Shape-Retaining Non-Flat Devices via Anchor Elements
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Solution Overview
Problem
Existing methods for manufacturing shape-retaining non-flat devices by deforming flat devices face challenges in accurately and reproducibly positioning electronic and mechanical components on complex, arbitrarily shaped surfaces, often requiring complex modeling and expensive equipment.
Innovation Solution
A method involving the design of a flat device layout with mechanical interconnections that are either stretchable or non-stretchable, allowing for accurate positioning of components during thermoforming, where the flat device is embedded in a thermo-formable material and deformed into a non-flat shape, with anchoring elements providing mechanical reference points for precise placement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If FEM modeling is used to predict final component positions during thermoforming, then prediction capability is improved, but process complexity increases significantly
Solution Approach 1:
The patent uses disposable anchor elements made of inexpensive material that are embedded in the flat device. These anchor elements serve as reference points for component positioning and are deformed along with the device during thermoforming. Instead of using complex FEM modeling to predict positions, the system relies on these simple, disposable physical references that automatically define component locations after deformation, eliminating the need for sophisticated computational models.
2Manufacturing precision
If complex FEM modeling is employed to account for material properties, temperature, and process parameters, then positioning accuracy is improved, but manufacturing cost and time increase
Solution Approach 1:
The patent implements preliminary action by embedding anchor elements in the flat device before thermoforming. These anchor elements pre-establish the geometric relationships and reference frames that will define final component positions. During thermoforming, components are positioned relative to these pre-placed anchors, eliminating the need for post-process computational modeling to determine positions. The positioning logic is built into the physical structure beforehand.
Solution Approach 2:
The anchor elements and flat device structure serve themselves by automatically defining component positions through their geometric arrangement and deformation behavior. The system does not require external FEM modeling or complex calculations to determine positions - the physical deformation of the anchored structure inherently provides the positioning information, making the process self-determining rather than computation-dependent.
3Adaptability or versatility
If components are positioned on non-flat surfaces after thermoforming, then design flexibility is improved, but positioning reproducibility becomes difficult to control
Solution Approach 1:
The patent introduces anchor elements as intermediary reference objects between the flat device structure and the components to be positioned. These anchors serve as mediators that translate the deformed geometry of the flat device into stable, reproducible positioning references. Components are positioned relative to these anchor intermediaries rather than directly on the complex non-flat surface, ensuring consistent positioning across multiple production cycles despite variations in thermoforming outcomes.
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 accurate, predictable, and reproducible positioning of components on non-flat surfaces without the need for complex modeling or expensive equipment, using standard industrial tools, and reduces the risk of mechanical interconnection failure during deformation.
Implementation Method 1
heating the structure to a temperature above the glass transition temperature of the thermoplastic material
Implementation Method 2
cooling down. During the thermoforming step the electrical connections are stretched
Data Source
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AI summary
Methods are provided for manufacturing shape-retaining non-flat devices comprising elements such as components integrated on a device surface, the non-flat devices being made by deformation of a flat device. Based on the layout of a non-flat device, a layout of a flat device is first designed. A method for designing the layout of such a flat device is provided, wherein the method includes inserting mechanical interconnections between pairs of elements to unambiguously define the position of the elements on a surface of the non-flat device, thus leaving zero or less degrees of freedom for the location of the components. Based on the layout of a flat device thus obtained, the flat device is manufactured and next transformed into the shape-retaining non-flat device by means of a thermoforming process, thereby accurately and reproducibly positioning the elements at a predetermined location on a surface of the non-flat device.