3D Aperture Structures for Light, Sound, and Airflow Control
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Solution Overview
Problem
Existing three-dimensional structures for electronic devices lack advanced tailoring of shapes to provide additional functionality and simplified manufacturing, limiting their performance and versatility.
Innovation Solution
The formation of three-dimensional structures by removing material from opposing surfaces using methods like chemical and laser etching, machining, casting, or injection molding, allowing for the creation of customized patterns of positive and negative space that intersect to define apertures with specific properties, such as linear or non-linear paths, to achieve desired optical, thermal, and acoustical properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If material is removed from opposing surfaces to create customized patterns, then functionality and versatility are improved, but manufacturing complexity increases
Solution Approach 1:
The manufacturing process is segmented into multiple sequential steps: applying first and second patterns to opposing surfaces, selectively removing material based on pattern intersections, and creating distinct aperture types (first apertures from first pattern, second apertures from second pattern, third apertures from intersection). This segmentation allows complex functionality to be achieved through systematic, modular manufacturing operations.
Solution Approach 2:
The invention transitions from two-dimensional surface patterns to three-dimensional aperture structures by removing material through the thickness of the component. The intersection of patterns on opposing surfaces creates apertures that extend through the component in the third dimension, enabling sophisticated light blocking and transmission properties.
2Adaptability or versatility
If complex patterns are created to control light transmission, then optical properties are improved, but manufacturing precision requirements increase
Solution Approach 1:
Patterns are applied to opposing surfaces before material removal occurs. This preliminary patterning step establishes the precise geometric configuration that will guide subsequent material removal, ensuring that apertures are created at the correct locations with the desired shapes and orientations.
Solution Approach 2:
Different regions of the component have different aperture configurations tailored to local optical requirements. First apertures, second apertures, and third apertures can have different sizes, shapes, and distributions, allowing each region to be optimized for its specific function (light blocking, light transmission, structural support).
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 approach enables the creation of structures with tailored characteristics, such as lightweight, stiff, and flexible designs suitable for various applications, including electronic device housings, speaker covers, and heat sinks, while allowing for airflow and sound transmission while preventing visibility.
Implementation Method 1
Example methods of removing material include chemical and laser etching and machining.
Implementation Method 2
Example methods of removing material include chemical and laser etching and machining.
Implementation Method 3
Example methods of removing material include chemical and laser etching and machining.
Implementation Method 4
In other embodiments material may be combined (e.g., via casting or injection molding) or compressed (e.g., via forging) to form the three-dimensional structures.
Implementation Method 5
In other embodiments material may be combined (e.g., via casting or injection molding) or compressed (e.g., via forging) to form the three-dimensional structures.
Implementation Method 6
In other embodiments material may be combined (e.g., via casting or injection molding) or compressed (e.g., via forging) to form the three-dimensional structures.
Data Source
AI summary
The present disclosure provides three-dimensional structures and related methods. The three-dimensional structures may define patterns of positive and negative spaces on opposing surfaces that combine to form the three-dimensional structures. The negative spaces of the patterns may intersect to form apertures through the three-dimensional structures, which may define linear or non-linear paths therethrough. The apertures may be configured to provide desirable characteristics with respect to light, sound, and fluid travel therethrough. Further, the three-dimensional structures may be configured to define desired stiffness, weight, and/or flexibility. The three-dimensional structures may be employed in embodiments including heat sinks, housings, speaker or vent covers, springs, etc.