Curved Surface Electronic Apparatus Using Segmented Substrate

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Solution Overview

Problem

Electronic devices with a Gaussian curvature of 0 cannot be transformed into a 3D shape with positive or negative curvature without generating crinkles or folding, leading to potential breakage due to applied stress.

Innovation Solution

The method involves approximating a 3D structure's surface with 2D meshes, developing these meshes into a 2D plane, manufacturing an electronic apparatus with the same shape, and attaching it to the 3D structure, using a substrate with branches that connect and separate to maintain contact without bending.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If an electronic apparatus with Gaussian curvature of 0 is transformed into a 3D shape with positive or negative Gaussian curvature, then the electronic apparatus can be attached to a curved surface, but crinkles, bending, or folding are inevitably generated due to applied stress

Engineering Contradiction:

Improveadaptability to curved surfaceVSAvoidstructural integrity

Core Design Contradiction:

Adaptability or versatilityVSReliability

Solution Approach 1:

The substrate is divided into multiple rigid branches that are connected through flexible connection portions. Each branch maintains its rigid structure while the connection portions allow relative movement and deformation, enabling the overall structure to adapt to curved surfaces without generating crinkles or folding in the rigid branches.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The connection portions between branches are designed to be flexible and deformable, allowing dynamic adjustment of the substrate's shape. This dynamic characteristic enables the rigid branches to remain stress-free while the connection portions absorb the deformation required to match curved surfaces.

Inventive Principle:

Principle #15Dynamics

2Ease of manufacture

If an electronic apparatus is manufactured in a flat state, then manufacturing is simplified, but the apparatus cannot maintain close contact with a curved surface

Engineering Contradiction:

Improvemanufacturing simplicityVSAvoidsurface conformity

Core Design Contradiction:

Ease of manufactureVSShape

Solution Approach 1:

The substrate is segmented into multiple rigid branches connected by flexible portions. This segmentation allows each branch to be manufactured as a simple rigid structure using conventional flat manufacturing processes, while the flexible connection portions enable the overall structure to conform to curved surfaces when deployed.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The connection portions are designed as flexible structures that can deform to bridge the rigid branches. These flexible portions act as adaptive elements that enable surface conformity without requiring complex curved manufacturing processes, thus maintaining ease of manufacture while achieving surface conformity.

Inventive Principle:

Principle #30Flexible shells and thin films

3Reliability

If the electronic apparatus is made rigid to maintain structural integrity, then reliability improves, but the apparatus cannot deform to match curved surfaces

Engineering Contradiction:

Improvestructural integrityVSAvoiddeformability

Core Design Contradiction:

ReliabilityVSAdaptability or versatility

Solution Approach 1:

The substrate is divided into rigid branches (providing structural integrity) and flexible connection portions (providing deformability). This segmentation allows the rigid branches to maintain their shape and protect electronic devices, while the flexible connections enable the overall structure to deform and adapt to curved surfaces.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Different portions of the substrate have different mechanical properties: the branches are rigid to maintain structural integrity and protect electronic devices, while the connection portions are flexible to enable deformation. This local differentiation of mechanical properties allows simultaneous achievement of reliability and adaptability.

Inventive Principle:

Principle #3Local quality

4Shape

If the electronic apparatus deforms to match a curved surface, then surface contact is improved, but stress is applied to the apparatus causing potential breakage

Engineering Contradiction:

Improvesurface contactVSAvoidstress resistance

Core Design Contradiction:

ShapeVSStrength

Solution Approach 1:

The substrate is segmented into rigid branches and flexible connection portions. When the apparatus deforms to match a curved surface, the flexible connection portions bear the deformation stress while the rigid branches remain relatively stress-free, preventing breakage of the electronic devices mounted on the branches.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The flexible connection portions act as intermediaries between the rigid branches and the curved surface. These connection portions absorb the stress of deformation and protect the rigid branches and mounted electronic devices from direct stress exposure, thereby maintaining strength while achieving surface contact.

Inventive Principle:

Principle #24Intermediary (Mediator)

Data Source

PatentUS11570922B2Electronic apparatus attachable to surface of 3D structure having curved surface and method of manufacturing the same

Publication Date: 2023.01.31 SEOUL NATIONAL UNIVERSITY R&DB FOUNDATION

AI summary

Provided is a method of manufacturing an electronic apparatus, the method including approximating a surface of a three-dimensional (3D) structure with two-dimensional (2D) meshes, forming a developed view by developing the 2D meshes, manufacturing an electronic apparatus having the same shape as a shape of the developed view, and attaching the electronic apparatus to the surface of the 3D structure.