Display Tile Frame Stiffness Control via Subtractive Machining
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Solution Overview
Problem
Existing frame designs for display tiles face challenges in managing thermal expansion mismatches between materials, leading to excessive stress on adhesives due to inadequate control over bending stiffness, particularly when using etching techniques which are imprecise for metals like steel or aluminum.
Innovation Solution
The frame is divided into three parts with grooves in the second part that are straight and parallel to the substrate, where material is removed through subtractive machining processes like laser cutting, punching, or drilling to create openings or reduce thickness, allowing for precise adjustment of bending stiffness and reducing strain on adhesives.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If etching techniques are used to reduce frame stiffness, then material can be removed to decrease bending stiffness, but manufacturing precision is insufficient for metals like steel or aluminum
Solution Approach 1:
The patent changes the manufacturing parameter from chemical etching to mechanical subtractive machining processes. This allows precise control over material removal depth and geometry, achieving the required bending stiffness adjustment with tolerances suitable for metals like steel or aluminum, while maintaining the desired frame flexibility.
Solution Approach 2:
The patent replaces the chemical etching process with mechanical machining processes such as laser cutting, punching, or drilling. This substitution enables precise material removal through mechanically controlled methods, achieving better manufacturing precision for metal frames while still reducing bending stiffness through controlled material removal.
2Adaptability or versatility
If material is removed from the frame to decrease bending stiffness, then flexibility increases and adhesive stress reduces, but frame strength may be compromised
Solution Approach 1:
The patent applies local material removal through subtractive machining at specific locations where stiffness reduction is needed, rather than uniformly thinning the entire frame. This localized approach decreases bending stiffness in critical areas while preserving frame strength in load-bearing regions, maintaining both flexibility and structural integrity.
Solution Approach 2:
The patent segments the frame into regions with different stiffness requirements. Material is selectively removed from specific segments (second part of the frame) to reduce bending stiffness where flexibility is needed, while other segments maintain full thickness and strength for structural support, achieving a balance between flexibility and overall frame strength.
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 increases the flexibility of the metal frame, effectively reduces stress on adhesives, and improves strain relief by allowing for precise control over bending stiffness, enhancing the reliability of the assembly.
Implementation Method 1
a frame made of a first material with a first coefficient of thermal expansion and being fastened to a first substrate made of a second material with a second coefficient of thermal expansion
Data Source
AI summary
A frame for a display tile made of a first material with a first coefficient of thermal expansion and fastened to a first substrate made of a second material with a second coefficient of thermal expansion. The frame is divided into three parts: a first part to be glued by the adhesive to a lateral side of the substrate, a third part to serve as fastening interface to another structure and a second part to isolate the third part from strain in the first part. Grooves are formed in the second part, the grooves being substantially straight and substantially parallel to the first substrate, the frame having at least one opening made in one of the grooves etched in the metal frame to locally adjust the bending stiffness of the metal frame.