductive layers, the injection parameters allowing the adjustment and obtaining of the desired thicknesses.