Flexible Dial with Undercut Zones for Complex Reliefs

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Solution Overview

Problem

Current watch dial manufacturing techniques limit design freedom due to the inability to create undercut surfaces and complex reliefs, requiring expensive machining or stacking and gluing of multiple layers, and only allow for cylindrical or tapered insert fittings.

Innovation Solution

A one-piece dial made from flexible materials like elastomers or silicone, featuring undercut surfaces, which allows for the integration of inserts and complex reliefs through a molding process using a relief surface mold, enabling the production of dials with undercut zones and flexible or rigid inserts.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Shape

If traditional molding processes are used for dial production, then manufacturing is simpler, but undercut surfaces and complex reliefs cannot be created

Engineering Contradiction:

Improvedial geometryVSAvoidmanufacturing process

Core Design Contradiction:

ShapeVSEase of manufacture

Solution Approach 1:

The invention divides the dial into a rigid base structure and a flexible relief layer that can be separately molded and then combined. This segmentation allows the relief layer to incorporate complex undercut geometries that would be impossible to mold as a single rigid piece, while the rigid base provides structural support for traditional manufacturing processes

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The invention changes the material parameter of the relief layer from rigid to flexible, enabling the creation of undercut surfaces through molding. The flexible material can be molded into complex three-dimensional shapes with undercuts, then attached to the rigid dial base, resolving the contradiction between geometric complexity and manufacturing simplicity

Inventive Principle:

Principle #35Parameter changes

2Manufacturing precision

If inserts are fitted in cylindrical or tapered housings, then insertion is simpler, but angular positioning precision is compromised

Engineering Contradiction:

Improveangular positioningVSAvoidinsert fitting

Core Design Contradiction:

Manufacturing precisionVSEase of manufacture

Solution Approach 1:

The invention applies different geometric properties to different parts of the insert housing: the outer housing remains cylindrical for easy insertion, while the inner gripping surface features undercut geometry that provides precise angular positioning. This local differentiation of geometric qualities allows both simple insertion and precise positioning to be achieved simultaneously

Inventive Principle:

Principle #3Local quality

3Shape

If multiple strata are stacked and glued to create undercut surfaces, then undercut geometry is achieved, but device complexity and manufacturing cost increase

Engineering Contradiction:

Improveundercut surfaceVSAvoidmulti-layer structure

Core Design Contradiction:

ShapeVSDevice complexity

Solution Approach 1:

The invention merges the relief structure and the undercut surface geometry into a single flexible layer that is molded as one piece. This eliminates the need to stack and glue multiple separate strata to achieve undercut surfaces, reducing device complexity while maintaining the desired geometric features

Inventive Principle:

Principle #5Merging (Combining)

4Manufacturing precision

If expensive machining is used to create undercut surfaces, then precise undercut geometry is achieved, but manufacturing cost increases

Engineering Contradiction:

Improveundercut geometryVSAvoidmanufacturing cost

Core Design Contradiction:

Manufacturing precisionVSEase of manufacture

Solution Approach 1:

The invention replaces expensive mechanical machining processes with a molding process for creating undercut surfaces. The flexible relief layer is molded directly into the desired shape with precise undercut geometry, eliminating the need for subsequent machining operations and significantly reducing manufacturing cost while maintaining geometric precision

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

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 dials with intricate designs and precise undercut geometries, facilitating the angular positioning of inserts and reducing manufacturing costs by allowing for the production of complex shapes in a single piece, while maintaining stability through a rigid sole option.

Implementation Method 1

said flexible material or silicone or flexible elastomer is left in said mold for a time sufficient for its polymerization or vulcanization until a stable dial at room temperature is obtained

Methodology Applied

Scientific EffectPolymerization: Photopolymerisation

Implementation Method 2

said flexible material or silicone or flexible elastomer is left in said mold for a time sufficient for its polymerization or vulcanization until a stable dial at room temperature is obtained

Methodology Applied

Scientific EffectVulcanization:

Data Source

PatentEP2653939B1Dial for a clock piece

Publication Date: 2017.08.30 ETA SA MFG HORLOGERE SUISSE

Figure 1~7
Figure 8~13

AI summary

The dial (1) has a front face forming a visible display surface and arranged opposite to a back face. A cavity extends into a portion of thickness of the dial between the visible surface and the back face. An undercut surface (5) extends into the portion of the thickness of the dial between the visible surface and the back face. The dial is single piece made of flexible material selected from flexible elastomer or silicon or rubber or leather. A peripheral surface extends into the portion of the thickness of the dial between the visible surface and the back face. An independent claim is also included for a method for making a dial.